ELECTRO PNEUMATIC PRESSURISED FLUSHING

SYSTEM

DISMANTLING, TROUBLESHOOTING & MAINTENANCE MANUAL

National Engineering Industries Limited

Khatipura Road
Jaipur (Rajasthan) India
Contact: 8306009991, 9414717510 Email: rbservice@nbcbearings.in

MAINTENANCE MANUAL OF EPPFS FOR LHB COACHES 1|Page

 CONTENTS
Page No.
1. About Us 03
2. Functions and Specifications 04
2.1 Summary 04
2.2 Function Block Diagram 05
2.3 Specifications 05
2.4 Method of Measurement 05
3. Configuration 06
3.1 Parts Identification 06
3.2 Main Components of the System 07
3.3 Parts List 10
4. Installation Instruction 11
4.1 Mounting 11
4.2 Check Points for Operation 12
4.3 Dismantling the System 13
4.4 Wiring and Connections 13
5. Preventive Maintenance Plan 15
6. Troubleshooting 16

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 About Us

National Engineering Industries is making huge investments on various projects to support IR under
honorable Prime Minister’s “Make in India” initiative by indigenization of costly imported products
enhancing passenger safety and amenities. NEI has recently developed “Vacuum Evacuation System” and
“Electro-Pneumatic Pressurized Flushing System” indigenously for LHB and BG, AC and Non-AC
Coaches as per IR specifications “RDSO2017CG-06 Rev.03”, “RCF MDTS 24317 REV 01” and
“MMDTS 19027 Rev.01” and successfully conducted the trials in house. We have successfully executed
the supply order for Vacuum Evacuation System to ICF, successfully demonstrated the product at
production units and further having a vision to support Indian Railways initiative by indigenization of
product enhancing passenger safety and amenities.

Further, NEI Jaipur plant have its own in house Machine Building and Automation Division which works to
provide Industrial Automation solutions for in house manufacturing and testing facilities with technical
collaboration with numerous suppliers. Ever since department started, it has been striving for excellence in the
field of Industrial Automation by providing advanced technical products and Cost effective Integrated
Automation Solutions (consisting of both Mechanical and Electrical & Electronic Control) based on its long
association with numerous suppliers like Ash & Alain India Pvt. Ltd which has long history of working with
Global Japanese Brands Like CKD Japan (pneumatic control components, pneumatic auxiliary
components, and fluid control components), Omron (Global leader in industrial automation), Oriental Motors
Co. Ltd. & Patlite (best known manufacturer of visual and audible signaling devices).

We are equipped with well versed quality control team which works in order to create the environment
focusing quality control over the mass production. NEI is having all kinds of specially equipped facilities &
certifications justifying quality control.

Our Machine Building and Automation division has developed expertise in the following fields and
has been providing continuous technical assistance.
FA Systems
 Sensing Solutions

 Motion Controls
 Vision Inspection
 Identification/Tracking Systems

 Pneumatic System
 Safety Solutions

 Control Panel Building (Both Electrical & Pneumatic)

To ensure reliability of our Systems, we manufacture critical mechanical parts and design and assemble all the
MAINTENANCE MANUAL OF EPPFS FOR LHB COACHES 3|Page
Control Panels in-house. We have set up a well furnished Tool Room and Control Panel Building facilities.
We are able to provide total automation solutions for all types of industry. We, with help of our technical
collaborators manufacture Special Purpose Machines and Control & Pneumatic Panels incorporating PLCs
and other critical components as per the specifications of the customers.

Also, we would like to take this opportunity to introduce ourselves as one of the largest manufacturer and
established supplier of bearings and axle boxes to Indian Railways since last seven decades. NEI is
recognized today as a pioneer brand in the railway bearings industry for manufacture of range of critical
bearings and allied components for different types of rolling stock such as:

 Axle Box Bearings & Housings (for e.g. Bearing Adapter Assembly for EMD Locos),
 Cylindrical Roller Bearings (for e.g. CRU150 for WAG9/WAP7 Locos)
 Traction Motor Bearings (ALCO & Conventional Electric Locos)
 Traction Motor Suspension Tube Bearings (ALCO, EMD, Conventional Electric Locos)
 Spherical Roller Bearings (Conventional ICF Passenger Coaches & EMUs)
 Cartridge Tapered Roller Bearings (Wagons and EMD Locomotives)
 Forged finished components, etc. for rolling stock applications.

NEI is having all kinds of specially equipped facilities & certifications as mentioned below:

 Internationally accredited quality certifications viz., Deming, IRIS, AAR, TS, etc.
 Design centre equipped with all Software for modeling and simulations e.g. Romax, Pro-
Engineer 3D Modeling & Analysis Software
 In house Research and Development wing with more than 200 dedicated engineers
 World class testing facilities with more than 50 different test rigs.
 World class in house metallurgy lab to support testing of material.
 Established vendor base for supply of bulk castings, precision machining, radiographic and
ultrasonic testing facility with RDSO approved “Class A Foundry”.
 Independent State of Art Machine Building and Automation Division

MAINTENANCE MANUAL OF EPPFS FOR LHB COACHES 4|Page

2. Functions and Specifications

2.1 Summary

Electro Pneumatic Pressurized Flushing System (EPPFS) is positive displacement type having “Piston-
Cylinder arrangement” type set up for creating pressurized water supply without allowing water coming
into contact with pressurized air and has been designed to provide long trouble free service and uses
standard components easily available from globally renowned manufacturers who have been operating in
India for a long time and are well known for quality. While designing the System, safety and convenience
of the passengers have been paid special consideration. The system is non corrosive type and would render
satisfactory performance for a long time.
The System would dispense 1.5 Liter water @ pressure of 2-3 Kg/cm² each time with light pressing the
Push Button Switch having metallic body and would be ready for next use in 7-8 Seconds.
Our system is user friendly, modular in design, durable, portable and very easy to use install and maintain.
All the electrical, electronic and pneumatic parts of the system are shock and vibration proof and comply
with IEC 61373 category -2 or equivalent international standard.

2.2 Function Block Diagram

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 2.3 Specifications:

Pressurization time 7-8 Seconds

Flushing Pressure 2-3 Kg/nm²
Water Consumption 1.5 Liters
Air Consumption 3 Liters approx
Power Consumption ≤10 Watt

2.4 Method of Measurement

Water Pressure By Dial Gauge

Water Volume Measurement by Measuring Flask
after 10 Cycle & taking average
Cycle Time By HMI of Test Bench

1. The electro pneumatic pressurized flushing system will be ready to use within maximum 8
seconds after each use.
2. Maximum discharge of water during the flush will be 1.5 liters.
3. No mix of air and water will be released in the bowl at the time of flushing.
4. There will be no leakage from the system at 5 bar pressure and dispense approx. 1.5 liters of
water at the time of flushing.
5. Consumption of air will be 3 liters per flushing operation.
6. Electro pneumatic pressurized flushing system is designed for a usage of minimum 150 times
within 24 hours.
7. Total peak power per coach will not exceed 40 watts.
8. Railway grade components are used in all electrical and electronic items.
9. The system has been so designed that it doesn’t require day to day maintenance

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3. Configuration
3.1Parts Identification

17
S.NO. ITEMS QTY. UNIT

1 WATER PRESSURIZED 1 NOS. 7

2 FILTER REGULATOR 1 NOS.
3 2 PILOT VALVE 1 NOS.
2
4 STRAINER 1 NOS. 17
5 BALL VALVE 1 NOS.
6 SOLENOIDE VALVE 1 NOS. 8
7 HOSE PIPE 3 4" 3 MTR
8 HEX NOZZLE 3 4" 4 NOS. 5
9 SS PIPE 3 4" 1.5 MTR
10 ELBOW 43" 1 NOS. 4
11 NYLON TUBE 10mm 6 MTR
ILLlUMINATED GREEN PUSH C 233
12 1 NOS.
BUTTON
13 NRV 3 4" 1 NOS.
14 COCK 1 4" 1 NOS. 20 22 21
15 TEE 10mm 1 NOS. 19
PNEUMATIC
16
ELBOW(10mmx14") 5 NOS.
9
3
17 HOSE CLAMP 4" 5 NOS. C
M10x35 HEX BOLT WITH
18 4 NOS.

275
NUT AND SPLIT PIN
19 C MOUNTING CLAMP 43" 2 NOS. B
20 TIMER 1 NOS.
21 POWER CONVARTOR 1 NOS. PRESS TO FLUSH
70

22 PANEL BOX(200X325X100) 1 NOS.

23 L BRACKET 1 NOS.
70
B
12 2

585 3
16 15 14

16

1 13 7 10
17
20
240 240
4 11
C
MOUNTING CLAMP

60 DETAIL A:A 23
110

L BRACKET
80
50

18 SECTION VIEW B:B

150
25

25

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3.2. Main Sub-assemblies of the System
(i) Water Pressure Pump.
(ii) Illuminated Push Button Switch
(iii) Preset Air Filter Regulator
(iv) Control Panel
(v) Power Convertor
(vi) Timer
(vii) Relay with Base

(i) Water Pressure Pump:

Inlet of water pump sucks the line water and amplifies the water pressure to generate enough flow
through the flushing nozzles to clean the toilet bowl. We use ¾” NRV on Inlet Port and 2/2 Piston
Valve (3/4”) on Outlet Port. We preferred 2/2 Piston Valve to Angle Seat Valve as the former
has virtually no leakage and no NRV is, therefore, required to be used and thus Systems becomes
more reliable.

2/2 Piston Valve ¾”

Aluminum
Tube for
SS Tube
Air
for Water NRV3/4”

MAINTENANCE MANUAL OF EPPFS FOR LHB COACHES 8|Page

 (ii) Illuminated Switch:
The Illuminated Push Button is used for starting the flushing operation. This switch is in
metallic body and operates on 24VDC. Green light is on when the System is ready for use. No
light is displayed when the Flushing operation is on. Once Flushing Cycle is completed and the
System is ready for next use, Green Light appears again. The Switch is protected from back
side by a Cover. 70 mm

70 mm

(iii) Preset Air Filter Regulator:

Filter Regulator ensures clean Air and Pressure of the Inlet Air is 3 bar ( as per specifications )

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 (iv) Control Panel:

The Panel houses Power Convertor (Input 110AC and Output 24VDC), Timer (24VDC) used
for controlling the flushing cycle time, Relay (24VDC), Filter and 5/2 Solenoid Valve,

Control Panel

Power Converter Relay with Base

VALVE 5/2 WITH MANIFOLD

Filter Regulator

(v) Power Convertor:

Functions at Input Voltage 110 AC/DC And converts the same to 24 VDC for control components and
Solenoid Valve and withstands ± 30% voltage fluctuation and 30% Ripple.

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 (v) Timer:-
Operates at 24 VDC and facilitates control of flushing cycle time. This item is shock and vibration
proof and comply with IEC 61373 tests. This component is also complying with EN 50155 for
environmental protection. Item is able to withstand ±30% voltage fluctuations.

(vii) Relay with Base:-

Operates at 24 VDC and is used at the start of the cycle. This item is shock and vibration proof and
comply with IEC 61373 tests. This component is also complying with EN 50155 for environmental
protection. Item is able to withstand ±30% voltage fluctuations.

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 3.3 Parts List
S
DESCRIPTION MODEL NO UNIT
NO.
BOM ELECTRO-PNEUMETIC PRESSURIZED FLUSHING SYSTEM
1 Hose Nipple 3/4" Thread 1"( For Tank) SS304 1
2 Hex Connector 3/4" SS304 2
3 Pipe Nipple 3/4"x50mm SS304 1
4 Elbow 3/4" SS304 1
5 SS Pipe Nipple 3/4"x1500 SS304 1
6 Ball Valve 3/4" SS304 1
7 Y Strainer 3/4" SS304 1
8 Hose Nipple 3/4" SS304 4
9 Hose Pipe 3/4" Thermo Plastic IS-12585-88 TYPE-2 As Required
10 Hex Connector1/4" Brass Brass 1
11 Hose Clamp 3/4" SS304 6
12 NRV 3/4" Vertical SS304 1
13 Bally Valve Female 1/4" STD 1
14 Push Button Plate (SS304) 270-02-00-002 1
15 Mounting Plate with Stud (SS304) 270-02-00-003B 4
16 CYL MTG Bracket (SS304) 270-01-00-006 2
17 Push Button Cover 270-02-00-005 1
18 Z Mounting Stud plate with clamp 270-02-00-001 2
19 Hex Bolt M10x30 with Split Pin SS305 4
20 SS Seal Nut M10 SS306 10
21 SS Seal Nut M8 SS308 8
22 PRESURIZER CYLINDER AACT-100-1.5LE 1
23 PRESET REGULATOR (3 BAR) W1000-8-W-F1 1
24 Angle Seat Valve or 2/2 Piston Valve SAB1W-20A-0 1
25 VALVE 5/2 WITH MANIFOLD 4GB210R-08-E2-3 1
26 STRAIGHT FITTING TUBE 10mm THREAD 1/8" GWS10-6 1
27 STRAIGHT FITTING TUBE 10mm THREAD 1/4" GWS10-8 1
28 ELBOW FITTING TUBE 10mm THREAD 1/4" S6520 10-1/4 5
29 TEE FITTING TUBE 10 mm 6540 10 1
30 NYLON PNEUMATIC PIPE 10 mm EA1080WHT As Required
31 Flat Silencer BRASS1/4" 3
32 Flat Silencer BRASS1/8" 1
Cable Conduit metallic for Pneumatic Pipe ID = 11
33
mm As Required
34 Timer H3DKZ-A1 AC/DC24-240 1
35 Switching Power Supply S8FS-C01524J 1
36 Illuminated Green Push Button (Metal Body) 2ALRF3L24VDC 1
37 NO CONTACT S1 1
38 RELAY 24V DC MY2N DC24 1
39 RELAY BASE PYF08A-N 1
40 Panel Box according to drg. 270-02-00-003 1

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 4. INSTALLATION INSTRUCTION

4.1 Mounting

Mounting Stud:-
Mounting Studs are pasted on FRP using a Structural Adhesive keeping the Control Panel
Mounting Dimensions in view.
50 mm 3 mm

50 mm
Stud
M8 x25mm

Panel Mounting:-
Put Control Panel on Pasted Mounting Studs and fix the same with using M8 Nyloc Nut.
233 mm

275 mm

Inlet
Air Main Line Port 1 Port 2

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 Water Pressure Pump :-
Water Pressure Pump is to be mounted at Coach Under Frame using 4 Nos of M10x35 Hex
Bolts, Nyloc Nuts and Split Pins

04 Nos.M10
Hex Bolt, with
Nyloc Nut and 60 mm
Split Pin

585 mm

Water Main Line:-

It is to be fitted on studs fixed on FRP using C Clamps and M8 Nyloc Nuts. Main Line is to be
connected with the Main Water Tank from up side with Hose Pipe (20mm) with SS sleeve and Hose
Clamp, down side connect to NRV Port with using Hose Pipe (20mm) and Hose Clamp.

Main Water Tank with

20 mm Hose Pipe

SS C Clamp ¾”

Water Pressuriser
NRV Port with 20
mm Hose Pipe

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 BEFORE CONNECTING THE SYSTEM TO THE MAIN LINE, ALLOW THE AIR
TO FLOW IN THE ATOMSPHERE FOR 30 TO 60 SECONDS

4.2 CHECK POINTS BEFORE OPERATION

 Check all the connections with nuts and bolts are properly mounted or tightly fixed.

 Check all air connections are correct or as mentioned in the drawing.

 Check all the water hose pipe connections are correct or as mentioned in drawing.

 Check all the Ball Valves (for water line and airline) are in open condition.

 Check the required Air pressure is available at Coach as specified in the Drawing

 Check the water is there in the Main Water Tank of thecoach.

4.3 Dismantling the System

For Dismantling the System follow the following Steps

Step 1:- First of all we need to close the all supply like Water ,Air ,Power
Step 2:- Disconnect the power connection and Push Button connection.
Step 3:- Disconnect the all water line which is connected 20 mm Hose Pipe.
Step 4:- Disconnect the all Pneumatic connections.
Step 5:- Dismantling the system as reverse of Mounting.

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4.4 Wiring and Connection :

S.NO TAG DESCRIPTION

1 T-16 TIMER NC CONTECT

2 RNO-1 RELAY NO CONTECT 1

3 RNC-1 RELAY NC CONTECT 1

4 RNO-2 RELAY NO CONTECT 2

5 A1 & A2 TIMER COIL INPUT

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 SCHEMATIC DIAGRAM FOR
ELECTRO PNEUMATIC WATER PRESSURISER
ILLUMINATED SWITCH
9

RELAY
POWER LINE AIR LINE
110 AC/DC POWER 7
TIMER ELECTRIC LINE
CONVERTOR
10 WATER LINE
8
WATER TANK
(CUSTOMER)
12
AIR IN LINE 4
13
16
2
Tube 10mm 11

UNDER FRAME

15 14
1

ITEMS LIST
S.NO. DESCRIPTION QPA UNIT MODEL NO. MAKE

1 Pressuriser Cylinder 1 Nos. AACT-100-1.5LE A&A

2 Fillter Regulator (3Bar) 1 Nos. W1000-8-W-F1 CKD
3 Piston Valve 1 Nos. SAB1W-20A-08 CKD
5
4 2 Valve 24VDC 1 Nos. 4GB210R-08-E2-3 CKD
5 Nylon Tube (10mm) 8 Mtr. EA1080B PISCO
6 Timer 1 Nos. H3DKZ-A1DC24-240 OMRON
7 Power Convarter 1 Nos. S8FS-G01524C OMRON
Illuminated Green Push
8 1 Nos. 2ALRF3L24VDC TECHNIC
button
9 Relay 1 Nos. MY2N-GS24VDC OMRON
3
10 SS Pipe 4" 1 Nos. SS304
3
11 Ball Valve 4" 1.5 Mtr. SS304 HITTCO
3
12 Y-Stainer 4" 1 Nos. SS304 HITTCO
3
13 Hose Pipe 4" 1 Nos. THARMO PLAST KESARA
14 Check Valve 3 Nos. SBM20 SANT
1
15 Bally Valve 4" 1 Nos. NIL TECHNO

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 5. Preventive Maintenance Plan:

S. No. Description
 Cleaning the surface of the lavatory bowl/pan a regular
Every day intervals. If water is not coming out there may be a chance of
1 clogging of lavatory pan nozzles.
 Clean the Y-Strainer. If water is not coming out there may be a
chance of Strainer filter Chock
 Check whether there is water or air leakage on Western Style
Every Module/ Indian Style Module.
2
Month  Check all the Hose Pipes Under frame, replace them if
necessary.
 Rubber Seal Kit of Water Pump to be cleaned / replaced
3 Every six  Spool Seal Kit of Pneumatic Valve to be cleaned / replaced
Month
 Spring of NRV , 2/2 Valve and Piston valve to be checked /
replaced.

 Filling 4% lemon acid solutions into the lavatory bowl/pan. The

Every liquid should cover the spray nozzles. Immerse for one hour and
Year then clean the lavatory bowl/pan with clean water and soft
4
brush.
 Clean the lavatory bowl/pan nozzles.
 Check the leak tightness of the discharge valve (2/2 Piston
Valve)
 Check the ageing condition of Hose under the Coach, and
replace it if necessary.
 Remove the safety Valve on the interim tank, repair or replace it
if necessary.

Every 3  Replace all the Hoses and Rubber Joints under the Coach.
5 Years  Disassemble the discharge Valve completely, replace the seal
components, and replace it completely if necessary.
 Disassemble the nozzles, waste pipeline fittings and water pipe
fittings, and clean these components after steeping them with
4% citric acid solution for 1 hour.
 Check the pneumatic valve and other parts, and replace them if
necessary.
 Reassemble the system, and conduct a comprehensive test
according to the requirements of test program.

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 6. TROUBLESHOOTING
GENERAL PROBLEMS
Airline not working properly
Water line not working properly
Water output not available in the toilet
pan/bowl.
MAINTENANCE MANUAL OF EPPFS FOR LHB COACHES
REMEDIAL ACTIONS
 Check pneumatic connections as per assembly drawing 270-04-
00-000
 Check input pressure using pressure gauge.
 Check air Ball Valve is open.
 Check the Air Line for any clogging.
 Check output pressure from pressure regulator using pressure
gauge.
 Check water connections as per the assembly drawing 270-05-
00-000
 Check input connection from the overhead tank to the
pressuriser unit.
 Check water ball valve is open
 Check the water line for any clogging.
 Check output connection of water pressurization system up-to
the toilet pan/bowl.
 Check the all connections as per the assembly drawing 270-03-
00-000
 Check pneumatic connections of Solenoid Valve in Penal.
 Check pneumatic connections of pressuriser unit.
 Check air pressure available.
 Check the input N.R.V and output 2/2 valve for any Clogging.
 Check the Power Supply is Working or not
 Check the Timer and Relay
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