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895731/2022/O/o Dy.CEE/Chg/HQ/NR NORTHERN RAILWAY

Headquarters Office,
Baroda House
New Delhi

No. 3-Elect/1/TLICamtech Pt-I. Dated 26:07:2022

The Director General (PS & EMU),

RDSO, Manak Nagar,
Lucknow

Sub.:-Draft Revised (2022) Maintenance Manual for LHB AC & Non AC

Coaches Electrical.

As subjected above, the Draft Revised (2022) Maintenance Manual for LHB AC &
Non AC Coaches Electrical has been examined and following comments are made
1. Issues related to Coach Description:
Para 6.2.2: All types of coaches are not defined.
Para 6.5.1.1: Servomotor for fresh air damper is indicated, however, it is obsolete
now.

Chapter 8: KOEL make DA set is not included.

2. Issues related to Maintenance Schedules:
Para 8.18: A. B, C, D, E checks are given as per old guidelines. However, Rly. Bd
vide letter no. 97/Elect. (G)/114/1 Pt. dt. 14.01.2021 (enclosed as Annexure-l) had
revised the periodicity.
Chapter 11 Maintenance schedules to be reviewed to avoid over maintenance
(Comments of NR are attached as Annexure-lI, 3 Pages).
Annexure 10.7 List of Must Change Items to be reviewed (Comments of NR are
attached as Annexure-lll, 2 Pages).
Annexure 10.9 Electrical Tools, Machines & Plants to be reviewed including
T&P like LCR meter, Thermal Imaging Camera.
3. New items to be included:
Circuit for interlocking of heater circuit, HT MMR circuit, Contactor K01 & K02,
Contactor K41 & K42, Contactor K43 & K44, safety devices in power cars (UVR,
AVR, AEL, FEL, FOL, RFR, LCWL, HWT, LLOP, LOT, OSR etc) should be
included and their testing procedure during maintenance should be included.
Testing of SBC during SS-1& S$2 to be included (as per Annexure-IV attached).
A schedule for thermography has been prepared at NR and being ensured during
maintenance. This should be included (copy enclosed as Annexure-V).
A schedule for data downloading of microprocessor based controllers has been
prepared at NR and being ensured during maintenance for improved reliability.
This should be included (copy enclosed as Annexure-VI).
Maintenance schedules for LSLRD, Capacitor bank, PACIL (Passenger Alarm
Chain Indication Lamp), WC (Water Closet Indication) Light, AEL (Accidental
Emergency light), Call bell checking/replacement maintenance & USB/USB cum
charging point maintenance to be included.
PG cable gland of all equipments checking in SS-1& replacement/provision in SS-
2 to be included.
Rodent Entry prevention measures to be taken should be included.
New coach commissioning Performa (copy attached as Annexure-Vil), after POH
checking Performa and POH Booking format to be standardized and included.
Format for user depot containing work done with list of materials replaced during
POH should be standardized and included.
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895731/2022/O/oCooling coil, condenser coil cleaning procedure with details of cleaning agent to be
Dy.CEE/Chg/HQ/NR
used &water pressure value, Filters cleaning procedure with standard value for air
pressure for LHB Coaches should be mentioned.
Define superheat, sub-coling values for different type of vendors and testing
procedure to added in SS-2 & SS-3 schedules.
Safety equipments list & all clearance should be defined at single sheet.
Codal life of Electrical items should be added.
Rating of all wires and thimbles being used in coach & power car.

Note:
1) All efforts should be made to avoid over maintenance, since over maintenance not
only results in wastage of man power but also prone to the premature failures due to
loose connections/mishandling
i) This Maintenance Manual should be open for revision in future since new IT based
equipments are being proliferated in coaching stock. Also, Rly. Bd. guidelines &
RDSOILKO's SMI/MS from time to time should be included/updated.
in) A meeting with Zonal Railways before finalizing this manual for brain storming and
including the experiences will be appreciated.

DA/-as above,

(Veena Sinha)24|2
Chief Electrical Services Engineer
Copy/
PCME/NR for kind inf. please
2 Director/Elect./CAMTECH/
Gwalior for inf. & necessary action please.

2
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 Annexure-II 262/493
Comments on Maintenance Schedules
895731/2022/O/o Dy.CEE/Chg/HQ/NR

 Para 8.17.1 Alternator: (9) These activities are currently being carried out during
D & E check of diesel engines.
 Para 8.17.6 Power Panel/Control Panel: Maintenance instructions are required
on HOG Contactors, HOG control transformer
 Para 8.17.7 Radiator, Radiator Pipeline and Radiator Chamber: (2) Add
“Remove internal scaling if any, with the help of suitable descaling agent. Activity
to be added in SS-2 also.
(8) To be deleted since covered in (2).
 Para 8.17.11 Fuel Tank: (5) To be deleted since not provided in LHB power
cars.
 Para 8.17.12 Safety System: Calibration/Replacement should be Calibration/
Replacement on Conditional basis.
Item no 10 to be included for RFR (Radiator Fan Relay), Circuit checking during
D1, D2, D3, SS1 & Calibration/ Replacement on Conditional basis during SS2.
 Para 8.18 & 8.19: Maintenance schedules of diesel engines: To be updated
as per Rly.Bd.’s guidelines.
 Para 8.20 List of Must Change Items for Power Cars: For engine items for
Must change items, the periodicity should be in sync with C/D/E checks rather
than 1st & 2nd POH.
 Para 10.1.2 Battery: (e) Activity should be carried out in SS-2 Schedule.
 Clause 10.1.3 REBC:
(4) Air pressure/blower shall be used in place of Vacuum cleaner.
(8) Air pressure/blower shall be used in place of Vacuum cleaner.
 Clause 10.1.6: Step Down Transformer 100 VA, 750/415V is given, it should be
100/200VA
a. This activity shall be deleted from T1 (D1) (as not possible in every trip
maintenance schedule).
b. This activity shall be deleted from T1 (D1) (as not possible in every trip
maintenance schedule).
c. This activity shall be deleted from T1 (D1) & M (D2) (as not possible in every
trip maintenance schedule and is also very earlier in Monthly schedule).
d. Instead of 1 A write as 2A as per latest RDSO guidelines.
e. Make wise nominal values of Winding Resistance 100 VA & 200 VA are also
to be mentioned for reference.
 Clause 10.1.7 RC Filter:
a. This activity shall be deleted from T1 (D1) (as not possible in every trip
maintenance schedule).
b. This activity shall be deleted from T1 (D1) (as not possible in every trip
maintenance schedule).
c. Check value of capacitor by LCR meter, If the value is low, replace the RC
filter should be as Check value of capacitor and resistance by LCR meter, If
the value is low, replace the RC filter.
This activity shall be carried out in IOH (SS1) and POH (SS2) Schedules only
and deleted from D3..
 Clause 10.1.8 Z.S. Coupler on non-vestibule side for attachment in
Locomotive:
c. How to check proper mating of IV Couplers with thermo-vision device is not
clear. So, clarity with proper procedure to carry out this activity is required
before including it in this maintenance schedule.
 Clause 10.1.9 Isolating Contactors:
a. This activity shall be written as “Cleaned with blower/Compressed air and
checked for any loose connection”
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d. This
895731/2022/O/o activity shall be carry out in POH (SS2) Schedules only.
Dy.CEE/Chg/HQ/NR
This should be as Check condition of contacts by measuring the Contact area,
mili-volt drop, closing & opening time etc. Replace them on condition basis if
fails in test.
Limits for Contact area, mili volt drop are to be defined.
 Clause 10.1.11 Miscellaneous Equipments:
Feeder Cable
b Check proper clamping arrangement should be as Check proper clamping
arrangement and healthiness of rubber hose connector pipe.
Under frame
A new item should be added as (b) Check condition of feeder junction boxes.
Ensure proper sealing to avoid water ingression (D1, D2, D3, SS1 & SS2)
Earthing
b. This activity shall be as check earthing connections of disconnecting and
earthing switch (since replacement of disconnecting and earthing device
complete rotary switch is covered in 10.2.1 Switch Board Cabinet part- n)
d. This activity is to be deleted as covered in 10.2.1 Switch board cabinet part - q
One more activity DC positive & negative insulation failure checking is to
be added in SS1 & SS2 Schedule
 Clause 10.2.1 Switch Board Cabinet:
c. This activity shall be as Clean the panel with blower/Compressed air and
checked for any loose connection “
l. This activity shall be as “Replace MPCBs/MCBs for blower motor, condenser
motor, compressor, heater, exhaust fan, pantry equipment and pumps”.
m.Limits need to be defined for contact area, mili volt drop.
n. Replace disconnecting & earthing device complete rotary switch should be as
Check the condition of disconnecting & earthing device complete rotary switch,
replace if required.
r. Delete this item since obsolete.
s. This activity shall be as “Replace contactor for K01, K02, K44 and
compressors”.
t. Delete this activity since external modules are not used in existing contactors
used in latest spec.

 Clause 10.2.2.1 General:

c. This activity shall be carried out in HY (D3), IOH (SS1) and POH (SS2)
schedules only.
f. This activity shall be as “check the working of LCD Display for Temp. Setting”.
p. To be replaced in SS-1 & SS-2 schedule.
q. This activity shall be deleted from M (D2) and to be added in HY (D3).
r. This activity shall be deleted from M (D2) and to be added in HY (D3).
t. In this activity OHP complete switch shall be replaced in POH (SS2) schedule.
w. Delete this activity as it is a repeat of activity –v above.
y. This activity shall be on condition basis in SS1, if Meta/Para Armid canvas
below is used.
z. This activity shall be deleted as servo drive is not used in existing system as
per latest RDSO spec.
aa. This activity shall be as “check anti vibration mounting of overall package unit.
Replace, if required” (Anti vibration mounting is not used in Blower Motor,
Condenser Motor and Compressor)
bb. This activity shall be as “Cleaning of air grill in SS1 / cleaning & painting in SS2
schedule”
cc. SS-4 shall be as SS-3 Schedule.
ee. This activity shall be as “Replace harting connector sealing gasket & Harting
connector to be replaced (condition basis in SS1)”
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 Clause
895731/2022/O/o 10.2.3 Refrigerant Pipe Line/Capillary:
Dy.CEE/Chg/HQ/NR
d. This should be Replace Over Heat Protector and ensure tripping at 65°C.
 Clause 10.02.5 Condenser Fans Motor/Blades and Blower Motor/Impeller:
h. “Perform HV (Di-ectric test) on stator by applying 1.5kV AC supply for one
minute. During test the leakage current shall also be measured, which shall
not be more than 1.0mA” This Instructions need to be reviewed as this is a
prototype test.
Instruction “Run motor on no load for 15 minutes and check the following.
Bearing noise – Normal noise.
Bearing temperature rise above ambient should not be more than10°C.
SPM reading – 20 dB max.(Green zone) should be deleted and it should be as
“Bearing shall be replaced” as must change item for POH
 Clause 10.2.7 HP/LP/OHP cut out switch:
f. In this activity OHP complete switch shall be replaced in POH (SS2) schedule
 Clause 10.2.8 Heater:
Add (d) Check the condition of heating element and replace if required in D3,
SS1 & SS2.
(e) Check the condition of heater assembly terminals and replace overheated/
corroded fasteners & metallic washer in SS1 & SS2.
 Clause 10.2.9 NTC Sensor:
c. In this activity NTC Sensors shall be replaced in POH (SS2) schedule
 Clause 10.2.11 Evaporator Coil:
a. This activity shall be as “Clean the coil through water jet”
 Clause 10.02.12 Filter Drier & Sight Glass: Add “Ensure replacement of
filterdrier every time whenever refrigerant is charged”
 Clause 10.2.16 Micro Processor Controller:
One more activity of Data down loading is to be added in IOH (SS1) & POH
(SS2) Schedule
 Clause 10.4 Main Pantry Items:
c. This activity shall be as “Check water supply” (Drainage of pantry area is C&W
(Mechanical) work)
g. OTG to be deleted.
j. This activity shall be carried out on condition basis in M (D2) & to be added in
HY (D3) & SS2
o. This activity to be carried out in SS2 also.
v. Delete this activity as already covered in Clause 10.1.11 (Lavatory Equipment
part a & c)
y. Replace all old hot water boiler /geysers with new one should be as Replace
all old hot water boiler /geysers as per codal life/ on condition basis with new
one.
Note:
i) Some of the activities have been deleted from D1 & D2 schedules to avoid over
maintenance.
ii) Check list for D-1, D-2, D-3 schedules shall also be formulated and attached as
Annexure.
iii) IOH of coaches from electrical side is not being carried out in workshops. This
aspect shall be examined.
iv) Thermal Vision Cameras are not available at depots/workshops. Instructions with
complete details of the same shall be circulated by RDSO/LKO.

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Annexure-III
LIST OF MUST CHANGE ITEMS FOR LHB AC COACHES

1st 2nd
SN Items
POH POH
1 Switch Board Cabinet:
a* MCBs for Pantry Equipments F-16, F-18, F-19, F-20 Y
b* MCBs for Pump Controller F-36 Y
c* MPCBs for Compressors F-03, F-05, F-09, F-11 Y
d* MPCB for Pumps F-21 & F-22 Y
e Contactor for Compressor K-33, K-34, K-38, K-39 Y
f Contactor for Blower Fan Motor K-26, K-28 Y Y
g Contactor for Condenser Fan Motor K-31, K-32, K-36, K-37 Y
h Contactor for Heater K-35, K-40 Y
i Contactor for Output of 60KVA Transformer, K-44 Y Y
j* Timer for External Power Supply/LMS, K-18 Y
k* Timer for Light ON/OFF, K-17 Y
l* Minimum Voltage Relay (MVR),U-2.3 Y
m* Rotary Switch for Disconnecting & Earth Device, A-2 Y
DC to DC converter (110V/24V) for Pump control & Sanitary
n* Y
control, U-2.1
o* Rotary Switch Power Supply ON/OFF, S-01 Y
p* Rotary Selector Switch Net-1,Net-2 & LMS, S-02 Y
Interlock Contactor for Change over of Coach light supply from
q Y
110VAC to 110V DC & Vice versa, K-48 (Obsolete)
r* Measuring & Monitoring Relay MMRs, K-03 & K-04 Y
s Main Feeder Contactors, K-01 & K-02 Y
t Electronic Module for Contactors, K-01, K-02 (Obsolete) Y
u Door for complete Switch Cabinet unit Y
2 Light Fittings
a Lavatory Light Fitting Y
b Lavatory Exhaust Fan Y
c Diffuser for Rajdhani Exp Coaches Y
d Mobile Switch Socket complete Y
3 Pantry Equipment
a* 3 Pin Sockets/MCBs for operation of equipment Y
b Hot Water Boiler/Geyser Y
c Heating Element assembly complete with Blower unit rotary Y Y
switch, thermostat & indicator for Hot cases
d Filter of Electric Chimney Y
e Pantry Exhaust Fan Y
4 Roof Mounted AC Package Unit
a Canvas Duct for Return Air Y
b Canvas Duct for Supply Air Y
c Canvas Duct for Fresh Air Y
d Anti Vibration Mounting Pad Y Y
e Filter media mix air Y
f Filter cassette Fresh air Y
g ESTI cartridge Bulb Y
h Over Heat Protection Switch Y
* Conditional replacement item
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1st 2nd
SN Items
POH POH
i NTC sensors Y Y
j Thermal Insulation Sheet Y
K* Earthing Shunt Y
l* Rotary Switch ON/OFF for AC plant Y
m Fresh Air Filter Assembly Y
n FRP Blade for Condenser Fan Blade Y
5 ZS Coupling
a* Contact Pin assembly for Phases, Neutral & Earth with Springs Y
b* Connector Female assembly Phases, Neutral & Earth with Y
Springs
c* Ratchet arrangement for coupling sockets assembly Y
d* Insulating Base with fixing screw kit for coupling socket Y
e* Insulating Base with fixing screw kit for Jumper Plug assembly Y
f* Hinged cover assembly for Blind socket Y
g* Ratchet arrangement for Blind socket assembly Y
h PMA protective sleeve for cables Y
i Conduit seal ring & all type gaskets Y
j* Coupling socket housing assembly Y
k* Lever Tie Bow RH & LH Y
l* Connecting link lever arm Y
m* Rivet Pin link long Y
Complete ZScoupling with ratchet sockets assembly & Blind
n Y
socket
6 Monoblock Pump
a Complete Mono block Pump unit Y
7 Battery Fuse Box
a* Positive Battery Fuse Box Complete Y
b* Negative Battery Fuse Box Complete Y
8 Additional Proposed New Must Change Items
a PACIL Fitting Y
b Limit Switch used for Socket Assembly Feeder Junction Box Y
c WC engagement Light Y
d Capacitor Bank Y
e Rodent control glands, sockets, wire mesh etc Y
* Conditional replacement item
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ANNEXURE-IV
895731/2022/O/o Dy.CEE/Chg/HQ/NR
OPERATONAL TESTING OF SWITCH BOARD CABINET

1. Visual Inspection, Including inspection of wiring and electrical operation test

a) SBC found free from all manufacturing defects & wiring of SBC as per drawings.
b) Electrical operation of SBC as given below.
 APPLIED SUPPLY 110V DC:-
DC 110V was connected at the input side of 25Amps. Fuses (S1F42 & S1F43).
 ANTI SKID DEVICE: - Voltage measured at the out put of fuses (S1F63 & S1F65) it found to be 110V DC and
voltage also measured at the following terminals:
S1X1-41 & S1X1-33 110VDC
S1X1-41 & S1X1-42 110VDC
S1X1-41 & S1X1-43 110VDC
S1X1-41 & S1X1-44 110VDC
Terminal Block 41 & 42 shorted and voltage measured between terminals 43 & 44 was 110V DC.
 LIGHTING CONTROL: - MCB DP (S1F24) for light control was made ON, Voltage 110VDC measured at terminals
87 & 88, On pressing Push Button (S1S08) contactors (S1K49) closed & DC voltage checked at different terminal
blocks after closing respective lighting MCB’s as follow:-
MCB’s Terminals Voltage measured Remarks
S1X1-103
S1F25 111V DC MAIN LIGHTS ENTRANCE & SENITORY AREA
S1X1-106
S1X1-108
S1F26 110V DC SPARE
S1X1-109
S1X1-118
S1F27 110V DC 50% READING LIGHTS PASSENGER AREA
S1X1-119
S1X1-121
S1F28 110V DC 50% READING LIGHTS PASSENGER AREA
S1X1-122
S1X1-116
S1F34 110V DC NIGHT LIGHTS PASSENGER AREA
S1X1-117
S1X1-114
S1F39 110VDC 50% MAIN LIGHTS PASSENGER AREA
S1X1-115
S1X1-112
S1F40 110V DC 50% MAIN LIGHTS PASSENGER AREA
S1X1-113
By Pressing Push Button (S1S10), Contactor S1K49 will de-energised and lighting circuit will switched OFF.
 DC – DC CONVERTER (S1U2.1):- MCB DP S1F29 closed and supply measured at input of DC – DC converter
S1U2.1 were 110V DC. Output supply of DC – DC converter S1U2.1 at terminals S1X1-27 & 28 through MCB S1F38
for loud speaker system also checked & at terminals S1X1-25 & 26 through MCB S1F37 for sanitary system also
measured and found to be 24V DC.
 DIAGNOSIS: - MCB S1F32 closed and pressed the test push button S1S05 for indication lights and all indication lights
were observed ‘ON’.
 AIR CONDITION UNIT: - At terminals S1X1-124, S1X1-125 & S1X1-126, S1X1-127, 110V DC was measured by
closing the MCB S1F35 for air condition unit.
PUMP CONTROL:-MCB S1F36 closed and voltage at terminals S1X1-23 & 24 for Pump Controller was measured
110V DC.
 APPLIED AC SUPPLY 750V AC:-
Over voltage tripping test on MMR:-Variable supply of 3ф 750V AC provided to voltage phase control relay of 750V
AC. To check over voltage tripping test, set relay at 10% setting, than increase supply voltage up to 10% of rated
supply voltage of relay. During increasing voltage, relay will trip. Observation is as under:-

Relay rating Applied voltage Tripping time

750V AC 815V AC 7sec
Under voltage tripping test on MMR:-Variable supply of 3ф 750V AC provided to voltage phase control relay of
750V AC. To check over voltage tripping test, set relay at 10% setting, than decrease supply voltage up to 10% of
rated supply voltage of relay. During decreasing voltage, relay will trip. Observation is as under:-

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Relay rating Applied voltage Tripping time
750V AC 690V AC 7sec
Single phasing tripping test on MMR:-Variable supply of 3ф 750V AC provided to voltage phase control relay of
750V AC. To check single phasing tripping test. Disconnect any phase of relay, Single phasing indication will display
on relay and output supply will disconnected. Observation is as under:-

Phase provided Phase disconnected Observation

RYB PHASE Y PHASE RELAY TRIP
 MAIN CONTACTOR OPERATION: - Supply 750V AC given at input of Earthing & Disconnecting device and
connections found to be in order as per wiring drawing. Supply sequence checked at MMR S1K03 & S1K04 and found
O.K. Control supply of 415V AC through Transformers & respective O/P fuses for Net-1 & Net-2 goes to Power
supply ON/OFF switch (S1S01). Set Power supply ON/OFF switch (S1S01) at ‘ON’ Position and Rotate Rotary
Switch S10S2 at Net-1 position, the contactor S1K01 turns ‘ON’ and contactor S1K02 remains ‘OFF’, Now set Rotary
Switch S10S2 at Net-2 position and the contactor S1K02 turns ‘ON’ and contactor S1K01 remains ‘OFF. It is observed
that main contactors working properly.
 DIAGNOSIS:-
 Check IR At 110V DC: - Connect negative of 110V DC supply from bus bar to earth point in panel through electric
bulb. And similarly connect positive of 110V DC supply from bus bar to earth point in panel. Relay A6 will Show
Indication & 110V Insulation Failure Indication Will Glow at Door.
 Check IR At 415V AC: - Connect neutral of 415V AC supply from bus bar to earth point in panel through electric
bulb. And similarly connect all phase of 415 AC supply one by one from bus bar to earth point in panel. Relay A7
Will Show Indication & 415V Insulation Failure Indication Will Glow at Door.
 Check fault Indication:-
1) Battery Float Prvide short link between terminals 95 & 96 lamp should glow
2) Battery Boost Prvide short link between terminals 95 & 97 lamp should glow
3) Antyskid Device Prvide short link between terminals 95 & 98 lamp should glow
4) Test Lamp Press Push button TEST LAMP All lamps will glow
 APPLIED AC SUPPLY 415V AC:-
3PHASE 415VOLTS AC TESTING:- 3-phase, 415V AC supply was given at the input of the Transformer fuses
S1F44, S1F45 & S1F46 of 100Amps and neutral is connected to contactor S1K44 . After closing contactor S1K44, the
supply was checked at the following points:-

Description MPCB/MCB closed Contactor Terminals Supply Status

S1X1-231
Ventilation fan unit - I S1F01 S1K26 S1X1-232 3 Ø 415 Volts O.K.
S1X1-233
S1X1-235
Ventilation fan unit - 2 S1F02 S1K28 S1X1-236 3 Ø 415 Volts O.K.
S1X1-237
S1X1-239
Compressor unit 1.1 S1F03 S1K33 S1X1-240 3 Ø 415 Volts O.K.
S1X1-241
S1X1-243
Compressor unit 1.2 S1F05 S1K34 S1X1-244 3 Ø 415 Volts O.K.
S1X1-245
S1X1-253
Condenser Fan 1.1 S1F06 S1K31 S1X1-254 3 Ø 415 Volts O.K.
S1X1-255
S1X1-256
Condenser Fan 1.2 S1F07 S1K32 S1X1-257 3 Ø 415 Volts O.K.
S1X1-258
S1X1-247
Electrical heater 1 S1F08 S1K35 S1X1-248 3 Ø 415 Volts O.K.
S1X1-249

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S1X1-259
Compressor unit 2.1 S1F09 S1K38 S1X1-260 3 Ø 415 Volts O.K.
S1X1-261
S1X1-263
Compressor unit 2.2 S1F11 S1K39 S1X1-264 3 Ø 415 volts O.K.
S1X1-265
S1X1-273
Condenser Fan 2.1 S1F12 S1K36 S1X1-274 3 Ø 415 Volts O.K.
S1X1-275
S1X1-276
Condenser Fan 2.2 S1F13 S1K37 S1X1-277 3 Ø 415 Volts O.K.
S1X1-278
S1X1-267
Electrical heater 2 S1F14 S1K40 S1X1-268 3 Ø 415 Volts O.K.
S1X1-269
S1X1-279
Exhaust Fan S1F15 S1K29 S1X1-280 3 Ø 415 Volts O.K.
S1X1-281

Over voltage tripping test on MMR415VAC:-Variable supply of 3ф 415V AC provided to voltage phase control relay
of 415V AC. To check over voltage tripping test, set relay at 10% setting, than increase supply voltage up to 10% of
rated supply voltage of relay. During increasing voltage, relay will trip. Observation are as under:-

Relay rating Applied voltage Tripping time

415V AC 460V AC 7sec
Under voltage tripping test on MMR415VAC:-Variable supply of 3ф 415V AC provided to voltage phase control
relay of 415V AC. To check over voltage tripping test, set relay at 10% setting, than decrease supply voltage up to
10% of rated supply voltage of relay. During decreasing voltage, relay will trip. Observation are as under:-

Relay rating Applied voltage Tripping time

415V AC 400V AC 7sec

Single phasing tripping test on MMR415VAC:-Variable supply of 3ф 415V AC provided to voltage phase control
relay of 415V AC. To check single phasing tripping test. Disconnect any phase of relay, Single phasing indication will
display on relay and output supply will disconnected. Observation are as under:-

Phase provided Phase disconnected Observation

RYB PHASE Y PHASE RELAY TRIP

 APPLIED AC SUPPLY 415V AC (Local Main Supply ):-

Pre-cooling:- 3 phase 415V AC supply with neutral connected at contactors S1K41 and S1K42 alternatively and the
neutral connected at terminals S1X1-229 & 230. 415V.Control supply through fuse 33F76 (1A) goes to Power supply
switch ON/OFF S1S01. Set Power supply switch ON/OFF S1S01 switch at ‘ON’ & Selector Switch S1S02 at the local
mains position. Contactor S1K43 closed, & Voltage measured at various terminals again as done in case of 415V
(Normal supply) and found to be confirming as per wiring diagram.
For local main supply, contactor S1K41 & S1K42 closed one by one and relay S1K18 energized, Voltage measured at
the terminals S1X1-99 & 101 for the passenger alarm indication light and found to be O.K.
2) Temperature rise test as per clause 8.2.1 of IS: 8623:
Report of this test enclosed as per Annexure – C.
3) Mechanical operation and sequence test as per clause 8.2.6 of IS: 8623:
This test has been carried out with electrical operational test and SBC found to be O.K.
4) Test for verification of clearance and creepage distance as per clause 8.2.5 of IS: 8623:
The layout of the Electrical Components/ Terminals in the Panel is as per RDSO drg.No:- RDSO/PE/SK/AC/0191-2015
(Rev. “0”).During test clearance & creepage distance found satisfactory.
5) Test for verification of dielectric properties as per clause 8.2.2 of IS: 8623:
The Control Panel is tested with following test voltage as mention in specs between live parts and earthed body & test

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withstood the result:

Applied Voltage Timing Condition Observation

Disconnected Phase monitoring relay
S1K03 & S1K04.
60 seconds (Withstood the test for Not leakage current
3 KV Disconnected Insulation monitoring
one minute.) is found
relay S0A6 & S0A7
DC-DC converter

6) Test for verification of insulation resistance as per clause 8.3.4 of IS: 8623:
The auxiliary relay connected with circuit shall be disconnected from main supply and kept Earthing Device switched
on with all fuse in circuit. Now applied 500 VDC supply between each phase & panel body. Observation are as under:-

S.No. Test Conducted Insulation Tester Time Result Condition

Relay & contactor coil
1 Between R-phase and body 500 V DC 60 sec Found>100MΏ
disconnected from phase
Relay & contactor coil
2 Between Y-phase and body 500 V DC 60 sec Found>100MΏ
disconnected from phase
Relay & contactor coil
3 Between B- phase and body 500 V DC 60 sec Found>100MΏ
disconnected from phase
Relay & contactor coil
4 Between R-phase and Y-phase 500 V DC 60 sec Found>100MΏ
disconnected from phase
Relay & contactor coil
5 Between Y-phase and B-phase 500 V DC 60 sec Found>100MΏ
disconnected from phase
Relay & contactor coil
6 Between B- phase and Rphase 500 V DC 60 sec Found>100MΏ
disconnected from phase

7) Verification of effectiveness of protective circuit as per clause 8.2.4 of IS: 8623:

Effectiveness of protection Circuits was checked during the electrical operational test of the Switch Board Cabinet.
(Refer to clause 1 of this report).

8) Checking for satisfactory operation of Rotary switches by rotating 10 times clockwise and 10 times
anticlockwise:
All the Rotary Switches are checked by rotating 10 times clockwise and 10 times anti-clockwise. The result found to
be satisfactory.

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a
895731/2022/O/o Dy.CEE/Chg/HQ/NR
Annexure

SN Activityy Perlodicity
1 Thermal screening of power panel equlpment D2 schedule.
including D&ED rotary terminals.
2Thermal screening of power Harting connector at D2 schedule.
roof.
3 Thermal D2 schedule.
screening of ZS coupler plug assembly.
4Thermal screening of ZS coupler/wrachet terminal D3 schedule.
junction box.
5Thermal screening of 60/19/5 KVA Transformer D3 schedule.
terminal plate connections
6 Thermal screening of power ESTI Connector & heater D3 schedule &
assembly connection terminal. during winter
drive.
7 Thermalscreening of Cells coupling. D3 schedule.
8 Thermal screening of Blower motor ,condenser D3 schedule.
motorcompressor motor and water mono block
pump terminal box
9 Thermal screening of under slung constant voltage, D3 schedule.
regulated cum emergency battery charger terminals
connections.
10 Thermal screening of Pantry Equipments like water D3 schedule.
boiler & hot case connection terminals.

Note: Please be ensure all electrical equipment load put ON beforee

one hour of thermal screening
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Performa for commissioning of new coaches (LHB AC)
895731/2022/O/o
A. Coach Particulars
Dy.CEE/Chg/HQ/NR
Coach type
Date of
SG/EOG/LHB/Co
Coach No. & Code Coach Manufacturer Month & Year of Manufacture Receiving at Remarks
nv./Hybrid (Steel
Depot
Body)

B. Equipment Details

NPP side (Unit-I) PP side (Unit-II) Current Current

Current With Current Without
S. No. Detail of equipments With Without Working of Equipment
Capacitor Capacitor
Make S. No. Make S. No. Capacitor Capacitor

1 AC Unit Make

CP-1.1 CP-2.1
Compressor
2
(07-10 Amps)
CP- 1.2 CP-2.2

CD-1.1 CD-2.1
Condensor Motor
3
(1.5 – 2.1 Amps)
CD-1.2 CD-2.2

Blower Motor
4
(1.5-2.5 Amps)

5 HOG Control Panel Make:

6 D&ED

7 Accidental Emergency Light Make:- Qty:-

8 Switch Board Cabinet Make:- Sr.No:-

9 CPU Make:- Sr.No:-

10 Emergency battery changer Make:- Sr.No:-

11 Regulated battery changer Make:- Sr.No:-

12 Battery 70 AH (Make/Lug date) Make:- Lug Date:-

13 Pump Controller Make:- Sr.No:-

14 Mono-block pump Make:- Sr.No:- Make:- Sr.No:-

15 60 KVA Transformer Make:- Sr.No:-

16 5KVATransformer Make:- Sr.No:-

Unit-I Unit-II
CP 1.1 CP1.2 CP 2.1 CP1.2
Make- tripping Make- tripping pressure:- Make- tripping Make- tripping
17 HP Cutout Tripping at 415 psi pressure:- pressure:- pressure:-

Make- tripping Make- tripping pressure:- Make- tripping Make- tripping

18 LP Cutout Tripping at 35 psi pressure:- pressure:- pressure:-

Sensor name RT-I RT-II AT-I AT-II ST1 ST2 HYGROSTAT 1 HYGROSTAT 2
19 NTC Sensor
location

20 Heater Current

21 OHP Setting 65 Degree C

Remarks if any:-
HT MMR (Wkg/ Not wkg)
Remarks if any:-
LT MMR (Wkg/ Not wkg)
22 Protection Relay
Remarks if any:-
MVR (Wkg/ Not wkg)
Remarks if any:-
MCB/MCCB (Wkg/ Not wkg)
Remarks if any
23 Refrigeration Pipe line Modified/Non modified
Make Qty Remarks if any
24 ZS Coupler

25 ZS Ratchet Coupler

26 Junction Box

27 Dummy Plug

28 Coach Light

29 Berth Light

30 Call bell

31 Switch & socket position

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32 No. of Mobile charging point
895731/2022/O/o Dy.CEE/Chg/HQ/NR
33 Exhaust Fan

Insulation Monitoring Relay

34
(110 V DC)
Insulation Monitoring Relay
35
(415 V AC)

36 Power Bank

37 Total current of coach at full load

Earthing of all Current carrying

38
electrical equipments
39 Rodant protection

ESTI-1 wheather it is in
circuit/bypass
Heating mode testing (Check the ESTI-2 wheather it is in
40 tripping of heaters i.e. OHP. The circuit/bypass
OHP setting is 65°C. OHP-1(tripping time)

OHP-2(tripping time)

41 Air Flow

42 Underframe Fastner

43 Cable trench

44 Canvas Duct

Pantry Equipments:-

45 Hot Case-1
46 Bottle Cooler
47 Deep Freezer 1 2
1
48 Chimney 2
3
1
49 Water Boiler 2
3

50 Refrigerator

51 Hot Plate

C. Detail of Equipment Replacment/Repair During Commissioning

Date of attended
Date of Failure Equipment Detail Make & S. no. Reason of Failure Detail of Action taken & joints with the firm
by firm

S.N Technician Name Designation Signature of Technician

Signature of supervisor