modification sheets and special maintenance · pdf fileother equipment (auxiliary motors,...

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

VOLUME - V

MODIFICATION SHEETS

AND

SPECIAL MAINTENANCE INSTRUCTIONS

ON

OTHER EQUIPMENT

(AUXILIARY MOTORS, SEMICONDUCTOR DEVICES & BATTERY CHARGER)

MAY - 1999

RESEARCH DESIGNS AND STANDARDS ORGANISATION LUCKNOW – 226 011

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CONSOLIDATED MODIFICATION SHEETS

AND

SPECIAL MAINTENANCE INSTRUCTIONS

FOR ELECTRIC LOCOS

GENERAL

The special maintenance instructions and modification sheets issued by RDSO till May 1999 have been compiled in five volumes. The contents of these five volumes are as under :

1. VOLUME - I

Systems including mechanical and pneumatic items.

2. VOLUME - II

Traction Motors 3. VOLUME - III Tap Changers 4. VOLUME - IV Static Equipments(Transformer, DJ, VCB, SL, Pantographs, EP & EM Contactors, Relays) 5. VOLUME - V

Other Equipments(Auxiliary Motors, semiconductor devices, battery charger)

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MODIFICATION SHEETS FOR AUXILIARY MOTORS

S.No

Modification Reference Title Page no.

1. WAG 4/68 & WAM 4/35

EL/3.2.11/D5 dt. 12.6.74

Modification to the terminal stud of the Jyoti arno converter

8-11

2. RDSO/ WAM4/61

EL/3.2.70/D4 dt. 16.1.1978

Replacement of existing terminal blocks by epoxy moulded terminal blocks of improved design

12-15

3. RDSO/ WAM4/171

EL/3.2.92.3 dt. Nov. 1992

Rewinding details of Siemens make of MCP 9.4KW/12.6 HP, type 1 LA6 186-6.

16-19

4. RDSO/ WAM4/177

EL/3.2.92.3 dt. 15.10.93

Rewinding of MCP ` Siemens make` of 10.5 KW/14 HP TEFC, having Dual coat wires or double glass covered copper enamelled conductor type ILA 6 188-6YA90-Z.

20-24

5. RDSO/ WAM4/183

EL/3.2.48 dt.30.12.94

Provision of anti-vibration pads for MVMT 25-26

6. RDSO/ WAM4/184

EL/3.2.11 dt. 30.12.94

Tolerances between rotor bars and slots to be adopted on M/s Jyoti make of Arno convertor.

27-29

7. RDSO/ WAM4/195

EL/3.2.15 dt. 15.11.96

Provision of Electro magnetic unloader valve on Electric locomotives.

30-33

8. RDSO/ WAM4/197

EL/3.2.15 dt. 4.6.97

Provision of EMU Type after cooler on air brake locomotives.

34-38

9. RDSO/WAM4/189 Amendment 1

EL/3.2.70 dt. 7.8.97

To provide capacitors across u, v & w terminals of MCP and Arno converters.

39-41

10. RDSO/ELRS/MS/0290

EL/3.2.70 dt. .8.2000

To provide epoxy moulded terminal box cover for auxiliary motors of electric locomotives.

208-221

11. RDSO/ELRS/MS/0295

EL/3.2.70 dt.25.9.2000

Rewinding of stator winding og MVMT and MVRH of CGL.Siemens make with dual coated enameled winding wires conforming to IS:13730 Part 13.

222-224

12. RDSO / ELRS/ MS/0296 (Rev.`0’)

EL/3.2.15 dt.29.9.2000

To increase the oil filling interval of compressor type TRC 1000 MN of M/s Elgi make by increasing the sump capacity.

225-227

Note 1. Modification sheet Nos. WAM4/78, WAM4/106 are not applicable and modification sheet No. WAM4/189, WAM4/190 are superseded.

Note 2. Modification sheet Nos. WAM4/36, WAM4/60, WAM4/71, WAM4/73 are not included being of older version of machines.

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SPECIAL MAINTENANCE INSTRUCTIONS FOR AUXILIARY MOTORS

Sl. No.

SMI No. Reference Title Page no.

1. RDSO/ELRS/ SMI/3

EL/3.2.70/J2 dt. Nov. 1978

Procedure for rewinding of auxiliary motors. 42-44

2 RDSO/ELRS/ SMI/5

EL/3.2.70/D4 dt.21.12.1977

Procedure for connecting the lead wire with the stator winding wires of auxiliary motors.

45-46

3. RDSO/ELRS/ SMI/16

EL/2.2.48/J2 Dt. 3.5.1978

Fits and limits on bearings Of auxiliary motors used on Electric locomotives

47-49


EL/2.2.48/J2 dt.7.5.1978

Procedure for measuring the bearing clearances of a “free bearing” that is a bearing off the machine

50-52


EL/3.2.70/J2 21 Nov 1978

Procedure for fixing the socket with the lead wires of auxiliary motor stator Winding.

53-57


EL/8.11.12/DB3 dt. July 1979

On condition monitoring of bearings. 58-60


EL/2.2.48 dt.2.5.1981

Fitment of outer race of bearing in the bearing housing.

61-62


EL/2.2.48 dt.11.6.81

Testing/checking of new bearings for Auxiliary motors

63-64


EL/3.2.70/JTMU dt.13.10.82

Procedure for impregnation of stator auxiliary motors

65-68

10. RDSO/ELRS SMI/87

EL/3.2.48/JTMU dt.23.5.82

Puller for extracting traction motor cooling blower Impellers.

69-71


EL/3.2.70/J-3 dt.30.10.92

Use of button type of grease nipple on auxiliary motors fitted on Electric loco

72-74


EL/2.2.48 dt.21.10.92

Guidelines to identify genuine and spurious/ reconditioned bearings.

75-77


EL/3.2.70/ -10-1992.

Special instruction for surge test on 3 phase AC auxiliary motors.

78-86


EL/3.2.70/J-3 dt.15.12.92

General guidelines to follow for balancing of rotor and blower impellers.

87-91

15. RDSO/ELRS/ SMI/153 (Revised)

EL/2.2.8.4/J-3 Dt. 1.4.98

Characteristic properties of enamel used on enamelled winding wires.

92-99


EL/3.2.70 dt.22.4.93

Special instructions for essential requirements of facilities to rewind 3 phase AC auxiliary motors in loco sheds and rewinding shops

100-101

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S.No. SMI No. Reference Title Page no. 17. RDSO/ELRS

/ SMI/163 EL/3.2.11 Nov. 94

Detection of rotor bar and end ring cracks on Arno converter and auxiliary motors by “Search coil and motor tester”

102-104


EL/3.2.114.3 dt. 30.3.95

Fixing of armature spider of motor (KPC-1) frame 110 VDC on the shaft of compressor 3 HC-55.

105-111


EL/3.2.70 Feb.1997

Rewinding material for auxiliary motors 112-119

20. RDSO/ELRS/SMI/199

EL/3.2.70 dt.1.4.98

General guidelines to follow for balancing of rotors and cooling blower impellersin position.

120-122


EL/2.2.8.4 dt.1.4.98

Characteristic properties of impregnating resins and insulating varnishes (Superseding SMI-154).

123-144


EL/3.2.70 dt.20.9.2000

Special Instruction for essential requirements of facilities to rewind 3-Phase AC Auxiliary Motors used in Electric Locomotives in Loco Sheds and rewinding shops.

205-207

Special Maintenance Instruction Nos. SMI/E-10/001. SMI/E-10/002, SMI/59, SMI/77, SMI/98, SMI/98(Revised), SMI/154 are superseded. Special Maintenance Instruction SMI/89, SMI/92, SMI/93, SMI/95, SMI/96, SMI/99, SMI/100, SMI/111 are not included being of older version of machines.

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MODIFICATION SHEETS FOR AUXILIARY MOTORS,SEMICONDUCTOR DEVICES & BATTERY CHARGER

S. No. SMI NO. FILE NO. Dt. OF ISSUE

DESCRIPTION Page no.

1. RDSO/ WAM4/72

EL/3.2.12/EC2 dt. 28.8.78

Simplified control card for static battery charger type BCF6 of M/s Control and drives Ltd

146-147

2. RDSO/ WAM4/83

EL/3.2.12/EC2 July 1979

Shifting of bleeder resistance (R5) out side the BCF7 battery charger of M/s Control & Drives corporation, Coimbatore

148-149

3. RDSO/ WAM4/84

EL/3.2.12/EC2 July 1979

Provision of current limiting resistor on static battery charger type BCF7 of M/s Control |& Drives Corporation, Coimbatore

150-152

4. RDSO/ WAM4/85

EL/3.2.12/EC2 July 1979

Re-soldering filter capacitor C3 and provision of leatheroid paper in its container and terminal for filter capacitor connections

153-155

5. RDSO/ WAM4/86

EL/3.2.12/EC2 July 1979

Replacement of 3K OHM carbon resistor (R’4) by wire wound resistor in BCF7 battery charger of M/s Control & Drives corporation Coimbatore.

156

6. RDSO/ WAM4/87

EL/3.2.12/EC2 July 1979

Modification of the flexible cable connection on printed card board of BCF7 battery charger of M/s Controls & Drives Corporation Coimbatore.

157-159

7. RDSO/ WAM4/101

EL/2.2.24/1/EC2May 1980

Loco head light voltage stabilizer modification.

160-162

8. RDSO/ WAM4/102

EL/2.2.24/1/EC2June 1980

Loco head light voltage stabilizer modification.

163

9. RDSO/ WAM4/104

EL/3.2.27/EC2 Silicon rectifier damping capacitor failures.

164-166

10. RDSO/ WAM4/105

EL/3.2.12/EC2 July, 1980

Increase in output voltage setting of battery charger type BCF6 and BCF7

167

11. RDSO/WAG - 7/ELRS/MS WAG- 7/11

EL/11/1.2.9 (A) 18.3.99

Provision of separate fuse for Static inverter control circuit.

202-204

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SPECIAL MAINTENANCE INSTRUCTION FOR AUXILIARY MOTORS,SEMICONDUCTOR DEVICES & BATTERY CHARGER

S. No. SMI NO. FILE NO. Dt. OF ISSUE

DESCRIPTION Page no.

1. RDSO/ELRS/SMI/35

EL/3.2.28/2/EC22.2.79

Re-forming of selenium stacks 168-172


EL/3.2.28/EC2 2.2.79

Testing of polarised selenium surge suppressor type C 125L of M/s Westinghouse used across rectifier diode on frequency regulators of AEI make

173-175


EL/2.2.28/EC2 2.2.79

Testing of NON POLARISED selenium surge suppressor type C-186 106C on frequency regulator M/s AEI used with motor-alternator set

176-178


EL/3.2.28/2EC2 2.2.79

Testing of three phase selenium rectifier(CREX) used on generator field excitation circuit of motor-alternator set

179-183


EL/2.5.27/EC2 6.12.79

DC Damping unit resistor failure 184-185


EL/3.2.2/S1/EC2Sept.1980

Silicon Diode testing 186-189

7.

RDSO/ELRS/ SMI/68

EL/3.2.2/S1/EC2 July 1980

Silicon rectifier maintenance diode forward voltage classification

190-191


EL/3.2.2/S1/EC2 July 1980

Silicon rectifier maintenance mounting of diode and heatsink

192-194


EL/3.2.2/S1/EC2 Aug.1980

Silicon rectifier maintenance care of diode and heatsink

195-196


EL/3.2.12/THY 12.12.83

Setting of simplified battery charger on ac electric locomotives for 110V dc battery (50 cell)

197


EL/3.2.12/1-THY 17.11.83

Setting of battery charger type BCF3,BCF6 and BCF7 of M/s Control & Drives Ltd.

198


EL/3.2.135/J12 25.11.91

Checking the capacitance of the 199


EL/3.2.135/J12 13.8.92

Failure of capacitor terminals in Failure of capacitor terminals in silicon rectifier cubicles on ac electrical locomotive.

200-201

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Research, Designs & Standards Organisation, Lucknow

MODIFICATION SHEET NO. WAG4/68 & WAM4/35

Title of modification :

Modification to the terminal stud of the Jyoti Arno convertor. Purpose of modification :

In the present design of the terminal arrangement current passes from the incoming lead of the stator winding to the out going lead through the solid portion of the stud, nut and partially threaded portion of the stud. Any mismatching or slackness between the stud and nut threads results in high contact resistance and in turn causes overheating of the terminal stud and damage to the threads.

To eliminate the existing problem, it is decided to modify the present arrangement as per drawings No. SK. EL. 2047 and 2048 enclosed. Work to be carried out :

The existing studs in service to be replaced by modified studs. Execution of the work and material schedule :

The modification should be carried out by the sheds POH shops on all the terminal box of Jyoti Arno convertor.

Issued vide RDSO letter No. EL/3.2.11/D5 dt. 6.6.74 and 12.6.74

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Government of India Ministry of Railways

Research Designs & Standards Organisation Manak Nagar , Lucknow - 226011

No. EL/3.2.70/D4 16 Jan 1978

Modification sheet No.RDSO/WAM4/61

1. Title of modification : Replacement of existing terminal blocks by epoxy moulded terminal blocks of improved design.

2. Application to class of rolling stock :

All electric rolling stock, modification may be carried out on types of motors where terminal block failures are experienced.

3. Object of modification :

It has been reported by Railways that some failures of auxiliary motors have occurred due to failure of terminal boards, caused by cracks in the plastic breakage of terminal studs, terminals getting loose and short circuits between the terminals. Investigations have shown that these failures are due to poor mechanical strength, inadequate clearance and shrinkage of plastic material. The modified terminal board described herein incorporates features meant to eliminate such problems.

4. Modification drawing No. :

RDSO Sketch No. SK EL 2754 & 2784.

5. Agency for modification :

i) All electric locomotives and EMU shade

ii) POH shops of the railways

iii) Chittaranjan Locomotive works for locos under production and future builds.

6. Material required and specification :

The material schedule and relevant specification have been given in RDSO SK. EL. 2754 & 2784.

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7. Material rendered surplus : The existing terminal boards of defective design should be scrapped.

8. Work to be carried out :

i) The existing terminal blocks should be replaced, if they are subject to type defects by blocks of improved design as per drawing SK. EL. 2754 and SK. EL. 2784.

ii) Mild steel plates of appropriate thickness and shape may be fitted, if necessary, to facilitate bolting of the new terminal blocks.

iii) After tightening the screw (Item 7 of SK. EL. 2754 & 2784) the hole should be half filled with cold setting epoxy - Dobefil 60 with hardener 750 of Dr. Beck & Co., Poona ) mixed in the ration 100:4.5 and cured at room temperature for 24 hours.

9. Distribution :

As per enclosed list.

Sd/-( Lallan Prasad ) for Director General/Elec.

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No. EL/3.2.92.3 Dated - 11-92

MODIFICATION SHEET NO.RDSO/WAM4/171 1.0 Title of modification :

Rewinding details of Siemens make of MCP type ILA6 186-6. 2.0 Application to class of electric locomotives. All electric locos which are fitted

with Elgi Compressor TRC 1000 M and driven by Siemens make of motor type ILA6 186-6.

3.0 Object of modification: 3.1 Railway have reported large number of failures of M/s Siemens make of motor

during service on account of stator winding burnt. Detailed investigations in to the failure revealed that these motors have failed on lower voltage i.e. below 320V due to higher current density adopted with the glass covered enamelled copper conductor used for stator winding.

3.2 In order to arrest the bruning of these motors in service a modified rewinding data

is being issued to follow by the shed and shop of the Railways. 3.3 It is proposed that rewinding details which is furnished in this modification sheet

should be incorporated on the motors having serial No. less than 170636(inclusive)

3.4 This modification have already been incorporated on the motors having serial No.

greater than 170636 by M/s Siemens. 3.5 Modified stator winding will be suitable from 290V-500V to take care of problem

of low voltage reported by Railways. 4.0 Material Required 4.1 Dual coat enamelled winding wire conforming to IS:4800 Pt. XIII. The dual coat

wire have first coat of Dr. Beck enamel MT533.39 and top coat with Allotherm 602 of Dr. Deck & Co.

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4.2 Till such time dual coat wire is procured by shed and Shop. Rewinding shall be done with enamelled winding wire confirming to IS:4800 Pt.IX having enamel MT533.39 of Dr. Beck & Co.

4.3 Other insulating material viz. for slot liner inter phase separator, coil separator &

wedges etc. shall be followed as advised in SMI No.98 except that VPI impregnation shall be done with solventless resin FT 1052 of Dr. Beck & Co.

4.4 No impregnation shall be done by Elmotherm F 40 or F 50 of Dr. Beck & Co. or

H-71. 4.5 Glass covered enamelled copper conductor shall not be used. 5.0 Details of Modification or Works to be carried out : 5.1 Remove the failed stator winding and follow the rewinding procedure as per SMI

No.RDSO/ELRS/SMI/98 issued vide RDSO letter No.EL/3.2.70 dated 15/16.10.92. Test on the rewound motor will be done as per SMI/98 also.

5.2 Following rewinding data shall be followed. 1. Type of winding - Single layer 2. Slot/pole/phase - 2+1 3. No. of coils - 27 4. Conductor per slot - 12 ( each conductor shall

have 5 wires in parallel of size 1.0 mm dia i.e. 5 x 1.0) 5. Wire size - 1.0 mm (bare ) 1.093 mm( insulated ie enamelled) 0.785 mm2 (Area of one wire ) 6. Class of insulation - F 7. Winding wire - i) Conforming to IS : 4800 Pt. IX ii) Conforming to IS : 4800 Pt.XIII 8. Copper Weight - 9.00 kg. approximately 9. Coil per phase in series - 3 10. Connection of phase - Star 11. Coil pitch - 9/9 12. Coil Span - 1-10/2-9; 11-18

13. Total resistance for - 1.0427 at 20 degree C 3 phase

18

6. Modification Drawing No. M/s Siemens Drawing No.TME 6.1-6313

7. Agency for modification :

All electric loco Sheds & Shops of the Indian railways 8. Periodicity of modification to be carried out whenever stator winding is burnt. 9. Distribution


Encl : As above ( P.K.Jain )

for Director General/Elect.

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No. EL/3.2.92/3 15th October, 1993

MODIFICATION SHEET NO. RDSO/WAM4/177 1.0 Title of the modification

Rewinding of MCP “Siemens Make” of 10.5 KW/14 HP, TEFC with dual coat wire or double glass covered copper enamelled conductor type ILA6 188-6YA90-Z.

2.0 Application to class of electric locomotives :

All electric locos which are fitted with Elgi compressor TRC 1000 M and driven by Siemens make of motor 10.5 KW/14 HP as indicated in para 1

3.0 Object of modification : 3.1 Siemens has supplied MCPs of following designs : i) ILA6 186-6-9.4KW, TEFC, 320-500V, DGCC, Machine Sl. No. less than

170637. ii) 1LA6 186-6-9.4kw, TEFC, 290-500V, DGCC, Machine Sl. No.170637

onwards. iii) 1LA6 188-6, 10.5kw, TEFC, 290-500V, dual coat machine sl. No.185640

to 185739 and 185273 to 185322 and all TEFC MCPs supplied subsequently.

iv) 1LA6-188-6, 10.5 kw TEFC, 290-500V, DGCC, Machine Sl. No.182380 to 182394

v) 1RAD 187-6, 10.5kw, SPDP, 290-500V, dual coat. 3.2 For the rewinding of the 9.4 kw, TEFC, MCPs of design i) and ii) mentioned in

para 3.1 above, in case of failure RDSO has already circulated the rewinding scheme with dual coat wire vide SMI 171 of Nov.’1992.

It is expected that railways would have adopted the same by now.

3.3 Further for rewinding of the 10.5 kw, TEFC, MCPs supplied by Siemens(Dual coat or DGCC), the rewinding scheme is enclosed for adoption. This should be incorporated on all 10.5 kw TEFC MCPs of designs (iii) and (iv) in para 3.1 above.

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3.4 Modified stator winding will be suitable from 290V-500V to take care of problem of low voltage reported by Railways.

4.0 Material Required : 4.1 Dual coat enamelled winding wire conforming to IS:4800 Pt. XIII. The dual coat

wire shall have first coat of Dr. Beck & Co. enamel MT 533.39 and top coat with allotherm 602 of Dr. Beck & Co. India procured from RDSO recommended sources contained in RDSO’s letter No.EL/2.2.8.4 dated 21/23.6.93 updated from time to time.

4.2 VPI impregnation shall be done with solventless resin FT 1052 or FT 2005 of Dr.

Beck & Co. only. 4.3 No. impregnation shall be done by Elmotherm F40 or F50 of Dr. Beck & Co. or

H-71. 5.0 Details of modification and works to be carried out. 5.1 Remove the failed stator winding and follow the rewinding procedure as per SMI

No.RDSO/ELRS/SMI/98 issued vide RDSO letter No.EL/3.2.70 dated 15/16.10.82. Test on the rewound motor will be done as per SMI/98.

5.2 Following rewinding data shall be followed : 1. Type of Motor - 10.4 kw/14 HP TEFC (DGCC or dual coat) type 1LA6-188-6 2. Type of winding - single layer concentric 3. Slot/pole/phase - 2+1 4. No. of coils - 27 5. Conductor per slot - 11 each conductor shall have 5 wires in parallel of size 1.06 mm dia i.e. 5 x 1.06) 6. Wire size - 1.06 mm (bare) 1.115 mm (insulated i.e. enamelled)

0.882 mm2 (cross sectional area of one bare wire)

7. Class of insulation - F 8. Winding wire - Conforming to IS : 4800 Pt. XIII 9. Copper Weight - 10.0 kg. approximately 10. Coil per phase in - 3

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series 11. Connection of phase - star 12. Coil pitch - 9/9 13. Coil Span - 1-10/2-9; 11-18 14. Total resistance - 0.9057 ohm at 20 °C for 3 phase

6. Modification Drawing No. : For all types of motor No. 1) Drawing No. SK. EL. - 4262 indicating developed winding diagram.

2) 4H-2618-7114-0224937 indicating coil dimensions. 7. Agency for implementation : All electric loco shades & shops and other rewinding agencies of Indian railways 8. Periodicity : During rewinding on need basis 9. Distribution : As per enclosed list.

(G.R.Agarwal) for Director General/Elec.

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No. EL/3.2.48 Dated 30-12-1994

MODIFICATION SHEET NO. RDSO/WAM4/183 1.0 Title of the modification :

Provision of Anti vibration pads for MVMT.


WAM4, WAG5. 3.0 Object of modification :

TO reduce the mechanical and hearing failures and to improve the reliability of MVMT.

4.0 Material Required :

Modified MVMT base, fitted with metallistic pads as per RDSO Drg. NO. SK. EL.-4314.

5.0 Details of modification :

(1) Remove the existing MVMT mounting top base. (2) Eit the modified mounting top base fitted with anti vibration metallistic

pads in place of existing base. (3) Mount the MVMT on modified base. Fix the motor with mounting. bolts.

6.0 Modification Drawing NO. : Drawing No. SK. EL.-4314

7.0 Agency of implementation : All electric loco sheds and shops.

8.0 Periodicity of Implementation : During IOH/any major modification to the loco.

9.0 Distribution : As per enclosed list.

DA : As above (R.K.Kulshrestha)


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No. EL/3.2.11 Dated - 29-12-94

MODIFICATION SHEET NO. RDSO/WAM4/184

1.0 Title of the modification

Tolerances between motor bars and slots to be adopted on M/s Jyoti make of Arno Convertor.


All electric locos which are fitted with Jyoti make of Arno Convertor.

3.0 Object of modification :

3.1 Railways have reported regarding the cracking of rotor bars of arno convertor. Detailed investigation into the failure and discussions with M/s Jyoti revealed that these defects are caused mainly by thermal stresses produced as a result of the expansion and contraction of the bars and end ring during starting, running and rest.

3.2 In order to arrest the cracking of rotor bars in service, it is emphasised the need for providing adequate but not excessively tight fits between the copper bar and the slots. In view of this a modification is being issued to follow carefully, the dimension and tolerances on the bars and on the slots of the rotor to be adopted.

4.0 Material Required : 4.1 Copper rotor bar as per IS: 1897 latest. 5.0 Details of modification or works to be carried out. 5.1 Examine the working drawing , dimension, tolerances relating to rotor bars and slots. 5.2 Railways are advised to follow the following dimensions as furnished by M/s. Jyoti :-

Dimension Nominal Minimum Maximum Slot width 7.11 7.085 7.135 Copper bar width 6.5 6.39 6.61 Tolerance between slots & bar - 0.475 0.745 Slot height 20.37 25.345 20.395 Copper bar height 20 (Not specified in IS:1897)

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5.3 Following tolerances should be adopted on the rotor bars :-

Bar width 6.5 + 0.11 mm

Bar height 20 + 0.0 mm - 0.1mm The above tolerances will ensure that the minimum clearance is 0.345 mm.

However, radial clearance has not been clearly defined in the drawings and in IS:1897 But M/s Jyoti has advised that this radial clearance will be about 0.4 mm.

5.4 In order to achieve the radial clearance of 0.4 mm the rotor bars must all be firmly bedded down in the core slots.

5.5 While repairing any rotor with cracked bars, it is desirable to replace all the bars and both the end rings i.e. old bars and rings should not be reused.

5.6 Rotor bars should be “Araldited” only in the middle third of the rotor slots leaving the end third portion free for expansion and contraction.

6 Modification Drawing. No. SK. EL.-4318

7 Agency for implementation :

All electric loco sheds and shops of Indian Railways.

8 Periodicity of modification :

To be carried out whenever rotor bar is required to be changed.

9 Bibliography :

Retest on “Reliability engineering study on electric locomotives" prepared by RITES in the month of July,1992 for Arno failure.

10 Distribution :

As per enclosed list. (R.K. Kulshrestha)

for Director General/Elec.

30


Research Designs & Standards Organisation Manak Nagar , Lucknow – 226011

No. EL/3.2.15 Dated : 15 Nov., 1996

MODIFICATION SHEET No.RDSO/WAM4/195

1. TITLE OF MODIFICATION :

Provision of Electro Magnetic Unloader Valve on Electric Locomotives. 2. APPLICATION TO CLASS OF LOCOMOTIVES :

All type of a. c. electric locomotives. 3. OBJECT OF MODIFICATION :

Railways have reported the burning of stator winding of MCP’s due to seizure. Details of investigation into the failure revealed that one of the reasons attributed is due to inability of motor to start against back pressure available in the delivery pipe of the compressor.

3.1 In order to start the motor against back pressure, starting torque of the motor was increased for starting of 2000 LPM compressor at 290 V. However, motor was not able to start even with a bleed hole of 0.4mm/1.0 mm in the delivery pipe.

3.2 In view of the above, an electromagnet unloader valve was provided having a port size of 7 mm in place of bleed hole on the delivery pipe of compressor. With the provision of the VEUL Electromagnetic unloader Motor was able to start within stipulated time and the delivery pipe pressure was dropped to ‘0’ kg./cm2 within 9 seconds.

3.3 An additional advantage of this circuit over the bleed hole is that this arrangement prevents continuous leakage of air through the pipe which was leading to drop in free air delivery from the compressor.

3.4 On the basis of test conducted as mentioned above, RDSO has finalised the circuit with the unloaders and advised CLW to provide on the locomotive for trial purpose. This arrangement has been provided by CLW on 25 locomotives.

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4.0 MATERIAL REQUIRED :

4.1 Three number of Electro valve(VEUL) for unloader of NC-7 type having 7 mm of port size.

4.2 A LT control Cable for increasing the length of cable number 100 to accommodate auxiliary interlock of C101, C102, C103 contractor and QTDX(Time delay relay).

4.3 One Time delay relay QTDX having a delay of 5 seconds OFF with N/O interlock.

5.0 DETAILS OF MODIFICATION OR WORKS TO BE CARRIED OUT :

5.1 Connect the N/C interlock of C101 and C102 and C103 contractor in series with the time delay relay (QTDX) between cable No.100 and B as shown in SK. EL. 4359.

5.2 Provide interlock of QTDX relay in the series of valves VEUL1 VEUL2 and VEUL3 where the valves are connected in parallel as shown in SK. EL. 4359.

5.3 Number of valves and interlocks shall depend upon the number of compressor on the locomotives i.e. two/three. The valves VEUL1, VEUL2, VEUL3 shall be located in between the compressor delivery and flexible delivery hose pipes.

6.0 DESCRIPTION OF THE CIRCUIT :

6.1 As soon as compressor stops by any reason due to opening of contactors C101, C102, C103, the auxiliary N/C interlock contacts of contactors C101, C102, C103 closes and QTDX relay energize and closes its N/O contact in the electrovalves circuit valves VEUL1, VEUL2 and VEUL3 gets energised and valve open to atmosphere. Air present in the delivery pipes goes to atmosphere and pressure in the pipes reaches at `O` kg./cm2 . The valves remain open till `5` seconds after the start of compressor. After 5 second from the start of the compressor, time delay relay gets denergised and the interlock of the QTDX relay opens out in VEUL circuit and valves port closes.

6.2 Circuit Shown in sketch No. RDSO SK. EL. 4359 have following special features.

i) Unloading facility to the compressor at the time of start.

ii) This arrangement can be introduced in the existing circuit.

iii) In this arrangement compressor can be started through BLCP or BLCPD as usual.

32

iv) Modified loco is suitable for multiple operation of electric locomotives which does not have the modification.

v) Unloader valves remains open even after 5 seconds from the start of compressor.

vi) With the provision of valve there is no leakage of air from the air pipe as in the case of bleed holes.

7.0 MODIFICATION DRAWING NO. : RDSO SK. EL. No.4359

8.0 AGENCY FOR IMPLEMENTATION :

All Electric Loco Sheds and Shops of Indian Railways.

9.0 PERIODICITY OF MODIFICATION :

To be carried out during AOH or any time whenever loco visits to Shed and is expected to be there for some time for repairs etc.

10. DISTRIBUTION :


Encl. Distribution list.

(R.K. Kulshrestha)

for Director General (Elec.)

34

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

RESEARCH DESIGNS & STANDARDS ORGANISATION Manak Nagar, Lucknow-11 NO. EL/3.2.15 Dated 4.6.1997

MODIFICATION SHEET NO.RDSO/WAM4/197

1.0 Foreword : This modification sheet supersedes the modification sheet No.RDSO/WAM4/190.

2.0 Title of Modification :

Provision of EMU type after-cooler on air brake locomotives. 3.0 Application to the class of modification :

WAG4A, WAG-5, WAG-7, WAP-1, WAP-3 and WAP-4 4.0 Object of modification :

This existing after-cooler provided in the compressor line is considered inadequate with the conversion of WAG4 Locomotives into dual brake system. Similarly, it is observed that the compressed air contains moisture on other air brake locomotives like WAG5, WAG7, WAP1, and WAP4 also. The moisture results in rusting of the pipe line and the valves. The rust particles also enter the valves and result in mal-operation of the valves.

Electric loco shed, Kanpur has replaced the existing after-cooler with

EMU type after-cooler, which is of higher capacity, on a few locomotives. The length of pipe for condensation is 2.5 mts. in existing after-coolers and 17 mts. in the ones used on EMUs.

These after-coolers have been mounted on the underframe in series with

the compressors and a drain in each has been provided for easy drainage of the condensate at regular intervals on line.

Kanpur loco shed have reported a considerable reduction of failures of

pneumatic valves and have also reported that a large quantity of water gets condensed.

EMU type after coolers may be fitted in WAP class of locomotives as per

CLW drawing No.03/1/34/50 Alt (1) and in WAG5 and WAG7 locomotives as per CLW drawing No.06/2/34/23.

35

5.0 Material Required : EMU after-cooler as per RDSO sketch 7.2.043 - 2 nos. per loco.

6.0 Details of modification for WAG5 and WAG7 locomotives : 6.1 Remove the existing after-coolers and its mounting brackets from its present

location. 6.2 4 mounting angles 75x75x10 thick are to be welded at the location as shown in

CLW drawing No.06/2/34/23. 6.3 Mount each EMU after-coolers with the help of 4 Nos. Bolts M-12x60 and nuts

(M-12) as per CLW drawing No.6/2/34/23. 6.4 Connect the pneumatic circuit as per RDSO Drg. No. SK. EL. 4406. 6.5 The drain cock on the after cooler may be brought out so that it can be operated

periodically by the running staff. 7.0 Details of modification for WAP class of locomotives : 7.1 Remove the existing after-cooler and its mounting brackets from its present

location. 7.2 Supporting brackets are to be welded as per CLW drawing No.03/1/34/50 Alt (1) 7.3 Mount both EMU after coolers with 4 nos. bolt and nuts as shown in CLW

drawing No.03/1/34/50 Alt(1). 7.4 Connect the Pneumatic circuit as per RDSO Drg. No. SK. EL.-4406. 7.5 The drain cock on the after-cooler may brought out so that it can be operated

periodically by the running staff. 8. Modification Drawing Nos. :

CLW drawing Nos 06/2/34/23, 03/1/34/50 Alt(1), RDSO Sketch 7.2.043 and RDSO drawing No. SK. EL.-4406. Copy of CLW drawings may be obtained from CLW.

9. Special Instructions :

Running staff may be advised to drain the water from the reservoir periodically.

36

10. Agency of Implementation :

All Electric Loco Sheds and shops. 11. Periodicity of implementation :

During IOH/POH or during any major repairs to locomotives. 12. Distribution :

As per mailing list enclosed.

Encl : As above (R.K.Kulshrestha)


39


Research Designs & Standards Organisation Manak Nagar , Lucknow – 226011

No. EL/3.2.70 Dated : May, 1997

MODIFICATION SHEET NO. RDSO/WAM4/189 (Amentment-1)

1. TITLE OF MODIFICATION : To provide capacitors across U, V, & W terminals of MCP and Arno convertors.

2. APPLICATION TO CLSS OF LOCOMOTIVES.

All A.C. electric locomotives provided with Arno and MCP’s both.

3. OBJECT OF MODIFIVCATION : Railways have reported the failure of stator winding of MCP and Arno convertors. Detailed investigation into the failure revealed that one of the cause may be due to the presence of switching `on` and `OFF` surges. In order to arrest the failure of Stator winding, this modification is being issued.

4. MATERIAL REQUIRED : 4.1 0.5 Microfarad, 1000V, AC capacitors - 3 nos. 4.2 Bakelite board and transparent plastic box of suitable size. 5. DETAILS OF MODIFICATION OR WORK TO BE CARRIED OUT. 5.1 Provide one number each of capacitor of 0.5 microfarad, 1000 V AC across U, V &

W terminals and earth of MCP and Arno convertors as shown in drawing SK. EL. 4346 Alt (1).

5.2 The capacitors should be fixed on a bakelite board and mounted in a transparent

plastic box and 4 terminals should be brought out for connections between U, V & W and earth.

5.3 Mount the plastic box containing the capacitors in the frame of motor compressor set

and at suitable place near Arno convertors. 5.4 Mounting bolt for fixing the box should be strong enough to resist vibration

encountered in service. 5.5 Mounting should not infringe with the parts available in surrounding, e.g., the motor

compressor set and Arno convertor.

40

6. MODIFICATION DRAWING No. SK. EL. -4345 Alt (1) 7. Agency for Implementation : All Electric Loco Sheds and Shops of Indian Railways. 8. Periodicity of Modification : To be carried out during AOH, IOH & POH. 9. BIBLIOGRAPHY :

“Report on a Reliability Engineering Study on Electric Locomotives” prepared by RITES on Arno and Auxiliary motors failure.

10. DISTRIBUTION : As per enclosed list

(R.K. Kulshrestha)

for Director General (Elec )

42



No. EL/3.2.70/J2 Dated : November, 1978.

SPECIAL MAINTENANCE INSTRUCTIONS No.RDSO/ELRS/SMI/3.

1. Title :

Procedure for rewinding auxiliary motors. 2. Application :

All auxiliary motors of electric rolling stock. 3. Object :

1. Failures of auxiliary motors in many cases are due to use of non standard materials during rewinding and incorrect procedure for rewinding the motors.

2. The special instructions which follow are to lay down a uniform standard

procedure, so that a minimum quality of rewinding is assured. 4. Reference :

Draft code of practice for Rewinding of Auxiliary Motors for electrical locomotives issued vide RDSO letter No.EL/3.2.70/J3 dated 27.4.77.

5. Details of Special instructions : 1. Discard the first layer of winding wire from the beginning of the reel, so that

scratches etc., if any on the wire may not come in the winding portion. 2. Form the coils using the specified wire size with the specified number of turns and

parallel paths, with the help of the correct former, taking care not to exert excessive tension. Lay the turns of the coils preferably in uniform layers to avoid excessive inter-turn voltage.

3. Clean the stator slots free of the old insulation and file lightly to remove any

sharp corners and burrs. Wipe off all foreign material. 4. Insert a “U” shaped slot liner, properly cuffed at the ends, with the overall length

extending approximately 10 mm beyond slots ends.

43

5. Insert the coil in the insulated slot carefully, turn by turn, ensuring adequate protection to the insulating enamel. Lay the coils preferably in uniform layers to minimise interturn voltage. Use a revolving stand for the stator to facilitate insertion of the coil in the vertical position.

6. Insert the coil separator (width about 1 to 1.5 mm more than the slot to give a

slight U shape). Complete the insertion of coils in all slots. Insert interphase separator in the overhang regions.

7. Consolidate the winding in slot and overhang portion using a light rubber faced

mallet. 8. Insert the wedge separator and place the wedge in the slot applying light mallet

blow from the end tightly, lubricate the wedge by applying varnish before driving into the slots.

9. Make the coil connections for each phase separately as per winding diagram after

verifying the continuity and correct sequence of the coils. Make the joints either by brazing, using Rupatam 14 Silver Alloy or by fusion welding. DO NOT USE tin or tin lead, solders for any connections in auxiliary machines.

10. Carry out a dielectric test between phases and phases to earth before making

phase connections at 2.0 KV for 15 seconds. 11. Make the star points inside, suitably insulate it and support the joint at the

overhang portion. Locate this on the overhang conveniently and use a marker for easy identification and access of the star point.

12. Make the phase and neutral connections by brazing or fusion welding, using

connecting leads of specified dimensions. Insulate the joints using glass sleeve and rigidly support them on the winding overhang portion using glass cord. The method to be used for connecting the lead wires from the coils of auxiliary motor are given in special maintenance Instruction No.RDSO/ELRS/SMI/5.

13. Tie glass cord tightly at intervals on the coil overhangs. Anchor the overhangs

with the stator frame with glass cord, wherever the arrangement exists. 14. After completion of winding conduct the following tests before impregnation :-

a. Continuity of winding and insulation resistance. b. Measurement of winding resistance (cold). c. Surge voltage test.

44

15. Follow the procedure for impregnation indicated in special maintenance instruction No. SMI /E-10/002

16. Assemble the motor and fit the terminal box and epoxy Moulded terminal blocks 17. After assembly conduct the following tests :-

- Continuity of winding and insulation resistance - Measurement of winding resistance - Surge Voltage tests. - No load run for one hour at 460 volts 50HZ and check the phase current to verify whether they agree closely with routine test values. - Dielectric test at 2.0 KV for one minute.

6. Periodicity of Implementation of the SMI`s : Whenever rewinding of auxiliary motor is done. 7. Agency for implementation : - Electric loco sheds. POH shops if rewinding is done.

- Rewinding shops of the Railway in case rewinding is done by outside agencies (suitable clauses to be incorporated in the specifications in the contracts).

8. Distribution : (Two copies each).

As per list attached.

(V. Venkateswaran)

for Director General (Elec)

Government of India

45

Ministry of Railways Research Designs & Standards Organisation

Manak Nagar , Lucknow - 226011 Ref : EL/3.2.70/D4 Dated : 2 Dec. 1997

SPECIAL MAINTENANCE INSTRUCTIONS NO.RDSO/ELRS/SMI/5 1. Title :

Procedure for connecting the lead wire from the winding wires of auxiliary motor. 2. Applications :

All auxiliary motors of electric rolling stock. 3. Object 3.1 Railways have reported failure of auxiliary motors due to breakage of connecting wire-connecting the end of winding wire to the terminal block. 3.2 It has also noticed that sometimes the winding wire of all the three phase windings are directly brought to the terminal block. This is not desirable. Quality of connecting lead wires also have been found to be sub-standard. 3.3 The special instructions which follow are for connecting lead and sleeve from the winding wire to the terminal block. 4. Reference :

Nil . 5. Details of special instructions :

5.1 The insulation of the phase winding wire should be properly cleaned for connection with a connecting lead wire. This should be joined either by fusion welding or brazed using copper-silver-phosphorous brazing alloy BACUP5 conforming to IS :2927. Tin or Tin lead soldering must not be employed for any connection in auxiliary motors.

5.2 Fibre glass sleeve impregnated with class F varnish (BS : 2848-1973, type 1/180 Tb) of suitable diameter and length shall be inserted over the brazed joints. It should be ensured that the sleeve not only covers the brazed portion but also cover well beyond the scratched insulated portions of the winding wire and the connecting lead wire.

5.3 The lead wire should not be excessively long.

5.4 The lead wire should be tied up so that it is not loose.

46

5.5 The connecting lead wire from the phase connection should be brought to the terminal block.

6. Material Required : (!) Connecting lead –

Varnished fibre glass flexible copper cable suitable for class F insulation of size given below should be used :

S.No Type of Motor Nominal Sectional area of copper

(mm2)

Stranding

Nominal wire dia (mm)

No. of wires

1 MVMT, MVRH 10 0.4 80 2 MVSR, MCP, MPV 6 0.3 84 3 MVSR, MCP, MPV,

MAR 4 0.3 56

*As per tech. specification for flexible cable No.Spec/R-13/03 Table 2 Page II issued by RDSO Dec. 1977. (ii) Sleeve Fibre glass sleeve impregnated with class F varnish (BS : 2848-1973-type 1/80 Tb) of sizes given below : S. For Flexible Sleeve Tolerance Sleeve wall No. cable of internal (mm) thickness (mm) copper area (mm2) dia (mm) Min. Max. 1 10 10 +0.25 0.9 1.15 2 6 8 +0.25 0.6 0.85 3 4 8 +0.2 0.6 0.85 iii) Copper-silver-phosphorous brazing alloy - BACUP5 conforming to IS : 2927 (Say Rupatam 14 of M/s Indian Oxygen Ltd., Calcutta) 7. Agency for implementation i) All Electric Locomotive and EMU sheds. ii) POH shops of the Railways iii) Rewinding shops of the Railways.


47


No.EL/2.2.48/J2 Dated :3 May 1978

SPECIAL MAINTENANCE INSTRUCTIONS NO.RDSO/EL-RS/SMI/16 1. Title :

Fits and limits on bearings of auxiliary motors used on electric locomotives. 2. Application to class of locomotives Auxiliary motors of all electric locomotives. 3. Object of special maintenance instructions : 3.1 It is necessary to ensure that the fits between bearing races and shafts/housings are

correctly made in order to prevent bearing failures. Excessive interference leads to reduced clearance and eventual failure of bearing. Inadequate clearances lead to revolution of races, overheating and again to bearing failures.

3.2 Loco Sheds and Car Sheds have sometimes experienced difficulties in the matter of

deciding the tolerances on dimensions of bearings, shafts housings, etc. This document gives the required limits.

4. Instructions 4.1 The limits for rotor shaft and bearing housing diameters should be adopted as per

Tables below. For ready reference the limits for the bores of inner races and outer dias of outer races are also given in the following Tables. These should be checked during inspection of bearings.

(A) TOLERANCES ON SHAFTS & BEARINGS INNER RACES

1 Micron = 0.001 mm

48

————————————————————————————————— S. Nominal Shaft Inner race No. shaft dia tolerance bore tolerances h B range mm K5 microns Microns ————————————————————————————————— 1. 10 to 18 + 9 -8 + 1 0 2 18 to 30 + 11 -10 + 2 0 3. 30 to 50 + 13 -12 + 2 0 4 50 to 80 + 15 -15 + 2 0 5. 80 to 120 + 18 -20 + 3 0 ———————————————————————————————— (B) TOLERANCES ON HOUSING BORES & BEARINGS OUTER RACES ————————————————————————————————— S. Nominal Housing dia. Outer race No. Housing dia tolerance tolerances h B range mm J6 Microns Microns. ————————————————————————————————— 1. 18 to 30 - 5 0 + 8 - 9 2 30 to 50 - 6 0 + 10 - 11 3. 50 to 80 - 6 0 + 13 - 13 4 80 to 120 - 6 0 + 16 - 15 5. 120 to 150 - 7 0 + 18 - 18 6 150 to 180 - 7 0 + 18 - 25 7. 180 to 200 - 7 0 + 22 - 30 ————————————————————————————————— 4.2 The limits for bearing clearances for new bearings are given below. These should

also be checked during inspection of bearings. RADIAL INTERNAL CLEARANCE OF DEEP GROVE BALL BEARINGS

1 Micron = 0.001 mm.

49

—————————————————————————————————- S. Nominal C3 type clearance No. bore dia (Greater than normal) range (d) mm Minimum. microns Maximum. microns. —————————————————————————————————- 1. 10 to 18 11 25 2. 18 to 24 13 28 3. 24 to 30 13 28 4. 30 to 40 15 33 5 40 to 50 18 36 6. 50 to 65 23 43 7 65 to 80 25 51 8. 80 to 100 30 58 ————————————————————————————————— 4.3 References

i) SKF General Catalogue No.3000 E/GB 666, Nov 1975 for K5 see page 87 for J6 see page 91 for C3 see page 66 clearance for deep groove ball bearings.

ii) Guide for selection of fits - Indian standards Institution specification No. IS :

2709 – 1964.

5. Agency for implementation

a) All Electric Locomotive Sheds b) POH shops of the Railways c) Rewinding shops of the Railways.

6. Distribution Secretary (Electric Traction), Railway Board, New Delhi-110001 Chief Electrical Engineer, Central Rly, Bombay VT-400 001 Chief Electrical Engineer, Eastern Rly., Calcutta-700 001 Chief Electrical Engineer, Northern Rly, New Delhi-110 001 Chief Electrical Engineer, Southern Rly, Madras -760 003


Research Designs & Standards Organisation

50

Manak Nagar , Lucknow - 226011 No.EL/2.2.48/J2 7.5.1978

SPECIAL MAINTENANCE INSTRUCTIONS No. RDSO/EL-RS/SMI/23

1. Title : Procedure for measuring the bearings clearance of a “free bearing”, that is a bearing off the machine.

2. Application :

All auxiliary motors of electric rolling stock. 3. Object :

Railways have reported abnormal sound, overheating and failures of bearings on auxiliary motors. Some of these defects and failures are due to incorrect bearing clearance. The special instructions which follow are for measuring the bearing diametral clearances of “free bearing”.

4. Reference :

1. AEI Maintenance Manual on Ball and Roller Bearing - pages 27 & 28.

2. BS : 817 - 1957 and IS : 2092 - 1962 5. Details of special instructions

5.1 Take a standard type of small cast iron surface plate of 8" x 5" size as per BS : 817-1957, Table I, which can be easily bench mounted.

5.2 Clamp the inner race between the surface plate and a top plate by means of a central bolt. The outer race is not clamped but rests lightly on the surface plate so that it is free to move but is, at the same time, held parallel to the inner race. The thumb screw shown at the front is a pinch screw which permits the vertical spindle, on which the dial gauge is mounted, to be adjusted for height (Fig. 1 of SK. EL.-2874).

5.3 Clamp bearing is in such a position that approximately a mid scale reading is obtained on the dial gauge. Adjust the height of dial gauge so that it operates in a plane nearly through the centre of the bearing.

5.4 Apply light hand pressure just sufficient to ensure that all clearance is taken up, pushing the bearing first away from the dial gauge and then towards the dial gauge. Record the difference between the two dial gauge readings. This is the total clearance or in precise terms “the free diametral clearance” (Fig.2 of SK. EL.-2874). The recommended clearance for various auxiliary machines in use is given in Special Maintenance Instructions No.RDSO/ELRS/SMI/16 dated 3.5.78.

51

5.5 In the sketch the weight of the bearing is sufficient to keep the outer race in contact with the surface plate. With a lighter bearing when taking measurements, it is necessary to apply a light pressure downward to ensure that errors are not introduced by canting the outer race.

5.6 For small bearings the horizontal pressure should not be maximum possible with the thumbs because such pressure can exceed the normal loading of the bearing and will produce false readings by introducing deflections of the balls or rollers and the races.

6.0 Material and equipment required

6.1 Small cast iron surface plate, dial gauge as per IS:2092-1962 for measuring clearance the least count of which shall be 1 Micron (0.001 mm).

7. Periodicity of implementation

1 During every overhaul of the auxiliary motor 2. On new bearing for acceptance tests.


1 All Electric Locomotive/EMU Sheds 2. POH shops 3 Rewinding shops of Railways

9. Distribution : (2 copies each)


(V. Venkateswaran)

for Director General/Elec.

53



No. EL/3.2.70/J2 Dated : 21 November, 1978

SPECIAL MAINTENANCE INSTRUCTIONS No.RDSO/EL-RS/SMI/32. 1. Title :

Procedure for fixing the socket with the lead wires of auxiliary motor stator windings. 2. Application :

On auxiliary motors of electric rolling stock. 3. Object :

Railways have reported some cases of failures of auxiliary motors due to use of improper cable sockets for crimping, such as breakage of lead wire at the socket opening end. This SMI outlines the correct practice for fixing the sockets on the outgoing leads.

4. References : 1. Annexure I of draft code of practice for rewinding of auxiliary motors for

electric locomotives, (RDSO’s letter No.D.O.EL/3.2.70/J3 dt. 27.4.77).

2. Special maintenance instructions No.RDSO/EL-RS/SMI/5 for procedure for connecting the lead wire from the winding wires of auxiliary motor (RDSO’s letter No.EL/3.2.70/D4 dt.21.12.77).

3. Dowell’s catalogue No. Solderless/73.

4. Drawing - As per RDSO SK. EL. No.3001 (Attached)

5. Details of special Instructions : 1. Strip the insulation, including enamelling of the strand off the lead wire

ends taking precaution not to severe or damage any strands. Leave the ends of the insulation clean and square. If the lay of strands is displaced while removing the insulation, compose them by a light twirl. The lead wires should be as clean as possible before inserting into the terminal lugs or ferrule.

2. Check the socket for correct as well as quality. Examine on cracks.

54

3. In case the stranded wire is a loose fit in the ferrule or sockets, fill up the

space by using small bits of strands carefully. 4. Crimp terminal socket to the lead using a suitable die and crimping tool

ensuring that the cable insulation as well as the conductor have been secured. (See technical circular No.4 of RDSO issued under D.O.No.EL/DSE/2 dt.20.10.78). Slip on the hot shrinking PVC sleeve over the joint and shrink it by application of heat uniformly with a blow lamp. Subject the cable sockets joints to a load test at 25% of yield point of corresponding cable size viz. @10.0 kg/mm2, for proving the joint.

5. Periodically, say once in every 30 or 40 joints, check the efficient

functioning of the crimping tool. Check the efficient functioning of the crimping tool. Check the process also by cutting across a completed joint to see if there is poor flow or air pockets or fracture of strands during crimping.

6. Material and equipment required 1. Terminal lugs – Dowell crimping copper terminals as shown in RDSO SK. EL.

3001 - For 10 mm2 cable – Tubular terminal type III Dowell’s Cat. No. CUS/68

with E=8.2mm as shown in Fig. 1 - For 6 mm2 and 4 mm2 cable – Dowell’s copper terminals type PII 7113A6

with crimping tool of KOP PSD-12-10K type as shown in Fig.2

7. Agency for implementation :

- All Electric locomotive/EMU sheds & POH shops during repairs and annual over hauls of the motors.

- Rewinding shops (for outside agencies undertaking windings, this should be stipulated in the contract specifications)

8. Distribution : ( 2 copies each)

As per list attached (V. Venkateswaran) For Director General (Elect.)

55



No. DSE/2 Sheet 1 of 2.

Dated : 20th October, 1978.

Technical Training Circular No. 4

Breakage of Stranded Wires There are literally thousands of electrical connections in each Electric

Locomotive or Electric Multiple Unit stock. Stranded wires are used for control circuits. A very common type of failure is caused by breakage of strands in service. Such failures are often 'written off' under the heading 'material failure'. Such failures are avoidable. It is necessary to understand clearly the mechanism of failure if the correct remedial steps are to be taken.

A common misconception is that stranded wires can withstand vibration. This is

not correct. Stranded wires are flexible. The force required to bend them is less; but for any given applied force, the maximum stress produced in a stranded wire is actually more than that in a solid conductor of the same total cross section.

56

In the two sketches A, B shown above, the defect in B is obvious. What is perhaps not equally obvious is that such a defect is fatal as far as the copper wire is concerned if there is any vibration of the wire. Due to the higher stiffness of the insulated portion, the effect of vibration is concentrated in the mechanically weaker uninsulated portion 'C'. The alternating stresses produced in the copper by vibration exceed the endurance limit and failure is inevitable, sooner or later. It may be recalled that the endurance limit for annealed copper is only 6 kg/mm2. Actual stresses can often be much higher the average stresses due to the effects of stresses concentration at nicks or scratches.

The only way to prevent such failure is : -

a) to ensure that the cable insulation is well gripped by the socket.

b) to tie up the cable to an insulated rod fixed near the socket to prevent flexing of the wire.

c) to ensure that there is no relative vibration between the socket and the insulated support rod.

58



No. PI/8.11.12/DB3 Dated : July, 1979

SPECIAL MAINTENANCE INSTRUCTIONS No RDSO/EL-RS/SMI/58 ON CONDITION MONITORING OF BEARINGS

1. Object :

Railways have reported failure of bearings due to lack of lubrication, contaminated lubricant, mismatching, misalignment and damaged race ways etc. on auxiliary motors/traction motors. M/s SKF, in collaboration with M/s S.P.M have developed a method of diagnosing faults in bearings in situ, using the high frequency shock impulse transmitted by the rolling elements and have developed an effective instrument for the purpose. This special maintenance instruction contains norms for on condition monitoring maintenance instructions of the shock pulse meter by taking corrective action in case of inadequacy of lubrication, misalignment etc. and timely replacements in case of more severe damage.

2. Instructions :

2.1 Set the SPM before measurement. Turn the calculator dial in relation to the thumb wheel until shaft diameter (d) and speed (n) of the bearing under test align.

2.2 Place the tester probe as close as possible to the load zone of the bearing.

2.3 Turn the thumb wheel clockwise until sound pulses are heard, then turn the thumb wheel in increments counter clockwise until the pulses occur with random intervals with an average of 10 seconds.

2.4 Read the value on the dBN dial and determine the bearing condition as follows :-

dBN 20 - Green sector - Good condition

20 dBN - 35 - Yellow sector - Caution, the bearing is likely to fail.

35 dBN - Red Sector - Damage.

2.5 In order to fix up actual norms for accepting/rejecting the bearings, test trials were carried out on few auxiliary motors/traction motors in association with CNB and BSL sheds and on the basis of these trials the following norms are recommended :-

59

Limits of normalised decibal value (dBN) for auxiliary motor/traction motors or New bearings

(i) All bearings revolving between 0 & 1000 rpm. to be accepted at values 10 dBN and below.

(ii) All bearings revolving between 1000-3000 rpm. to be accepted at values 10-20 dBN.

When to reject :

(i) All bearing revolving between 0-1000 rpm. to be rejected at values 45 dBN and above.

(ii) All bearing revolving between 1000-3000 rpm. to be rejected at values 35 dBN and above.

2.6 For the nature of defects in rejected bearings, consult the evaluation flow chart given in SPM catalogue.

2.7 Any deviation from the above mentioned norms may be advised to RDSO for reconsideration since these values are based on a limited number of trials.

3. Instruction Drawing :

Nil .

4. Application :

Auxiliary motors and traction motors of Electric Rolling stock


(i) All electric locomotive/EMU sheds

(ii) POH shops

(iii) Rewinding shops of Railways.

6. Reference :

Specification for shock pulse tester issued vide this office letter No. PI/8.11.12/DB3 dated 6.3.79 and 13.6.79.

7. Periodicity of implementation :

60

(i) On new bearings for accepting tests.

(ii) During every overhaul of the auxiliary motor/traction motor.

(iii) During IC inspection on auxiliary motor

(iv) Abnormal noise/behaviour of bearing reported by Driver.

8. Precautions :

8.1 Check the battery voltage (12V) before measuring. Do not leave the SPM with batteries for long time.

8.2 The measuring point should be located as close as possible to the load zone of bearing.

8.3 Maintain records.

9. Distribution : (2 copies each)


Sd/- ( R. S. Grover ) for Director General (Elec.)

61


Research, Designs & Standards Organisation Manak Nagar, Lucknow - 226 011

No.EL/2.2.48 Dated 2.5.1981

SPECIAL MAINTENANCE INSTRUCTIONS No. RDSO/EL-RS/SMI/78

Fitment of outer race bearing in the bearing housing 1. OBJECT: 1.1 Railways have reported cases of bearing outer races revolving in their housings.

Investigations have revealed that this defect is due to inadequate fits caused by in correct machining of the bearing housing bores.

1.2 This SMI suggests a method for reclamation of such bearing housings. It may also be

adopted in case of doubt i.e: accuracy of machining of the housing bores. 2. METHOD FOR RECLAMATION: 2.1 Clean the inner surface of the housing and ensure that it is free of oil and grease by

use of “Locquic Primer T”. 2.2 Clean the bearing thoroughly with kerosene and wipe out all traces of kerosene with

fine cloth. Remove all traces of oil and grease on the outer surface of the bearing outer race by application of “Locquic Primer T .”

2.3 Apply a thin film of Bearing Mount (Loc/147) Product No. 601 evenly over the

bearing outside surface and on the end shield bores. 2.4 Mount the bearing in the housing of the end shield and press it firmly into position. 2.5 Do not apply any grease to the bearing for four hours after applying Loctite to ensure

that the Loctite resin is fully hardened. 2.6 Source of Procurement: Name of products:

i) Loctite bearing mount LOC/147 Product No. 601 or M/s. Loctite Corporation. ii) “LOCQUIC PRIMER T “ Supplier : M/s. AET CORP Pvt. Ltd., 10, Lall Bazaar Street, Calcutta-700 001.

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3. APPLICATION: All auxiliary motors of Electric Rolling Stock. 4. AGENCY FOR IMPLEMENTATION: 4.1 Electric Loco Sheds, EMU Sheds and POH Shops. 4.2 Rewinding Shops of Railways in case rewinding is done by outside agencies (

suitable caluses to be incorporated in the specifications for the Contract). 5. PERIODICITY OF IMPLEMENTATION OF THE SMI: 5.1 Whenever rewinding of auxiliary machines is done. 5.2 During annual overhaul of auxiliary machines. 5.3 During special repairs from the auxiliary machines. 6. DISTRIBUTION: As per list attached. Sd. xx xx xx xx ( Kewal Kumar ) for director General / Elec.


63

Research, Designs & Standards Organisation Manak Nagar, Lucknow - 226 011

Electrical Date - 11.6.81 EL/2.2.84

SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/EL-RS/SMI/79

Testing / Checking of New bearings

for Auxiliary motors 1. OBJECT 1.1 Defective bearings are one of the major contributory causes of auxiliary machine failures.

Investigation of a number of such cases has shown that the quality of the bearings procured was not satisfactory and there were indication that re-conditioned or second hand bearings were being received from the suppliers.

1.2 This SMI suggests methods for minimising such failures. 2. DETAILS OF SPECIAL INSTRUCTIONS 2.1 It is not possible to detect fatigued bearings by any inspection procedures. The only way to

ensure that the bearings purchased are new and in good condition is to buy them from the original manufacturers or their authorised dealers.

2.2 Even when bearings are purchased from original manufacturers or their authorised dealers, it

is desirable to make the following checks and tests. 3. CHECKS AND TESTS ON BEARINGS 3.1 Check the appearance of the surfaces. Original and new bearings have a typical ground

finish. Reconditioned bearings are likely to have an unusual and highly polished surface produced by polishing or buffing. This by itself is not a ground for rejection but it is an indication that bearings may be reconditioned. The other points mentioned below need to be checked carefully.

3.2 Check the boundary dimensions viz. Bore of inner race, outer dia of outer race and widths of

both races. Reject the bearings if any dimensions are outside the limits specified in the Maker’s Catalogue. As the tolerances are very small, accurate measuring instruments correct to few microns have to be used for these measurements.

3.3 Check the condition of surfaces or rollers and active Surfaces of inner and outer races. If

there are visible rust marks, pitting, etc., reject the bearing. 3.4 Check bearing clearances with a dial gauge as shown in SMI No. RDSO/EL-

RS/SMI/25 dt. 7.6.1978. If the clearance is more than the limits indicated in the Maker’s catalogue, reject the bearing.

3.5 During overhaul if the motor is otherwise in good working order, carry out Shock

Pulse Meter Test ( SMI No. RDSO/EL-RS/SME/58 issued vide RDSO letter No. 8.11.12/DB3 dt 20.7.79) before dismantling the motor so that the defective bearings

64

can be replaced during overhaul. 3.6 For acceptance tests on bearings, a motor driven mandril running on Sleeve bearing

should be set up. The mandril should run at about 2900 RPM. The mandril should be provided with a spigot which has a push fit on the bore of the inner race. The bearing to be tested is pushed on to this mandril and run at full/speed. The outer race can be held by hand while the probe of the SPM meter is placed on the outer race. If the measurement of the SPM Meter is excessive, the bearing should be rejected.

4.0 APPLICATION

All auxiliary motors of Electric Rolling Stock. 5.0 AGENCY FOR IMPLEMENTATION Electric loco sheds, and EMU sheds, POH shops. Rewinding shops of the Railways in case if bearing is changed in the shop. 6.0 PERIODICITY OF IMPLEMENTATION OF THE SMI Whenever old bearing is replaced by new bearing on auxiliary motors. 7.0 DISTRIBUTION As per list attached.

( Kewal Kumar ) for director General / Elec.

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No. EL/3.2.70/JTMU dt. 15.10.82 SPECIAL MAINTENANCE INSTRUCITONS NO. RDSO/EL-RS/SMI/86** 1. Titles : Procedure for impregnation of induction motors. 2. Application : Auxiliary motors of all Electric locomotives and Electric Multiple Units. 3. Object : 3.1 Railways have reported auxiliary motor failure due to various reasons. One of

the most important and common cause is the failure of inter-trun insulation of the enamelled wire windings.

3.2 Investigations have shown that these failures can be minimised following proper varnish selection/application, thereby making the winding more rigid and preventing vibration/relative motion between wires.

4. Reference Drawing : No. SK. EL. No. 3455 5. Details of Special Instructions : 5.1 Impregnation tank as per enclosed schematic shall be used for auxiliary motor

impregnation. Till this facility is developed the impregnation in ordinary tank may be resorted to following general guide lines.

5.2 Impregnation procedure : .1 Pre-heat the stator in the oven for two to three hours at 1200C and cool

the same in the oven or outside to 600C before carrying out dip impregnation.

.2 Place the motor stator to be impregnated, vertically after it has been cooled to 600C in the tank. Regulate varnish rise rate and ensure that varnish rises upto motor level, from the motor base, in 1 hr. This shall be achieved as per procedure indicated in the drg.

.3 Allow the motor to get soaked in varnish for minimum period of 1 hour.

.4 Drain the varnish from the tank at speed regulated as per procedure shown in Drg. , in 1 hr. from motor top to bottom surface.

.5 Allow the impregnated unit to drip for 10 minutes. Mark the direction in which the motor has been kept during driping.

** This supersedes SMI No. SMI/E-10/002.

Comment:

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.6 Reverse the stator direction and allow it to drip for 10 minutes.

.7 Motor is now ready for baking. The procedure of baking shall be as per foregoing para.

6. Remarks : As per revised insulation scheme of the auxiliary machines Dr. Beck's Elmotherm F-40 varnish has been recommended. The detailed special instructions indicated below pertains to use of only Elmotherm F-40 as impregnating varnish.

6.1 Keep the oven at an initial temperature of about 900C and place the job inside the oven.

6.2 Maintain oven temperature of about 900C for 6 hours (this is to provide the solvent ample opportunity, to voltalize without fear to premature film formation which, if formed would prevent further escape of solvent from the deeper windings.

Note : The temperature specified do not refer to the temperature of the air in the oven, but are intended to apply to the interior of the slots and to those parts of the windings which are most unfavorably situated.

6.3 Rise over temperature to 1600C in approximately two hours. Ensure that minimum value of temperature reaches all parts of the windings. This will ensure thorough cure of the impregnated windings.

6.4 Maintain oven temperature 1600C, 1 to 2 hours. 6.5 Remove the motor from the oven and allow it to cool up to 600C, impregnate the

motor in the varnish as mentioned 5 (.4 to .7) and cure as per para 6.2 to 6.4. However at this stage baking at 1600C shall be done for 16 hours.

6.6 Epoxy GEL Coat : Allow the motor to cool to ambient temperature. Apply Epoxy GEL coat two

cycles on in the stator overhang portion as per procedure enclosed in Annexure - I.

7. Periodicity of implementation : 7.1 As soon as possible on all motors after rewinding. 7.2 On the auxiliary machines in service after 2 years of service 20000 hours the

motor, re-impregnate as per procedure described earlier.

8. Precautions : 8.1 In view of the aggressive solvent vapor of F-40, no other components treated with

other varnishes should be heated in the oven. 8.2 As a precaution the check tank varnish periodically for sludge formation /

contamination and if necessary take steps for filtration through phosphor Bronze wire mesh (150 mesh size)/muslin cloth.

8.3 Check the tank varnish periodically (once in 6 months) for viscosity, solid contents etc.

9. Distribution :

As per list attached. (Kewal Kumar)

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for Director General ANNEXURE - I

EPOXY RED GEL COAT FINAL FINISHING PAINT FOR CLASS 'F'

1. This procedure is recommended for adoption on the auxiliary machine stator overhangs to obtain glossy finish, with high track resistance and moisture proofing.

2. Material : i) Epoxy Red GEL Coat - 100 parts by weight ii) Diluent Debecket 'C: - 10 parts by weight iii) Hardner EH 411 - 40 parts by weight iv) Thinner E for above Resin - 25-30 parts by weight

The proportion of Thinner E needs to be adjusted depending upon the ambient temperature and mix viscosity desired.

(ALL THE ABOVE MATERIALS ARE TO BE PROCURED FROM DR. BECK & CO. LTD. INDIA)

3. Preparation of the Resin

3.1 The resin and the diluent should be first thoroughly mixed in the proportion given above. The hardner shall then be added and mixed thoroughly. In order to bring down the viscosity of the resin mix suitable for brush/spray coating the thinner specified above or MEK solvent could be added to a maximum of 15 parts by weight.

3.2 The pot life of the above mix is about 45 minutes after addition of the hardner. Therefore, while preparing the mixture resin should be mixed in a small quantity of maximum of 2 kg. mix at a time.

4. Application :

4.1 Apply the above mix to the auxiliary machine stator overhangs with a brush/spray gun ensure that this penetrates the voids, to maximum extent, in the stator overhang.

4.2 Allow the stator overhang to dry in open atmosphere for 16 hrs. 4.3 Bake the overhang in the overn for 4 hrs. at 800C 4.4 For second coat, repeat steps as per para 4.1 to 4.3 above.

5. Precautions :

i) After application of each mix, the spray gun should be throughly cleaned.

ii) Epoxy barrier cream (i.e. Kerodox) should be used to prevent skin irritation, if any.

iii) Suitable breathing mask should be used during continuous working.

70



No. EL/3.2.48/JTMU Dated 23.05.1982


PULLER FOR EXTRACTING TRACTION MOTOR COOLING BLOWER

1. Object :

A number of reports have been received from the Railways indicating unsatisfactory performance of the traction motor cooling blowers. Besides other problems, one of the major causes of damage to the blower blades is the unsatisfactory method being adopted for extraction of blower from the motor shaft.

In the existing dismantling process sheds use hand operated extractor. This extractor induces considerable amount of rotational forces and to overcome this iron/wooden bar is used to stop the rotation of blower by inserting it in between the impeller blades. This results in premature failures of blades on account of their overstressing.

This SMI indicates the method of extracting traction motor cooling blowers with hydraulic process which avoids damage to the blades.

2. Instructions :

The following procedure shall be adopted for extracting the blowers :-

i) Fit the extractor plate on the blower as shown in the drawing.

ii) By holding 10 ton capacity hydraulic puller as shown in the diagram. Tighten splindle with hand till it is tight fit in the assembly.

iii) Apply hydraulic pressure by hydraulic pump lever.

This will result in extraction of the blower from the shaft. The process may be continued till blower fully disengages from the motor shaft.

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NOTE : As no rotational forces are involved, it is not necessary to provide any iron bar to prevent rotation of the blower. The hydraulic puller for this application may be procured from M/s VANKOS AND CO. Their complete address is as under :

“VANKOS & COMPANY 13/2 Industrial Estate PATNA - 800 013”

3. Periodicity :

Whenever the blowers are required to be dismantled.


RDSO SK. EL. 3484

5. Application of class of locomotive :

Electric locomotives

6. Agency of implementation :

All electric loco sheds and POH shops of Railways

7. Distribution :

As per list enclosed.

Encl : SK. EL. 3484 & Mailing list.

(Kewal Kumar) for Director General (Elect.)

73



NO. EL/3.2.70 Dated : 30.10.1992


1. TITLE :

Use of button head type of grease nipple on Auxiliary motors fitted on Electric Loco.

2. APPLICATION TO CLASS OF LOCOMOTIVE :

All ac Electric locomotives fitted with 3 phase Induction Motors.

3. OBJECT OF SMI :

Railway have reported use of various types of grease nipples provided by the different manufacturers on their motors resulting in to difficulty in replenishment of grease into the motor bearing by a particular type of grease gun. In view of this RDSO has decided to use only standard type and size of grease nipple as per IS:4009 Part I of 1981.

4. INSTRUCTION DRAWING :

RDSO Drawing No. SK. EL. 4103

5. INSTRUCTIONS :

1. All grease nipple should be replaced by M10x1 size button head type of grease nipple made of brass as per IS:4009 Pt. I - 1981.

2. The grease nipple should be free from burrs cracks and manufacturing defects. Its finish should be smooth.

3. Brass nipple shall be nickle plated.

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6. PERIODICITY OF IMPLEMENTATION :

During AOH

7. AGENCY OF IMPLEMENTATION :

All Electric Loco sheds and shops.

8. REFERENCE :

Reliability to improve performance of auxiliary motor in service circulated vide RDSO letter No. EL/1.2.14/1 dated 12.6.1991.

9. DISTRIBUTION :


(P.K. Jain)

for Director General /Elect.

76



NO. EL/2.2.48 Dated : 21.10.1992 SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/EL-RS/SMI/148

1. TITLE :

Guidelines to identify genuine and spurious/reconditioned bearing.

2. APPLICATION :

Bearings fitted on Auxiliary motors including ARNO for Electric locomotives.

3. OBJECT :

3.1 One of the major problems faced by the Indian Railways is how to detect a spurious/reconditioned bearings. This malpractice of supplying spurious/reconditioned bearings is generally confined to those sizes which are specially in short supply.

3.2 This SMI indicated the method of distinguishing between genuine and spurious/reconditioned bearing.

3.2.1 SPURIOUS BEARINGS :

Spurious bearings are those which are not manufactured by the manufacturer whose trade mark/name appears on the bearings/bearing packages.

3.2.2 RECONDITIONED BEARINGS :

Reconditioned bearings are those which have been serviced or have been damaged during storage/transportation and have been reconditioned to look like new bearings and supplied as new bearings to the users. This category would also include those bearings on which modifications have been carried out by the suppliers without the permission of the manufacturers.

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4. INSTRUCTION DRAWINGS :

Nil

5. INSTRUCTIONS :

With experience it is generally possible to distinguish spurious/reconditioned bearing in majority of the cases from genuine bearings by visual inspection. Some of the instructions to follow are as under :--

5.1 Compare the packaging , marking on packages and the marking on the bearings with the one supplied by original manufacturers.

5.2 Compare the rust preventive coating on the bearings with the bearings supplied by the original manufacturer.

5.3 Any axial marks on the bore diameter or the OD of the bearing would envisage that the bearing has been mounted on the shaft or in the housing.

5.4 Compare the grain flow of the bearing surfaces with the original bearing.

5.5 Any bearing which has been service would acquire a slightly dull finish on the receways.

5.6 Look for polishing marks which would be normally uneven caused by fine emery paper to remove rust spots. If the trade marks have been changed on the bearing side face, these polishing marks would be prominent near the surface where the trade mark is stamped/etched.

5.7 In some cases of spurious bearings the restamping is done after heating the rings. The blue black discolouration can be observed near the stamping/etching.

5.8 Measure the radial internal clearance of the bearings and compare it with the catalogue values given for new bearings.

5.9 Any bearings having rust spots/nick marks on the critical surfaces like raceways or rolling elements should not be accepted for use.

5.10 The change of trade mark on the bearing would involve removal of material from the bearing side faces at those positions. This would alter the tolerances on the width of these bearings and this measurement would help in distinguishing spurious bearings with the original bearings by comparing them to catalogue tolerances. These tolerances are also standardised by ISO as well as ISI.

5.11 It is not advisable to make any indentations on the side faces of the ring since these points would lead to development of areas of stress concentration.

5.12 In general the best course of action would be to procure bearings from the original manufacturers.

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6. PERIODICITY OF CHECKING :

Whenever new bearings are purchased.

7. AGENCY FOR IMPLEMENTATION :

All electric loco sheds and POH shops/TM shops including Production Units eg. CLW.

8. REFERENCE :

Item 1 of XLX MSG (EL)

9. DISTRIBUTION :


(P.K. Jain)


79



No. EL/3.2.70 Dated : -10- 1992

SPECIAL MAINTENANCE INSTRUCTION NO. RDSO/EL-RS/SMI/149

1. TITLE :

SPECIAL INSTRUCTION FOR SURGE TEST ON 3 PHASE AUXILIARIES.

2. Application :

All electric locomotives fitted with 3 phase Induction motor.

3. Object :

3.1 A large number of auxiliary motor failures have been reported by Railways on account of inter turn shorts and earth fault. After detailed investigation into the failure pattern it has been decided by RDSO to introduce special test on this motor before put into service. The test which shall be conducted on the stator of three phase motors, is known as ‘SURGE COMPARISION TEST’.

3.2 Test on the motors would weed out the following types of faults, thus preventing the entry of defective motor into the traction service. (Refer. Fig. 2 )

a) Turn to turn short in the same phase.

b) Coil to coil short in the same phase.

c) Phase to phase short complete.

d) Improper coil connection.

e) Open coil connection

f) Earth fault


SK. EL. NO.

5. Instruction :

5.1 The controls for the JABBAL surge tester shall be as follows —

5.1.1 The tester is operated as described below :-

5.1.1.1 Turn the main power switch off.

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5.1.1.2 Connect the tester line card to 220 V AC out-let

Precaution : This tester must be grounded to prevent possible hazards due to static build up in winding under test and to ensure proper operation of the tester.

5.1.1.3 Set all switches and controls present on tester model 5000 as listed below :

INTENSITY MID Scale

FOCUS MID Scale

VER POS MID Scale

HOR POS MID Scale

SWEEP Fully Center Clockwise

VOLTS/DIV 500 for model 5000

Precaution : Contact with the test leads on this equipment can cause harmful or fatal electrical shock. Do not touch the test leads while a test is in process.

Test : Not pressed

% output : 0 (Zero)

Test Select : Any position

5.1.1.4 Turn the unit on by placing POWER ON switch in the on position. RED LIGHT will glow. After few seconds a trace will appear on the oscilloscope screen and allow the unit several minutes to warm up and stabilize prior to proceeding.

5.1.1.5 Adjust the INTENSITY, FOCUS VER POS, HOR POS and sweep controls to obtain a sharp oscilloscope trace centered on the screen and about 75 mm long.

5.1.1.6 Connect the test leads to the winding to be tested. Refer Para 5.1.2 for information on how to connect test leads.

5.1.1.7 Set the TEST SELECT switch to the proper position for the test to be performed. Refer Para. 5.1.2.

5.1.1.8 Press the TEST BUTTON. The red TEST ON lamp will light. Rotate the % output control slightly clockwise and a pattern is obtained as mentioned in Fig.1 Wave form thus obtained is for two good or defective winding under test. Adjust the sweep control to obtain the proper duration display.

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5.1.1.9 Adjust the % output control and the VOLT/DIVISION Switch to the desired test voltage.

Precaution : Do no operate the TEST SELECT or VOLT DIVISION switch while a test in progress.

5.1.1.10 Release the test button and rotate the TEST SELECT switch to the next position or connect the test leads to the next windings to be tested.

Precaution : Contact with the test leads on this equipment can cause harmful or fatal Electrical shock. Do not touch the test leads while a test is in progress.

5.1.1.11 Applied voltage determination.

The actual voltage applied to the winding under test is affected by the inductance of the winding.

Applied Voltage = No. of scale division between the top of the highest peak and the lowest negative peak X volts/division.

5.1.2 Test Procedure :

5.1.2.1 GENERAL

The JABBAL Surge Tester will check single phase or three phase winding with either iron or air cores. The tester operates by discharging energy storage capacitors into the two output leads and alternately displaying the waveshapes of the voltages present in the windings under test. By means of the TEST SELECT Switch, a pair of single phase winding or an entire three phase winding set may be tested without changing the test lead connections to the windings under test. In the table below ‘Hot’ is an energised lead and ‘Gnd’ is a grounded or return lead.

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Table - 1

Switch Position Test Leads 1 2 3 GND

1↓ HOT GND HOT GND C GND HOT HOT GND B HOT GND HOT GND A HOT HOT GND GND

Test lead potential vs. Test Select Switch Position most testing performed is comperison testing where the inductance of two identical windings, for two windings of a three phase. Windings are tested simultaneously and the output waveshapes are compared against each other. The tester can be used to test for voltage breakdown of a single winding, but results are difficult to judge due to lack of a comparison. When two matched windings with no faults are being tested, a single waveshape such as shown in Fig. 1 will result (Ref. Figure. 1)

If the windings are mismatched, a dual waveshape such as shown in Figure a(b) (Ref. Figure.1) will appear or one trace will be erratic. The dual waveshape indicates the two windings under test have different inductances, e.g. the winding generating the higher frequency waveshape has less turns or shorted turns. An erratic waveshape indicates that the insulation in one coil is momentarily breaking down.

Note : Irregularities or discontinuities in the first cycle of the wave shape may occur, particularly when testing small windings at low voltage. This is normal and should be ignored.

83

If one or both tester channels are operating into a short circuit a flat trace will appear. The test leads should be checked for inadvertant shorting and the setting of the TEST SELECT Switch should be checked before rejecting the winding as totally shorted.

If one or both tester channels are operating into an open circuit, a step function waveshape will appear, as mentioned in Fig. 1(C) (Ref. Figure. 1) Again test leads and TEST SELECTION switch settings should be checked prior to rejecting the winding.

A test is performed as follows :-

1. The unit is turned on and adjusted as described in Para 5.0

2. The test leads are connected to the windings to be tested. Table 1 & para 5.13 will aid in explaining test lead connections.

3. The % OUTPUT control is set at zero, and the TEST SELECT Switch is set at the proper location for the test lead connections and test to be performed. (See table 1 and para 5.13)

4. The TEST Switch is engaged and the % OUTLET control and the VOLTS/DIV switch are set for the proper test voltage.

5. Upon test completion, the TEST is released and the TEST SELECT Switch is moved to the next test position or new windings are connected to the test leads.

NOTE : For repetitive testing the % OUTPUT control may be a preset value and not returned to zero between tests.

5.1.3 TESTING OF THREE PHASE WINDING TESTING :

Three phase winding assemblies are tested by comparing each winding with the other two windings in the assembly. Only TEST SELECT Switch positions, A,B, or C may be used for three phase testing. ‘Hot’ is an energized lead, and “Gnd” is a grounded or return lead. The diagram on the tester front panel shows typical winding connections for 3φ. delta or star testing.

When testing star winding with the switch in position, A, test leads 1 and 3 are energized and 2 is grounded. Channel 1 test current flows through windings U and

84

W and Channel 2 test current flows through windings V and W. Since winding W is common to both channels, any fault in winding W will show on both CRT traces. If winding W is open , both traces will be flat or a step function as shown in figure (C) (Ref. Figure.1) If winding W has a momentary type short both traces will be erratic. Other types of faults in winding W will be difficult to notice in this switch position as both CRT traces will be identical but these faults will show in switch position B and C. If a fault is present in either winding U or V, the two traces will not be identical and the fault can be isolated. The following ground rules can be used in conjunction with Figure. 2 (Ref. Figure. 2) to determine which winding in a three phase winding is defective.

5.1.3.1 INDICATION :

ONE ERRATIC TRACE

Try each switch position (A, B and C) until both traces become erratic. When both traces are erratic the defective winding is in the common leg. If both traces are erratic in position A, the winding tied to test lead 3 is defective.


ONE FLAT OF STEP FUNCTION (OPEN) TRACE :

Try each switch position (A, B and C) until both traces show the open, and the defective winding is in the common leg. If the switch is in A, the winding tied to test lead 3 is defective.


TWO TRACES AT DIFFERENT FREQUENCIES :

Try each switch position, (A, B & C) until both traces are identical which indicates that the defective winding is in the common leg. If the switch is in position A, the winding tied to test lead 3 is defective.


ONE FLAT (GROUND) TRACE :

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Try each switch position (A, B & C) until both traces are identical which indicates that the defective winding is in the common leg. If the switch is in position A, the defective winding is in the leg tied to test lead 3.

Using the instructions above Table 1 and the diagram on the front panel will allow the operator to isolate a fault in any one winding in a three phase winding. However, if two windings in a three phase have the same fault, erroneous results will be obtained. Therefore, it is advisable to check the windings as single phase windings prior to beginning winding rework.

6. PERIODICITY OF IMPLEFICATION :

1. During Annual over-haul

2. After rewinding or any major repair to winding

7. AGENCY OF IMPLEFICATION :

All Electric loco sheds, shops and Production Units.

8. REFERENCE :

i) Reliability and improve the performance of auxiliary motor in service

ii) SMI No. 98 issued vide RDSO letter No. EL/3.2.70 dated 15.10.1982

9. DISTRIBUTION :


(P.K. Jain) for Director General /Elect.

88



No; EL/3.2.70/J3 Dated 15-12- 1992

SPECIAL MAINTENANCE INSTRUCTION NO. RDSO/ELRS/SMI/152

1. TITLE :

General guidelines to follow for balancing of rotor and blower impellars.

2. APPLICATION :

i) Rotor of all auxiliary motor fitted on Electric locomotive.

ii) Impellars of all blowers used for cooling traction motor, transformer oil smoothing reactor and rectifiers.

3. OBJECT :

3.1 Squirrel cage rotors when repaired and fitted alongwith the impellars of blowers, abnormal sound or delivery of less quantity of air have been reported by Railways. Investigation reveals that is happened due to unbalanacing of rotor and impellar individually as well as collectively.

3.2 This SMI indicates the general method to be followed for balancing of rotor, and impellers separately and then collectively.

3.3 The method which have been described in the following paragraphs shall exclusively for Blue Star make of balancing machines. However, main procedure and the balancing parameter shall be almost common to every balancing machine.

3.4 In case any difficulty is experienced, the matter may be clarified from RDSO/Electric Loco shed, GZB.


RDSO SK. EL. - NIL

5. INSTRUCTIONS

89

5.1 For details instruction on balancing machine type FIE/DBM/MD-1000 marketed by M/s Blue Star, Bombay shall be followed. This machine is installed at Electric Loco Shed, Northern Railway, Ghaziabad.

5.2 PRINCIPLE OF BALANCING

The rotor is placed on a work-support which is rigidly fixed by side plates. They prevent any movement of rotor while rotating. Motor rotates around it shaft axis. The centrifugal force resulting from the unbalance is observed the ‘work support’. A pressure transducer senses the centrifugal forces transmitted by the work support and produces an electrical signal, which is proportional to the rotor/impellar unbalance.

5.3 The electrical signal is further amplified to in various stages and processed through the analogue computer to read the angle of unbalance and the amount of unbalance on two different meters.

5.4 By means of ‘Plane Selector Switch’ unbalance readings of both left and right places are measured during a single run of rotor.

5.5 The other control on the control panel are provided to feed the dimensional data of the rotor / impeller to the computer.

5.6 All the adjustment shall be done as per the SMI mentioned under para 5.1.

5.7 Description of the operating elements as per SMI mentioned under para 5.1.

5.8 BALANCING METHOD

5.8.1 After the rotor is mounted and coupled to the spindle shaft, the following procedure should be followed :

i) Select the position of programme selector switch 1 according to the position of the ‘correction planes’ and the bearing places.

ii) Dial the controls ‘A, B, C’ accordingly.

iii) Dial the control R1 and R2 as per correction radius.

iv) Keep the sensitively switch on maximum weight range.

v) Make the amplifier on by operation of ‘ON-OFF SWITCH’ of the control panel. The dial lamp will glow up.

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vi) Start the machine by pressing green push button.

vii) Let the reading on meters respective to ‘Plane Selector Switch’ should be steady. Then change the plane selector switch to other plane (the previous plane meter reading are stored) Let the meters indicated the steady reading. Then stop the machine by ‘OFF BUTTON’ on the starter.

(The meter reading for the plane also get stored). Apply the brake and stop the rotor/impellar.

viii) Apply corrections according to the meter readings on left and right correction plane. For re-checking un-balance in rotor, repeat the procedure.

ix) If unbalance is found beyond balancing tolerance follow procedure stated above under 7, 8 until the rotor is balanced within limits.

5.8.2 Sensitively of the machine shall be calculated as following

For the determination of the sensitively of the machine for a particular rotor, the same is balanced first as described in para 5.8.1. A known unbalance is then introduces at a distance from the rotating axis. The unbalance is then recorded in a number of division of the meter reading. The following formula can be used for calculating the sensitively of the machine for the said rotor.

Sensitively of machine per division of meter reading = (U x r ) / (W x M) Microns

When U = Unbalance in grams (Meter is calibrated in gms.)

r = Distance of unbalance ‘U` from rotating axis of rotor in mm.

W = Weight of rotor in kgs.

M = Number of division of meter reading.

5.8.3 Care and Maintenance lubrication schedule shall be followed as laid down in Maintenance Instruction of balancing machine type FIE/DEM/HD 1000

91

5.8.4 Following procedure shall be adopted for balancing of coupling Adopter with Rotor (Index Balancing Procedure)

i) Verify that clearance between adopter bore and rotor shaft is minimum under worst condition it should not be more than 0.04 mm

ii) Verify that motor shaft which is connected to adopter is co-centre with reference to shaft (Journal) axis within 0.005 mm. This can be checked by dial gauge on machine itself by moving on roller/Vee bearing of machine.

iii) Balance rotor with adoptor and coupling etc. making connection on rotor at two planes of rotor with in 1 meter division at max. required sensitivity range (multiplier position)

iv) Index rotor with shaft axis by 1800C for this purpose make a common mark on adopter and end of rotor shaft and also take reference of graduated disc for accurate indexing.

v) Then take unbalance meter reading of plane I and note down amount in No. of division and angular position. Now balance the rotor as described under para 5.8.1

vi) If coupling is balanced separately then 1800 indexing to be done from coupling flange by removing four fixing screws of coupling flange with reference to adopter flange (rotor shaft not be indexed with adopter bore etc.) Other procedures shall be adopted as mentioned above.


After any repair to rotor of motor and impellers of blowers.

92


All Electric Loco Sheds and Shops

8. REFERENCE :

Item 1.0 of XIX MSG (EL) held at Madras in December 1991

9. DISTRIBUTION :


(P.K. Jain) for Director General /Elect.

93



NO. EL/2.2.8.4 Dated 20.04.1998

SPECIAL MAINTENANCE INSTRUCTIONS NO. ELRS/SMI/153 (REVISED)

1. TITLE :

Characteristic properties of enamel used on enamelled winding wires.

2. APPLICATION :

Enamelled winding wires used in auxiliary motors and coils of electro-magnetic contactors for electric LOCOS and EMUs.

3. OBJECT :

Railways have reported a large number of failures of auxiliary motors and coils due to inter-turn shorts. These failures can be attributed to inappropriate application of enamelled winding wire obtained from the trade. To arrest these failures in service special instruction is being issued to follow the right enamel for specific enamelled winding wire required for rewinding of auxiliary motors and coils of EM contactors.

4. 0 DRAWING/CATALOGUE NO. :

4.1 Following catalogues on enamel are given below for guidance and adoption for winding wires :

Sl. No.

Reference No. Name of enamel of Dr. Beck & Co.

Governing IS/ Temp. Index

Application

1. Tech. Data Sheet 1-50, Revision March 3, 96

TEREBEC TR 543-38 IS : 13730-PT.8/ Temp 180 Class

-

2. 1-29-8903 DUAL COAT WIRES with Base Coat of TEREBEC TR 543-38 and over Coat of Allotherm 602L-35A.

IS : 13730 – Part 13/ Temp 200 class.

Startor winding of 3 phase Aux. Motors.

NOTE : Application as per RDSO existing SMI's and as well as motor manufacturer's recommendations.

94

5. MAINTENANCE INSTRUCTIONS :

5.1 All auxiliary motors shall be rewound with a specific class of enamelled winding wire. The enamel used on winding wires shall be as per para 4.0 above.

5.2 Procurement of winding wire with enamel shall be as per Para 4.0 above depending on its application.

5.3 Before use of the winding wires, railways shall conduct test as per IS Specification given in Para 4.0

5.4 In the case of varnished (with H69 of Dr. Beck & Co.) double glass covered enamelled (TR 543-38) winding wire, Railway shall use compatible of H69 varnish used on top of glass with the impregnating varnish like Dobeckon FT1052/2005 (500 EK).

5.5 Procurement of the enamel winding wires shall be from the RDSO's approved suppliers only.

6. 0 AGENCY OF IMPLEMENTATION :

Electric Loco sheds and shops of Electrified Railways.

7. 0 PERIODICITY OF IMPLEMENTATION :

i) During rewinding of auxiliary motor in sheds or shops.

ii) During the procurement stage of motor for various applications.

8. DISTRIBUTION :


Encl : As above.

(R.K. Kulshrestha )


95

Chemical Base, Salient Properties and Applications Terebec TR 543-38 is a THEIC polyesterimide wire enamel having Temperature index > 200. Terebec TR 543-38 is characterised by :

UL approved as a base coat with top coat of Allotherm 602C/L-35 Improved flexibility and adherence to copper Excellent resistance to hot transformer oil and refrigerants Good burn out resistance High cut through temperature at high processing speed High tan delta

Terebec TR 543-38 is a medium viscosity wire enamel which is specially suitable for 0.05 to 2.0 wire sizes. For felt wiping application, the enamel may be thinned down to 35% solids (approx. viscosity 450 mPa.s) using Thinner 115. Terebec TR 543-38 is an ideal choice as base coat enamel for production of dual coated wires using top coat of polyamid-imide such as Allotherm 602 L -35A. Such dual coated wires have high tan delta bending point, and excellent resistance to refrigerants. They satisfy requirements of IS 13730-13/IEC 317-13 (specification for class 200, dual coated enamelled wires). Terebec TR 543-38 as a base coat with overcoat of Allotherm 602L-35 is recognized by Underwriters Laboratories under file No. E73276 providing temperature index 220. Enamelled wires coated with Terebec TR 543-38 find applications in hermetically sealed motors, ballasts, thermal class H electrical machines etc. Wires coated with Terebec 543-38 meet specification requirements of IS 13730-8/IEC 317-8. Terebec TR 543-38 properties :

Table 1 : Terebec TR 543-38 properties ( as supplied )

Appearance (*) DBI 1001 (**) Brown coloured clear liquid

Solids Content (*) DBI 1022(**) 1g/180 °C/1h % 37-39 Viscosity at 23 °C (*) DBI 3005(**) Brookfield Viscometer m Pa.s 750-850 Flash point DBI 1005(*) (closed cup) °C 40 (typical) Storage stability In original sealed container at room

temperature months 12

(*) These properties form our sales specification (**) DBI are internal test methods and are available on request

Technical data sheet 1/50 Revision: 3, March 1996

96

Properties of Terebec TR 543-38 Enamelled Wires Table 2 : Typical Properties of 1.0 mm dia. Gr. 2, enamelled copper wire coated with Terebec TR 543-38 processed on vertical machine, 4200C/4500C, 19 m/min. Test methods according to IS 13778-1 to 6/ICE 851-1 to 6 or unless otherwise specified.

Increase in dia mm 0.070 Elongation to break Springiness Flexibility and Adherence Mandrel winding Jerk test Peel test Resistance to abrasion

20%+1xd

av./min

% degree

n x d N

36 40

OK OK 182

13.8 / 12.4 Solvent resistance (Pencil hardness)

Initial Std. Solvent

4H-5H 3H-4H

Break-down voltage Dielectric dissipation factor (Tan delta)

at R.T. at 180°C Beck Test 5003 - At 194° C - bending point

kV kV

°C

10.0 9.2

0.01-0.02 180-200

Heat shock Cut-through Temperature Index (Thermal endurance)

2.24 mm d/220°C 350°C/2 min

IS 5825/IEC 172

OK OK 209

Packing and storage Terebec TR 543-38 : 205 kg in MS drums Thinner 115 : 180 kg and 20 kg in MS drums The drums with original seal, should be preferably kept in a covered godown, away from direct sunlight and rain water. Safe Handling : Terebec TR 543-38 is a flammable liquid. PVC handgloves, safety goggles, face sheild etc. should be used while handling the product. Use foam, CO2 or dry chemical for fire fighting. Inhalation and direct contact with the skin to be avoided. In case of contact, the affected area should be washed with soap and plenty of water. For further details ask for product safety data sheet 1-50. Notice : This information is intended only for general guidance in the application of our product. It has been obtained by careful investigation and represents the present state of our knowledge and experience. Because of the large number of possible methods of application and processing, we are not able to assume responsibility in any one particular case for either the technical results or the patent rights situation applicable to the country under consideration. dr. deck * co.(India) ltd. Marketing Head Office : Indravani , 92/11 Chiplunkar Road. Pune 411004 . Phone : (0212) 335796, 331080 Tix : 01457209 DRBK IN / 01457250 BECK IN . Fax : (0212)336074, 363256 . Gram : BECKINDIA Technical Services :Pimpri. Pune 411018 . Phone : (0212) 776241-4 . Fax : (0212) 774648 . Gram : INSUBECK Regional offices : • 403 World Trade Centre, Babar Road New Delhi 110001 Phone : (011) 3311664/3712940 Telefax : (011) 3713408 • 5 & 6 Fancy Lane Calcutta 700001 Phone : (033) 2486881/2462019 Telefax : (033) 2420970 • 302, T V Industrial Estate S K Ahire Marg. Worli Bombay 400025 Phone : (022) 4932654 Telefax : (022) 4923191 • 1176, 12th B Main H. A. L. IInd stage Bangalore 560008 Phone : (080) 5281649/5283093 Telefax : (080) 5280831

97

Chemical Base, Salient Properties and Application :

Allotherm 602… is a polyamide imide based wire enamel having a Temperature Index 230. The enamelled wire processed with Allotherm 602… has excellent thermal properties, particularly the heat shock The enamelled wire coated with Allotherm 602… has excellent abrasion resistance and resistance to refrigerants R-12\R-22. The enamel film retains dielectric properties after exposure to humid conditions and higher temperatures. Allotherm 602… has very low stack loss resulting in lower enamel consumption Allotherm 602… is suitable for the wire range of 0.2 mm to 1.6 mm dia copper conductors In view of its excellent windability, Allotherm 602… is often used as a top coat enamel, while manufacturing dual coated wires. Due to high abrasion and low coefficient of friction, Allotherm 602… coated wires are ideal for high speed winding machines. Allotherm 602… enamelled wires have low extractable matter in R-12 and R-22 refrigerants and hence make best choice for hermetically sealed motors. The excellent thermal properties of Allotherm 602… enamelled wires make it suitable for thermal class 180 and above (class H & C) electrical machines for continuous operation.

Properties of Table 1 : Allotherm 602.35 properties (as supplied) Allotherm 602…

Chemical base Polyamide-imide Appearance High viscosity dark

brown clear liquid Solids content 1g\200C\2h % 34 -36 Viscosity at 20° C Brook field

viscometer mPa.s 2500-3500

Density at 20°C DIN 51757 g\ml 1.17 (Typical) Flash point DIN 53213

(closed up) °C 42

Compatibility with Thinner 129

1:1

98

Application Data for Allotherm 602…

Allotherm 602… wire enamel can either be used as a single coat or as a top coat in the dual coat system. While applying it as a top coat, Allotherm 602… is compatible with polyester, polyesterimide and polyesteramide-imide as base coat enamels. While used as top coat, Allotherm 602… wire enamel should not get mixed with conventional base coat enamels containing solvents such as cresylic acid, solvent naptha etc.

Allotrherm 602… is available in two viscosity versions

• Allotherm 602.35 : with higher solids and higher viscosity for die application on vertical enamelling machines.

• Allotherm 602.25 : with lower solids and medium viscosity for felt application on horizontal and vertical enamelling machines.

Table 2 gives typical processing conditions obtained on our pilot plant. The actual processing conditions on the production plants may vary depending upon the oven design and processing parameters.

Table 2 : Application Data

Wire size

¼ mm

Covering Oven Number of Passes

**

Proce-ssing speed m/min

Type Heating length m

Temperature

Zone 1 °C

Zone 2 °C

1.6 Medium Vertical Catalytic 5.0 420 450 8 9

1.0 Medium Vertical Catalytic 5.0 420 450 8 15

*.05 Medium Vertical Conventional

3.0 275 450 7 11

*.03 Medium Horizontal convential

2.5 275 425 6 20

* Using low viscosity grade Allotherm 602.25 ** After annealing in inert atmosphere.

Properties of Allotherm 602 … Enamelled wire

Table 3 : Properties of 1.0 mm enamelled copper wires processed with Allotherm 602.35

99

Test methods according to IS 4800 (Part III) unless otherwise specified

Diameters : Conductor Increase in dia Covering Elongation to break Springiness

mm mm

%

degree

1.000 0.070 medium 36 43

Flexibility and adherence : Mandrel winding Jerk test Peel test

15 % 1 d

R * d

OK OK 72

Abrasion Unidirectional scrape

N

16.5

Heat Shock Cut through Burn out resistance High temperature failure test

1d/280° C/30 min 350° C/2 min NEMA-MW-1000 IEC : 251 – 1 at 475° C at 450° C at 425° C

OFM

min

min

min

OK OK 12

143

241 399

Solvent resistance Trichloroethylene extraction Blister test

Pencil hardness

initial

Std. Solvent

%

6H 5H

<0.05

No blistering

Break-down voltage Dielectric dissipation factor (tang) Break-down voltage 16h/R-22 immersion

at R.T. at 2200C Break Test E 102 at R.T. at 2200C

kV kV

kV

10.8 10.0 0.007 0.015 10.0

Available Grades Table 4 : Available grades of Allotherm 602 …

Trade Designation Viscosity at 20° C Solids

100

DIN 53211/ cup 4 (s)

(mPa.s)

1g/2h/200°C (%)

Allotherm 602.25 100-120 24-26 Allotherm 602.35 2500-3500 34-36

Packing and Storage Allotherm 602 : 205 kg in MS drums Thinner 129 : 180 kg and 21 kg MS drums Allotherm 602 wire enamel can be stored for 6 to 9 months and Thinner 129 for 1 year at room temperature. The drums with original seal should be kept in a covered godown away from direct sun light and rain water.

NOTICE :

This information is intended only for general guidance in the application of our product. It has been obtained by careful investigation and represents the present state of our knowledge and experience. Because of the large number of possible methods of application and processing, we are not able to assume responsibility in any one particular case for either the technical results or the patent rights situation applicable to the country under consideration.

dr. beck * co. (India) ltd. Marketing Head Office : Indravani , 92/11 Chiplunkar Road. Pune 411004 . Phone : (0212) 335796, 331080

Tix : 01457209 DRBK IN / 01457250 BECK IN . Fax : (0212)336074, 363256 . Gram : BECKINDIA Technical Services : Pimpri. Pune 411018 . Phone : (0212) 776241-4 . Fax : (0212) 774648 . Gram : INSUBECK

Regional offices : 403 World Trade Centre, Babar Road New Delhi 110001 Phone : 3311664 Telex : 031 66067 BECK IN

5 & 6 Fancy Lane Calcutta 700001 Phone : 2486881 / 2462019 Telex : 021-7441 BECKIN Gram : INSUBECK

Arcadia, 10th Floor 195, Nariman Point Bombay 400 021 Phone : 2332255 / 1232224 Telex : 011-2966 Gram : INSUBECK

1176, H A L IInd stage 13th Main, I Cross Indira Nagar Bangalore 560 038 Phone : 561649 / 562093 Telex : 0845-2952 BECK IN Gram : BECKINDIA

101



NO. EL/3.2.70 Dated 18.03.1993


Title : Special Instruction for Essential Requirements of Facilities to rewind 3↓ AC Auxiliary motors in Loco sheds and Rewinding shops.

1.1 OBJECTIVE :

Large No. of Aux. motor failures are being reported regularly by Railways due to inter turn short and earthfault. RDSO conducted detailed investigation to find out the causes of such failures.

1.2 Based on above, it is considered that significant improvement in reliability level of motors can be achieved by adoption of correct winding procedure. It also emphasis for special precaution while rewinding these motors.

1.3 This SMI indicates the minimum essential facilities which are required for rewinding of Auxiliary Motors.

2.0 MACHINES AND PLANTS :

2.1 VPI PLANT :

VPI Plant suitable for vacuum impregnating using solventless varnish FT 1052 of Dr. Beck shall be required to work under following conditions -

2.1.1 Vacuum level - 1 Torr

2.1.2 Pressure - 2 to 3 kg/cm2

2.2 OVEN :

Basic requirement of oven to operate shall be followed --

2.2.1 Temperature Range --0-3000C

2.2.2 Temperature Control - Auto cut in and cut out.

2.2.3 STORAGE FACILITY :

102

Air conditioned room with min. two air conditioner for keeping insulating materials.

2.2.4 Coil making facilities.

2.2.5 Slot wedge cutting machine (All cut machine)

2.2.6 Brazing facility

2.2.7 Dynamic balancing machine for rotor balancing

2.2.8 Miscellaneous tools e.g. mallet, Hylem or Nylon round bar, wire cutter.

2.3 TESTING FACILITIES :

2.3.1 Winding wire testing facility as per IS 4800 Pt. (III) (Testing facility should include for winding wires confirming to IS 4800 Part V, IX, XIII and IS : 11184)

2.3.2 Resistance measurement facility

2.3.3 Surge comparison tester

2.3.4 Shock Pulse meter

2.3.5 High Voltage Testing facility

2.3.6 Megger

2.3.7 Suitable test bed having 3 ∅ regulated supply

3.0 AGENCY OF IMPLEMENTATION :

All Electricl Loco sheds motor rewinding and repair shops of Railways doing rewinding of Auxiliary Motor.

4.0 DISTRIBUTION :


( Pradeep Jain )

for Director General / (Electrical)

103



NO. EL/3.2.11 Dated .11.94

SPECIAL MAINTENANCE INSTRUCTIONS : RDSO/ELRS/SMI/163

1. TITLE :

Detection of rotor bar and end ring cracks on 'Arno-convertor' and 'Auxiliary Motors' by "Search coils and Motor tester."

2. APPLICATION :

i) All electric locomotives filled with 3 phase induction motors and Arno-convertors.

ii) EMU motor coaches fitted with auxiliary motors.

3. OBJECT :

3.1 To detect the rotor bar and end ring cracks on Arno-convertors and auxiliary motors.

3.2 This method is applicable for Die Cast rotors also.

4. PROCEDURE :

4.1 Place the search coil (which wound on a core) on the curvature surface of rotor as shown in the enclosed sketch.

4.2 Measure the inductance of the coil on the motor tester while the search coil is moved along the core straddling a slot or rotor is rotated slowly.

4.3 Repeat the process as mentioned in para 4.2 by placing the search coils at vulnarable locations of the rotor and end ring. If , there is any cracked bar, the meter will show an unusual deflection.

4.4 Rotor bar cracks may also be detected on Arno-convervor in stationary position during the maintenance schedule like "IC". In this case, only disconnect the supply cable from Arno-convertor and connect the motor tester terminal to one of the phase or between two terminals of the Arno stator and rotate the rotor slowly, meter will show an unusual deflector if there is any cracked bar. A normal rotor will produce small variation as the bars pass under the hole.

4.5 If any cracked bar and end ring is detected in step No. 4.4 Arno should be replaced.

4.6 Step No. 4.4 & 4.5 shall be followed for only Arno convertor while the step No. 4.1 to 4.3 are applicable for. Arno and Auxiliary motor rotors.

4.7 While repairing any rotor with cracked bars, replace all the bars and both the end rings, by new bars and end rings.

104

4.8 Rotor bars should be "Araldiled" only in the middle third of the rotor slots leaving the end portion free for expansion and contraction.

5.0 DRAWING / SKETCH :

No. SK. EL. 4320

6.0 AGENCY FOR IMPLEMENTATION :

i) All electric loco sheds and shops of Indian Railways.

ii) EMU car sheds

7.0 PERIODICITY OF IMPLEMENTATION :

i) During every 'IC' inspection schedule for Arno rotors only.

ii) Whenever any abnormal sound is reported from rotor of Arno and Auxiliary motors.

8.0 REFERENCE :

Reliability Engineering study on electric locomotives Part - 12 for Arno Failures, prepared by RITES, New Delhi.

9.0 SOURCES FOR PROCUREMENT OF THE MEASURING INSTRUMENT

i) Electric Motor checker EMC-22 excluding search coil . Marketed by

M/s SPM Instrument Pvt. Ltd. 7-1-27/1 Srinivasa Complex Ist Floor, 'B' Block, Ameerpeat Hyderabad - 500 016

10. DISTRIBUTION :


( R.K. Kulshrastha )

for Director General / (Elec.)

106



NO. EL / 3.2.114.3 Date : 30.3.95

SPECIAL MAINTENANCE INSTRUCTION NO. ELRS/RDSO/SMI/176

1.0 TITLE :

Fixing of Armature Spider of Motor (KPC - 1 ) Frame 110 VDC on the shaft of compressor 3HC - 55.

2.0 APPLICATION :

All 25 KV AC EMU’s fitted with KPC make compressor type 3HC - 55.

3.0 OBJECT :

EMU’s sheds of Indian Railways have reported the following type of defects on the motor compressor sets.

i) Matching of inadequate area of key way with armature bore.

ii) Free movement of the armature on the shaft, instead of press fit.

iii) Wearing of key and key way.

iv) Wear of the shaft at the tappered mating surface.

In order to prevent the above mentioned defects during repair and maintenance of the compressor set special maintenance instruction furnished below to be followed

107

4. PROCEDURE :

Procedure for fixing armature spider on compressor shaft.

4.1 Dummy motor shaft to be removed as follows .

4.1.1 Remove the commutator cover

4.1.2 Remove the air inlet chamber (item No. 22) by releasing the 8 nos. hex. head Screws securing the end bell.

4.1.3 Remove 4 studs securing the bearing cap (item no 5) and take out the bearing cap. Remove the locknut (item no 10) by using caliper face spanner.

4.1.4 Lift or remove all brushes (item no 7). Disconnect the end connecting leads from the brush bar and terminal board. Protect the commutator by feeding in a strip of press board under the brush holder (item No. 6)

4.1.5 Apply a lifting sling to end bell.

4.1.6 Remove the bolt securing the end bell to the frame (item no 1). Remove the end bell, with brush gear and bearing outer race, taking care to prevent damage to the commutator.

4.1.7 Remove the bearing inner race from the shaft using bearing puller.

4.1.8 Release the plate locking washer and remove the armature shaft nut (item No. 9)

4.1.9 Slightly hammer the shaft from commutator end and remove the shaft from the spider.

4.1.2 After removing the spider from the dummy shaft following precautions to be taken before assembling on to the compressor

4.1.2.1 Remove all the sharp corners on the compressor shaft and armature spider.

4.1.2.2 Clean all the matting surfaces of compressor shaft and armature spider and ensure these are free from dust and rust.

4.1.2.3 Check the dimension of key and key way of shaft and spider. Ensure key has interference fit on crankshaft and slinding fit on the spider. Ensure that there is no damage on either M 36x1.5P and M24x3P threads. Apply thin layer of anti rust oil on shaft and dome of armature spider.

108

4.1.3 Assembly procedure of armature on to the compressor shaft.

4.1.3.1 Lift the armature horizontally and insert it in to the compressor shaft.

4.1.3.2 Align the key and keyway and push the armature in to the shaft.

4.1.3.3 Place a collar/sleeve on to the shaft to fit against the spider face tighten the nut provided at the end of the shaft (M 24x3P). Ensure a distance of 15 mm approximately from spider face to M36x1.50 thread outer face of the shaft. For correct taper matching of crank shaft and spider armature lock nut M36x1.5P (9) is to be tightened by applying torque of 51 kg.m. After proper tightening, lock the spider with tab washer (8).

4.1.3.4 Assemble the stator on to the compressor by proper location of the spigots using appropriate hardwares.

4.1.3.5 Insert the bearing collar (item 10) and inner race of the roller bearing fix the end bell alongwith the outer race of the roller bearing.

4.1.3.6 Lock the bearing with tab washer (14) and locknut (15) tightened with a torque of 32 kg.m. Fix outside bearing cap with SHIMS (17) using hardwares provides.

4.1.3.7 Fix the armature inlet cover (22), alongwith gasket (23).

4.1.3.8 Fix all the brushes properly into the brush holder.

4.2 Procedure for checking taper angle of crank shaft and spider by blue matching method.

4.2.1 There are two types of gauges available

i) Ring gauge - To measure taper on shaft.

ii) Plug gauge - To measure taper on spider for identification, part no and/ or name of part are engraved on gauges.

Railways should procure the gauges from M/s KPC, M/s KEC for measurement.

4.2.2 Before measurement deburr and clean component thoroughly if necessary it should be lightly polished with 400 or 600 grit polish paper to remove any traces of burr.

109

4.2.3 Wipe taper portion of gauge and component with a clean piece of cloth.

4.2.4 Apply blue lightly and evenly on entire taper surface of gauge. The amount of blue applied is very important. Too little will not transfer the blue colour to the component. Too much blue will not show the taper defect of the component.

4.2.5 Insert the gauge on/in the component and press firmly (Refer enclosed sketch). Do not hammer or tap the gauge or else it will get locked into the component.

4.2.6 Rotate the gauge clockwise by about 10 degree. This rotation is required to transfer the blue color. Rotation should not be more then 20 degree. This back and forth movement should be once or twice only.

4.2.7 Remove gauge from component. The taper angle is satisfactory if about 90% of the gauge surface makes contact with the component. This can be seen either by appearance of blue colour from the gauge.

4.2.8 In case the blue matching is below 70%, the component needs either revisioning or replacement.

5. DRAWINGS :

i) For fixing armature on compressor shaft follow SK. EL. - 4332

ii) For checking taper angle of crank shaft and spider by blue matching method, follow SK. EL. - 4333


All EMU shed and shop of Indian Railways where 25 KV EMU’s are in service.


7.1 During assembly of the compressor and motor when new and after major repairs of maintenance/overhaul in the shed/shop.

7.2 Whenever abnormal noise is observed in the compressor during normal operation.

8. REFERENCE :

110

Document No. CP 2616 & CP 2618 issued by M/s KPC vide M/s KPC letter No. MKTG : ACD : HO: RBS dated 5th January 1995.

9. DISTRIBUTION :


Enclosure : As mentioned above.

( R.K. Kulshreshtha ) for Director General (Elect.)

113



NO. EL/3.2.70 Dated 18/20 Feb., 1997


1. TITLE : Rewinding materials for Auxiliary Motors.

2. APPLICATION :

Auxiliary motors for all electric locomotives and EMUs. It supersedes earlier SMI/98 (Revised) of 30.12.96/14.1.97 and SMI/98 of 19/15.10.82

3. OBJECT :

3.1 Railways have reported number of failure on auxiliary motors on account of stator winding burnt. Detailed investigation in failures revealed that most of the failures have occur due to interturn shorts caused by failure of insulating materials.

3.2 In order to arrest the burning of these motors in service, details of the materials to be used by rewinding shop/shed are given in the following paragraphs which may be used during rewinding of the failed stators.

4. MATERIALS REQUIRED :

4.1 The materials to be used, the specifications, the recommended sources of supply and acceptance tests are indicated in Annexure-I.

5. PERIODICITY :

Whenever rewinding/repairs of stator of auxiliary motors are undertaken. 6. INSTRUCTION DRAWING :

Nil 7. AGENCY OF IMPLEMENTATION : All electric loco and EMU sheds and rewinding shops of Railways. 8. DISTRIBUTION : AS PER ENCLOSED LIST.

(R.K. KULSHRESTHA )


Annexure - I

114

MATERIALS FOR REWINDING OF 3 PHASE AUXILIARY MOTOR STATORS

1. POLYESTERIMIDE OVER COATED WITH POLYAMIDE - IMIDE ENAMELLED BOUND COPPER WIRE, CLASS 200-CONFORMING TO IS 13730 - PART 13 - 1993

1.1 Material specification :

Enamelled round copper wire conforming to IS 13730-Part 13 of 1993. The wires shall have the base coat of Polyesterimide enamel MT 533.39 A and top coat with Polyamide-imide known as Allotherm 602.35A of Dr. beck & Co. Enamelled copper wire is also known as Dual Coated enamelled winding wire and falls in the category of temperature Class 200.

1.2 Recommended Suppliers :

As per the latest approved suppliers list of RDSO.

1.3 Acceptance Tests :

Acceptance tests shall be as per guidelines laid down at Annexure - II

1.4 All auxiliary motors shall be rewound with this type of enamelled winding wire for Electric Loco & EMUs except MVMT and MVRH motors for loco application.

2.0 ENAMELLED AND VARNISHED BONDED GLASS FIBRE COVERED ROUND COPPER WIRES - CONFORMING TO IS: 11184-1984.

2.1 Material Specifications :

There shall be double glass covering over the enamelled winding wires which shall have the enamel of MT 533.39A of Dr. Beck & Co. and conform to IS : 13730 Part 8. As the name indicates, the glass should be varnished which should be compatible with the impregnating varnish viz. FT 1052/2005/500 EK of Dr. Beck & Co. Therefore, top of the glass braiding should have varnish known as H-69 of Dr. Beck’s which is compatible with the impregnating varnish as mentioned above. However, unvarnished double glass enamelled conductor can also be used.


As per latest list of approved suppliers issued by RDSO.

2.3 Acceptance Test :

As per Clause 3 to 6.6 of IS:11184 - 1984.

2.4 Application :

MVMT & MVRH of Electric locomotives only.

3. 0 IMPREGNATING RESINS :

115

3.1 Material Specification :

Dobeckan FT 1052 of Dr. Beck & Co.

3.1.1 Salventless unsaturated Polyesterimid (UP) impregnating resin with tough elastic bonding and temperature index 180.

3.1.2 Dobeckan FT/2005/500EK of Dr. Beck & Co. — One component solvent less ‘UP’ impregnating resin of temperature index 200.

3.1.3 Application :

i) Resin as mentioned under para 3.1.1 shall be used for Class ‘F’ insulated stators.

ii) Resin as mentioned under para 3.1.2 shall be used for all Class ‘H’ motors.

3.1.4 Method of impregnation shall be by vacuum pressure impregnation only for all motors.

3.1.5 Acceptance Test :

As per manufacturer’s recommendation and tests certificate. However, impregnating resin shall be tested for viscosity, solid content and dielectric strength etc. to establish conformity with the manufacturer’s declared properties.

4. 0 INSULATING MATERIAL :

i) Slot Liner - Nomex 410(Calendered)/Nomex-Mica-418 (Calendered)

ii) COLL SEPARATOR - Nomex 410 - Calendered Nomex

iii) WEDGE SEPARATOR - Nomex 410 - Calendered Nomex

iv) OVERHANG INTER PHASE SEPARATOR - Nomex 411 and glass fibre tape.


Nomex - 410 upto 0.25 mm thickness



4.2 Recommended sources of supply :

i) M/s Thorn 4, Dr. P.C.S. Marg, Opp. Kumkum Hotel, Bombay - 400 007

ii) M/s Iycoon IB, 87 Kika Street, P.B. No. 3644, Bombay - 460 004

iii) M/s Star Gaston Pvt. Ltd., 104 Neelam, R.G. Thadami Marg, Worli, Bombay - 400 013.


116

As per manufacturer’s test certificate. However, materials shall be tested for dielectric strength, tensils strength and these values should be in conformity with the limits shown in manufacturer’s catalogue.

5. SLOT WEDGE :


Epoxy fibre glass laminate.

5.2 Recommended Sources of Supply :

i) M/s Hatim & Co., 90 Rippon Street, Calcutta.

ii) M/s Permalio Wallace Ltd., Central India Flour Mill Estate, P.B. No. 38 , Bhopal - 8

iii) M/s Glass Fibre & Allied Bombay 95 J.P. Road, P.B.No. 9029, Goregaon, East Bombay - 400 063


As per manufacturer’s recommendations and drawing of the individual Railways for various auxiliary motors.

6. CONNECTING LEAD WIRE :


This is also known as Terminal Lead. Flexible insulated fibre glass copper connecting lead wire with fire retardant silicone elastomer for temperature 50C to (+) 180C as per BSS 6195/1969 type 8’b’ category C/D with BDV of 6KV minimum (category ‘C’ for 4 & 6 mm2 sizes and category ‘D’ for 10 mm2 size of lead wire). Insulating varnish will be replaced by silicone

i) For 35HP motors : 80/0.4 (10 mm2)

ii) For 10-15 HP Motors : 84/0.3 (6 mm2)

iii) For 2 to 3 PH : 86/0.3 (4 mm2)

6.2 Recommended sources of supply :

i) M/s Jhaveri Thanawala Corpn., 114-A, Pokhran Road, Khopat, Thane - 400 601

ii) M/s Universal Cable Co., Satna (M.P)

iii) M/s Fort Gloster Industries, 31 Chowringhee Road, P.B.No. 9126, Calcutta - 700 016

iv) M/s Thorn, Bombay


As per BS specification as mentioned above.

117

7. SLEEVE :


Flexible insulated fibre glass sleeve with coating of Fire-retardant silicon elastomer applied by extrusion multi-dip process having temperature index of 1800C as per BS 2848 type 1/180 Tb having wall thickness of 0.9 mm and capable to withstand minimum BDV of 5KV for one minute.

7.2 Recommended Sources for Supply :

i) M/s Jhaveri Thanawala Corpn., Thane

ii) M/s Thorn , Bombay

iii) M/s Tapac Industries (P) Ltd., Mohan Mill Compound, S.V. Road, Mulund, Mumbai 400 607


As per BS 2848 type 1/180 Tb and material should withstand BDV value of 5KV. Fire retardant test as per IS:4249 Appendix ‘B’

8. BRAZING MATERIAL :


Rupatam Silver ‘14’ Alloy shall be used for internal winding connection and between the terminal lead and winding wire. Rupatam 43 (BACUAG 16 to IS 2927) shall be used between rotor bars and end rings.


i) M/s Indian Oxygen Ltd., ii) M/s Eyre’s Smelting, Calcutta iii) M/s Advani Oerliken, Bombay iv) M/s Maxiflow Industries, 4721 GIDC, Phase IV, Vatva Ahmedabad - 382 445


As per chemical Proportion to grade BACUP5 for Ruptam ‘14’ and BACUAG 16 for Rupatam 43 to IS 2927.

9. OVERHANG BINDING/TAPING :


As per CLW specification No. 4 TMS. 091.010 Alt. 3 or latest for fibre glass twines and tapes.

i) Glass cord of 1.0 mm size shall be used.

118

ii) Each coil emerging from the slot shall be covered with 1/2 lap impregnated glass tape of size 0.13 x 25mm


i) M/s Hatim & Co., Calcutta ii) M/s INTAF, Calcutta iii) M/s Jhaveri Thanewala Corpn., Thane


As per CLW specification 4 TMS.091.010 Alt 3 or latest

10. INSULATION AT STAR POINT :


i) On the brazed joint apply RTV silicon sealent and overtape with two layers of half lap “Fusa Flex” 76593 tape. Joint shall be sealed with heat gun

ii) Cover the brazed joint with Nomex 410, 2 mil thick and impregnate the joint.

10.2 Recommended Source of Supply :

i) M/s Thorn, Bombay ii) M/s Tycoon, Bombay iii) M/s Star Gascon Pvt. Ltd., Bombay


As per manufacturer’s recommendation

11. TERMINAL LUG :


Copper Tubular lug as per RDSO Drg. SK. EL. 3001 (Ref. also SMI No. RDSO / ELRS / SMI / 32 issued vide letter EL/3.2.70/J2 dt. 21.11.78)


M/s Dowell’s Electro Works

Satguru Estate, Office Aarey Road

Goregaon East, Bombay 400 063


As per relevant IS or Manufacturer’s recommendations.

119

12. TERMINAL BLOCK :


Epoxy moulded glass reinforced terminal Block to RDSO SK. EL. 2754A & 2784 A.

(Ref. RDSO Modification Sheet No. WAM4/61 issued vide RDSO letter No. EL/3.2.70/D4 dt. 16.1.78)


i) M/s Sincos, 134 DDA Industrial Estate, Okhla Phase-I, New Delhi 110 020

ii) M/s Hind Engg., Calcutta iii) M/s Hatim Dielectrics, Calcutta uv) M/s Dusada Engg. Kanchrapara, Distt.-24 Parganas (W.B)

ANNEXURE - II

120

TEST FOR INSPECTION AND ACCEPTANCE OF ENAMELLED WINDING WIRE AS PER IS:13778 PART 1 TO 6 OF : 1993

The following tests shall be conducted as per IS:13778 Part 1 to 6 at the manufacturer works before acceptance. However, the test shall be repeated at the user sheds and shops before putting the winding wire into the service. For each test the winding wire should meet respective minimum acceptable value as indicated in IS:13730 Part 13 for dual coated enamelled winding wires. IS:13730 (Part O/Sec. I) -1993 deals with general requirements of enamelled winding wires. IS : 13778 Part 1 - deals with the lists of the tests which are to be conducted on the enamelled winding wires. IS : 13778 Part 2 - deals with the determination of dimensions - diameter shall be checked as per this IS. IS : 13778 Part 3 - deals with tests pertaining to Mechanical properties. Following are the tests which shall be conducted on Part 13 enamelled winding wire. - Elongation - Springiness - Flexibility and adherence - Resistance to abrasion IS : 13778 Part 4 - deals with chemical properties tests and following tests shall be applicable for Part 13 wire. - Solvent test - Resistance to transformer oil in the presence of water. IS : 13778 Part 5 - deals with the test pertaining to electrical properties of the enamelled winding wire. Following are the tests which shall be conducted on Part 13 wires - Electrical resistance - Breakdown voltage - Continuity of covering IS : 13778 Part 6 - deals with the tests pertaining to Thermal properties of the enamelled winding wire. Following are the tests which shall be conducted on the dual coated i.e. Part 13 enamelled winding wires. - Heat shock tests - Cut through tests - Thermal endurance

- High temperature failure tests.


Research Designs & Standards Organisation

121

Manak Nagar , Lucknow - 226011

NO. EL/3.2.14 Dated .04.1998

SPECIAL MAINTENACE INSTRUCTIONS NO. ELRS/SMI/199

1. TITLE :

General guidelines to follow for balancing of rotors and cooling blowers in position.

2. APPLICATION :

2.1 Impeller of all blowers used for cooling traction motor, transformer oil smoothing reactor and rectifiers.

2.2 RDSO have already issued SMI-152 for balancing of rotor, impellers individually as well as together, which may also be followed for general guidelines only.

2.3 Procedure mentioned in SMI-152 is only pertains to a particular type of dynamic balancing (Blue Star) machine. However, any other dynamic balancing machine can be used which is suitable for balancing rotor, motor fan, blower impellers, individually as well as together i.e., machine should be capable to balance weight of atleast 100 kg. with balancing quality grade of G 2.5 as per IS: 11723-1985 or ISO 1940 -1973.

3. OBJECT :

3.1 Rotors, with motor fans or individually, and impellers of cooling blower are balanced at motor, and blower manufactures work respectively upto the quality grade of G 2.5 as mentioned under para 2.3. However, when rotor, fan and cooling blower impellers are balanced together at blower manufacturers end, it is noted that residual unbalanced weight has crossed the limit of G 2.5 (i.e. 8 gms mm/kg of rotor and impeller weight in the case of MVMT rotor + VMT impeller). Since blower manufacturers are not balancing the rotor and impeller together at their works, during the fitment of these blowers in the locomotive, a lot of centrifugal forces are produced around the driving bearing which in turn produces the vibrations on blowers casing and on motors beyond acceptable limit of 40 microns and 15 microns respectively.

3.2 Similar phenomenon is also noted whenever rotors and impellers after repairs are fitted together and also in the case whenever rotor and impellers are interchanged during the maintenance for any reasons.

3.3 This Special Maintenance Instruction indicates the general method to be followed for balancing of rotor and impellers together in position, i.e. when the blowers are installed on the locomotive or blower set has been brought down on the shop floor for repair etc.

3.4 The balancing of rotor and impeller shall be done with the help of portable balancer.

122


NIL

5. INSTRUCTIONS :

5.1 Follow the instructions as laid down in the balancing instruction manual of a particular type of portable balancer.

5.2 Sensor of the portable balancer shall be kept at least on the following places while balancing the impellers in position —

i) On both end of bearing - in the perpendicular direction of the axis of rotation of impellers.

ii) Parallel to axis of rotation, on the NDE side of bearings.

iii) On the top of the casing.

iv) Atleast on 4 places of the casing parallel to axis of rotation, i.e., two in front of the impeller casing and two behind the impeller casing.

5.3 Weld the unbalance mass (as indicated by the portable balancer) at the root of welded impeller which is just diametrically opposite from the impeller where the unbalance has been shown by the stroboscope of the portable balancer. Alternatively, residual unbalance mass can also be removed from the impeller which has been detected by portable balancer stroboscope.

5.4 Sheds, shops of Indian Railways and Blowers and Motor manufacturers should follow the balancing quality grade G 2.5 of IS : 11723 - 1985 or ISO : 1940 - 1973 which amounts to be 8 gm. mm. per kg. of rotor/impeller/rotor and impeller weight, i.e. 4 gm. mm. per kg. of weight at each plane of rotor, motor fan, and impeller.

5.5 Therefore, the magnitude of residual unbalance mass shall not exceed the maximum limit of 8 gm. mm/kg of rotor plus impeller weight as explained vide para 5.4 above.

6. PERIODICITY OF BALANCING :

6.1 Whenever any repair is done on rotor, fan and on impellers of blowers or improper working of blowers are reported in service.

6.2 In AOH on all the impellers of traction motor cooling blowers.

7. AGENCY FOR IMPLEMENTATION :

7.1 All Railways shed, shops of Electric Locomotives.

123

7.2 All blower and motor manufacturers.

8. REFERENCE :

8.1 As per the decisions taken during the meeting held between Railways, RDSO, CLW and manufacturers on 8.12.97 at TKD Electric Loco Shed of W. Rly.

8.2 Source of procurement of the “Portable Balancers 1000” are as follows —

BASELINE TECHNOLOGIES

E-17 Green Park

New Delhi 110 016

FAX No. 011-6866720

Telephone 011 668885

Approximate Cost : Rs. 70,000/-

Alternatively, equivalent portable balancer may be used.

9. DISTRIBUTION : AS PER ENCLOSED LIST.

(R.K. Kulshrestha)

for Director General (Elect.)



124

NO. EL/2.2.8.4 Dated 20.04.1998

SPECIAL MAINTENANCE INSTRUCTIONS NO. ELRS/SMI/200

1. TITLE :

Characteristic properties of impregnating resins and insulating varnishes.

2. APPLICATION :

Auxiliary motors for Electric Locomotives and EMU Applications.

Traction motors for Electric Locomotives except Hitachi Traction Motor type HS 15250A/HS 1050Er.

3. OBJECT:

RDSO have issued Special Maintenance Instruction No. ELRS/SMI/154 in the past enclosing the catalogue and technical details of various insulating varnishes used for impregnation of stator windings of 3-phase auxiliary motors and traction motors for various applications.

The above RDSO SMI - 154 is being superseded with the present SMI and the catalogue and technical properties of impregnating varnishes and resins used for above applications are being furnished.

4. DRAWING / CATALOGUE NUMBER :

4.1 Following catalogue on various types of impregnating resins and antitracking varnishes are being enclosed for necessary guidance and adoption and to follow correct and compatible resins/varnishes for a particular application.

Sl. No.

Catalogue No Name of impregnating resins/Varnishes

Class of insulation /

Temperature

Application

125

1. 3-14-9301 Dobeckon FT-1052 of Dr. Beck & Co. (Solventless unsaturated polyesterimide (UP) and impregnating resin)

H/180 deg. C 1. Stator winding of 3-phase aux. motors.

2. Traction motors

2. Solventless unsaturated polyester insulating varnish RE-002 of M/s Rotomac Electricals which is equivalent to GE - 702

H/180 deg. C Traction motors only

3. 3-15 (Revision

1 Apr. 95)

Dobeckon FT 2005/500EK of M/s Dr. Beck & Co.

H/180 deg. C 1. Stator winding of 3-phase Aux. Motor. 2. Traction Motor

4. 2-31-8912 Becktol (Red) of Dr. Beck & Co. (Antitracking varnish) An alkyd based air drying finishing varnish.

B/130 deg. C - do -

5. S-36-8806 Epoxy Gel coat (Red & White) of Dr. Beck & Co. A room temp. curing Epoxy compound)

-- Overhang of auxiliary motors

5. Maintenance Instructions :

5.1 Type of varnish to be used for a particular application shall be as per Para 4.1 above. However, for a specific application, SMI issued earlier by RDSO or manufacturers instructions may also be followed.

5.2 Before use of the resin/varnish, railways shall conduct test to watch the characteristics as per catalogue indicated in para 4.0 above for a particular application. This procedure shall be mandatory.

5.3 Railways shall use only those resins/varnishes declared compatible with the present system of insulation already adopted.

5.4 After application of this varnish, BDV test on auxiliary motors/stators, armature of Traction Motors and traction motor field coils shall be conducted by railways.

5.5 All components shall be vacuum pressure impregnated with a varnish/resin for an application as per method specified in a particular catalogue.


126

All Electric Loco/EMU Sheds and Shops of Electrified Rlys.


Whenever any auxiliary motors/traction motor is rewound in shed/shop.

8. DISTRIBUTION :


(R.K. Kulshrestha)


Solventless UP Impregnating Resin with tough elastic bonding and Temperature Index 180 Structure Salient Properties and Applications

Dobeckan FT 1052 is a solventless unsaturated polyestenmide (UP) impregnating resin

Dobeckan FT 1052 in combination with Hardener P cures into an elastic and tough mass

127

Dobeckan FT 1052/Hardener P system is characterised by Good penetration Short cunng time Long activated resin (useful) life Tough elastic bonding Excellent dielectric properties Good resistance to chemicals

Dobeckan FT 1052 is suitable for all customary methods of impregnation such as dip. vacuum + pressure, roll etc. Dobeckan FT 1052/Hardener P is suitable for impregnation of standard and special motors upto frames size IEC 355, HT motors , DC machines, traction motors and altemators of class E, B & F. For HT motors and generators whose windings are insulated with glass/mica paper/epoxy novalac tapes. Dobeckan FT 1052 + Hardener P provide excellent consolidation of overhangs. Such machines are conveniently impregnated by roll or dip impregnation methods. Dobeckan FT 1052/Hardener P system is also suitable for impregnation of windings with fine size wires as also for rectangular wires of heavy sizes.

Properties of Dobeckan FT 1052 Components :

Chemical base Unsaturated Polyestenmide resin

Colour and appearance

Brown, clear liquid

Viscosity at 23°C (*) at 27°C

ISO 2555 IS 3944 / Cup No. 4

mPa.s s

480-520 128 (typical)

Density at 23°C ISO 1675 g/ml 1.05 (typical) Flash point ISO 1523

(closed cup) °C 32 (typical)

Compatibility Resin : Diluent M Pbv 1 : > 1 Storage stability In original sealed

container at 20 °C or below

Months 6

Technical Data Sheet 3-14-9301

Hardener P

Chemical base Tertiary butyl cumyl peroxide


Brown, clear liquid

Density at 23°C

ISO 1675 g/ml 0.96 (typical)

128

Storage stability When stored in original sealed container at 20°C or below

Months 6

Mixing Dobeckan FT 1052 100 parts by weight Proportions Hardener P 1 part by weight

Properties of Resin + Hardener Mixture

Viscosity at 23°C

ISO 2555

mPa.s

480-520

Density at 23°C ISO 1675 g/cc 1.05 (typical) Flash point ISO 1523

(closed cup) °C 32 (typical)

Drying in thin layer

IEC 455 2 h at 140°C

Tackfree film with uniform flow

Drying in thick layer

IEC 455 10g/ 140°C/ 2h

Tough-non tacky, free from blisters Top : non tacky smooth Bottom : non tacky

Gelling time (*) of mixture at 100°C

ISO 2535

min

40-60

Activated resin life

At storage temperature upto 23°C

months

6

(*) These properties shall be our sales specifications.

Suggested 2 hours at 140 C Curing

The suggested curing time is after the unit attains the specified temperature. Depending upon the size and weight of the unit, heating time is required to be added.

Properties of Test methods according to IEC 455-2 the Cured Resin Specimen curing 2 h at 140°C

Dielectric Strength

At 25°C at 155°C

kV/mm kV/mm

90 80

129

Volume resistivity

1000 VDC at R T at 155 C after 168 h water immersion at R T

Ohm cm Ohm cm Ohm cm

10°** 10°** 10**

Dielectric (**) dissipation factor

30 V & 1 KHZ at 25°C at 155°C

0.007 0.125

Dielectric (**) constant

30 V & 1 KHZ at 25°C at 155°C

3.3 3.6

Track resistance

DIN 53480

Grade

KB > 600 KA 3C

Adhesive Strength at 25°C at 155°C

N/mm 2

N/mm 2 1.2 1.2

Bond strength at 25°C at 155°C

216 86

Water absorption at 25°C mg 11

Resistance to chemicals

Reduction in dielectric strength after 7 days immersion in - Transformer Oil - Chlorinated

diphenyl - Washing detergents IEC 216

No decrease No decrease No decrease

Temperature Index (***)

°C 180

(**) As per DIN 46448 (***) Decrease of BDV on Impregnated twisted specification

Methods of Application :

Dobeckan FT 1052/Hardener P is suitable for all customary methods of impregnation such as dip, vacuum-pressure, roll, etc. For better bond strength, resin should be used for impregnation in as supplied viscosity. Viscosity reduction of the resin is possible by addition of monostyrene. Figure 1 gives viscosity temperature characteristic of Dobeckan FT 1052. Figure No. 2 gives viscosity reduction characteristic of Dobeckan FT 1052 on addition of monostyrene.

Cleaning Uncured resin can be easily cleaned by washing with hot detergent solution, acetone or styrene. It is difficult to remove cured resin and for this reason, tools and containers, contaminated with activated resin mixture should be cleaned after use.

130

Safe Handling Inhalation and direct contact with skin of resin, hardener or their mixture should be avoided. In case of contact, the affected area should be washed with soap and water. Protective barrier and cleansing creams are suggested for hand. For detailed instructions ask for our Technical information 3-51 "Safe Processing with Dobeckan Resin"

Recommended Storage

The resin and hardener should be stored at a temperature not exceeding 2300C in original sealed containers. At this temperature , the activated resin will remain good for 3 to 6 months. At higher storage temperature the storage life would decrease sharply. The resin and hardener containers should not be expose to sunlight avoid premature gelation.

Packing Dobeckon FT 1052 : 30 kg in polyethyience containers Hardener P : 1 kg and 5 kg in polyethylene containers.

Vacuum impregnation of traction motor armature

132

NOTICE :


dr. beck * co. (India) ltd. Export Division : ‘Construction house’ 796/189B, Bhandarkar Road, Pune 411 004 ( India )

Phone : (0212) 331387, 338842 , Telex : 01457209 DRBK IN/ 01457250 BECK IN Fax : (0212) 336074 , Gram : BECKINDIA. Marketing Head Office : Indravani , 92/11 Chiplunkar Road. Pune 411004 . Phone : (0212) 335796, 331080






133

Structure Salient Properties and Applications

Dobeckan FT 2005/500 EK is a one component solventless unsaturated polyesterimide (UP) impregnating resin . Dobeckan FT 2005/500 EK is classified as Temperature Class 200 (ASTM D 3251). Dobeckan FT 2005/500 EK cures into an elastic and tough mass. Dobeckan FT 2005/500 EK is characterised by

Good dielectric and mechanical properties upto 220 0C Good penetration Tough elastic bonding Higher flash point Long storage life Good resistance to chemicals UL approved as Class 200 under File No. E 73288

Dobeckan FT 2005/500 EK is suitable for all customary methods of impregnation such as dip, vacuum + pressure, roll, etc. Dobeckan FT 2005/500 EK is suitable for impregnation of standard and special motors upto Frame size IEC 355, HT motors, DC machines, traction motors, and dry type transformers. For HT motors and generators whose windings are insulated with glass mica paper epoxy novalac tapes, Dobeckan FT 2005/500 EK provides excellent consolidation of overhangs.

Properties of Dobeckan FT 2005/500 EK

Chemical base Unsaturated Polyestenmide resin


DBI 1001 [**] Brown, clear liquid

Viscosity [*] at 23°C at 23°C

DBI 1015 B [**] DIN 53015 DIN 53211/Cup No. 4

mPa.s s

480-520 100 (typical)

Density at 25°C ISO 1675 g/ml 1.05 (typical) Gelling time (*)

at 120 0C ISO 2535 min

20-30 Recommended

diluent

Diluent V Flash point DBI 1005 [**]

ISO 1523 (closed cup) °C 51 (typical)

Storage stability In original sealed container at 23 °C or below

months 12

(*) These properties form our sales specification (**) DBI are internal test methods and are available on request.

Technical data sheet 3-15 Revision : 1, April

134

Suggested 2 – 4 hours at 160° C Curing

The suggested curing time is after the unit attains the specified temperature. Depending upon the size and weight of the unit, heating time is required to be added.

Properties of the Cured Resin (Typical)

Test as per IEC 455 / 464 Specimen curing 4 h at 160°C

Dielectric strength at 23°C at 155°C at 180°C at 220°C at 25°C/ 24 h water immersion

kV/mm kV/mm kV/mm kV/mm kV/mm

115 92 80 68 99

Bond strength (Twisted coil) at 25 0 C at 155 0 C at 180 0 C at 220 0 C

N N N N

315 90 60 50

Flexibility on mandrel (3mm) at 230 C (Thickness)

mm

No crack up to angle 60 0

0.035 Volume resistivity

at 230 C at 230C after immersion in water

for 7 days at 2200 C

Ohm.cm Ohm.cm Ohm.cm

0 10E16

10E15

10E11

Resistance to solvent vapour after 7 days exposure to acetone, benzene, hexane, methanol, carbondisulphide

Good

Resistance to liquids at 23 C Alkali solution 30% Sulphuric acid Transformer oil

No change in weight Resistant Resistant

Temperature Index Decrease of BDV on

impregnated twisted enamelled wire specimen

Bond strength

ASTM D3251 ASTM D3145

200

220

135

Methods of Application Dobeckan FT 2005/500 EK is suitable for all customary methods of impregnation such as dip, vacuum- pressure roll, etc. Diluent V is used for reduction of viscosity Dobeckan FT 2005/500 EK.

Cleaning Uncured resin can be easily cleaned by washing with hot detergent solution and solvent such as acetone or styrene or vinyl toluene. It is difficult to remove the cured resin and for this reason, tools and containers contaminated with activated resin mixture should be cleaned using Diluent V.

Safe Handling Inhalation and contact with skin of resin, hardener or their mixture should be avoided. In case of contact, the affected area should be washed with soap and water. Protective barrier and cleansing creams are suggested for hands. For detailed instructions ask for our Product Safety Data Sheet 3-15.

Recommended Storage The resin should be stored at a temperature below 23 0C in original sealed containers. At this temperature resin will remain good for 12 months. At higher storage temperature the storage life would decrease. The resin container should not be exposed to sun light to avoid premature gelation.

Packing Dobeckan FT 2005/500 EK : 30 kg in polyethylene containers 210 kg in EP lined drum

Diluent V : 21 kg M.S. drum.

136

NOTICE :


dr. beck * co. (india) ltd. Marketing Head Office : Indravani , 92/11 Chiplunkar Road. Pune 411004 . Phone : (0212) 335796, 331080






137

STRUCTURE SALIENT PROPERTIES AND APPLICATIONS

Becktol (Red\Grey)is an air drying finishing varnish based on alkyd resin. The cured varnish film exhibits excellent resistance to tracking, mild acids and alkalies and prevents ingress of moisture into the windings. Becktol (Red\Grey) is suitable for applications a finishing varnish for field coils, overhangs of stators, armatures, transformers and other electrical windings to provide additional protection against moisture and chemical attack to the impregnated windings. Becktol (Red\Grey) can be applied by all customary methods of application such as dipping, crushing and spraying. The varnish contains fillers and pigments which have tencency to settle down on storage and hence necessary to stir the contents to a homogenous mass before use.

Becktol is available in two snaces red and grey Properties of Becktol (Red/Grey)

Becktol (Red)

Becktol (Grey)


Red opaque liquid

Grey opaque liquid

Non volatile content

Kg / 150 0 C / 2h % 60 - 65

60 - 65

Viscosity At 200 C At 270 C

DIN 53211 Cub No. 4 IS 3944 / Cub No. 4

S S

.50-180 .75

typical

.50-180 .75

typical Density

At 270 C

DIN 51757 g/ml

0.990

.006

Flash Point

DIN 53213 Cup No. 4 IS 3944 / Cup No. 4

oC 35 35

Recommended thinner

Thiner

234

Thiner

234 Storage life

In original sealed

container under covered storage at 25 oC

months .2

.2

Curing Schedule 24h at room temperature

or 16 at room temperature 4-6h at 60-800C

138

Properties of the Specimen curing - 24h at room temperature Cured Varnish Film of Becktol Test according to DIN 46449 unless otherwise specified (Red)* Dielectric

strength at 25°C

at 130°C 24 h water immersion

KV/mm KV/mm

kV/mm

51 43

20

Volume resistivity

(1000 VDC)

at 25°C at 130°C

240h water immersion

ohmxcm ohmxcm

ohmxcm

1014

1010

1010 Tracking Index is 8264 Volts 300-330 Water

absorption at 25°C Mg

% B

1.6

Bectol (grey) has performance properties comparable to those of Bectol (Red)

Storage and Remixing Becktol (Red/Grey) should be stored at room temperature (25 C - 35 C) under covered storage. Since Becktol (Red/Grey) contains fillers and pigments, which have setting tendency during storage varnish must be stirred well before use to homogenous mass

Packing Becktol (Red/Grey) - 14 and 21 Fg in mild steed contains Thinner 234 - 0.9.4 and 20 Kg in mild steed containers.

NOTICE : This information is intended only for general guidance in the application

of our product. It has been obtained by careful investigation and represents the present state of our knowledge and experience. Because of the large number of possible methods of application and processing. We are not able to assume responsibility in any one particular case for either the technical results or the patent rights situation applicable to the country under consideration.

dr. beck * co. (india) ltd. Marketing Head Office : Indravani , 92/11 Chiplunkar Road. Pune 411004 . Phone : (0212) 335796, 331080






139

Insulating Materials VARNISH PRODUCT DATA

RE 002 SOLVENTLESS CLASS ‘H’ VARNISH

PRODUCT DESCRIPTION RE 002 solventless varnish is a two component, semi flexible, unsatured polyester insulating varnish having excellent thermal capability, electrical properties, moisture resistance and tank stability RE 002 varnish consists of RE 002 A and a premeasured quantity of RE 002 B catalyst. This system has been designed specially for the impregnation of DC traction motors by vacuum impregnation. APPLICATION AREAS • Traction Motors and Generators • D C Mill Motors • High Torque D C Motors • (used in Cranes, Hoists, Mining, Earth Moving Machinery etc.) SALIENT FEATURES • Solventless Polyester Varnish of Thermal Class 180 C • Cured Film retains flexibility and hence resists failure due to severe thermal cyling • Excellent Anti-track properties and moisture resistance • Negligible losses during VPI Processing • Provides good film build • Low toxicity compared to other insulating varnishes APPLICATION METHODS • Vacuum Pressure Impregnation • - Dip and Bake PHYSICAL PROPERTIES RE 002 A • Viscosity at 25 0C 800 + 200 CPS • Density at 25 0C 1.06 + 0.02 • Gel time - 1% RE 002 B at 118 0C 14-25 minutes • Flash Point (Pensky- Martens) 43oC (110oF)

141

APPLICATION PROCEDUR RE 002 A varnish must be thoroughly blended with RE 002 B catalyst before use Catalyst RE 220 B is a pale yellow to white grannular low melting (380C) solid The proper premeasuted quality of RE 002 B (1%) by weight is to be added to RE 002 A. Catalyzed can be applied by not or cold dipping but is suitable particularly for VPI or Roll Flow application.

Suggested Vacuum Pressure Cycle 1. Pre heat part to be treated to 1000C 1100C to 450C 600C 2. Palace in vacuum tank. 3. Draw vacuum of 28” 30” of mercury 4. Admit varnish to cover part 5. Partially break vacuum 15” 20” of vacuum with inert gas (Nitrogen of Carbon Dioxide) 6. Continue to break vacuum with air ( or inert gas) and apply pressure with air (50-60 psi) 7. Hold pressure for 20-30 minutes 8. Return varnish to storage tank and release pressure 9. Allow part to drain 5-15 minutes 10. Cute 8-10 hours at 180-1850C Although RE 002 A is supplied in a viscosity range of 800 + 200 cps. It may be desirable to reduce the viscosity to approximately 500 cps with RE 101 viscosity reducer in order to obtain faster impregnation and low surface builds. STORAGE LIFE Storage life of 002 A Varnish (uncatalysed ) is six months at 200C lower Catalyzed tank life of RE 002 is 3 months at 200C or lower and can be extended by proper monitoring of the get time.

As Rotomac Elecricals has no control Over the use to which others may put the material. It does not claim or warrant that in your particular

circumstances the results you will obtain from the use of the product will be the same as described in this communication, or that you will find the

information or recommendations complete accurate or useful The Company accepts no liability for any damages

For your specific applications, please contact:

Rotomac Electricals Pvt. Ltd. 503-504 International Trade Tower, Nehru Place, New Dehli-110019 Phone : 6461915, 6460097, Telex : 031 - 71413 REL IN, 031-71067 REL IN

Fax : 91-11-6423748

Works : B -16 Site IV, UPSIDE Industrial Area, Sahibabad - 201010 (U.P.) Phone : 860145, 864423, Fax : 91-11-6423748

Regd. Office : 105, Park Street, Calcutta -700 016

Phone : 299155, 294297, Telex : 021-5955 REL IN Fax : 091-33-294177

142

Beck Epoxy CompoundsEpoxy Gel Coat (Red/White)A room temperature curing thixotropic pigmented epoxycompound

Structure and Salient Properties Epoxy Gel Coat (Red/White) is a specially

formulated compound having thixotropic consistency, It is used in combination with room temperature curing hardeners such as Hardener 758 (Polyamine) or Hardener EH 411 (Polyamide) Epoxy Gel Coat (Red/White) + Hardener 758 is a fast curing system with hard cured mass. Epoxy Gel Coat (Red/White) + Hardener EH 411 is a slow curing system with elastic cured mass. Epoxy Gel Coat (Red/White) with Hardener 758 or EH 411 has the following characteristics

• Good adhesion to most organic and inorganic materials • Good mechanical and electrical properties • Excellent chemical and humidity resistance

Application Methods Epoxy Gel Coat (Red/White) with Hardener 758 or EH 411 can be applied by brush or spray. Thinner 221 addition is necessary to adjust the viscosity for a particular application.

Suggested Coating Formulations For brush coating application Formulation I Formulation II Mixing proportion (Parts by weight) Epoxy Gel Coat (White/Red)

100 100

Hardener 758 10 - Hardener EH 411 - 35 Thinner 221 15 to 20 10 to 15 Viscosity of mixture at RT IS 3944/Cup 4

100 to 120 seconds

covering capacity for two coats approx. 0.3 mm coating thickness

0.5kg/m2 Actual consumption of Gel Coat mixture will vary depending upon unevenness of substrate

Formulation characteristics

Low pot life of mixture Fast cure at RT Hard & Brittle cured film Good adhesion Excellent chemical and water resistance

Long pot life of mixture Slower cure at RT Hard & flexible cured film Excellent adhesion Moderate chemical and good water resistance

143

For spray application (*) Formulation III Formulation IV Mixing proportion (Parts by weight) Epoxy Gel Coat (White/Red)

100 100

Hardener 758 10 - Hardener EH 411 - 35 Thinner 221 35 to 45 30 to 40 Viscosity of mixture at RT IS 3944/Cup 4

60-80 seconds

covering capacity for two coats coating thickness approx. 0.15 mm to 0.2 mm

0.25kg/m2 Actual consumption may vary depending upon unevenness of substrate

Formulation characteristics

Low pot life of mixture Fast cure at RT Hard & brittle cured film Good adhesion Excellent chemical and water resistance

Long pot life of mixture Slower cure at RT Hard & flexible cured film Excellent adhesion Moderate chemical and water resistance

(*) Use dry compressed air with pressure 3-4 kg.f/cm2 and normal paint spray gun. Curing Epoxy Gel Coat (Red/White)/Hardener EH 411 at 20 0C - 48 hours or at 30 0C - 20-24 hours or at 40 0C - 10-20 hours

Posturing 4h/80-100 C suggested in all cases Epoxy Gel Coat (Red/White) Hardener 758 at 20 0C - 24 hours or at 30 0C - 16 to 20 hours or at 40 0C - 10 to 12 hours

Postcuring 4h/80-100 0C suggested in all cases Physiological Characteristics Epoxy Gel Coat (Red/White) has hardly any effect

on the skin and mucous membrane. Hardeners do affect the skin. Direct contact with hardeners and resin + hardener mixture should be avoided by using rubber gloves and goggles. Affected area of the skin should be scrubbed with 5% acetic acid and washed with plenty of water and soap. For detailed instructions, ask for our technical information 5-03 'Safe Processing with Dobeckot Epoxy Resins and Hardeners.'

144

Properties of Cured Compound Specimen curing : 24 hours at RT + 4 hours at 80o C with Hardener 758 48 hours at RT + 4 hours at 80o C with Hardener EH 411 Epoxy Gel Coat

(Red/White)+ Hardener 758

EpoxyGel Coat (Red/White)+ Hardener EH411

Electrical Properties Track resistance

DIN 53480 KA KB

3C >600

3C >600

Dielectric strength at RT

DIN 53481 (3mm thick specimen)

kV/mm

17

17

Volume resistivity at RT

DIN 53482 Ohm.cm

1015

1014

Chemical Properties Water absorption

DIN 53473

mg

17

26

Effect of Chemicals 25% H2SO4 25% HCl 25% NaOH

DIN 53473

% change in weight

+ 0.50 (Not affected) +0.40 (Not affected) +0.15 (Not affected)

+0.17 (Not affected) +0.35 (Not affected) +0.35 (Not affected)

Field of Application Epoxy Gel Coat (Red/White) with Hardener 758 or EH 411 is

suitable as • Finishing coat on varnish impregnated coils, transformers,

stators, armatures, bus bars and other components of electrical machines for improved resistance to track, moisture and chemicals.

• Coating of metallic and concrete structural parts for preventing corrosion in fertilizer, sugar and other chemical manufacturing plants

• Coating of concrete slabs and water storage tanks for preventing water leakages (water proofing)

• Coating of electronic components such as capacitors, thermistors for moisture resistance and retention of electrical characteristics in service

Packing Epoxy Gel Coat (Red/White) : 1.5 and 25 kg in metal containers

Hardener 758 : 50g, 250 g, 1 kg, 5 kg and 25 kg in

145

polyethylene containers Hardener EH 411 : 250 g, 1 kg and 5 kg in polyethlene

containers and 25 kg in metal containers

Thinner 221 : 0.9, 4 & 20 kg in metal containers Notice This information is intended only for general guidance in the

application of our product. It has been obtained by careful investigation and represents the present state of our knowledge and experience. Because of the large number of possible methods of application and processing, we are not able to assume responsibility in any one particular case for either the technical results of the patent rights situation applicable to the country under consideration.

Dr. deck * co.(india) ltd. Marketing Head Office : Indravani , 92/11 Chiplunkar Road. Pune 411004 . Phone : (0212) 335796, 331080 Tix : 01457209 DRBK IN / 01457250 BECK IN . Fax : (0212)336074, 363256 . Gram : BECKINDIA Technical Services :Pimpri. Pune 411018 . Phone : (0212) 776241-4 . Fax : (0212) 774648 . Gram : insubeck Regional offices : 403 World Trade

Centre, Babar Road New Delhi 110001 Phone : (011) 3311664/3712940 Telex : 031 66067 BECK IN Telefax : (011) 3713406 BECK IN .

5 & 6 Fancy Lane Calcutta 700001 Phone : (033) 2486881/2462019 TelefaX : 0217441 BECKIN Gram : INSUBECK Calcutta

302,T V Industrial Estate S K Ahire Marg. Worli Bombay 400025 Phone : (022) 4932654 Telefax : (022) 4933362

1176, 12th B Main H. A. L. IInd stage Bangalore 560008 Phone : (080) 5281649/5283093 Telex : 08452952 BECK IN Gram : BECKINDIA, Bangalore

146

SEMICONDUCTOR DEVICES &

BATTERY CHARGER

147


Research Designs & Standards Organisation Manak Nagar, Lucknow 226011.

No. EL/3.2.12/EC2 Dated : August 23, 1978


1. Title of modification : Simplified control card for static battery charger type BCF 6 of M/s Control and Drives Ltd.

2. Application to class of locomotive : WAM4 Locos. 3. Object of modification : Railways had reported a number of failures of static battery charger type BCF6

of M/s Control & Drives and the failures were primarily of components such as transistors, Zener diodes, diodes, resistors, capacitors etc. Investigations have indicated that the failures were attributable to some limitations in the design and multiplicity of components. It is proposed to simplify the design as per RDSO Sketch No. SK. EL. 2750 to improve upon the performance of the equipment.

4. Modification Drawing No : RDSO SK. EL. : 2750 5. Agency of Modification : Railways - All locomotives provided with BCF 6 chargers.

6. Material Required :

a. additional components

i) Carbon resistors (as per IS : 2903-1964)

R 27 10 K. ohms +/- 10%, 1W

R 28 68 K. ohms +/- 10%, 0.5W

ii) Vitreous Enamelled wire wound resistor “RCL”

between 0.6 to 0.7 ohms. 300W

b. Components reused in modified circuit

Zoner diods ZD3 Existing

Diode D22 Existing

148

RDSO /WAM4 / 72

7. Material rendered as spares

i) Carbon resistors Qty. per charger

R8 to R17 12

R24 to R25

ii) Transistors Q1, Q2, Q3 3

iii) Diodes D18, D19 & D20 3


The existing “Control module 1” of static battery charger type BCF6 should be modified as per RDSO Sketch No. SK. EL. 2750 using two additional carbon resistors and one wire would be resistor of rating indicated above. After carrying out the modifications the charger should be tested (without) provision of series current limiting resistor “ROB” after adjusting dc output voltage to 110V at input voltage of 380V rms. The output voltage variation with dc load upto 20A should be within +/-1 volt. After the test, the current limiting resistor side. The resistor should be mounted outside the battery charger, cubicle to avoid heating up of the static components of control cards.

9. Reference :

Nil

10. Distribution :

As per distribution sheet enclosed.

sd/- (S.Malviya) DA : Distribution Sheet for Director General / Elect. & SK. EL. 2750

149


Research Designs & standards Organisation Manak Nagar, Lucknow 226011.

No. EL/3.2.12/EC2 Dated : July, 1979.


1. Object of modification :

1.1 Railway have reported a number of failures of BCF7 battery chargers mainly due to failures of various components such as resistors, capacitors, transistors etc. On investigations it has been found that high ambient temperature around the components inside the charger is one of the contributory causes. To reduce the ambient temperature of air inside the charger it is proposed to shift the bleader resistance (R’5) to a location outside the charger.

1.2 This modification has been earlier carried out on BCF 6 battery chargers with satisfactory results.


2.1 Shift bleeder resistor (R’5) presently mounted inside the battery charger to outside the charger and mount it on the side panel of the charger in the similar may as done on BCF6 chargers.

3. Application to class of locomotive :

3.1 Rail and other locomotives provided with BF7 battery charger.

4. Material required : Nil 5. Material rendered surplus : Nil 6. Reference : Nil 7. Modification Drawing : RDSO SK. EL. 3151 8. Agency for modification : Railways - All locomotives provided with BCF7 battery chargers.

9. Distribution : As per list enclosed

(S. Kumar)

Encl : 1. Mailing list for Director General/Elec 2. SK. EL. 3151

151



No. EL/3.2.12/EC2 Dated : July, 1979


PROVISION OF CURRENT LIMITING RESISTOR ON STATIC BATTERY CHARGER TYPE BCF7 OF M/S

CONTROLS & DRIVES CORPORATION, COIMBATORE 1. Object of modification : 1.1 Railways have reported a number of cases of failures of BCF7 chargers due to blowing of fuse, failure of diodes, current transformer and other components. Similar failures were reported on BCF-6 battery charger of the same make. Investigation indicated that these failures were mainly due to inrush of excessive current to the discharged batteries. To limit the excessive current, a current limiting resistor (RCL) was provided and the failures of the component were arrested. This modification is also proposed to be incorporated on BCF7 battery chargers. 2. Work to be carried out : Mount the current limiting resistor (RCL) of resistance 0.6 to 0.7 ohm, 300W as shown in RDSO drawing No. SK. EL. 2813/B outside the battery charger on the side panel as indicated in RDSO drawing No. SK. EL. 3151 enclosed with modification sheet No. 83 3. Application to class of locomotive : 3.1 WAM4 and other electric locos with BCF7 battery charger provided. 4. Material required : 4.1 Vitreous enamelled wire wound resistor between 0.6 to 0.7 ohm, 300W as per IS: 3373 (Part-II) - 1967 as for BCF-6 chargers. 5. Material rendered surplus - N I L 6. Reference - N I L 7. Modification Drawing : RDSO. SK. EL.. 2813/B RDSO. SK. EL.. 3151

152

8. Agency for modification : Railways - All battery chargers type BCF-7 provided on electric locomotives. 9. Distribution : (As per list enclosed.)

Encls. 1. Mailing List 2. Drg. SK. EL. 2813/B (S. Kumar) for Director General (Elect.)

154

Government of India , Ministry of Railways Research Design & Standards Organisation

No. EL/3.2.12/EC2 Lucknow – 226011 Dated : July `79


RE-SOLDERING FILTER CAPACITOR C3 AND PROVISION

OF LEATHEROID PAPER IN ITS CONTAINER AND TERMINAL FOR FILTER CAPACITOR CONNECTIONS

1. OBJECT OF MODIFICATION : 1.1 A number of BCF7 battery chargers have failed in service due to failure of filter capacitors “C3”. On investigation it was found that the failure were due to (a) poor soldering and use of single strand thin wire used for connecting the capacitors in series/parallel, (b) loose fitting of capacitors in the container and (c) poor connection to battery positive and negative output wires. 1.2 Resoldering of capacitors with continuous multistrand wire, provision of leatheroid paper in its container to avoid vibration, provision of terminals for proper connections to battery positive and negative has improved the performance considerably at Ghaziabad Elec. Loco Shed. During the last two years there is not even a single case of filter capacitor failure. 2. Work to be carried out :

i) Resolder as per technical circular No. EL/8 filter capacitor bank “C3” with multistranded cable as shown in RDSO SK. EL. 3152

(ii) Inspect solder points as per tech. circular No. EL/13.

(iii) Provide leatheroid paper packing on side walls so that the capacitors are held in position rigidly to avoid vibration. iv) Provide standard terminals block for proper connection of battery positive and negative connections.

3. Application to class of locomotive : WAM4 and other locos provided with BCF7 chargers.

155

4. Material required : i) 60-tin 40 load solder ii) Multiple stranded cable to suit capacitor terminal hole iii) Two terminals and 10 mm thick bylam sheet of suitable size 5. Material rendered surplus N I L 6. Reference : N I L 7. Modification Drawing : RDSO : SK. EL. 3152 8. Agency for modification : Railways - All BCE 7 chargers provided on Electric locos. 9. Distribution : (As per list attached.) D.A. 1. Mailing list sd/- 2. DRG. SK.EL 3152. (S. Kumar) for Director General (Elect)

157

Government of India , Ministry of Railways Research Design & Standards Organisation

No : EL/3.2.12/EC2 Lucknow-226011 Dated : July, 1979 MODIFICATION SHEET NO. RDSO/WAM4/86

REPLACEMENT OF 3K OHM CARBON RESISTOR (R’4)BY WIRE WOUND RESISTOR IN BCF7 BATTERY CHARGER OF M/S CONTROLS AND DRIVES CORPORATION, COIMBATORE 1. Object of modification : 1.1 Railways have reported some cases of failures of 3K ohm carbon resistor (R’4) and erratic output voltage on BCF7 chargers. Investigations indicated that two 3K ohms carbon resistors connected in parallel in bias winding were getting overheated and in some cases surface coating had completely peeled out. This also results in drift in resistance value and consequent erratic output voltage. 1.2 It is proposed to replace these carbon resistors by two 3K ohms, 10W wire wound resistors connected in parallel to give an effective value of 1.5K ohms, 20W. 2. Work to be carried out : i) Mount 3K ohm, 10W wire wound resistor in place of 3K ohm carbon resistor (R’4) and solder the leads with 60 tin. 40 lead solder as per IS : 193-1977 ii) Test for proper functioning of charger. 3. Application to class of locomotives : 3.1 WAM4 and other locos provided with BCF7 battery chargers. 4. Material required : 4.1 Two vitreous enamelled wire wound resistors as per IS : 3373 (Part-II) 1967 of 3K ohm + 5%, 10W each. 5. Material rendered surplus : N I L 6. Reference : N I L 7. Modification Drawing : N I L 8. Agency for modification

Railways - on all the BCF7 barrery hargers.

9.Distribution : (As per list attached.) Encls : One mailing list S. Kumar for Director General (Elec.)

158

Government of India - Ministry of Railways Research Design & Standards Organisation

No. EL/3.2.12/EC2 Dated July 1979


MODIFICATION OF THE FLEXIBLE CABLE CONNECTION ON PRINTED CARD BOARD OF BCF7 BATTERY CHARGER OF M/S CONTROLS AND DRIVES CORPORTION, COIMBATORE

1. Object of modification : 1.1 Some cases of breakage of flexible connecting cables at the soldered point on P.C. board have been reported. Since these cables are directly soldered on P.C. board any vibration or movement of card or connector cable exerts excessive stress at the soldered point. 1.2 It is suggested that the wires should be passed through holes and then soldered. Suitable size of holes may be drilled as shown in SK. EL. 3153. 2. Work to be carried out :

i) Drill holes for connector cables as shown in SK. EL. 3153. ii) Desolder one wire and pass it through the hole and then re-solder as shown

in SK. EL. 3153 iii) Repeat the process for other wires one after the other. Do not de-solder all

the wires first to avoid wrong connections iv) Inspect other card for proper soldering and verify for correct connection by

card listing method followed by the shed. v) Refer to Technical Circular No. ERL/8 & EL/13 regarding precautions and

inspections 3. Application to class of locomotive : 3.1 WAM4 and other electric locos provided with BCF7 chargers. 4. Material required : N I L 5. Material rendered surplus : N I L 6. Reference : N I L 7. Modification Drawing : RDSO SK. EL. 3153 8. Agency for modification :

159

8.1 Railways - All battery chargers type BCF-7 provided on electric locomotives 9. Distribution : (As per list attached)

Enclosures : 1.Mailing list S. Kumar 2. Drawing SK. EL. 3153 for Director General (Elect.)

161


Research Designs & standards Organisation Manak Nagar, Lucknow 226011. No. EL/2.2.24/1/EC2 Dated : May, 1990

MODIFICATION SHEET NO. RDSO/WAM4/101 LOCO HEAD LIGHT VOLTAGE STABILIZER MODIFICATION 1. Object :

Sheds have reported failures of Loco Headlight stabilizer of M/s Light Equipments manufacturing Company provided on 25KV as locomotives. Investigations have shown that failures are mainly due to no-load operation during day time as under this unstable oscillation condition at sub-harmonic frequencies are generated in the ferro resonant circuit.

2. Work to be carried out : 2.1 Connect 32 ohms, 50W resistor across 32V winding and mount it above the top cover of the stablizer. 2.2 Provide a 15A HRC fuse in 32V output as shown in the drawing No. SK. EL.- 3296 3. Applicable to class of locomotives : Locomotives provided with M/s Light Equipment make head light stabilizers. 4. Material required : i) Vitreous enamelled wire would resistor 32 ohms, 50W, as per IS - 3373 Part - II - one ii) 15A, 100V, HRC fuse as per IS : 2208 with holder - one 5. Modification Drawing : RDSO SK. EL. 3295, 3296 6. Agency for modification : Electric loco sheds. 7. Distribution : As per enclosed list

Encls. Mailing list S. Kumar for Director General (Electrical)

164


Research Designs & standards Organisation Manak Nagar, Lucknow 226011. No. EL/2.2.24/1/102 June, 1980

MODIFICATION SHEET NO. RDSO/WAM4/102 LOCO HEAD LIGHT VOLTAGE STABLIZER MODIFICATION 1. Object : Failure of 10 mfd, 400V capacitor provided in loco head light stablizer of M/s Light Equipments make have been reported by Railways. On investigations it has been observed that the voltage across capacitors may arise upto 500V under worst condition and the voltage rating of the existing condensers is therefore marginal. 2. Work to be carried out : Replace existing 10 mfd, 400 V capacitors by 10 mfd, 600V capacitors in the same location. 3. APPLIED TO CLASS OF LOCOMOTIVE : Locos provided with M/s Light Equipment make head light voltage stablizers. 4. MATERIAL REQUIRED : Capacitor 10 mfd, 600V as per IS : 2993-1975 specification for motor capacitors 5. MODIFICATION DRAWING : N I L 6. AGENCY FOR MODIFICATION. Electric loco sheds. 7. DISTRIBUTION. As per enclosed list. DA/one list. sd/- (S. Kumar) Krite Maha Nideshak (Vidyut)

165

Government of India Ministry of Railways Research Designs & standards Organisation

Manak Nagar, Lucknow 226011. No. EL/3.2.27/EC2

MODIFICATION SHEET NO. RDSO/WAM-4/104

SILICON RECTIFIER DAMPING CAPACITOR FAILURES 1. OBJECT : 1.1 Sheds have reported failures of damping capacitors of ac damping panel and hold storage capacitors provided on silicone rectifiers. On investigations it was observed that the problem is mainly confined to capacitors not provided with terminals with adequate creepage distance as a result of which tracking is taking place between terminals. 2. WORK TO BE CARRIEDOUT : 2.1 Clean the capacitor terminals and the space around it thoroughly so that it is free from dust and oil contamination. Apply about 1 mm thick M-seal Tough set -B epoxy compound with brush on capacitor terminals and area around it as marked in red on the enclosed drawing No. SK. EL. 3304 Fig. A for capacitors provided with slip on clips. The distance upto which the coating is to be done is indicated separately for the soldered connection and slip on clip connections. 2.2 After allowing first coating to set, apply second coat on coated capacitor terminals with M-seal Toughest - B epoxy compound of approx 1mm thick upto height of 2 mm below hold provided on capacitor terminals as shown in red on drawing No. SK. EL.-3304 Fig. B where soldered connection are provided. 2.3 In case of any oil leakage near the terminals has been observed, seal the hole or crakced surface with araldite before applying tough set compound. 2.4 Inspect capacitor terminals during every IC schedule and touch up the coated surface where necessary. Note : (1) Capacitor terminals which are not easily accessible for cleaning

and applying tough set ‘B’ compound in position, capacitors may be removed from the mounted position and modification carried out on the shop floor.

166

(2) Blowing of the dust from the terminals is to be done during every monthly schedule. 2.5 Whenever damping capacitors are being replaced, it should be ensured that they have terminals mounted on insulators with adequate creepage distance. 3. Application : 3.1 Loco/EMU Rectifier sets of all makes where the capacitors are not provided with terminals on the procelain insulators. 4. Material required : Materila Supplier M-seal Toughset-B M/s Mahindra Electro Chemical Products Ltd. epoxy Compound 145 Bombay - Poona Road, 411 018 5. Reference Drawing : RDOS SK. EL.-3304 AN 6. Agency for modification :

Electric Loco Shed , Car Sheds.

7. Distribution :

As per enclosed lilst.

DA : Drg. No. SK. EL.-3304 Sd/- (S. Kumar) for Director General /Elect.

168


Research Designs & standards Organisatio Manak Nagar, Lucknow 226011.

No. EL/3.2.12/EC2 July, 1980

MODIFICATION SHEET NO. RDSO/WAM-4/105 INCREASE IN OUTPUT VOLTAGE SETTING OF BATTER CHARGERS TYPE

BCF6 AND BCF7 1. OBJECT :

Provision of 0.6 to 0.7 ohm current limiting resistor (RCL) has been advised for battery chargers type BCF6 & BCF7 vide this office modification sheet No. RDSO/WAM-4/72 dated 23.8.1978. The additional series resistor has caused voltage drop of about 3 to 4 volts with normal current load. It is, therefore, necessary to increase the output voltage setting to 115V +1 V at no load/light load of about 1 Amp. -0 2. WORK TO BE CARRIED :

2.1 Connect the battery charger to 380V, single phae, 50 HZ input supply and adjust potentiometer “PL” after loosening potentiometer locking arrangement such that the output voltage before current limiting resistor “RCL” is 115V + 1V instead 110V + 1V at present. -0

2.2 Tighten the locking arrangement of potentiometer “PL” after setting and verify that the setting is not disturbed.

3. APPLICABLE TO CLASS OF LOCOMOTIVES :

Locomotives provided with Battery Chargers type BCF6 and BCF7

4. MATERIAL REQUIRED : N I L

5. MODIFICATION DRAWING N I L

6. AGENCY FOR MODIFICATION Electro Loco Sheds

7. DISRIBUTION As per list enclosed.

DA: Mailing list (S. Kumar)

Krite Maha Nideshak (Vidyut)

169



No. EL/3.2.28/2/EC2 Dated : 2.2.1979

SPECIAL MAINTENANCE INSTRUCTION NO. RDSO/EL.RS/SMI/35

1. Title :

Re-forming of Selenium stacks.

2. Application :

Selenium stacks on all types of locomotives and EMUs.

3. Object of special maintenance instructions :

Selenium stacks have a tendancy to lose considerably their reverse characteristic when stored for long periods or when operated continuously at voltages appreciable lower than their rated voltage and the reverse resistance of the stack falls considerably below its original value. If the rated voltage is re-applied directly, a high reverse current will flow. In some cases even sparking may occur. It is necessary to reform such stacks before use, since otherwise they are likely to fail in service.


RDSO SK. EL. 3043 Fig. 1 and Fig. 2

5. Instructions :

a) Connect the Selenium stack as shown in SK. EL. 3043 Fig.1 if it is a bridge rectifier unit and as in Fig. 2 with a series diode, if it is a single stack used as a blocker.

b) b) Increase the AC voltage gradually from zero until the reverse current reaches the permissible limit. In the absence of specific information this limit may be taken as approximately 5 mm/cm2 of the Selenium plate size.

170

c) Maintain the applied voltage as above. It will be noticed that the reverse current gradually falls and then stabilised at some lower value.

d) Now further increase the applied voltage, so as to bring the reverse current back to the specified limit as in (b) above. The reverse current will agian gradually fall to some lower value and stabilize there.

e) The process as in (c) & (d) should be repeated until the rated reverse voltage is reached while keeping the reverse current within the specified limit.

f) Keep the stack “ON” with rated reverse voltage applied for about an h our for forming the plates.

g) In case it is not possible to achieve rated reverse voltage with reverse current within the specified limit, it may be concluded that some plates have failed and the stack is defective. The stack should be rejected.

Warning :

i) Connect the stack with correct polarity as shown

ii) Re-form the stack upto rated voltage only

iii) do not apply full voltage directly

iv) Increase the voltage gradually in such a way that reverse current is kept within the limit

6. Periodicity of implementation :

The stacks which are stored for more than 6 months or operated at low voltage continuously


Electric Loco Sheds, Car Sheds and Shops.

8. Distribution :

(As per list enclosed).

DA : i) RDSO SK. EL. 3043

ii) DistributionList ( S. Malaviya )

For Director General /Elec.

Comment:

174



No.EL/3.2.28/EC2 Dated 2.2.79.

SPECIAL MAINTENANCE INSTRUCTION NO. LOCO/EL RS/SMI/36

1. Title:-

Testing of POLARISED Seleniun surge suppressor type C 125 L of M/s. Vestinghouse used a across rectifier diode on frequency regualators of AEI make.

2. Application to class of locomotives:

WCM1 and WCG2 locomotives.

3. Object of Special Maintenance Instrucion:

Railways have reported a number of failure cases of surge suppressors provided across rectiffer diodes for protection. It is, therefore, suggested that the selenium surge suppressor units should be periodically tested for serviseability and replace, if necessary.

4. Instruction Drawing: RDSO SK. EL. 3045

5. Instructions:-

(a) Any seleniun stick has a tendency to lose its reverse characteristics when stores for long duration or when continuously operated at a voltage lower than rated valve. It is, therefore, recommended that in such cases the stacks should be re- formed before use upto 600 V as per general instructions contained in RDSO/EL.RS/SMI/35-Fig.2. The maximum reverse current after re-forming should not exceed 150 mA.

(b) The polarised surge suppressor stack consists of 24 plates of 22 mm x 22 mm size, connected in series. Connect the stock terminal marked ‘RED’ to positive supply and negative to other extreme and terminal as shown in RDSO SK. EL. 3045.

(c) Increase the voltage gradually till the voltmeter reads 600 V. Allow the reverse current to stabilise, which may take about 2 to 3 min. and record the ameter reading. The reverse leakage current should be less than 15 mA after stabilisation at room temperature.

175

(d) Increase the voltage further till the knee- point, the point beyond which there is a large increase in reverse current with nomical change in voltage. The recoreded knee point shall not exceed 700 V + 10 V with reverse current of approx. 30 mA.

(e) Reject the stack in case the reverse current recorded is more that 15 MA for voltage below 600 V and/or knee point is above 700 V+ 10 V.

Warning:-

i) Connect the stack with correctpolarity.

ii) Do not apply voltage directly to the stack.

iii) Take reverse current reading only when it stabilises.

iv) Re-form the stack before test, if necessary.

v) Do not cannibalise the stack with plates removed from old stacks.

6. Periodicity of implementation:-

- Initial checking at the time of putting in service and then yearly for the first two years. The stack shall be checked every six months after two years of service.

7. Agency for implementation:-

Electric Loco Shed and Shops holding WCAM1 and WAG2 locomotives.

8. Distribution:- As per list.

Sd. xx xx xx (S. Malaviya)

For Director General(Elect.) AD: 1) RDSO SK EL 3045

177


Manak Nagar, Lucknow 226011. No. EL/3.2.28/2/EC2. Dated 2.2.79

SPECIAL MAINTENANCE INSTRUCTION NO. RDSO/EL RS/SMI/37

1. Title.

Testing of NON-POLARISED selenium surge suppressor type C-186 I06C on frequency regulator of M/s AEI used with motor-alternator set.

2. Application to class of locomotives

WCAM-1 and WCG-2 locomotives

3. Object of special Maintenance instruction

Railways have reported a few cases of failures of seleniun non-polarised surge suppressor of frequency regulator provided across motor field of motor-alternator set. It is, therefore, recommended that the surge suppressor units should be periodicity tested and replaced, if necessary.

4. Instruction Drawing RDSO SK. EL. 3044

5. Instructions

a) Any selenium stack has a tendency to lose its reverse characteristics when stored for long periods or when operated continuously at voltages much lower than its rated value. In such cases the stacks should be re-formed before use upto 400 V, If necessary, as per the general instructions contained in RDSO/EL RS/SMI/35 Fig.2. The maximum reverse current after reforming should not exceed 40 mA.

b) The surge suppressor stack consist of two arms, each with 18 plates of 50 mm x 50 mm size connected in series. To obtain this arrangement, three stacks are used and suitably connected with centre terminal at middle stack and extreme and terminals on the other two stacks, forming the two arms. Test each arm by connecting centre terminal of middle stack to positive supply and negative terminal of top or bottom stack the supply negative as shown in RDSO SK. EL. No. 3044.

c) Increase the voltage gradually till the voltmeter reads 400 V. Allow the reverse leakage current to stabilise, which may take about 2 to 3 min. and recore the

178

ammeter reading. The reverse leakage current should be less that 40 mA after stabilisation at room temperature.

d) Then increase the voltage further till knee point, i.e. the point at which there is a large increase in reverse current with a nominal increase in applied voltage. The recorded knee-point shall not exceed 500 + 10V with reverse current of approx. 60 mA

e) Repeat the test for the other arm of the stack after bringing the test voltage back to zero keep positive supply connection as in the first case and shift the negative supply to the other end terminal. Increase the voltage gradually from zero and record. reading as in (c) and (d) above.

f) Reject the assembly if reverse current is more than 40 mA at 400 V and/or if knee-point is beyond 500V+ 10V.

Warning:

i) Always keep the variao in zero position before and after the test.

ii) Correct the stack in reverse polarity only.

iii) Do not apply full voltage directly to the stack: increase should be gradual.

iv) Take reverse current reading only when it has stabilised after some period.

v) Re-form the stack, if necessary, before test.


Initial checking at the time of putting in service. For stacks in service, at the end of the 1st and 3 years and there after every 6 months. Intervals may be increased if test results are invariably found satisfactory.


Electric Loco Sheds and Shops where WCAM1 or WCG2 are maintained.

8. Distribution As per enclosed list.

DA: i) RDSO SK. EL. 3044 ( S. Malaviya) ii) Distribution list. for Director General (Elect.)

181



No.EL/3.2.28/2/EC2 Dated:2.2.79.

SPECIAL MAINTENANCE INSTRUCTION NO.RDSO/EL RS/SMI/38.

1. Title

Testing of three phase selenium rectifier (CREX) used on generator field excitation circuit of motor-alternator set.

2. Application to class of locomotives

WCM1 and WCG2 locomotives

3. Object of Special Maintenance Instruction

Railways have reported failures of three phase selenium rectifier stacks used in generator field excitation circuit of M.A. set. Special tests are, there fore, specified to verify the serviceability of rectifier stack and ensure timely replacement of defective unit to avoid line failures.

4. Instruction Drawing : RDSO SK. EL. 3042 Fig. 1 and Fig.3

5. Instructions

Three phase rectifier assembly consists of three stacks. Each stack comprise of two rectifier arms (12 plates in series per arm). The following tests should be carried out.

(i) Forward Voltage drop test

a) Contact the stack as per RDSO SK. EL. 3042(Fig.1) and increase the voltage gradually till the forward current values is reached as indicated in TABLE 1 for the given type of rectifier stack.

b) Take the forward voltage drop reading across each arm within 5 min. to avoid overheating of plates.

c) The recorded forward voltage drop across each arm shall not exceed the special and limit value given in TABLE 1. If higher voltage drop is obtained, reject she stack.

182

TABLE-1.

Forward Voltage drop limit values

S.No

Type of

stack

Make Plate size in mm

Plates in series per arm

Test current in Amp (ave)

Forward Voltage drop limit Values

New Old

1. KHINDT 12 DIP Khandelwal HERMANN

63x100 12 7.0 13.8V 26V

2. D12 DIST ELD usha Rectifiers

77x77 12 2.24 14.5V 29V

(ii) Reverse current test (at room temperature)

a) Connect each arm of stack as per circuit diagram SK. EL. 3042,Fig.2 and increase voltage gradually. if the reverse current is more then 100 mA at voltage less than 200 V, The rectifier stack should be ‘re-formed’ as per RDSO/EL.RS/SMI/35, otherwise proceed as follows:

b) Increase the reverse voltage gradually till the reverse current is obtained as per TABLE-II and record the applied reverse voltage after about 2 to 3 min, to allow stabilisation of reverse current. The recorded dc reverse voltage should not be less then 430 V.

c) Reject the selenium stack in case the recorded reverse blocking voltage is less than 430 V dc for reverse current limit value indicated in TABEL-II of the given type of stack.

Table-II

Reverse current limit values

S.No

Type of stack

Make Plate size in mm

Reverse Current For new & old

dc reverse voltage applied not less than

1. KHINDT 12 DIP Khandelwal Hermann

63x100 150 mm 430 V 430 V

2. D12 DIST ELD Usha Rectifiers

77x77 do

Warning

183

i) Connect the stack in correct polarity

ii) Do not apply full voltage directly

iii) Take the forward voltage drop reading within 5 minutes and then reduce the current to zero.

iv) Do not cannibalise rectifier stack from old.


Check the new stack before installation and every year therafter fo two consecutive years, After two years, check every six month, since the expected life of the stack is about 3 years.


Electric Loco sheds and Shops where WCAM-1 or WCG-2 locos are maintained.

8. Distribution

(As per list enclosed).

DA: i) RDSO SK. EL. 3042

in two sheets.

ii) Distribution list. Sd/-(S. Malaviya) for Director General (Elect.)

186



No.EL/2.5.27/E82 Dated 6th December 79.

SPECIAL MAINTENANCE INSTRUCTION NO.RDSO/ELRS/SMI/55

DC DAMPING UNIT RESISTOR FAILURE

1. Object

Sheds have reported failures of resistor C5 in dc damping units provided on WAG/4 Locomotive test silicon rectifier of M/s AEG/NGEE/CLE make. Investigation have shown that as per the connection arrangement provided, only half the portion of resistor r5 is in circuit and as a result overloading of the resistor is taking place. The correct connection form resistor 5 are shown in RDSO SK EL 3077

2. Instructions:-

Check the existing connections of each component on dc damping unit provided on M/s AEG/NGEF/CLW rectifiers as per RDSO Drawing No. SK.EL.3177. If not so, correct the connections as indicated in the sketch.

3. Instruction Drawing:-

RDSO Drawing No. SK.EL.3177.

4. Application to class of Locomotives:-

4.1 AC electric locomotives provided with M/s AEG/NGEF/CLW silicon Rectifiers.

Note: Not applicable for WAM4/B (Waltair-Kirandul)

locomotive rectifiers.

5. Agency for implementation:- Electric Loco Sheds.

6. Reference: Nil.

7. Distribution:- As per list.

Encl: Drg. No. SK.EL.3177 Mailing list. Sd.(Surender Kumar)

for Director General/Elec. (( TRUE COPY ))

188



No.EL/3.2.2/S1-EG2 Dated: Sept 14th 1980.


SILICON DIODE TESTING

1. OBJECT:

1.1 During Investigations of the failures of diodes in various sheds, it has been noticed that in some of the sheds proper testing of the diodes is not being done. As a result healthy diodes are sometimes being rejected and defective diodes sometimes reused. Different instruction for testing of the diodes have been given in the respective maintenance manuals supplied by the manufactures. It is, therefore, considered necessary to elaborate and standardise the instructions, detailing the correct procedure for all type of diodes presently in service.

1.2 The following procedure should be introduced immediately for testing diodes removal from the rectifier cubicle during POH or at other times in case of doubt.

2. INSTRUCTIONS:

2.1 Remove the suspected diode/diodes either with or without heat sink from the rectifier cubicle following the instructions given in the relevant maintenance manual supplied by the manufacturer.

2.2 Diodes need not to removed from heat sink for testing. The diode and heat sink must be cleaned before testing.

2.3 Place the diodes of diode heat sink assembly under test a clean fibre glass sheet to avoid surface leakage or flash over during testing.

2.4 Diode Test with 110 V dc:

2.4.1 Test the diode first with 110 V dc for forward conduction and reverse blocking properties as per procedure given below:-

(a) For diode Test:

First check the lamp is healthy by shorting the nut-put leads, then check the conductivity of diode unit test (DUT) by connecting to a 110V dc supply with a 110V, 30V, lamp in series as shown in SK. EL.-3320 Fig’A’ The lamp should

189

glow bright in case the lamp is dim or dark the diode under test is of their with high, forward resistance or open circuited and hence defective.

(b) Reverse Voltage Blocking Test:

Connect the diode with reverse polarity to a 110V dc supply in series with the 110V 30W, lamp as shown in No. SK. EL. 3320 Fig’B’ In case the lamp glows the diode is shorted and defective. If the lamp remains dark the diode is healthy.

2.4.2 Diodes which pass both tests (a) and (b) in para 2.6 should be subjected to high voltage reverse current test as in para 2.5

2.5 High Voltage Reverse Current Test:

a) Use a diode testing that as per the schematic indicated in the enclosed drawing No. SK. EL. 3360 (This type of diodes testing unit is already available in some of the sheds. It can be easily assembled by the sheds. Details guide lines for assy, of the unit are given in Annexure ‘A’).

b) Place the diode assembly under test, connect the diode under test as shown in No.SKEl 3320 with the positive (+) terminal of the diode (DUT) i.e. the terminal from which the forward current flows to the outer circuit and the negative (-) terminal of the test unit to the diode anode.

c) After ensuring that the variac is in its minimum position, switch on the supply of the test unit.

d) Incrase the voltage gradually by moving varinac from minimum position and observe readings on ammeter and voltmeter of the test unit. It the voltmeter reading is increasing and the ammeter reading is below 30-mA, increase the applied voltage gradually upto the test voltage indicated in reverse current to 10. The test voltage and reverse current limit value for various types of diodes in service are indicated in this, table.

e) In case the reverse current at specified test voltage is more than the limiting value indicated in the table for that particular type of diode under the test, the diode is not reliable and should not be used in traction rectified. The use of higher reverse leakage current, diodes, which are not non or shorted will be advised separately

f) Reduce the applied voltage gradually by bring the variac towards minimum position. Switch till the supply to diode testing unit before removing the diode from the test unit.

190

g) If the current tends to exceed the missing limits at a voltage well below the rectified test voltage the diode is defective.

h) Proceed in a similar manner as above for their diodes to be tested.

2.6 Reverse current limits for various types of Diodes:

S.No. Type of diode Voltmeter Ammeter reading not to exceed

1. ELOAN122 400V 30mA 2. N15L 400V 30mA 3. DJ15J 300V 30mA 4. L0570 400V 20mA 5. G19LM 400V 20mA 6. G15FN300 600V 30mA 7. D400/2000 700V 10mA 8. 121UMTH200 700V 15mA OR 9. 321 UMR 100 600V 15mA 10. 320 FEO 10A 600V 15mA 11. G18HFN 350 650V 30mA 3. INSTRUCTION DRAWING:

RDSO Drawing No. SK EL - 3320

4. APPLICATION TO CLASS OF LOCO/EMU:

Locos/EMU provided with Silicon Rectifiers.

5. PERIODICITY;

During POH and at other times on suspect diodes removed from rectifier.

6. AGENCY FOR IMPLEMENTATION:

Electric Loco Sheds/Car Sheds.

7. REFERENCE: Nil.

8. DISTRIBUTION: As per enclosed list.

(S. Kumar)

for Director General/Elect. DA/ 1. Distribution list.

2. 1030 Drgs. No. SK. EL.3. Annexure’A’ ANNEXURE “A”

Guide lines for Assembly of High Voltage Reverse Current Test Unit

191

1. High voltage reverse current testing unit may be assembled as per circuit diagram indicated in Drawing No. SK.EL.3320. The details of components required are also given in the drawing.

2. In case high voltage dielectric testing unit is available in the shed the same may be used as source of high voltage purpose. The unit may be set to trip at 50 mA. The remaining circuit may be assembled as per Drg.No. SK.EL.3320.

192


Manak Nagar, Lucknow 226011.

No.EL/3.2.2/S1/EC2 July, 1980

SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/68 SILICON RECTIFIER MAINTENANCE DIODE FORWARD

VOLTAGE DROP CLASSIFICATION 1. OBJECT:

During investigations of failures of silicon rectifiers in various sheds, it has been observed that some of the maintenance staff are not fully aware of some of the important aspects of maintenance repair and testing of silicon rectifiers. The purpose of this special maintenance instruction is to high-light a few important instructions regarding rectifier maintenance.

2. INSTRUCTIONS:

2.1 Forward Voltage Drop Grouping (FVD):

2.1.1 Rectifier diodes are classified into various forward drop groups(FVD) corresponding to their rated current under specified test conditions by the manufacturer. For each particular order of silicon rectifiers the diodes belonging to a few limited forward voltage drop groups, are used in rectifier assembly to ensure that current unbalance in parallel strings is kept within the specified limits. It is, therefore, necessary that the grouping of diodes in any string/arm should be maintained as on new built rectifiers. In case the combination of forward voltage drop(FVD) group diodes is changed forward current distribution in parallel connected strings/diodes will be disturbed with consequent effect of overloading of lower forward drop strings/diodes. It is, therefore, imperative that the replacement diode should belong to the same forward voltage drop group/class as that of originally used. In case the diode of same FVD group are not readily available, the adjustment FVD group diode may be used.

2.1.2 Different methods are being used by the different manufacturers to indicate the voltage drop group/class(FVD). The methods generally used are as follows:

(a) Stamping of forward voltage drop group code number at the end of diode type number at the base.

(b) Colour code at the anode/ cathode of diode. (c) Providing a cripped tag around the flexible load of diode etc.

193

Typical examples for the diodes at present in service on Indian Railways on EMUs stocks and Electric Locomotives are as under:-

Forward Voltage Drop Groups

S.No Type of diode

FVD group mark . Place of marking Manufacturers

1. 2. 3. 4. 5. 1. S.10AN1

25 S18FN 350 or S15 FN300

Color code i.e. White, Yellow, Green Red etc.

Anode or cathode of the diode

M/s westing House and M/s Hind Rectifiers

2. DJ15 L3 or DJ15 J3

Last number i.e. 3 in this case.

Diode base at the end of type No.

M/s Hitachi

3. D400/2000

Code numbers i.e. 41, 51, 61,etc.

Tag at flexible. M/s NGEF or M/s AEG

4. 321 UMR 200 or 321 UFR 200

Letter marking i.e. M1,M2,M3 or P1, P2, P3 etc.

Tag at the flexible or at the base.

Messrs Ruttonsha International Rectifiers

5. 321 UMR 140

Code number i.e. 01,0,1,2,3,4,5,etc.

At the end of diode Type Number or at the base.

- do -

3. DISTRIBUTION DRAWING: Nil.

4. APPLICABLE TO CLASS OF LOCO/EMU:

Locos/EMUs provided with Silicon Rectifiers.

5. AGENCY FOR IMPLEMENTATION

Electric Loco Sheds/ EMU Car Sheds.

6.REFERENCE: Nil.

7. DISTRIBUTION: As per enclosed list.

(S. Kumar)

Encl; One Distribution list for Director General (Elect.)

194


Manak Nagar, Lucknow 226011. No.EL/3.2.2/S1/EC2 Dated:July,1980.


SILICION RECTIFIER MAINTENANCE MOUNTING OF DIODE ON HEATSINK

1. OBJECT:

1.1 During investigations of silicon rectifier failures in various sheds, it has been observed that some of the maintenance staff ae not fully aware of some of important aspects of maintenance repair and testing of silicon rectifiers. Further to this office Special Maintenance Instruction No.RDSO/ELRS/68 regarding diode forward voltage drop classification, this special Maintenance Instruction is to high light a few instructions regarding inspection of heat-sink, diode mounting and lubrication of joints.

INSTRUCTIONS:

2.1 MOUNTING OF DIODE ON HEAT SINK:

2.1.1 Inspection of diode base and diode seat on heat sink,

2.1.2 On removal of diode inspect the diode seat on the heat sink and as well as diode based for surface finish and flatness. In case the threads are damaged/worn out the diode must be replaced. Rough and pitted surfaces of diode base/diode seat on heat sink will result in contact at only few points consequently, the effective cross sectional area for heat conduction will be greatly reduced. The overall flatness of the surfaces is even more critical than their surface finish. If the surfaces do not tough informally all over no amount of improvement of surface finish will help.

2.1.3 In case the surface finish is not good, clean the diode seat on the heat sink with emery paper. Clean the diode base with dry clean cloth or soaked in spirit. Do not rub the diode base with emery paper, as it will damage the plating. Check for flatness of the surfaces by colour method. Make sure to remove all traces of the colour coating. In case of badly pitted diode base and heat sink diode seat, diode and heat sink should be re-used.

2.2 MOUNTING TOROUE: 2.2.1 Good thermal electrical contact between the semiconductor (diode) and the heat sink requires adequate pressure between these two surfaces as applied by the torque on the threads of mounting stud. The microscopic detail of the surfaces is distorred by the

195

clamping pressure to push down the high points and bring the surfaces in better contact. However torque beyond a certain point no longer improved the thermal contact and may mechanically stress the device junction and material soldered or brazed to the stud inside the housing. Permanent damage to the device characteristics may result from excessive torque. Precise adherence to the manufacturers torque recommendations is therefore necessary. Torque Wrench should always be used in mounting devices/diodes. The recommended torque for each type of diode has been indicated by the manufacturers in respective maintenance manual. The clamping pressure must be applied uniformly, so that the overall flatness of the surface is not impaired. Other wise the clamping will disturb the surface flatness and the surfaces will not touch each other. Therefore, the studs must be tightened gradually and diagonally opposite.

2.2.2 In order to avoid any damage to the threads in case of stud type diodes, diodes should be first screwed by hand so that the threads are properly engaged and then only torque wrench should be used.

2.3 LUBRICATION OF JOINTS:

2.3.1 Any practical thermal joints will have trapped air pockets in the inevitable depressions and voids between the surfaces, Since air is relatively poor thermal conductor. the thermal transfer can be improved by applying a thin layer of heat sink compound to the contact interfaces before joining.

a) Wipe off the old heat sink compound by dry.

b) Only a small amount of compound should be used to just fill up the voids and still allow the high points of the metal surfaces to touch. While the heat sink compounds have a thermal conductivity which is higher than that of air, it is much lower than that of copper. For this reason the layer of heat sink compound must be kept very thin.

c) Care should be taken not to get the heat sink compound on the threads of the stud of the diode in case of stud base diode.

d) Make sure that there are no foreign objects in the compound (or between the contact surfaces of diode and heat sink) such as brush hairs or dust particles.

e) Remove the extra heatsink compound around the diode base. Ensure that heatsink component is not left over on any other part of diode assembly to avoid surface tracking or flashover.

196

These heat sink compounds are made of silicons low with thermally conductive metal oxides. They are in the form of thick white pastes which fill the voids between the

matching surfaces of the electronic components and the heat-sink. They will not leak out of the interactive try out harden or melt even after long exposure at atmospheres.

Use recommended heat sink compound as indicated is respective maintenance manual.

3. INSTRUCTIONS DRAWING Nil.

4. APPLICABLE TO CLASS OF LOCO/EMU:

Locos / EMUs provided with Silicon rectifiers.


Electric Loco sheds/EMU car sheds.

6. REFERENCE: Nil.

7. DISTRIBUTION:


(S. Kumar) for Director General/Elect. Encls/One

distribution list.

197


Manak Nagar, Lucknow 226011. No.EL/3.2.2/S1/Es2 Dated:Aug,1980.

SPECIAL MAINTENANCE INSTRUCTIONS RDSO/ELRS/SMI/71

SILICON HEATSINK MAINTENANCE DIODES AND HEATSINK

1. OBJECT:

During investigations of silicon rectified, failures in various sheds, It has been observed that some of the maintenance staff are not fully aware of some of important aspects regarding cares to be taken for diode heat sink handling transportation. Further to this office Special Maintenance Instruction Nos. RDSO/ELRS/67,68 and 70 ragarding diode testing, forward voltage drop classification and mounting etc. this Special Maintenance Instruction is to high light a few instructions regarding care to be taken during handling diode/heat sink and transportation.

2. INSTRUCTIONS:

2.1 CARE OF DIODE:

2.1.1 Following precautions have to be taken while handling/transporting diodes:-

-Protect diode base surface from scratches.

-Keep diode into its original package boxes. If not available keep diodes in polythene bags. Keep one diode in one bag to avoid damage due to rubbing with each other.

- Keep diodes in such a place that it does not drop.

-while during transportation the diode shall not be lifted from flexible lead wire and shall be supported from diode base.

- Carry diodes in a tray, Place clean dry paper in a tray before placing diodes.

-While removing or tightening diodes take care that no mechanical shock is given by spanners, torque wrenches etc.

2.2 CARE OF HEAT SINK:

Following care of heat sinks should be taken while keeping in store and replacement.

198

- Protect the diode sort on heat sink from sorted dents etc. by putting rubber sheet on in when in storage.

3. INSTRUCTION DRAWING:- Nil.

4. APPLICABLE TO CLASS OF LOCO/EMUs

Locos/EMUs provided with Silicon rectifiers.


Electric Loco Sheds/EMU Car Sheds.

6. REFERENCE: Nil.

7. DISTRIBUTION:


(S. Kumar) DA/One distribution list. Krite Maha Nideshak/Vidyut

199


Manak Nagar, Lucknow 226011. No.EL/3.2.12/THY Dated 17th Nov,/12.12.83

SPECIAL MAINTENANCE INSTRUCTION No.RDSO/EL.RS/SMI/108

1.TITLE Setting of simplified battery chargers on ac electric locomotives for 110 V dc

battery (50 cell). 2. OBJECT

To prevent over charging of lead acid battery provided on ac locomotives. Simplified battery charger for ac locomotives are provided with 3 or 5 tapping to set the charger at the required tap. It is suggested that the simplified charger should be set at the normal tap giving output voltage of 98/100V rms. (without the battery in circuit) with input voltage between 360 to 400 V rms. 3. WORK TO BE DONE:

Check the existing setting and set the simplified battery charger at normal tap giving 98/100 V rms. with input voltage of 360 to 400 V rms. 4. Reference Drawing:

Nil. 5. AGENCY FOR IMPELMENTATION

Electric Loco Sheds and POH Shops. 6. MATERIAL AND EQUIPMENT REQUIRED: Material Required: Nil. Equipment Required: Precision grade voltmeter having a sensitivity of not less than 24 K Ohm per volt for measuring the voltage. Tools to open and reconnect the charger lead at different tap if required. 7. DISTRIBUTION:

As per enclosed list. NOTE:- The locomotive where the battery does not pick-up the charge shall be charged externally or replaced by a fully changed battery.

Encl: Distribution list. (S. Kumar) for Director General(Elect.)

200


Manak Nagar, Lucknow 226011. No.EL/3.2.12/1-THY Dated 17th Nov, 1983.

SPECIAL MAINTENANCE INSTRUCTION NO.RDSO/EL.RS/SMI/109

1. TITLE Setting of battery charger type BCF3, BCF6 and BCF7 of M/s Control and Drive make and provided on ac locomotives for 110V battery (50 cells).

2. OBJECT:

To prevent over charging/under charging of 110V lead acid battery provided on ac locomotives.

3. WORK TO BE DONE

These battery chargers are provided with current and voltage feed back arrangement and maintain flat VI characteristic with an input voltage between 360V to 400V set the output dc voltage for 109+ 1V at light load say 1 A.

Increase the current upto 15 A and see that flat VI characteristic is obtained. Set the potentiometer P1 and P2 such that with increase of load current beyond 15 A the output dc voltage falls rapidly.

The battery chargers provided with external current limit resistor of .6 to .7 ohm should be set for 110 + 1 V dc instead of 109+ 1 V.

4. REFERENCE DRAWING: Nil. 5. AGENCY FOR IMPLEMENTATION:

Electric Loco Sheds and POH shops. 6. MATERIALS EQUIPMENT REQUIRED:

Material Required Nil. Equipment Required :-

i) A dc precision grade voltmeter having sensitivity of not less than 24 K Ohm per volt for measuring output Voltage. ii) DC ammeter range 0 to 50 A to measure the output current (already available in Sheds), iii) Loading facilities already available in the Sheds.

7. DISTRIBUTION As per enclosed list.

Encl: Distribution list. (S. Kumar) for Director General(Elec.)

201


Manak Nagar, Lucknow 226011. No.EL/3.2.135 Date 29.3.1991.

SPECIAL MAINTENANCE INSTRUCTIONS NO.RDSO/ELRS/SMI/110

1. TITLE:

Checking the capacitance of the capacitors in AC damping. DC damping and snubber circuits of silicon rectifiers used on electric loco.

2. Application to class of locomotives:

All electric locos fitted with silicon rectifier.

3. Object of special Maintenance Instructions:

To ascertain the state of capacitors in the rectifier circuit and to assess the performance.

4. Instruction drawing:

Nil.

5. Instructions:

Measure the capacitance of damping circuit snubber circuit in every AOH using portable capacitances meter of type :

i) Agronic model 57 or equivalent.

ii) Digital LCR-Q meter of M/s. Aplab Model 4910 or equivalent.

Capacitance of Individual capacitors to be measured and failures recorded with date, loco number, type of capacitor location etc. and reported.

6. Periodicity of checking:

During every AOH.

7. Agency of implementation:

All electric loco shed.

8. Distribution

As per list enclosed. (V. Sadasivam)


202


Manak Nagar, Lucknow 226011. No.EL/3.2.135/J12 Date:13.8.92

Special Maintenance Instructions No.RDSO/ELRS/SMI/142

1. TITLE

Failure of capacitor terminals in surge voltage damping pannels of silicon rectifier cubicles on ac Electric Locomotives.

2. APPLICATIONS TO CLASS OF LOCOMOTIVES

All ac Electric Locomotives provided with silicon Rectifiers.

3. OBJECT OF SMI

Capacitors terminals breakage, burning, loose connections were reported by various electric loco sheds. On investigation it was found that Ampan clips used for connections were loose in same cases and were not lockable type, resulting in burning of capacitor terminals.

The use of lockable Ampen-clips having small circular dent which side in capacitor terminal hole are pressing the clip in sure it is still loose in capacitor terminal or replacing of other clip solve the problem. No such failures have been experienced in GZB Elect. Loco shed for the last 10 months after this practice.

4. INSTRUCTION DRAWING

Nil.

5. INSTRUCTIONS

(i) Inspect that there is no loose connection

(ii) In case there is loose connections, check the Amper-Clips is lockable or not. If not lockable, replace it by a lockable clip.

(iii) Fit it back on capacitor terminal and see it is not loose. In case it is loose replace by other clip or tighten the same.

(iv) Check connections at AOH and replace defective clip.

203

6. PERIODICITY OF CHECKING

During AOH

7. AGENCY OF IMPLEMENTATION

Electric loco sheds

8. REFERENCE:

Item -19 of MSG XIX (EL)

9. DISTRIBUTION


s/d (S. Kumar) for Director General/Elect.

GOVERNMENT OF INDIA

204

MINISTRY OF INDIA RESERARCH, DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW- 226011

No - EL/11/1.2.9 (A) Dated : 18.3.99 22

RDSO Modification sheet No. RDSO/WAG - 7/ELRS/MS WAG- 7/11

1. Title-- Provision of separate fuse for Static inverter control circuit.

2. Object-- To prevent tripping of control circuit to Static Converter due to blowing of CCPT fuse.

There have been incidences of blowing of CCPT fuse resulting in tripping of control circuit for Static Inverter. Hence, it is proposed to segregate the control supply for the Static Inverter from Panto circuit, through a separate fuse.

3. Work to be carries out.—

1) CCEL fuse of 6, A which is in the fuse board, is to be marked as CCINV 2) The input cable no 003 should be kept as it is. 3) The output cable of CCINV that is B 620 is to be re-numbered as 700 INV. 4) The Cable no. B-620 which is re-numbered as 700 INV and to be connected

to a separate connector in BD. 5) The cable no PP- 700 which is initially in the BD with 700 cable bunch is to

be removed and to be connected with 700 INV cable in BD. 4. Application to class of locomotive. –

All WAG - 7 locomotives provided with Static Converter units.

5. Material required.—

1) 3-sq. mm 750 - grade cable of required length .

2) Insulted cable lugs suitable for 3-sq. cable is required quantity .

6. Material Rendered Surplus – Nil

7. References –

As per suggestions by Railways in the past.

8. Modified Drawing –

SKEL – 4515

9. Agency of implementation –

205

All Electric loco shed which are having WAG - 7 locomotives provided with Static Converter units, & Chittaranjan Locomotive Works / Chittaranjan

10. Distribution

As per mailing list

ENCL – As above.

( S. S. Joshi )

( For Director General / Elec.)

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