SG TL AND LHB 16-01-2025

A PRESENTATION ON
Train lighting and AC coaches

ON
04.02.2025
BY
C.RAJA MOHAN
ESTC/LGD/SCR ADEE/M/KZJ
1
TYPES OF TRAIN LIGHTING SYSTEMS
• SELF GENERATING SYSTEM (SG)
• MID ON GENERATION (MOG)
• END ON GENERATION (EOG)
• HEAD ON GENERATION (HOG)
2
Advantages of SG
• It gives better flexibility in rake formation.
• The system is independent of mode of traction.
• As each coach has battery, No separate power car required
• Defect in any particular coach do not affect the others.
• Feed extension is possible in emergency from adjacent coach
3
Disadvantages of SG
• Load restricted to 1X4.5 kW per coach at present.
• Bulky 120 Ah coach battery required as power is not generated during standby / slow
movement .
• No standby alternator /battery in coaches so system became poor reliability.
• Extensive maintenance due to under-slung alternator, v-belt, axle pulleys, tensioning

device, inverter, battery etc.
• Poor system efficiency around 57%.
4
End On Generating System
 Provided on Rajdhani, Shatabdi, Duronto, Garibeachrath type fully AC
trains with large power requirements.
 Two power cars each with 2X320 kW (high Capacity) Diesel

alternator sets.
 Each Alternator capacity of 500 KVA 385 Amps.
 Generated Power Supply is 750 V 3- ph 50Hz without neutral .
 Power is fed through feeders to IV couplers, ZS couplers 400Amps

either side of coaches one end power car to other power car .
5
End On Generating System
 Power is fed through feeders to IV couplers, ZS couplers
400Amps either side of coaches one end power car to other
power car .
 Power supply is stepped down 750V to 415 V 3 ph for AC by 60

kVA transformer.
 110 V ac lighting and fans by 415/110 ac transformer.
 LHB coaches lights work on 110V Dc and no fans.
 Garibrath and old rajadhani coaches Light & fans work on 110V
AC which is step down by 3 KVA transformer.
6
END ON GENERATING SYSTEM
FEEDER - I
ALT. ALT. ALT. ALT.
COACHES COACHES
FEEDER - II
GENERATOR GENERATOR
CAR CAR
COACH SUPPLY
750 V, 3 Ø AC
FEEDER LOAD
415 V, 3 Ø
50/60kVA TRANSFORMER 415 V, 3 Ø
LIGHTING TRANSFORMER
110 V, 3 Ø
LIGHTING LOAD
7
End on Generating System
8
Advantages EOG System
 No restriction of Load due to high capacity power cars.
 Does not require bulky batteries, alternators.
 Standby DA sets.
 Independent of mode of traction.
 Less maintenance required due to elimination of under slung

alternator, battery, axle pulley, V-belts etc.
 Higher system efficiency than SG system.

9
Disadvantages of EOG System
 Flexibility in rake formation not possible.
 High cost of energy due to high fuel cost.
 Noise and smoke pollution from power cars.
 Passenger capacity reduced due to provision of power car.
10
Head On Generation
ESTC/LGD SC RLY 11
Head ON Generation(HOG)
is step towards Energy Efficiency
 Indian Railways imported 22 no. of WAG-9 locomotives and 11 no. of WAP-5 locomotives from M/s.
ABB Switzerland in 1996-97.
 Chittaranjan Loco Works stared the production of WAP-7 is actually a modified version of WAG-9
freight locomotive.
 A hotel load winding in locomotive transformer of WAP-5 and WAP-7 has been provided to cater the
hotel load supply to the coaches through hotel load converter .
12
Head ON Generation(HOG)
is step towards Energy Efficiency
 Implementation of HOG scheme as per Railway board letter no. 95/elect(G)/114/13 Ptdtd.25/10/07.
 Manufacturing of 3 phase electric loco having minimum 2X500KVA hotel load converters with IGBT
technology.
 First HOG loco NO: WAP-7 is 30277 is manufactured on July 2010 .
 First train no:12005/06 Shatabdhi Exp NDLS to KLK run with M/s Siemens make 2X500 KVA converter
on 21-02-2011.
13
HOG
 Indian railways has decided to adopt an energy efficient power supply to coaches.
 With new technological transformation is developed as HOG.
 Presently system is running with End on Generation (EOG) in LHB type coaches.
 The LHB type are best suited for adoption of HOG.
14
HOG
 25 KV supply is trapped from OHE through pantograph to loco transformer.
 Loco transformer capacity is 7775 KVA .
 Hotel load winding are two numbers each of 622.5 KVA .
 The out put voltage of hotel load winding is 960 Volts single phase 50 Hz.
 The current carrying capacity hotel load winding is 1260 Amps .
15
MAJOR EQUIPMENTS IN SG TL COACHES
• ALTERNATOR (4.5KW)
• RRU/ERRU (4.5KW)
• BELT TENSIONING DEVICE
• V-BELT
• AXLE PULLEY
• BATTERIES
• LIGHTS AND FANS
• ROTARY JUNCTION BOX (RJB)

16
COACH ALTERNATOR
Purpose of ALT:
• Charging the coach battery on train run
• Working of lights and fans in the coach duringtrain run
• Sharing the load to other coaches in case of emergency
DESIGN
• No Moving contacts or windings on rotor
• AC Windings and field windings BOTH accommondated on stator
17
Alternators- Key parameters
Feature 4.5 kW
Rating 120 V, 37.5 Amp
Factory Setting 128.5±0.5 V at 19A, 1500 rpm
Efficiency 70% at full load and 1800 RPM
Field wdg resistance 4.5+/- 0.5 Ω
Stator wdg resistance (phase to phase) 0.4+/- 0.05 Ω
Suspension pin dia 31.75+0/-0.10 mm
Insulation class F
18
Alternators – Key parameters
Ripple content (max) 5%
Alt pulley width 110.5+/-1.5 mm

Axle pulley width 110.5+/-1.5 mm
Cut in speed (min)* 350rpm (19Km/h)
MFO (minimum speed for full out put)* 600rpm (31Km/h)
Alt pulley groove angle 34+/-0.5 0
Axle pulley groove angle 38+/-0.5 0
Tensioning device working length 310 mm

Distance of axle pulley from wheel hub 141±0.5mm
Weight (max) NM
* With new wheel dia (915 mm)

Sample Questions
1)The voltage settings of Alternator cum RRU/ERRU in TL coaches ()

A) 128.5±0.5 V B) 129.5±0.5 V C) 128.0 ±0.5 V D) 127.5±0.5 V
2)IR values of TL/AC coach should not be less than ---MΩ in fair weather ( )
A)1 B)2 C) 3 D)10
3) The voltage setting of Alt/RR unit is to be set in far with current and RPM for 4.5KW is ( )
A) Half rated capacity of the alt as load as 1500 RPM
B) ¼ rated capacity of the alt as load at 1000 RPM
C) Full rated capacity of alt as load at 2550 RPM
D) None of the above
20
Sample Questions
5)Rating of main fuses to be provided in 4.5kw MA type RR unit ()
A) 35A HRC B) 160A HRC C)Either A & B D)None
6)Give the off load setting of RRU/ERRU of 4.5KW at 1500RPM is ()

A) 37.5A B) 19A C) 97A D) 16A
7)Main function of RRU/ERRU is ()

A) Rectify and regulate alternator output B) To generate AC voltage
C) To control the battery voltage D) None
8) SMI on TL/AC is issued by ---- ()

A) RDSO B) Railway Board C) ICF D) None
9)Modified TL System is---wire un earthed system? ()

A) 1 B)2 C) 3 D) None
21
SAMPLE QUESTIONS
1)Coach alternator has winding ( )

A) on both rotor and stator C) on rotor only
B) On stator only D) Depends on manufacture to manufacture
. 2) The purpose of TL&AC alternator used in Railways ( )

A) Charging the coach battery on train run
B) Working of lights, fans and mobile chargers in the coach during train run
C) Sharing of the load to other coaches in case of emergency
D) All the three above
3) If Alternator of SG TL coaches is not generating voltage the reasons could be ( )

A) Field wire of Alternator may be open
B) Fuse in the regulator had blown
C) All V belts had dropped
D) All the above
22
SAMPLE QUESTIONS
4)The alternator of SG TL Coach leaving primary depot should have how many belts ( )
A) 4 B)3 C)
2 D)1
5) The capacity of alternator of 3Tier sleeper Coach is a ()
A)25kW B)18kW C) 4.5kW D)7.5kW
6) Cut in speed for B/L alternator for 4.5kW alternator ()

A)17KMPH B)19KMPH C)20KMPH D)22KMPH
7) The 4.5kW brushless alternator used for TL Coaches is of ()

A) 3 phase ,Hetro polar inductor type B) Single phase ,Hetro polar inductor type
C)3 phase , Hexagonal inductor type D) Single phase , Hexagonal inductor type
8) Cut in speed/minimum speed for full output of 4.5 kW alternator SG TL Coach is ( )

A)357/600RPM B)550/900RPM C)400/800RPM D)None of the above
9) For 4.5 kW TL coach alternator belt tensioning device assembly, minimum clearance between Fixing Nut Sleeve &
Bogie Support Bracket must be maintained at ______ mm
A) 75 B) 50 C) 100 D) 125
SAMPLE QUESTIONS
10)Cut in Speed of 4.5 KW alternator is ( )

A)357 RPM B)550RPM C)600RPM D)605RPM
11)MFO of 4.5 KW alternator is ( )

A)600 RPM B)930RPM C)650RPM D)1000RPM
12)The setting of ERRU in TL Coach is ( )

A)129V B)127V C)110V D)None of the above
13) Which of the following diode is used as voltage regulator ( )

A)PN Junction diode B)Zener diode C)Schottky Diode D)Lighting emitting diode
14)This is not main component of ERRU
A) Terminal box B)power unit C) UVC D) Battery charger
15) Alternator capacity of a BG SG TL coach is based on generation to non generation ratio of ( )
A) 1 B)2 C)3 D)4
16) Setting of OVP in SG TL coach is ()
A)145±1VDC B) 140±1VDC C) 135±1VDC D) none
Belt tensioning device
The purpose of belt tensioning device is to keep V belts in tight condition.
25
REGULATOR CUM RECTIFIER UNIT(RRU)
The Regulator cum Rectifier Unit has mainly Following functions

• Rectifying the 3Phase output of the Alternator to DC
• Regulating the voltage Generated by the ALT at the set value
• Regulating the output current at the set value
26
PULLEY
• AXLE PULLEY…..PCD 572.6±0.4mm

• ALTERNATOR PULLEY…200±0.3mm
27
Sample Questions
1)The voltage settings of OVP in 4.5 kw RRU/ERRU in TL coaches

A) 128.5±0.5 V B) 145±1 V C) 128.0 ±0.5 V D) 127.5±0.5 V
2)What is the rating of HRC fuse provided in L1 circuit in SG TL coach

A) 63 A B) 40 A C) 32 A D) 16 A
3)What is the rating of HRC fuse provided in SPM circuit in SG TL coach
A) 63 A B) 40 A C) 32 A D) 16 A
4)What is the rating of HRC fuse provided in Battery circuit in SG TL coach
A) 63 A B) 40 A C) 32 A D) 16 A
5)What is the rating of HRC fuse provided in FAN circuit in SG TL coach
A) 63 A B) 40 A C) 32 A D) 16 A
6)What is the rating of Battery in SG TL coach 28

Sample Questions
7)Rating of field fuse to be provided in 4.5kw MA type RR unit ()
8)ALT Coach Capacity of a BG SG TL Coach is based on Generation to non

generation ratio of ()
A) 1 B) 2 C)3 D) 4
9)--------- No of VRLA Batteries comprise a battery set in SG TL coach ()
A) 19 B)18 C) 57 D) 54
10)No of belts for Alternator in SG TL coach ()
A) 4 B) 12 C) 6 D)3
11)Battery Rating of ELU in SG TL Coach ()
A) 6V 120AH B)12V 12AH C)2V 1100 AH D) NONE OF THE ABOVE
29
AXLE PULLY
Description Particulars
4.5 KW Axle pulley – dia (pcd) width 572.6 ± 0.4 mm
200 ± 1 mm
4.5 KW Alternator pulley dia(pcd) width 200 ± 0.3 mm

210 ± 1 mm
gap between two halves of axle pulley to 3.0 ± 0.5 mm
Gap between axle pully and wheel hub 145 ± 3.0 mm
30
V-BELT
Type: C-122
TOP RUBBER
LOAD CARRYING CORDS
BASE RUBBER
RUBBER IMPREGNATED
FABRIC JACKET
40º
INCLUDED ANGLE
V BELT KEY PARAMETERS
• Size of V-Belt is C-122

C means circumstance of V-Belt
122 means nominal pitch length of V-Belt in inches.
• Nominal top width W = 22 mm 
• Nominal thickness T = 14 mm
• Angle = 40 degrees
• Nominal pitch length is 3155mm and graded as 50

32
SAMPLE QUESTIONS
1) What is the size of V-Belts for 4.5KW Alternator is ()

A) C-121 B) C-122 C) C-123 D) C-50
2)The angle of V-Belt or V-groove pulley of Alternator in SG coach is approximately ( )

A) 30◦ B) 40◦ C)50◦ D) 60◦
3)The size of V-Belts is C-122, C indicates is for ()

A) Circumference of V-Belts C) Coach type B) Centre type of V belts D) Coaxial
33
PROTECTIVE DEVICES in SG AC RMPU COACHES
• Over voltage protection (OVP)

• HRC fuses (6A, 16A, 40A, 35A)
• Rewirable fuse for light & fan circuit in FDB
• Rotary switches (RSW) 40A
• Push button for ELUs
34
REGULATOR CUM RECTIFIER UNIT(RRU)
The Regulator cum Rectifier Unit has mainly Following functions
• Rectifying the 3Phase output of the Alternator to DC
• Regulating the voltage Generated by the ALT at the set value
• Regulating the output current at the set value
35
Sample Questions
1)The voltage settings of Alternator cum RRU/ERRU in TL coaches ()

A) 128.5±0.5 V B) 129.5±0.5 V C) 128.0 ±0.5 V D) 127.5±0.5 V
2)Expand ERRU ()
A) Electronic Rectifier cum Regulator unit
B) Electromagnetic Rectifier cum Regulator unit
C) Electro static Regulator Rectifier unit
3) The voltage setting of Alt/RR unit is to be set in far with current and RPM for 4.5KW is
()
A) Half rated capacity of the alt as load as 1500 RPM
B) ¼ rated capacity of the alt as load at 1000 RPM
C) Full rated capacity of alt as load at 2550 RPM
36
Sample Questions
5)Rating of main fuse to be provided in 4.5kw MA type RR unit ()
6)Give the off load setting of RRU/ERRU of 4.5KW at 1500RPM is ()

A) 37.5A B) 19A C) 97A D) 16A
7)Main function of RRU/ERRU is ()

A) Rectify and regulate alternator output B) To generate AC voltage
C) To control the battery voltage D) None
8)IGBT stands for ()

A) Insulated Gate Bipolar Transistor B) Injection Gate Bipolar
Transistor
C) Indicator gate Bipolar Transistor D) None
9)IGBT is ()
A) Fast switching device B)Slow switching device 37
C) Very fast switching device D) None
RJB
• FUSES….6A,16A,40A.
• RSW(40A)…….L-I,L-II,FAN,SPM
• CIRCUITS…..L-I,L-II,FAN,EFT,PACIL,ELU.
38
RJB
L-I CIRCUIT
L-II CIRCUIT
DIFFERENT LIGHTS
COMPARTMENT LIGHTS
NIGHT LIGHTS
GANGWAY LIGHTS
WASH BASIN LIGHTS
TOILET LIGHTS
DOORWAY LIGHTS
39
ILLUMINATION LEVELS
CLASS OF COACH Min.ILLUMINATION LEVEL

• 1st class compartments 30 lux
• 2nd class compartments 30 lux
• Postal compartments 40 lux
• Pantry compartments 30 lux
• Lavatories and corridor 16 lux
• Luggage compartment of SLR coaches 20 lux
40
FDB
 The branch circuits for lights and fans shall be protected by re wirable tinned
copper fuses.
 These re wirable fuses shall be located on a distribution fuse board and all branch
circuits shall be protected by fuses on both negative and positive sides.
POSITIVE SIDE NEGATIVE SIDE

41
FANS
Types of fans
1. DC fans operating on 110V DC.
2. Brush less DC fans operating on 110V DC.
3. AC fans operating on 110V AC.

Sample questions
1. Rating of BLDC fan used in TL Coaches ( )
A. 20 W B. 32W C. 100 W D. 27W
2. Abbreviation of BLDC ( )
A. Brushless direct current B. Bearing less direct current C. Brushless dynamo current D. None
3.Codal life of Railway carriage fan ( )
A. 5 Years B. 10 Years C. 15 Years D. 20 Years
4.Working voltage of BLDC Fan in TL coaches ( )
A. 90- 140 V DC B. 230 V AC C. 415V AC D. None

EFT
• Purpose is to feed emergency supply from one coach to another coach in case of
failure.
• Each coach has 4 EFTs.
• Provided on end body.
• EFT has positive and negative terminals.
ELU
• Purpose is to give emergency light incase failure of underframe equipments.

• It has LED clusters and battery.
BATTERY
RATING: 6V,120 AH.

• LMLA BATTERIES…18 Nos
• VRLA BATTERIES…19 Nos
MAKES
• AMARRAJA
• HBL
• EXIDE
• MICROTEX
• SOUTHERN
Sample Questions
1)The instrument used to measure specific gravity of electrolytic is called

A) hygrometer B) hydrometer C) Acquameter D) Lactometer
2) Capacity of VRLA battery is reduced to---for every 10 ℃ increase in ambient temperature
A) 1/2 B) 1/3 C) 1/4 D) 3/4
3)What is the rating of batteries in SG TL coach is

A) 120 AH B) 70 AH C) 1100 AH D) 490 AH
4) no. Of cells are used in SG TL coach

A) 54 B) 18 C) 19 D) 57
5) No. of VRLA batteries are used in SG TL coach

A) 19 B) 18 C) 54 D) 57
6)What is the rating of Battery in ELU of SG TL coach

A) 120 Ah B) 1100 Ah C) 320Ah D) 12 Ah
47
NON AC LHB COACHES
Friday 7 February 2025 ESTC/LGD/SCR

INTRODUCTION
Conventional SG coaches are having limitations in terms of,
 Speed potential
 Heavy corrosion
 Poor riding comfort
 Wearing of parts in the under gear
 Heavy Electrical and Mechanical maintenance
 To overcome these limitations, LHB Coaches were introduced in Indian
Railways.
Friday 7 February 2025 ESTC/LGD/SCR 50

ELECTRICAL FEATURES OF LHB COACHES
 Constant voltage regulated battery charger.
 On board Switch Board panel with controls of lighting and fan and their fuses.
 Under slung panel for 750 volt and 415/ 190 volt supply.
 On board supply 110 volt dc and 190/110 V ac for mobile charging sockets.
 Provision of Dry type Transformer without encapsulation.
 Integrated modular mini pantry unit in Chair cars.
 Provision of Measuring and Monitoring relays in Feeder circuit.

ELECTRICAL FEATURES OF LHB COACHES
 Wheel set earthing equipment for high life of axle bearings.
 Provision of under slung mounted earthing and disconnecting device.
 Provision of under slung mounted water raising pump with pump controller (in 3
tier sleeper coaches only). As per Railway board L. no. 2010(M)(PU)/1/28 dtd.
06.03.2012, overhead water tanks are to be provided and WRA are to be
eliminated.
 Provision of Emergency Feed Terminal (EFT) in future coaches and the same is
to be implemented during POH in existing coaches.
 Provision of Battery Charging Terminal (BCT) in future coaches and the same is
to be implemented during POH in existing coaches.

BENEFITS OF LHB COACHES
Higher carrying capacity
Less weight
Low corrosion
Low Maintenance
Better passenger comfort, safety and amenities.
LHB Coaches have aesthetically superior interiors with FRP panels for side wall
and roof. They can be removed easily for maintenance, resist water seepage and
there are no visible screws inside the passenger compartment.

GENERAL DESCRIPTION (ELECTRICALS)
LHB VARIANT EOG NON-AC COACHES
Linke Hoffmann Busch (LHB) variant Non AC (TL) coaches can be

broadly classified into following types
 LHB variant General Second Class EOG Non AC Coaches = LS
 LHB variant 3 Tier Sleeper EOG Non AC Coaches = LWSCN
 LHB variant EOG Non AC Chair Car = LWSCZ

ADVANTAGES OF LHB COACHES OVER SG TLCOACHES
 There is no alternator, RRU/ERRU, large size battery boxes to house
battery,V-belts, belt tensioning mechanism in under frame in these LHB
EOG coaches, hence less chances of damage due to cattle run over and
flying ballast etc., hence very less maintenance and nil failure on account
of said equipments from under frame side.
 LHB type EOG coaches are HOG compatible.
 There is no dependency of train speed for power generation.

DIFFERENCE BETWEEN SG NON AC (TL) COACH AND LHB
NON AC COACH
S.NO. Item Description Conventional -Non AC LHB-Non AC
1 Battery 120AH, 110V DC 120/70AH, 110V DC
2 Battery Charger Battery being charged with Constant Voltage battery

RRU/ERRU Charger
3 Under frame panel 110V DC Junction box 750V and 415/190V
supply
4 On board supply 110VDC for Lights, Fans, 110VDC for lights &
MCP Fans, 190/110AC for
(mobile charging point) etc. Mobile charging points
9/15 KVA dry type
5 transformer without
Transformer ---------
encapsulation
6 Pantry Unit Pantry unit provided in Integrated modular mini
Pantry car coaches only. pantry unit in chair car

DIFFERENCE BETWEEN SG NON AC (TL) COACH AND LHB
NON AC COACH
S.NO. ITEM DESCRIPTION CONVENTIONAL- NON AC LHB-Non AC
7 Provision of MMR Not provided Provided in
Feeder circuit
8 Wheelset earthing
equipment for high Not provided Provided
life of axle bearing
9 Provision of under Provided in 3 tier

slung water raising Not provided sleeper coaches of
pumps with pump earlier version.
10 Exhaust fan for Not provided Provided

lavatory

LHB variant General Second Class EOG
Non AC Coaches = LS
Exterior view of LHB Interior view of LHB

EOG NON AC GS Coach EOG NON AC GS Coach

LHB variant 3 Tier Sleeper EOG
Non AC Coaches = LWSCN
Exterior view of LHB EOG NON Interior view of LHB EOG NON
AC 3 Tier Sleeper Coaches AC 3 Tier Sleeper Coaches

LHB variant EOG Non AC Chair Car = LWSCZ
Exterior view of LHB EOG Interior view of LHB EOG

NON AC Chair Car NON AC Chair Car

IV COUPLER
 Under-frame mounted Inter-vehicular coupler unit are used for transmission of 3

phase, 5 wire, 750 V, 50 Hz power supply from power cars to rake/ coaches
(LHB type) working on End On Generation (EOG) system.
Various sub assemblies of IVCoupler are given as under:
 Jumper Plug Assembly ----------------- 2 No.s
 Coupling Socket Assembly --------------2 No.s
 Blind Socket Assembly-------------------- 2 No.s
61
Friday 7 February 2025 ESTC/LGD/SCR
IV COUPLER WITH JUNCTION BOX
IVC PLUG Feeder Junction Box

(Ref: RCF EDML-020, Rev. 1)
U/F  Two types of feeder junction boxes

JUNCTION
BOX are provided on the LHB coaches as
given under:
FLEXIBLE
CONDUIT
 Feeder junction box- plug side –2
nos.
 Feeder junction box- socket side – 2

nos.

IVC JUMPER PLUG ASSEMBLY
Pin No. 1,2 & 3 Main contacts i.e., R, Y and B

Phases
Pin No. 4 Neutral wire
Pin No. 5 Earth wire
Pin No. 7 & 10 Control Pins.
Friday, 18 March 2022 ESTC/LGD/SCR 63

IVC SOCKET ASSEMBLY WITH RATCHET ARRANGEMENT
MAIN PINS
LIMIT SWITCH
(FOR CONTROL
PINS / SAFETY
LOOP)
RATCHET ASSY
FOR HOLDING
THE PLUG

DUMMY/BLIND SOCKET ASSEMBLY
END WALL
DUMMY
SOCKET
RATCHET
ASSEMBLY

IV COUPLER RATINGS
CURRENT CURRENT
S.NO. CIRCUIT CABLE SIZE RATING S.NO. CIRCUIT CABLE SIZE RATING
In Sq.mm In AMPS In Sq.mm In AMPS
1 R-Phase 150 500 1 R-Phase 120 400
2 Y-Phase 150 500 2 Y-Phase 120 400

3 B-Phase 120 400
3 B-Phase 150 500
4 N-Neutral 95 400
4 N-Neutral 95 400
5 E-Earth 70 260
5 E-Earth 70 260
6 C-1 and C-2 4 25
6 C-1 and C-2 4 25 Control Pins
Control Pins
IV COUPLER-500A IV COUPLER-400A
Friday, 18 March 2022 ESTC/LGD/SCR 66

DESCRIPTION OF VARIOUS ELECTRICAL EQUIPMENT
SET OF ELECTRICAL PANELS(Ref: RCF EDTS-355, REV-1, AM-2)
 High Voltage Cubicle (under-slung
mounted)
 Battery Charger Box (under-slung
mounted)
 Low voltage panel (onboard)
HIGH VOLTAGE CUBICLE
 This panel houses the disconnecting and earthing
device, switchgear and fuses for 750 V, 415 V, 190
V, 110 V,
 Pump controller, Anti skid device, MMR, RCBO
(Residual Circuit Breaker with Overload),
 rotary switches for feeder selection etc. From the
front of the panel all the equipment can be access
for maintenance.

D&ED
 A disconnecting and earthing device

is an OFF load device rated for 63 amps at
750 volts fed from Generator Car through ZS
couplings.
 It has two positions ON & EARTH.
 The main function of this device is to separate

the two feeders (input supply) and
simultaneously earthing 750 volts ac network of
the coach..

D&ED
It has two types of contacts

Main contacts
Auxiliary contacts
Main contacts are used for power

supply switching purpose.
Auxiliary contacts are used for

control supply switching purpose.

MMR
Measuring and monitoring relay

monitors following parameters
1. Phase sequence
2. Phase failure
3. Phase unbalance
4. Under voltage
5. Over voltage

Transformer 9/15 kVA ,750/415 /190 V AC
There are two types of transformers available in LHB Non AC coaches,
1. 9 KVA Transformer -------- for General and Sleeper coaches.
2. 15 KVA Transformer ------- for chair car coaches.
 Both types of the transformers are star- star-star connected, dry type and air cooled.
 class of insulation of winding ----- H class.
 Protection level-------- IP-67

9 KVA Transformer
9 KVA Transformer-----Train Lighting load (4.5 KVA - 415V AC+ 4.5KVA-190 V AC)
 Input Voltage --------- 3-phase, 4 wire,750V.
 Output Voltage -------- (1) 3-phase, 4 wire, 415V.

(2) 3-phase, 4 wire, 190V.
 Input current --------- 6.92 A at 750V
 Output current -------- (1) 6.26 A for 4.5 KVA winding at 415V.
(2) 13.67 A for 4.5KVA winding at 190V.
Total weight---------------200 Kg ( maximum)

15 KVA Transformer
15 KVA Transformer---Pantry car load & Train lighting load(10.5 KVA - 415V AC+ 4.5KVA-190 V AC)
 Input Voltage --------- 3-phase, 4 wire,750V.
 Output Voltage -------- (1) 3-phase, 4 wire, 415V.

(2) 3-phase, 4 wire, 190V.
 Input current --------- 11.54 A at 750V
 Output current -------- (1) 14.60 A for 10.5 KVA winding at 415V.
(2) 13.67 A for 4.5KVA winding at 190V.
Total weight---------------250 Kg ( maximum)

Transformer 9/15 kVA ,750/415 /190 V AC

9KVA & 15 kVA Transformer – Fuse ratings
9 KVA Transformer:
 HT(Input) HRC Fuse --------3.3 KV, 20 Amps.
 LT (Output) HRC fuse ------500 V, 16 Amps(415V side)

15 KVA Transformer:
 HT(Input) HRC Fuse --------3.3 KV, 32 Amps.


Sample Questions on Transformer
1) Step down transformer reduces------- ( )

A) Current B) Voltage C) power D) Frequency
2)The hum in a transformer is due to ....... ( )
A) Load changes C) Magntostriction
B) Oil in transformer D) Mechanical vibration
3)The basic function of a transformer is to change the ( )
A) level of voltage C) Power level
B) power factor D) frequency
4)In LHB coaches, 15KVA transformer connections on 750V/415V sides respectively ()
A) Delta-Star B) Star -Delta C) Delta-delta D) Star-Star
5)The rating of 750V’415V/190V under slung step down transformer of an LHB type non-AC ,
EOG general or sleeper coach is ()
A) 4.5KVA B) 15KVA C) 9KVA D) 60KVA
5)The rating of 750V’415V/190V under slung step down transformer of an LHB type non-AC ,EOG Chair
coach is ()
A) 4.5KVA B) 15KVA C) 9KVA D) 60KVA
6)Total number of 9KVA transformer in a LHB sleeper coach is ()
A) 01 B) 02 C)03 D) 04 76
100 VA Control Transformer
There are 2 No.s of 100 VA Control transformers available in LHB Non AC coach.
Technical specification:
 Input voltage…….750 V AC
 Output voltage…..110 V AC
 Class of Insulation….. H class
 Weight……..4.5 Kg (max.)
Fuse ratings:
 Input fuses…. 2A, 1.2 KV (2 No.s)
 Output fuses... 2A, 500V (2 No.s)

CONTACTORS

REGULATED CUM EMERGENCY BATTERY CHARGER
 The regulated cum emergency battery charger consists

of,
1. 4.5 KW Regulated battery charger (RBC)
2. 2.5 KW Emergency battery charger (EBC)

4.5 KW REGULATED BATTERY CHARGER
Technical specifications:
 Input voltage------ 3- phase,4-wire, 415 V AC (Min.350V- Max.480 V)
 Output voltage--110V to 135V DC
 During normal operation of battery charging , the output voltage setting is 122 V ±2%
 Output current------35A (Battery charging current:10A to 15 A, other loads:20 A)
 Output power -----4.5 KW

2.5 KW EMERGENCY BATTERY CHARGER
Technical specifications:
 Input voltage------ Single phase, 240 V ± 15% AC
 Output voltage--110V ± 5% DC
 Output current------22 A
 Output power -----2.5 KW

VRLA BATTERY 110 V (9 MODULES OF 12 VOLT, 70 AH)
 LHB coaches are provided with 9 modules of 12 volt

70Ah, VRLA battery in series , in one battery box
mounted in under-slung.

ON BOARD LOW VOLTAGE PANEL

SELF PRIMING MONO-BLOCK PUMP
 Mono-block pump set are used on non AC 3 tier sleeper coaches for lifting water
from main tanks mounted on the underframe to auxiliary tanks.
 Microprocessor based pump controller is programmed for alternate loading of

pumps during operation, isolation of faulty pump, overload protection, running
time etc.
 The nominal input voltage to controller is 110 V AC/DC.

PUMP CONTROL
CONTROLLER FRONT VIEW CONTROLLER BACK SIDE CONNECTIONS

COACH WISE AVAILABLE EQUIPMENT

SWITCH PLATE ASSEMBLY
SWITCH PLATE ASSEMBLY FOR LS/GS COACHES
 In 2nd general coaches 2 nos. fan switches and 1no. switch and 1
no. 5 pin mobile charging socket on each switch boards are
mounted and total 20 nos. (10 nos. cabin side + 10 nos. corridor
side) are provided in coaches.
 1 no. 500 mA glass fuse is provided in phase wire in mobile
charging socket with fuse holder.
SWITCH PLATE ASSEMBLY FOR 3 TIER SLEEPER

COACHES
 In 3 tier sleeper coaches switch plate assembly complete with
polycarbonate cover frame and powder coated steel plate with 4 nos.
ON-OFF switches (2 nos. fan switches and 1no. light switch and 1 no.
mobile charging switch) and
 1 no. mobile charging socket with 2 nos. 500 mA glass fuses (one each
in phase & neutral wire) with fuse holders are provided on either side of
each cabin
SWITCH PLATE ASSEMBLY
SWITCH PLATE ASSEMBLY FOR CHAIR CAR
 In chair car switch plate assembly complete with polycarbonate cover

frame and powder coated steel plate with 3 nos. ON-OFF switches (2 nos.
fan switches and 1 no. mobile charging switch) and 1 no. mobile charging
socket are provided. (16 nos. in a car)
 Switch plate assembly complete with polycarbonate cover frame and

powder coated steel plate with 2 nos. ONOFF switches (1 no. fan switch
and 1 no. mobile charging switch) and 1 no. mobile charging socket are
provided. (4 nos. in a car).
 1 no. 500 mA glass fuse is provided in phase wire in mobile charging

socket with fuse holder.

END ON GENERATION (EOG) SYSTEM
 End on generation (EOG) system envisages the equipment of the power car in
the front and rear end of a rake with diesel generating sets generating power at
750 V, 3 phase, 50 Hz ac supply.
 Appropriate arrangement for the control and distribution to the entire rake
composition through two sets 3 phase, 4 wire, 750 volts feeders.
 Feeders are taken to each coach in the rake composition with the help of inter
locked electrical couplers.

END ON GENERATION (EOG) SYSTEM
The neutral point of the 3 phase winding of the generator is solidly earthed in the power
cars. The neutral conductor of the 750 volts, 3 phase, 4 wire system shall not be earthed at
any other point in the rake composition.
or VL=Vph x

LHB EOG(END ON GENERATION) FEEDER CIRCUIT
POWER CAR NON-AC COACHES AC COACHES POWER CAR
FJB IV COUPLER FJB FJB IV COUPLER FJB FJB IV COUPLER FJB
ALT_1 ALT_3
BC
BC
FJB IV COUPLER FJB FJB IV COUPLER FJB FJB IV COUPLER FJB
ALT_2 ALT_4
R – RED PHASE WIRE

E – EARTH WIRE ALT – ALTERNATOR
Y – YELLOW PHASE WIRE FJB – FEEDER JUNCTION BOX
SL_1 – SAFETY LOOP WIRE_1
B – BLUE PHASE WIRE IV COUPLER – INTER VEHICULAR COUPLER
SL_2 – SAFETY LOOP WIRE_2 BC – BUS COUPLER
N – NEUTRAL WIRE
FROM FEEDER-A - IV COUPLER FROM FEEDER-B - IV COUPLER
3 PHASE 750V AC SUPPLY 3 PHASE 750V AC SUPPLY
MMR – MEASURING AND
MONITORING RELAY
EARTH
CONNECTION
D&ED – DISCONNECTING AND

EARTHING DEVICE
25A HRC 25A HRC

FUSES FUSES
1.2 KV, 1A 1.2 KV, 1A

1A FUSE FUSE FUSE 1A FUSE
TO K-01 TO K-02
CONTACTOR COIL CONTACTOR COIL
1 PHASE
1 PHASE
INTERLOCKING 750V/110V AC
750V/110V AC
MMR MMR 100VA HOG
100VA HOG
K-03 K-04 TRANSFORMER
TRANSFORMER
K-01 K-02
CONTACTOR CONTACTOR
CONTINUE ON NEXT PAGE

25A HRC
FUSES
Y-Y
3 PHASE
750V/190V+415V AC
SERIES RESISTOR 9KVA POWER SERIES RESISTOR
TRANSFORMER
CAPACITOR FILTER CAPACITOR FILTER
FOR HOG FOR HOG
16A HRC 3 PHASE 190V 3 PHASE 415V 25A HRC
FUSES AC SUPPLY FUSES
RC
AC SUPPLY
. RC
FILTER FILTER
URBC – UNDERSLUNG REGULATED

CUM EMERGENCY BATTERY CHARGER
3 PHASE, 190V 3 PHASE, 415V
AC BUS BAR AC BUS BAR
110V DC BUS BAR
LAVATORTY PUMP
FOR MCS-MOBILE URBC MOTOR
EXHAUST FANS AEL-ACCIDENTAL EMERGENCY LIGHTS
CHARGING 1&2
SOCKETS PUMP CONTROLLER
BETWEEN ONE
ANTI SKID DEVICE
PHASE AND 40A HRC
NEUTRAL 110V AC FUSE COACH LIGHTS
DC BRUSHLESS FANS
BATTERY BANK SPM – SOCKET PARALLELING MAIN

110V DC, 120AH PACIL – PASSANGER ALARM COACH INDICATION LIGHT
UPPER FRAME (SUPER STRUCTURE)
UNDER FRAME
CONTROL
TOWARDS 9 TRANSFORMER
2A MMR
2A
KVA NET-1 K-03
TRANSFORMER
NET-1 CONTACTOR K-01 FEEDER-1
25A
CONTACTOR 25A
K-01 25A
S
D&ED
NET-2 CONTACTOR K-02
HRC FUSES 750 V
25A
CONTACTOR 25A
K-02 25A
N FEEDER-2
CONTROL 2A MMR
TRANSFORMER
NET-2
2A K-04
UNDERSLUNG POWER PANEL

UNDER FRAME
UNDERSLUNG 9 KVA POWER TRANSFORMER
FROM OUTPUT 190 V OUTPUT 415 V

INPUT 750 V
POWER
PANEL
20A FUSE R
16A
25A
16A
16A
25A
25A
20A FUSE Y
20A FUSE B
TO ROTARY
TO BATTERY
JUNCTION
CHARGER
BOX
N
POWER CIRCUIT DIAGRAM

CONTROL CIRCUIT DIAGRAM

LHB NON-AC COACH CONTACTOR K-01 CONTROL CIRCUIT
ROTARY JUNCTION BOX
NC – NORMALLY CLOSE
NO – NORMALLY OPEN
POWER ON/OFF NET-1/2 SELECTOR
ROTARY ROTARY

UNDER FRAME
AUXILIARY CONTACT K-02_NC

HOG TRANSFORMER
NET_1 NC
MMR_NO
2A
NO
P A-2 A-1
25A
I/P (750V) O/P (110V) 25A A NC 1
2A
K-01_COIL 25A
N D&D AUXILIARY
CONTACT
NET_1 CONTACTOR K-01
2A
2A
UNDERSLUNG POWER PANEL

CABLE SIZES FOR NON-AC LHB COACHES
S.NO. DESCRIPTION CABLE SIZE
1 Feeder Jn.box to HV Panel 750V AC 25 Sq.mm E-beam
2 HV Panel to Transformer 750V AC 16 Sq.mm E-beam
3 Transformer to RBCR & Pump -415V AC 16 Sq.mm E-beam
4 Transformer to mobile charger 190V AC 6 Sq.mm E-beam
5 All U/F 110V dc 10 Sq.mm E-beam
6 All Roof 110V dc 4 Sq.mm E-beam
7 For lights, Fans & Mobiles 1.5 Sq.mm E-beam

WIRING SCHEME
() The lights are arranged in two circuits (L-I, L-II)
and fans in one circuit-F, each controlled by a rotary
switch.
Each circuit of lights and fans is protected by HRC
fuse which acts as back up protection in case of any
short circuit fault, isolating the faulty circuit only.
Glass fuses of proper rating protect the branch
circuits for lights and fans.
These glass fuses are located on a distribution fuse
board.
All branch circuits are protected by the fuses, both
on negative and positive sides.

COLOUR CODE OF CABLES
For easy identification of the cables, the various circuits have colour code
as indicated below:
Paralleling main and fan positive cables ………..… Red
Light positive cables. …………………..……….….……Yellow
Fan negative cables ………………………..……………… Black
All other negative cables except fan negatives … Blue

RATINGS OF IMPORTANT EQUIPMENT

DIFFERENT FUSES AND SWITCHES

MAINTENANCE SCHEDULES (ELECTRICAL)
Periodic Maintenance Schedules

Schedule D1 : Trip / Weekly
Schedule D2 : Monthly ± 3days
Schedule D3 : Half Yearly ± 15 days
Shop Schedule (SS-1), IOH : 18 Months / 6 Lakh kms whichever is earlier
Shop Schedule (SS-2), POH : 36 Months / 12 Lakh kms whichever is earlier

INTERNAL LIGHT AND FAN FITTINGS

BATTERY AND BATTERY BOX

BATTERY CHARGER

STEP DOWN TRANSFORMER 9/15 kVA

ELECTRICAL PANELS (Under slung HV and Onboard Panel)

MISCELLANEOUS EQUIPMENT

CODE OF PRACTICE FOR WIRING
S.NO. CIRCUIT CAPACITY OF MEGGAR USED MIN. VALUE OF IR

VOLTAGE REQUIRED
1 750V 1000V 05 M.ohms
2 415V 500V 03 M ohms
3 230V 500V 02 M ohms
4 190V 500V 02 M ohms
5 110V 500V 02 M ohms

Rail madad
• Rail Madad is a mobile app to register complaints by passengers through mobile phone.
• Rail Madad is linked with Railways existing ticketing system like PRS
• Rail Madad is a single portal for grievance inquiry and assistance for all railway costumers.
• Electrical Complaints registered the following cases in Rail Madad Portal
1)Mobile Charging not working

2)Lights and Fan not working
3) No power supply in coach
126
LIST OF MUST CHANGE ITEMS FOR NON AC LHB COACHES

ANY QUESTIONS

THANK YOU

SG TL AND LHB 16-01-2025

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A PRESENTATION ON

Train lighting and AC coaches

• SELF GENERATING SYSTEM (SG)

• MID ON GENERATION (MOG)

• END ON GENERATION (EOG)

• HEAD ON GENERATION (HOG)

• It gives better flexibility in rake formation.

• The system is independent of mode of traction.

• As each coach has battery, No separate power car required

• Defect in any particular coach do not affect the others.

• Feed extension is possible in emergency from adjacent coach

• Load restricted to 1X4.5 kW per coach at present.

• No standby alternator /battery in coaches so system became poor reliability.

• Extensive maintenance due to under-slung alternator, v-belt, axle pulleys, tensioning

• Poor system efficiency around 57%.

 Two power cars each with 2X320 kW (high Capacity) Diesel

 Each Alternator capacity of 500 KVA 385 Amps.

 Generated Power Supply is 750 V 3- ph 50Hz without neutral .

 Power is fed through feeders to IV couplers, ZS couplers 400Amps

 Power supply is stepped down 750V to 415 V 3 ph for AC by 60

 110 V ac lighting and fans by 415/110 ac transformer.

 LHB coaches lights work on 110V Dc and no fans.

 Does not require bulky batteries, alternators.

 Independent of mode of traction.

 Less maintenance required due to elimination of under slung

 Higher system efficiency than SG system.

 High cost of energy due to high fuel cost.

 Noise and smoke pollution from power cars.

 Passenger capacity reduced due to provision of power car.

 With new technological transformation is developed as HOG.

 The LHB type are best suited for adoption of HOG.

 25 KV supply is trapped from OHE through pantograph to loco transformer.

 Loco transformer capacity is 7775 KVA .

 Hotel load winding are two numbers each of 622.5 KVA .

 The current carrying capacity hotel load winding is 1260 Amps .

• BELT TENSIONING DEVICE

• LIGHTS AND FANS

• ROTARY JUNCTION BOX (RJB)

• Working of lights and fans in the coach duringtrain run

• Sharing the load to other coaches in case of emergency

• No Moving contacts or windings on rotor

• AC Windings and field windings BOTH accommondated on stator

Rating 120 V, 37.5 Amp

Factory Setting 128.5±0.5 V at 19A, 1500 rpm

Efficiency 70% at full load and 1800 RPM

Field wdg resistance 4.5+/- 0.5 Ω

Stator wdg resistance (phase to phase) 0.4+/- 0.05 Ω

Suspension pin dia 31.75+0/-0.10 mm

Ripple content (max) 5%

Alt pulley width 110.5+/-1.5 mm

Axle pulley groove angle 38+/-0.5 0

Tensioning device working length 310 mm

* With new wheel dia (915 mm)

1)The voltage settings of Alternator cum RRU/ERRU in TL coaches ()

6)Give the off load setting of RRU/ERRU of 4.5KW at 1500RPM is ()

7)Main function of RRU/ERRU is ()

8) SMI on TL/AC is issued by ---- ()

9)Modified TL System is---wire un earthed system? ()

1)Coach alternator has winding ( )

. 2) The purpose of TL&AC alternator used in Railways ( )