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Medha Servo Drives Pvt. Ltd.

2-3-2/A, Cherlapally, Hyderabad – 500051. India. Ph- 040-2726 4144

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On 11.11.2013 technical seminar on Auxiliary Power Unit was conducted

by Diesel Loco Faculty at ZRTI Bhusawal . This seminar presented by

Shree Dinesh Koasty who is working as service engineer in Medha Servo

Drives Pvt. Ltd.

Technical seminar on

Auxiliary Power Unit

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Medha Servo Drives Pvt. Ltd.

2-3-2/A, Cherlapally, Hyderabad – 500051. India. Ph- 040-2726 4144

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Welcome to All

Medha

Auxiliary Power Unit

Type MAP 756

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Locomotive Idling

� Most of the goods trains are waiting for long periods in station yards.

� Indian Railway statistics says almost 40% of the total run time of a diesel locomotive is IDLE only.

� Lot of fuel is wasted when the locomotive is waiting for long periods in the station yards especially goods trains.

� Loco pilot can shut down the diesel engine to save fuel.

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Why not shutdown…

� The Loco pilots can switch off the diesel engine and save fuel instead of running at IDLE.

� But they don’t do – because:

� BP pressure reduces in the formation due to leakages.� It takes longer time to charge the BP again.

� The crew does not have confidence that loco can re-crank.

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What is wasted ?

� The fuel consumed per hour on ALCO locomotives is around 25 liters / Hour.

� If you take Rs.56/- per liter, the cost per idle hour running is Rs. 1400/-.

� If you take an average 10 hours per day idling hours then the cost is Rs.14,000/-.

� Roughly if you take 330 days, it costs Rs.46,20,000/-.

� If a home shed is having 100 locos, almost Rs. 46.2 crores worth of fuel is wasted.

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What can be saved by crew

� Normally the Loco pilot is on duty for 8 hours per day.

� Out of that minimum 6 hours he is in locomotive.

� Out of 6 hours minimum one hour is the waiting period.

� In one Hour we can save 23 liters of fuel oil per day.

� On an average in a month the working days are around 24 days

� We can save 24 * 23 = 552 liters per month

� Financially equivalent to 552 * 56 = Rs.30,912/-per month

� On an average in a year we can save Rs.3,70,944/-.

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AESS with APU

� APU SWITCH is provided under alarm push button.

� Keep always this switch in NORMAL position to save fuel.

� If this switch is in OFF position, ‘1701 Operator disabled APU’message is displayed while the breakers are switched ON.

� There after for every 10 minutes the system reminds the driver with a message ‘2076 APU Enable switch is in OFF position. Warning: Cannot enter into fuel save mode’.

� Keep this switch in OFF position only when there is a problem with APU functionality.

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AESS with APU

� APU is located in the nose compartment under dynamic brake grid resistors and after the air brake panel.

� This is an Add on unit to Microprocessor based loco control system.

� It is called as AESS with APU.

� It starts automatically and stops automatically as per the drivers request.

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STATUTARY WARNINGS

� Do not perform any jobs on main engine or APU engine keeping ‘APU SWITCH’ in NORMAL position.

� Engine may automatically start / stop and can cause human injury / death.

� Switch OFF APU Switch and then perform the work on engines.

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MAP 756

Diesel Engine

Engine Air

intake filter

Compressor

Compressor Air

inlet filters

Alternator

Control Unit

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Diesel Engine

Air Lock

releasing pump

STARTER

motor

STOP

Cylinder

Water level

sensor

Water

filling cap

Expansion

tank

Fuel oil

secondary filter

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MAP 756

12V Alternator

Gauge panel

12V Battery

APU Knife

Switch

Manual

Shutdown

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Compressor

LP Cylinders

HP CylinderBreather Valve

Unloader Valves

Oil Fill Cap.

Oil sight glass

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Control Unit

MAP 756

Alternator

Regulator (AVR)

SMC

ASC ACC

FOLR

Diode

PanelTimer Unit

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APU inside the Nose compartment

� There is a glass door on the APU.

� Behind the glass door, there is a battery cut out switch.

� When the display prompts to open this cut out switch, Please open this switch manually.

� There is an emergency stop lever to stop the APU engine in case of any problem.

� When ever display prompts to manually shut down the APU engine, Pull the lever toward you to shut down the APU engine.

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AESS with APU working

� Stop the train with A9.

� Apply loco brakes and ensure BCP is more than 1.5 Kg/Cm².

� Keep the RH in neutral position.

� After every parameter is with in limits for 10 minutes, the Display is shown with a decremental counter.

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AESS with APU working

� After the counter is zero, the system automatically starts the APU.

� Main engine is shutdown.

� The display screen is changed to APU screen.

� All relevant parameters are displayed

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AESS with APU working

� MCBG screen is change to starting screen.� Small motors like DEM, CCEM, FPM and RBM are switched OFF.

� DEB (Eng), DEB (Carb) indications start glowing.� Aux.Fail indication glows but battery ammeter will be showing charging side.

Note: Do not worry about these indications.

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Warnings

� While APU is running if

� Battery ammeter is showing discharge side (or)

� MR is continuously dropping and reached below5.5 Kg/Cm².

� The APU is automatically stopped and main engine is cranked automatically.

Note: If APU is continuing to run in spite of the above, manually shut down the APU and crank the main engine.

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How to start the train

� As soon as the signal is in favour,� Simply through the RH to working direction.

� ‘2077 System returning from FUEL SAVE mode’ message is displayed.

� Small motors are switched ON.

� With in 15 seconds the main engine is cranked automatically.

� APU engine is shut down.

� Display returns to normal screen.

� Loco pilot can start the train as per rail road rules and regulations.

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Code Message

1700 Operator enabled APU

1701 Operator disabled APU

1277 APU cranking contactor circuit open fault.

1278 APU Cranking contactor stuck closed.

1287 APU shut down contactor circuit open fault

1284 APU shut down contactor stuck closed fault

1286 SMC contactor circuit open fault

1285 SMC contactor stuck closed

1293 FPC contactor circuit open

1292 FPC contactor stuck closed

Trouble shooting

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Trouble shooting

Code Message1279 APU fuel oil level low fault

1280 APU water level low / Temperature High fault

1281 APU lube oil pressure low fault

1290 APU Engine failed Engine RPM low

1291 APU Engine failed Engine over speed

1276 APU Engine shut down unexpectedly.

1282 APU battery charging faulty

1283 APU Air compressor faulty

1289 No APU Generator output

1288 Main Engine failed to crank while retrurning from APU mode.

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Trouble shooting

Code Message2075 Keep REV handle to neutral to enter into FUEL SAVE mode.

2076 APU Enable switch is in OFF position

2077 System returning from FUEL SAVE mode

2078 APU shutdown contactor failed. Manually pull the emergency

shut down lever to shutdown APU Engine.

2079 Loco brakes are not applied. May not enter into FUEL SAVE

mode

2606 BATI/EWT/EOT/MRPR are not full filled. Fuel save mode

prohibited.

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AESS with APU

Questions Please…...?

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Training Team

THANK YOU