Project On Wiring Details of LHB AC Coach

PROJECT ON WIRING DETAILS OF LHB AC COACH
PROJECT REPORT ON
Wiring Details of LHB AC Coach
PRINCIPAL
MR. YASHWANT URHEKAR
CETI , Thakurli
Guided By:
Mr. KESHAV KUMAR
Sr.instrutor
TL/AC
COURCE CO-ORDINATOR
Mr. KESHAV KUMAR Mr. V.N.GANVIR

Sr.instructor Sr.instructor
TL/AC TRD
ACKNOWLEDGEMENT
It is indeed a matter of great pleasure and proud to present this project

of “WIRING DETAILS OF LHB AC COACH”. We are highly indebted to Mr.
Keshav Kumar Sr. Instructor of CETI Thakurli for his invaluable guidance
and wish to record our deep sense of gratitude and appreciation for his
support.
We would like to render our sincere thanks to Mr. Yashwant
Urhekar, Principal CETI Thakurli, Mr. Keshav Kumar, Sr. instructor
(TL&AC) of CETI Thakurli and Mr. V. N. Ganvir, Sr. Instructor (TRD), course
coordinator of CETI, Thakurli for their continuous support, guidance and
inspiration in all the phases of our project work and encouragement that
we have received.
Project Team
Project Team
(Batch - I)
Sr. No. Name Designation Div. /Rly.
1 Mr. Manovar Khan APP SSE MTN/CR
2 Mr. Akash Pandey APP SSE BCT/WR
3 Mr. Brijesh Yadav APP SSE BCT/WR
4 Miss. Radhika Tyagi APP JE BCT/WR
5 Mr. Satyaranjan Chaturvedi APP JE IZN/NER
6 Mr. Yogendra Kumar APP JE IZN/NER
7 Mr. Mayuresh Raul APP JE MTN/CR
8 Mr. Kishan Singh APP JE MTN/CR
9 Mr. Hitesh Dwivedi APP JE MTN/CR
10 Mr. Yogesh Shirgaonkar APP JE MTN/CR
11 Mr. Jayesh Medbali APP JE MTN/CR
12 Mr. Akhilesh Upadhyay APP JE MTN/CR
13 Mr. Pappu Kumar APP JE BCT/WR

CERTIFICATE
This is certify that the project work entitled “LHB AC COACHES” is a

bona-fide work carried out by a Batch of Induction trainees of
Centralised Electrical Training Institute from 03 April, 2017 to 16
September, 2017 under my guidance and direction.
Signature of guide: Signature of course

coordinator:
Mr.KESHAV KUMAR Mr. V N Ganvir

Sr.instrutor Sr.instructor
TL/AC TRD
Signature of principal:
Mr. YASHWANT URHEKAR

Principal
CETI Thakurli
LHB TYPE COACH
(M/s LINKE HOFMANN BUSCH, GERMANY)
In order to make quantum jump in passenger coach technology and to bring it to

contemporary world standards, Indian Railway entered into supply and technology
Transfer contract with ALSTOM-LHB, Germany. As part of supply contract M/s
ALSTOM-LHB, Germany supplied 24 coaches consisting of 19 Second AC Chair cars
and 3 Generator cum brake Vans.
Rail coach factory, Kapurthala has been entrusted with the task of developing
and manufacturing of modern, high speed state of art coaches under transfer of
contract. RCF took the challenge, achieved the target and rolled out its first rake of
LHB coaches on 13-12-2003 for Rajdhani Express between New Delhi to Mumbai
Central.
ADVANTAGES OF LHB AC COACHES
Passenger Related Areas

 Improved ride comfort –ride index of 2.5/2.75 at 160 Kmph (As compared to
3.25/3.5 for ICF coaches at 130 Kmph)
 Higher speed potential of 160 Kmph
 Windows of big size allowing good visibility with functional roller blinds
Mechanical Advantages
 Modern designs of vestibule for inter car connection
 Anti – climbing feature to prevent climbing off during collision (CBC
COUPLING)
 Coach length is increased by about 1.7 m to provide extra carrying capacity.
Length of ICF coach is 21337 mm (21.3 meter) whereas LHB coach is 23040
mm (23.04 meter). This extra length means two additional rows of chairs in
chair cars or one additional bay in sleeper coaches.
 Weight reduction by 10% due to latest technology and SS material
1 AC 18 to 24
2 AC 46 to 54
3 AC 64 to 72
Electrical Advantages
 Low noise, microprocessor controlled AC unit
 Light weight epoxy molded 60 KVA Transformer
 Integrated modular single switchboard with controls of AC lighting
 Provision of FRLS cables
 Uniformity of illumination
 IGBT based battery charger used
 Humidity control by microprocessor
 Temperature control in seven step
 Disconnecting and earthing device provided
 Exhaust fan provided in toilet
 Flap motor to adjust volume of fresh air automatically
 NTC type sensor provided
POWER SUPPLY ARRANGEMENT

The power system for the coach has been designed to feed the various
electrical loads in the system operating at different voltages. There will be following
voltage systems for feeding the various electrical loads.
 750 V 3 Phase AC supply system

 110 V DC supply
 24 V DC supply
The coach will select the input supply from either of the two feeders available on
the coach at 750 V three phase supply through disconnecting and earthing device
provided in switch board cabinet.
The 750 V 3 phase supply is stepped down to 415 V, 3- phase supply with the help
of one 60 KVA epoxy cast and encapsulated transformer, which is provided on the
under-frame of the coach.
 The electrical equipment of roof mounted package units, exhaust fans and
pump equipment are supplied with 415 V, 3-phase supply received from 60
KVA transformer.
 Loads of electrical appliances provided in sub pantry such as hot case, bottle
cooler, and refrigerator shall be fed with single phase at 230 V, 50 Hz by using
one out of three phases and neutral connection of 3-phase 415V AC supply.
 The lights, electric razors socket etc. shall be supplied at 110 V, single phase
AC received from regulated battery charger.
 The 110 V DC is used for supplying control for roof mounted package unit ,
anti-skid device, light control, emergency lights, telephone, night lights,
berth reading lights, power contactors control etc.
 A DC-DC converter shall be used to obtain 24 V DC for control systems for

pump, sanitary and public address system, return air flap unit i.e. servo
motor of air conditioning system etc.
 The power and control supply arrangement to various electrical loads in the
coaches shall generally be similar to originally imported LHB AC coaches. The
415/230 V AC network is designed as unearthed IT-4 conductor system.
 Roof coach wiring shall be routed in PVC rigid conduit/trenches conduits.
Under frame wiring shall be with IP68 protection and shall be covered with
perforated cable trays as a primary safe guard against ballasts hitting.
 All the equipment above 250 V shall be earthed at two places and below 250
V at one place. Voltage segregation shall be ensured during wiring.
 As per rule 64-A of IE rules, over current protection shall be provided to

disconnect the supply automatically, if the rated current of the equipment,
cable or supply line is not designed to with stand.
 The system will have earth fault/earth leakage protection to disconnect the
supply automatically, if the earth fault current exceeds the limit of current
for keeping the contact potential within reasonable limits.
EQUIPMENT DETAILS
• Feeder Junction Box – 4 Nos.
• Disconnecting & Earthing Device (D&ED) – 1 No.
• ZS Coupling – 4 Nos.
• Measuring & Monitoring Relay (MMR) – 3 Nos
• Minimal Voltage Relay (MVR) – 3 Nos
• 1 KVA Transformer – 2 No.
• 60 KVA Transformer – 2 Nos.
• Mono Block Pumps – 2 Nos.
• RBC (6.5 KW) – 1 No.
• EBC (2.5 KW) – 1 No.
• Set of Batteries (12V x 09 Nos) 70 AH VRLA – 1 Set
• Water Boiler – 3 Nos.
• Deep Freezer – 2 Nos.
• Refrigerator – 1 No.
• Bottle Cooler – 2 Nos.
• Hot Case – 2 Nos.
• 1.1 KW Heating coil – 3 Nos.
• 2 KW heating coil – 3 Nos.
• Exhaust Chimney Motor – 3 Nos.

ZS COUPLER ASSEMBLY
Rated Current Capacity : Phase & Neutral wires - 400Amp

: Earth wire - 260 amp
: Control wires - 25Amp
Cable Size : Phase wire - 120/150 Sq. mm
: Neutral wires - 95 Sq. mm
: Earth wires - 70 Sq. mm
Insulation Resistance Value : More than 500 mega ohms
FEEDER JUNCTION BOX
 3 phases, 750 volts AC supply
 A Feeder is a conductor which connects the local generating station to the

area where the power is distributed
 The main consideration in the design of a feeder is the current carrying

capacity
DISCONNECTING AND EARTHING DEVICE
Disconnecting and earthing device is provided in switch board cabinet and is fed
750 V from power car through ZS couplings. It has two positions “ON” & “EARTH”.
It disconnects coach feed at 750V in case of emergency like contactor jamming and
earths the coach for maintenance even during running of coaches.
Capacity : 120 Amp
Purpose : It is an off load switch to ensure earthing before
maintenance.
Locations : In bottom right side of switch gear rack.
SWITCH-BOARD CABINET- S1
SWITCH BOARD CABINET
Disconnecting and
earthing device
Regulated battery charger
Emergency battery
charger
Contactors and relays
1 KVA transformer for

lights
Wheel skid protection
24 V dc to dc convertor
Microprocessor based
controller
Coaches are provided with modular, integrated single cabinet designed switch
board cabinet comprising all necessary equipment for control and protection of the
following coach systems.
 Heating, ventilation & Air conditioning
 Lighting
 Pantry
 Anti-skid protection
 Train destination indicator
 Public address system
 Sanitary system (except W.C. control)
 Battery charger
 Dis-connecting and earthing device.
MEASURING & MONITORING RELAY (MMR)

Measuring & Monitoring Relay(MMR)
• MMRs are provided to
detect abnormality
within any one feeder
supply.
• Two MMRs are
MMR MMR Indication Lamps provided for 2 feeders
of 750V.
• MMR indication lamps
are provided near
feeder selector switch.
Purpose : To check for phase sequence matching between IV

Coupler wires & coach 3-phase wires
Additionally it gives over voltage & under voltage
Protection also
Setting : +/- 10% of 750 V for O.V & U.V
MMR Contactors : K03 & K 04
1 KVA LIGHTING TRANSFORMER
01 KVA TRANSFORM
• 01 kVA trans
used to step
voltage from
110 V.
• This 110 V s
fed for lighti
purpose.
01 kVA Transformer
1 KVA transformer is used to step down voltage from 230 volts to 110 volts.
This 110 volts supply is fed for lighting purpose.
Rating (KVA/Volt/Amp) : 1KVA, 230/110 Volt AC
Quantity : As per coach requirement
60 KVA TRANSFORMER
Rating (KVA/Volt/Amp) : 60KVA, 750/415Volt 3 Ph. (46.2/83.4 Amp)

Type of Transformer : Cast Resin Dry type
Type of Mounting : Underslung, 4bolt
Location : Under frame
Cooling : Natural air cooled
Class of Insulation : H
Connections : Star-Star
MONO BLOCK PUMP CONTROLLER
PUMP CONTROLLER
Front Side View Back side View
Rated speed : 2800 RPM

Rating (HP/KW/AMP) : 0.5 H.P/0.37KW/1.2 Amp
Motor insulation Class : F
Total head : 8 Meters
Discharge : 42 LPM
Power supply of controller : 24/110 V D.C
REGULATED BATTERY CHARGER (RBC)
RBC (6.5 KW)
 Purpose : To give regulated voltage to the battery

 Rated output voltage (float) : 121 V at 4 amp
 Boost Charging setting : 127 V at maximum 6 amp
 Boost current limit : Above 6 amp
 Power : 6.5 kW/50A, 130V DC
 Input voltage : 415 V± 15%, 3-phase AC
 Input frequency : 50 Hz ± 10%
EMERGENCY BATTERY CHARGER (EBC)
 Power : 2.5 kw
 Input voltage : 230 V± 5%, 1-phase AC
 Input frequency : 50 Hz
 Output voltage : 110 V DC
 Output current : 20 A DC
BATTERY
Type : Pure lead tin VRLA monoblock batteries
Operating temperature range : - 40 to +50 deg. C
Terminals : High conductivity copper alloy terminals
Separator : High quality absorbent glass mat separator
Pressure valve : Self-releasing pressure regulating valve
Container : Impact resistant ABS container &lid
Plates : Plates with superior grids and active

materials
Charging for pure float : 13.5 V for 12 V battery
Application boost : 13.8 v for 12 v battery
Charging for semi cyclic float : 13.7 V for 12 V battery
Application boost : 14 V for 12 v battery

MICROPROCESSOR CONTROLLED A.C. PACKAGE UNIT (RMPU TYPE)
The coaches are provided with 2 microprocessor controlled A.C. package units.
Both package units are controlled by a microcomputer, mounted in switch cabinet
S1 and fed from battery net. This is a fully automatic mode. Depending on the
ambient temperature, the available modes of heating, ventilating, cooling and
dehumidifying are controlled.
Nos. of RMPU unit in each coach 2 units (2 X 5 Ton) capacity each in coaches and
in power car only one unit.
RMPU Unit
AIR INTAKE FOR

CONDENSOR FANS THE CONDENSOR FANS
RMPU View with side cover open

• CONDENSER AIR INTAKE GRILL
FLEXIBLE CONDUITS FOR

ELECT. CONNECTIONS TO
THE UNIT
ELECTRICAL JUNCTION
BOX ( ONE ON EACH
SIDE )
FRESH AIR DUCT

(CANVAS)
MOUNTING
BRACKET
RETURN AIR DUCT

The compact air conditioning unit has two separate cooling circuits consisting of
the following components:
• Refrigeration compressors with oil heaters - Two Nos

• Condensers with Copper pipes and Aluminum - Two Nos
• Axial fans for cooling the condensers - Two Nos
• Evaporators and heating assembly - Two Nos
• Twin-sucking radial fans for the supply air
(Driven by 1motor) - Two Nos
• Maintenance covers - Three Nos
• Air inlets for circulating air - Two Nos
• Air inlets for fresh air - Two Nos
• Mixed air filters & Fresh air filter - Two Nos
• Air outlet for supply air - One No
• Control and safety devices
• Pipelines/fittings
BLOWER MOTOR

Rating (HP/KW/Amp) : 1.0 HP/.75 KW/1.85 Amp.
Fan blade material : Plastic
Motor insulation class : H class
CONDENSER MOTOR
Rating (HP/KW/Amp.) : 1.0 HP/.75 KW/1.85 Amp
COMPRESSOR
Type of compressor : Hermetically sealed
Rating : 415 V 3ph AC 50 Hz
LP cut out (for scroll) : 20.0 BARS (max.)
HP cut out (for scroll) : 27.5 BARS (max.)
FILTERS
Fresh air size : 48 cm x 26 cm
Return air size : 83 cm x 43 cm
LHB AC COACHES CONTACTORS & RELAY
K01, K02 - Main contactor feeders
K03, K04 - MMR (measuring monitoring relay)

750 V
K05 - Anti stand drive
K06 - Brake application
K07 - Brake release
K08 - MVR (minimal voltage relay step 1)
K11 - Light control relay (AC light)
K12 - Light control relay (Reading light)
K13 - Light control relay (night light)
K14 - Light control relay (AC light)
K15 - Light control relay (DC light)
K16 - Light control relay (DC light)
K17, K18 - Light control relay

K19, K20 - UIC light remote control relay
K21, K22 - Aux cont. return air flap motor
K23 - 415 V OK relay
K24, K25 - Contactor pump control
K26, K28 - Blower motor cont.
K27 - Controller OK
K29 - Exhaust fan cont.
K31, K32, K36, K37 - Condenser motor cont.
K33, K34, K38, K39 - Comp. motor cont.
K35, K40 - Air heater cont.
K41, K42 - Local main supply cont.
K43 - Common cont. for LMS
K44 - Main cont. transformer output
K45 - MMR 415 V for LMS
K48 - Emergency light relay

LHB AC COACHES FUSES
1. F42/43 : 25 Amp Main 110V DC
2. F10/11/12 : 100 Amp Main transformer output 440 V
3. F47/48/49 : 80 Amp LMS incoming 440V
4. F50/51/52 : 63 Amp Net 1 feeder incoming 750 V
5. F53/54/55 : 63 Amp Net 2 feeder incoming 750V
6. F56/57 : 2 Amp UIC light remote control 24V DC
7. F58/59/60/61/62 : 2 Amp insulation control 110V AC/440V AC
8. F67 : 1 Amp LMS 230V (K41)
9. F68 : 1 Amp LMS 230V (K42)
10.F69/70/71 : 1 Amp MMR-LMS (K43)
11.F72 : 1 Amp main contractor X’mer o/p (K44)

12.F73 : 1 Amp 415V Ok (K23)
13.F74/75 : 10 Amp 1 Amp MMR net 1-750V
14.F90/91/92 : 1 Amp MMR net 1-750V
15.F94/95/96 : 1 Amp MMR net 2-750V

F-50
F-51
F-52
F-53
F-54
F-55
FUNCTION GROUPS OF WIRES IN LHB COACHES
1. High Voltage – 1201, 1202

2. High voltage control – 2101, 2102
3. 415 V AC – 3301 to 3308
4. 110 V AC, single phase –
5. 110 V AC ( battery distribution) – 3201 to 3204 and 3206 to 3208
6. 24 V DC – 3205
7. Lighting – 5201 to 5224
8. Air Conditioning Control – 6101 to 6107
9. Diagnosis – 4201 to 4203
10.Earthing plan – 00
11.Anti-skid device – 2302 to 2303
12.Brake – 2304
13.Earthing on under frame – 2305
14.Emergency brake – 4301
15.Public address system – 4501 to 4503
16.Train control line – 4601
17.Sanitary system – 7201 to 7206
18.Insulation control – 9301
19.Telephone – 9401
FEEDER JUNCTION BOX TO FEEDER CONTACTORS
FEEDER 1
Junction Box to D & ED
COLOUR CABLE CODE CABLE SIZE

Phase R 120101.01 50 sq.mm.
Phase Y 120104.01 50 sq.mm.
Phase B 120107.01 50 sq.mm.
Neutral 120110.01 50 sq.mm.
D & ED to HT Fuse

Phase R 120102.01 50 sq.mm.
Phase Y 120105.01 50 sq.mm.
Phase B 120108.01 50 sq.mm.
HT Fuse to Feeder Contactor (K-01)
Phase R 120103.01 50 sq.mm.
Phase Y 120106.01 50 sq.mm.
Phase B 120109.01 50 sq.mm.
Neutral (D & ED to K-01) 120140 50 sq.mm.
Supply for HT MMR

Phase R 120103.04 50 sq.mm.
Phase Y 120106.04 50 sq.mm.
Phase B 120109.04 50 sq.mm.
FEEDER 2
Junction Box to D & ED

Phase R 120115.01 50 sq.mm.
Phase Y 120118.01 50 sq.mm.
Phase B 120121.01 50 sq.mm.
D & ED to HT Fuse
Phase R 120116.01 50 sq.mm.
Phase Y 120119.01 50 sq.mm.
Phase B 120122.01 50 sq.mm.
HT Fuse to Feeder Contactor (K-01)

Phase R 120117.01 50 sq.mm.
Phase Y 120120.01 50 sq.mm.
Phase B 120123.01 50 sq.mm.
Neutral (D & ED to K-01) 120141 50 sq.mm.
Supply for HT MMR

Phase R 120117.04 50 sq.mm.
Phase Y 120120.04 50 sq.mm.
Phase B 120123.04 50 sq.mm.
K-01, K-02 to Main Transformer

Phase R 120112.01 50 sq.mm.
Phase Y 120113.01 50 sq.mm.
Phase B 120114.01 50 sq.mm.
LOCAL MAIN SUPPLY TO BUS BAR
TO BUS BAR
Local Main Supply-1 to Contactor K-41

Phase R 330101.01 50 sq.mm.
Phase Y 330102.01 50 sq.mm.
Phase B 330103.01 50 sq.mm.
Local Main Supply-2 to Contactor K-42

Phase R 330106.01 50 sq.mm.
Phase Y 330107.01 50 sq.mm.
Phase B 330108.01 50 sq.mm.
Contactor K-41, K-42 to Fuse
Phase R 330110.02 50 sq.mm.
Phase Y 330111.02 50 sq.mm.
Phase B 330112.02 50 sq.mm.
Fuse to Contactor K-43

Phase R 330118.01 50 sq.mm.
Phase Y 330119.01 50 sq.mm.
Phase B 330120.01 50 sq.mm.
Contactor K-43 to Bus Bar

Phase R 330125.01 50 sq.mm.
Phase Y 330126.01 50 sq.mm.
Phase B 330127.01 50 sq.mm.
Supply for MMR

Phase R 330118.02 50 sq.mm.
Phase Y 330119.02 50 sq.mm.
Phase B 330120.02 50 sq.mm.
MAIN TRANSFORMER TO BUS BAR
LOCAL MAIN SUPPLY
K-01, K-02 to Main Transformer

Phase R 120112.01 50 sq.mm.
Phase Y 120113.01 50 sq.mm.
Phase B 120114.01 50 sq.mm.
Main Transformer to LT Fuse

Phase R 120206 50 sq.mm.
Phase Y 120207 50 sq.mm.
Phase B 120208 50 sq.mm.
LT Fuse to Contactor K-44

Phase R 120210.01 50 sq.mm.
Phase Y 120211.01 50 sq.mm.
Phase B 120212.01 50 sq.mm.
Contactor K-44 to Bus Bar

Phase R 330125.03 50 sq.mm.
Phase Y 330126.02 50 sq.mm.
Phase B 330127.02 50 sq.mm.
Neutral (D & ED to K-01) 330128.03 50 sq.mm.
CONTROL CIRCUIT OF MAIN FEEDER AND LOCAL MAIN SUPPLY
REGULATED BATTERY CHARGER AND EMERGENCY BATTERY CHARGER
Input and Output of Regulated Battery Charger
S. NO. INPUT FROM INPUT OUTPUT OUTPUT TO

1. R 330125.22 320104.03 Temperature Sensor of Battery
2. Y 330126.23 320105.03 Temperature Sensor of Battery
3. B 330127.18 320210.01 +ve of 110 V DC Bus Bar
4. GND 320113.01 320110.02 +ve of 70 Ah Battery
5. 320111.02 -ve of 70 Ah Battery & -ve 110 V
DC Bus bar
S. NO. INPUT FROM INPUT TO EBC OUTPUT TO

1. R 330125.21 +ve of 110 V DC Bus Bar
2. N 330128 -ve of 70 Ah Battery & -ve 110 V
DC Bus bar
Contactors used in Circuit
CONTACTORS INPUT OUTPUT

K-RBC From Bus Bar 330125.21
330126.22
330127.17
110 V DC SUPPLY DISTRIBUTION
MCB USED FOR OUTPUT
F 24 Light Control 320303.01 (+ Ve)
320304.01 (-Ve)
F 25 Emergency Light 320305 (+Ve)
320306 (-Ve)
F 26 Emergency Light 320307.01 (+ VE)
320308.01 (-VE)
F 27 Reading Light 320309 (+ Ve)
320310 (-Ve)
F 28 Reading Light 320311 (+ Ve)
320312 (-Ve)
F 29 DC-DC Converter 320310.01(+ Ve)
320314.02 (-Ve)
F 30 MVR 320401.01 (+ Ve)
320402.01(-Ve)
F 31 Telephone (First Ac Only) 320403 +(Ve)
320404 (-Ve)
F 32 Diagnosis 320405.01 ( + Ve)
320405.01 (-Ve)
F 33 Power Supply 320407.01 (+ Ve)
320410.01 (-Ve)
F 34 Night Light 320408 (+ Ve)
320409 (-Ve)
F 35 Ac Unit 610101.03 (+ Ve)
610102.03. (-Ve)
F 36 Pump Control (New Coach) 320505.01 (+Ve)
320506.01 (-Ve)
110V/24V DC-DC CONVERTER
MCBs used in Circuit
F-29 MCB for Input 110 V DC

F-37 MCB for Sanitary Control
F-38 MCB for Loud Speaker System
Input to DC-DC Converter (110 V DC)
Bus Bar to MCB F-29
+VE 320301.08
-VE 320302.08
MCB F-29 to DC-DC Converter
+VE 320313.01
-VE 320314.02
Outputs of DC-DC Converter

Sanitary Control 320507.01(+ ve)
320508.01(- ve)
Loud Speaker System 320513.01(+ ve)
320514.01(- ve)
UIC Control 320511.02(+ ve)
320516.01(- ve)
LIGHT CIRCUIT
Switches used in Circuit

S-01 Switch Power Supply ON/OFF
S-08 Switch for Lighting ON
S-09 Switch for Night Lighting ON
S-10 Switch for Lighting OFF
MCBs used in Circuit

F-24 MCB Light Control
F-25 MCB Emergency Light
F-26 MCB Emergency Light
F-27 MCB Reading Light
F-28 MCB Reading Light
F-34 MCB Night Light
F-39 MCB AC Light
F-40 MCB AC Light
Contactors used in Circuit With Input and Output Wires
CONTACTOR USED FOR INPUT OUTPUT
K-08 Contactor MVR Level 1 320704.02 320402.02

(Reading Light OFF)
(DC/DC Conv. OFF)
(Emergency Light OFF)
K-11 Contactor Main Lights 33601.02 52501.03
33604.01 52502.03
K-12 Contactor Reading Lights 320309 520901.01
320310 520902.01
320311 521701.01
320312 521702.01
K-13 Contactor Night Lights 320408 520701.01
320409 520702.01
520102.18 520116.01
520101.18 520117.01
520402.01 520519.01
520401.02 520520.01
K-14 Contactor Main Lights 320605.01 520103.02
(Corridors + Sanitary) 320606.02 520101.01
320601.01 520401.02
320604.02 520401.01
K-15 Contactor Emergency Light 320305 520402.01
320306 520401.02
K-16 Contactor Emergency Light 320307.01 520102.01
320307.01 520103.01
320308.01 520101.02
320308.02 520111.03
K-17 Timer for Light OFF 320818.02 320819.02
K-48 Contactor Light Interlocking 330801.03 330804.03
MINIMAL VOLTAGE RELAY (MVR)
1. Minimal Voltage Relay (MVR) is a voltage sensing device which

senses the DC voltage level of the battery.
2. According to the pre-set value of voltage it controls the power
supply to the luminaries in three levels.
3. In healthy condition all three contactors k8, k9 and k10 remained
energized during failure of ac power supply MVR role comes in
play.
4. It works in level3 up to dc voltage 106 volts.
5. It works in level 2 up to dc voltage 104 volts.
6. It works in level 1 up to dc voltage 96 volts.
7. When voltage level goes down from 96 volts contactors k8, k9
and k10 de-energized and all power supply shuts off in coach
besides emergency lights.
110V DC (+VE)
(-VE)
MINIMAL VOLTAGE RELAY
LEVEL-1 (96V) LEVEL-2(104V) LEVEL-3(106V) -Ub
K08 K09 K10

MICROPROCESSOR BASED AC CONROL SYSTEM
 RMPU Microprocessor Unit is a fully automated control and monitoring of HVAC systems
along with sensors and actuators in AC Coaches of Indian Railways.
 There are 20 Digital Outputs designated X301,X302,X501 and X502.
 Each group above requires one output common
 A Real Time Clock (RTC) is provided to determine the date and time at which the fault has
occurred.
 There are (20) digital inputs designated as X701 & X702, which are divided into 3 groups.
Each group above requires one input common
Features and Man-Machine Interface

 CPU
Flash Memory : 64 Kbytes
RAM : 1Kbytes
Real Time Clock (RTC) : SPI based, with battery Backup
 External Memory
External Flash : 1 Mbytes
 LED Annunciation : Digital Input LEDs – 20 Nos
Digital Output LEDs – 20 Nos
Others – RUN, LIVE and Processor Fault
 Temperature Selection: 7 Position Rotary Switch
Electrical Specifications
• Power Supply Specifications

Feed Voltage : 110 V AC or 110 V DC +/- 30%
Power Consumption : 30 W Maximum
• Analog Inputs for Temperature Sensing
Number of Inputs : 6 (2 RT, 2 AT & 2 ST)
Sensor Type : NTC 5.0 k at 25C
Measuring Range : -25C to +75C
Resolution : 0.2C
• Analog Input for Set Point Generator

Number of Inputs :1
Sensor Type : Stepped Rotary Switch of 7 positions with NTC
Characteristics
Measuring Range : 20C to 25C in Cooling Mode & 17C to 21C
in Heating Mode
• Analog Input for Humidity Sensing

Number of Inputs :1
Sensor Type : 10 k at Normal and 1 k above Hygrostat set point
Measuring Range : 30 to 100 % RH
Set Point (Manually) : 60 % RH
Hysteresis : 3 to 6 % RH
Measuring Medium : Non – aggressive air
Ambient Temperature Range: -30 to 60C
• Digital Inputs
Number of Inputs : 20 in 3 Galvanically Isolated groups
Input Voltage : 0 – 150 V DC
Method of Connection : Optically Isolated
• Digital Outputs
Number of Outputs : 20 in 4 Galvanically Isolated groups
Type of Switching : Relay Contacts (NO)
Switching Voltage : 250 V AC Maximum
Switching Current : 1 A Maximum
• Serial Interface Specifications
Transmission Type : EIA Standard RS-232 C
Data Transmission Rate : 115.2 kbits/s
Termination : 3 Pole WAGO 231/232 Type
Wiring Details of Microprocessor Controlled AC System

110 Volt DC Supply (X104)
+VE – 610101.02
-VE – 610102.01
Contactors used in Circuit With Input and Output Wires
K-21 Contactor Fresh Air Flap 610115.02 610116

610102 610111
K-22 Contactor Re-circulation Air 610110.02 610111
Flap 610102 610116
K-23 Contactor 400 V OK 610101.08 610124.01
K-26 Contactor Ventilation Fan 1 610404.02 610102
610401.02 610405.01
K-27 Contactor Controller OK 610608.02 610102
K-28 Contactor Ventilation Fan 2 610413.02 610102
610401.02 610406.01
K-29 Contactor Exhaust Fan 610416.02 610102
K-31 Contactor Condenser Fan 1.1 610601.02 610102
K-33 Contactor Compressor 1.1 610604.02 610102
K-35 Contactor Heater 1 610610.02 610102
K-40 Contactor Heater 2 610710.02 610102
Analog Inputs Wires Details
S.No. INPUT CONNECTOR CODE

1. Room Temperature Sensor 1 (RT1) 610105.02 & 610106.02
2. Room Temperature Sensor 2 (RT2) 610108.02 & 610109.02
3. Outdoor/Ambient Temperature Sensor 1 (AT1) 610112.02 & 610113.02
4. Set-point Generator (SET) 610120.01 & 610122.01
5. Outdoor/Ambient Temperature Sensor 2 (AT2) 610118.02 & 610119.02
6. Duct/Supply Temperature Sensor 1 (ST1) 610116.02 & 610117.02
7. Duct/Supply Temperature Sensor 2 (ST2) 610121.02 & 610123.02
8. Moisture Meter/Hygrostat, 60% Threshold (HGS) 610103.01 & 610107.01
Digital Inputs Wiring Details (X701)

1. Air-Con Switch (HVAC On) 610401.03
2. Condenser Fan 1/1 Thermal Contact (CD 1/1 TC) 610407.02
4. Supply Air Fan 1 Thermal Contact (BLR1 TC)/ Vent 610405.02
Motor 1 Fault
5. Electric Heater 1 Thermal Contact (HTR 1 TC) 610410.02
6. Input Common 610102.04
7. Low Pressure 1/1 (LP 1/1) 610412.03
8. Low Pressure 1/2 (LP 1/2) 610414.03
9. Control Pressure 1 (CPR1) 610415.03
10. High Pressure 1/1 (HP 1/1) 610406.03
11. High Pressure 1/2 (HP 1/2) 610409.03
Digital Inputs Wiring Details (X702)

1. 400 V OK 610124.02
4. Supply Air Fan 2 Thermal Contact (BLR2 TC)/ Vent 610406.02
Motor 2 Fault
5. Electric Heater 2 Thermal Contact (HTR 2 TC) 610503.02
7. Low Pressure 2/1 (LP 2/1) 610504.02
8. Low Pressure 2/2 (LP 2/2) 610505.02
9. Control Pressure 2 (CPR2) 610506.06
10. High Pressure 2/1 (HP 2/1) 610706.02
11. High Pressure 2/2 (HP 2/2) 610709.02
Digital Outputs Wiring Details (X301)

1. Output Common 610101.01
2. Controller OK (CNTRL OK) 610408.01
3. Re-Circulating Air (RECR) 610115.01
4. Supply Air Fan 1 (BLR 1)/ Ventilation Fan 1 610403.01
5. By-Pass Cooling 1 (BYPS 1) 610603.01

2. Condenser Fan 1/1 (CD 1/1) 610601.01
3. Condenser Fan 1/2 (CD 1/2) 610602.01
4. Compressor 1/1 (CP 1/1) 610605.01
5. Compressor 1/2 (CP 1/2) 610608.01
6. Electric Heater 1 (HTR 1) 610610.01

2. Fault Pilot 610125.01
3. Outside Air (RECR)/ Fresh Air 610110.01
4. Supply Air Fan 2 (BLR 2)/ Ventilation Fan 2 610411.01
5. Exhaust Fan 610416.01
6. By-Pass Cooling 2 (BYPS 2) 610703.01

2. Condenser Fan 2/1 (CD 2/1) 610701.01
3. Condenser Fan 2/2 (CD 2/2) 610702.01
4. Compressor 2/1 (CP 2/1) 610705.01
5. Compressor 2/2 (CP 2/2) 610708.01
6. Electric Heater 2 (HTR 2) 610710.01
RMPU POWER CIRCUIT
MCBs used in Power Circuit of AC System (Unit - 1)
F-01 MCB Ventilation Fan 1

F-03 MCB Compressor 1.1
F-04 MCB Crankcase Heaters
F-06 MCB Condenser Fan 1.1
F-08 MCB Heater 1
Contactors used in Power Circuit of AC System (Unit - 1) With Input

and Output Wires

K-26 Contactor Ventilation Fan 1 330301 330302.01
330403 330404.01
330405 330406.01
K-31 Contactor Condenser Fan 1.1 330417 330418.01
330419 330420.01
330421 330422.01
330425 330426.01
330427 330428.01
K-33 Contactor Compressor 1.1 330401 330402.01
330403 330404.01
330405 330406.01
330435.01 330408.01
330412 330413.01
330414 330415.01
330435.02 330416.01
K-35 Contactor Heater 1 330430 330429.01
330431 330432.01
330433 330434.01
MCBs used in Power Circuit of AC System (Unit - 2)
F-02 MCB Ventilation Fan 2

F-10 MCB Crankcase Heaters
F-14 MCB Heater 2
Contactors used in Power Circuit of AC System (Unit - 2) With Input

and Output Wires

K-28 Contactor Ventilation Fan 2 330308 330309.01
330310 330311.01
330312 330313.01
330518 330519.01
330520 330521.01
330524 330525.01
330526 330527.01
330503 330504.01
330505 330506.01
330508.01 330534.01
330512 330513.01
330514 330515.01
330508.02 330535.01
K-40 Contactor Heater 2 330529 330528.01
330530 330531.01
330532 330533.01
PUMP POWER CIRCUIT
Contactors Used in Circuit
CONTACTORS USED FOR INPUT OUTPUT
K-24 Contactor for Water 330801 330802.01

Pump No. 1 330803 330804.01
330805 330806.01
Contactor for Water 330812 330813.01
K-25 Pump No. 2 330814 330815.01
330816 330817.01
MPCB (Motor Protection Circuit Breaker)
A-21 - For Water Pump 1

A-22 - For Water Pump 2
MAJOR FAILURES IN LHB AC COACHES
S. NO. FAILURES CAUSES
1. OHP i) Improper Setting

ii) Sensor Defective
iii) Manufacturing Defect
2. Compressor i) Over loading
ii) Gas leakage
iii) Single Phasing
3. Condenser Fan Motor i) Short Circuit in winding
ii) Breakage in blades
iii) Jamming of bearing
4. Transformer (60 KVA) i) Short circuit in primary winding or
Secondary winding
ii) Output voltage unbalance
iii) Transformer winding open circuit
5. Pump i) Pump motor overheated/ earthed
ii) Pump Jammed
iii) Water Seal leakage
6. MCB & Fuse i) Single Phasing, High Voltage and
Current
ii) Non-Contact
iii) Short Circuit
7. Sensors i) Operation in out of range
ambient conditions
8. ZS Coupler i) Ratchet Broken
ii) Ratchet Circuit
iii) Cable Lugs broken
9. Battery i) Reversed Cell, Cell Overheated
ii) Low Voltage
iii) Short Circuit
iv) Lug broken or lug melted
10. Battery Charger i) Improper Charging Voltage
ii) Battery Charger Card defective
iii) Printed Circuit Board defective
CONCLUSION
A brief study about the Wiring details of LHB AC Coaches has been done. This gives
us an advantage in quickly identifying the failures and troubleshooting of the same.
The function groups in the wire codes helps in quick understanding of the various
control and power circuits of the LHB AC Coaches.
LHB technology is one of the major resolution in the Indian Railways which makes
the railway to function in an efficient manner with better passenger amenities and
passenger carrying capacity.

Project On Wiring Details of LHB AC Coach

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Project On Wiring Details of LHB AC Coach

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PROJECT ON WIRING DETAILS OF LHB AC COACH

Mr. KESHAV KUMAR Mr. V.N.GANVIR

It is indeed a matter of great pleasure and proud to present this project

Sr. No. Name Designation Div. /Rly.

1 Mr. Manovar Khan APP SSE MTN/CR

2 Mr. Akash Pandey APP SSE BCT/WR

3 Mr. Brijesh Yadav APP SSE BCT/WR

4 Miss. Radhika Tyagi APP JE BCT/WR

5 Mr. Satyaranjan Chaturvedi APP JE IZN/NER

6 Mr. Yogendra Kumar APP JE IZN/NER

7 Mr. Mayuresh Raul APP JE MTN/CR

8 Mr. Kishan Singh APP JE MTN/CR

9 Mr. Hitesh Dwivedi APP JE MTN/CR

10 Mr. Yogesh Shirgaonkar APP JE MTN/CR

11 Mr. Jayesh Medbali APP JE MTN/CR

12 Mr. Akhilesh Upadhyay APP JE MTN/CR

13 Mr. Pappu Kumar APP JE BCT/WR

This is certify that the project work entitled “LHB AC COACHES” is a

Signature of guide: Signature of course

Mr.KESHAV KUMAR Mr. V N Ganvir

Mr. YASHWANT URHEKAR

(M/s LINKE HOFMANN BUSCH, GERMANY)

In order to make quantum jump in passenger coach technology and to bring it to

Passenger Related Areas

POWER SUPPLY ARRANGEMENT

 750 V 3 Phase AC supply system

 A DC-DC converter shall be used to obtain 24 V DC for control systems for

 As per rule 64-A of IE rules, over current protection shall be provided to

• Feeder Junction Box – 4 Nos.

• Disconnecting & Earthing Device (D&ED) – 1 No.

• Measuring & Monitoring Relay (MMR) – 3 Nos

• Minimal Voltage Relay (MVR) – 3 Nos

• 1 KVA Transformer – 2 No.

• 60 KVA Transformer – 2 Nos.

• Mono Block Pumps – 2 Nos.

• RBC (6.5 KW) – 1 No.

• EBC (2.5 KW) – 1 No.

• Set of Batteries (12V x 09 Nos) 70 AH VRLA – 1 Set

• Water Boiler – 3 Nos.

• Deep Freezer – 2 Nos.

• Bottle Cooler – 2 Nos.

• Hot Case – 2 Nos.

• 1.1 KW Heating coil – 3 Nos.

• 2 KW heating coil – 3 Nos.

• Exhaust Chimney Motor – 3 Nos.

Rated Current Capacity : Phase & Neutral wires - 400Amp

 3 phases, 750 volts AC supply

 A Feeder is a conductor which connects the local generating station to the

 The main consideration in the design of a feeder is the current carrying

Regulated battery charger

Contactors and relays

1 KVA transformer for

Wheel skid protection

MEASURING & MONITORING RELAY (MMR)

Purpose : To check for phase sequence matching between IV

Rating (KVA/Volt/Amp) : 60KVA, 750/415Volt 3 Ph. (46.2/83.4 Amp)

Front Side View Back side View

Rated speed : 2800 RPM

RBC (6.5 KW)

 Purpose : To give regulated voltage to the battery

Type : Pure lead tin VRLA monoblock batteries

Operating temperature range : - 40 to +50 deg. C

Terminals : High conductivity copper alloy terminals