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Designs & Standards Organisation

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E1/7 .2.2.8/Siemens Dated 12/110/99

Modification Sheet rlJo. RDSO/PE/MS/0003-99 (Rev 0)

~Modification for 25KVA "ON BOARD" Type invertor of MIs Siemens[ make for RM?P ofAC coaches conforming to ROSO specification No. SPEC/E-20/04 (R,v.3). I

2.0 Object

In order to improve upon the cooling arrangement within the inverter bide to reducel thetemperature rise of electronics in existing inverters of f\1/s Siemens ake conformiriS toRev.3. it is decided to provide cutouts and a small instrument fan in e cubicle betw~enchopper module and inverter module and Venturi type air exhau t ~rrangement I forexhausting hot air from the inverter compartment.

Work to be c:arried out-

As per annexure "1" enclosed.

Application to Class of coaches

1

2.

AC coaches with RMPU fitted with "ON BOARD" Rev.3 type inve~er of MIs SiemEtnsmake, on which cool air bleeding modification as per RCF's Mod.ficatioil Sheet ~o.21451 of 2.4.96 has been carried out. i II~F bu~t coaches with Rr..t1PU fitted with On Board Rev-3 ty~ inverter of ~iSSiemens. ,

Material ReQuired

a) Perforated mesh-size 180 x 180 mm to be welded on the cut-ou rOf size 150 x ¥omm made at the bottom of the inver:ter-. Details may be seen at heet No 2 of rg

No RDSO/PE/SK/PS/0006-99 (Rev 0)

b) Mounting of fan plate for' instrument cooling fan size 416 x 170 x 2 8-S per Sk-etbh

No.4 of drg No R_DSO/PE/SK/PS/0006-99 (Rev 0) I

Instrument cooling fan (E2) 24V DC of MIs EBM-Type W2G 113 ~ eo 03-01c)

d) 4-way terminal strip series 130S4 make 'Piri,Rapid .type as per ~nclosed sheet prequivalent. .' I "

e) 0.6 mm sq Teflon multi~strand red and black colour wire of leng 1h two meter eath

for instrument fan connections.

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f) Cable ties, Four hard war~~s (M,X10) nut bolts for mountln~ ~z fan and S.lX lu~S forwires .l f

9 Venturi type air exhaust. arrangement for inverter room ts per araWint No M1001293. M1001294 for RCF built coaches and-drawing No: ICF/SK-7-4072.

IC.F/SK-7-4-073 for ICF built coaches.

Material re~ndered surplus Louvers one number.

Reference

In order to reduce the temperature-rise of the electronic devices i1the inver1er ~bjCle and thus to improve upon the reliability, various test trials and running trials ere

conducted. Details of the same has already been circulated to Railw ys vide ROSa etterNo. EU7.2..~8/Siemens dated 26fl!~tp-

Modification Drawinq

J)r4wing~o: -RDSO/PE/SK/PS/0006-99 (Rev 0) (in 4 Sheets enclose<!l)

8Qency of 1mplementation

AC coaching depot during AOH/POH schedule of AC coaches.

!)istributio[!.

As per enclosed list

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Annexur~:1

(A) ~~

1) For removing left door, removing the circlips (4x) & hingepins(4x)

2) Remove ductplate by unscrewing hardware's

3) For removing chopper assemblya) Remove the plate above Chopper heatsink.b) Remove hardware for terminals X1:1, X1:2, E+, F. & X1:5.c) Remove earthing wire connection.d) Remove D-connector of X2 cable, from A-10 card by unscrewing th scre

the connelctor.e) Unscrew the 4 main screws size (M8) of heat'sink and slide out the hopper assem' Iy.

It shou:d be ensured that no hardware falls into the assembly ~hile dismountin~Precaution:

4) For removing inverter assembly.b) Remove the plate above Inverter heatsink.

b) Remove h,ardware forten-ninals .X1:4. x1:5. X1:6, Eo., F..c) Remove earthing wire connection.d) Remove C)-connectors of the cables X21 & X22, from A 10 card by u !ng the

fixing screws on the connector(s).e) Unscrew the 4 main screws (M8 size) -of h-eat sink and slide out the inverter assem Iy

Precauti.QD::.. It should be ensured that no hardwar.e fafls into the assembly ~ile dislnountjn~.

{B)-Mo(jification 1 -Cut out-on-th:e=buttom--olate

1) Mark the cutout on the bottom plate, as shown in Sheet No.2.(Drg. NoRDSO/PE/SK/PS/0006-99 Rev 0)

2) Make the cutout. It is suggested to use a nibbling tool 1 or gas cutter for r.la~ing the cutout

Cautio!:!.-: While making the cutout. -care should be taken-that the 3 -phase qutput cables an~

choke earthing wires are not damaged in any way. c I 1'1

3} Perforated mesh (as per Sheet No.2) to be tag welded over.the cutout

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1 Cut the cable ties on the service p:~te. so that the 3 output.cables are det~ch~d from theservice plate J

Caution: Care should be taken to avoid damage to the cables while cutting the cable ties. 91!!.9.! remove the saddles on the service plate. I

2 Remove the hardware from the bottom of the service plate.jCaution: The hardware shall becarefuliy removed from the botton). to avoid he hardware &

pJate from falling down. .

3 Make the cutout on the service plate, according to dimensions shown In Sheet No.3 (~rg.No. RDSO/PE/SK/PS/OOO6-99 (Rev._O) It is suggested to use a nibbling tool or gas cutter f rmaking the cutout. .

4 Refix the service plate carefully using the same hardware.

Caution:run.

The hard""are must be properly tightened so that the plate does no~ fall-down durinlg

5 Fix the cables to the saddles on the service plate with help of new cab~e ties

1) First mount the instrument cooling fan ([~2) and 4 way terminal strip (X8) onl top of the0mounting plate. E2 j'an to be mounted in SIJch a way that the direction shown ir Sheet No.1.( rg.

No. RDSO/PE/SK/PSIOOO6-99 (Rev.O) is maintained. I

2) Crimp suitabte°.Rfng tonglJe 1IJgs on-both th-e red & blackwires--orE2-ran-

3)-Connect the red ~~ btack-wires-to the t-en-ninal-strip

dummy.X 8)..Jeaving 2 s~rews inl between as

4) Loosely fasten this assembly on the rear two holes already existing on the ~eftHand suppot(betweenchopper-&inverter assemblies) with M6 hardw~re. Refer Sheet N .4 for

dimensional details. .I

5) Mark the holes to be drilled on the Right Hand Support. corresponding to thb holes alreadydriiled on-the fan-mounting plate. 1-

6) Remove the moul1ting plate and drill 2 holes of 8 mm dia. o~ the RH -suppoJ corresponding lothe marking. -'1.r

Caution: The care should be taken that the iron particle? do not fa" into the lchOke windings Ior the other electronic parts.

7) Firmly fasten the fan mounting plate with 4x M6 hardware\ P 1'- .Igc.. :-

8) Teflon wiring of 06 sq.mm with' appropriate ring tongue terminals to be done b~ tween ~2

te:mlnal X8 and A 1 power supply. The positive Red wire of E2 fan to be conn cted to A 1

terminal P24 (length 2mts) & black wire of E2 fan to A 1 terminal M24 (length 2 ! ts).

Note Please route the wiring along the ex:sting bunch

(E) Re-assemblinq the inverter:

Clean the metal dusVparticles in the panel completely

2) Refix the service plates on the top of the chopper & inverter heatsinks

3) Refix the chopper & inverter assemblies by tightening the screws on the heats l nks. Care

should be taken that no hardware falls into the assemblies while refixing. ,

4) Make the electrical connections of the in'/erter & chopper assemblies with ap~ropriatehardware and fix the earthing connection. I

5) Reconnect the cables on the A-10 card. The D-Connector of the cable from the-chopper to bconnected to X2 on the A-10 card and the D-connectors of the cables from trye inverterassembly to be connected to X21 & X22 on the A-10 card respectively. i

6) Refix the service plates on the top of the chopper & inverter heatsinks

7) Refix the duct plate

8) Refix the door with the help of hinge pins

(F) TestinQ

Check E2 fan.is rotating as soon as 24V is available from the A 1 power supplyI

2) Test1he-inverter without load-&-on-io-ad.

(G) Fitting of Venturi

Remove the existing louvers on coach side wall by removing handwares

:~ Fit the venture DrgNo: r.JI100129.3; M100129~for ~CF built-coaches and 9 rg No: ICF/SK-

ru/2 and ICF/SK-7..4-073 for ICF buIlt coaches wIth suItable hardwares.-I

-4

The det~led i~structions through the Coach Alteration Sheer to this eftect \,.ould be' issued b~. t~eproduction UnIts. i III'.

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