Introduction and Overview to Braking Systems Course 103 ...

1 PARTICIPANTGUIDEI ntroduction and OverviewtoPropulsion and Dynamic Braking SystemsCourse 103 PREVIEW ONLYCOURSE 103: Introduction AND Overview TO PROPULSION AND DYNAMIC Braking DRAFT Intended For Use by Rail Car Training Consortium Members Only Transportation Learning Center Page iii Table of Contents How to Use the Participant Guide .. ii MODULE 1 General Principles and Terminology ..1 1-1 Safety Review ..3 1-2 Overview of Propulsion ..10 1-3 Dynamic Braking ..15 1-4 DC and AC Motors ..17 1-5 Variation in Transit Rail Propulsion Systems ..20 1-6 Summary ..21 MODULE 2 Principles of Operation of AC Propulsion.

2 22 2-1 Overview ..24 2-2 Switching and Filtering ..25 2-3 Dynamic Braking ..35 2-4 Power inversion ..38 2-5 AC Motors ..42 2-6 AC Propulsion Circuit ..45 2-7 Summary ..47 MODULE 3 Principles of Operation of DC Propulsion ..48 3-1 Overiew ..50 3-2 Switching and Filtering ..51 3-2 Traction Control and Dynamic Braking ..63 3-3 Motors ..73 3-3 Summary ..75 MODULE 4 Principles of Operation of Dynamic Braking ..76 4-1 Overview ..77 4-2 Dynamic Braking ..77 4-3 Other Systems of Braking ..80 4-4 Summary ..82 MODULE 5 Tools and Materials ..83 5-1 Overview ..84 5-2 Tools ..84 5-3 Materials ..89 5-4 Specialized Tools ..89 5-5 Summary.

3 89 PREVIEW ONLYCOURSE 103: Introduction AND Overview TO PROPULSION AND DYNAMIC Braking DRAFT Intended For Use by Rail Car Training Consortium Members Only Transportation Learning Center Page iv Table of Figures Figure General Safety Precautions when Working Around the Rail Car s Propulsion system 3 Figure Lockout/Tagout Applied to High Voltage Power Line courtesy GCRTA .. 4 Figure Bump Cap Worn in Rail Car Maintenance Facility courtesy 5 Figure Rail Car Maintainer Preparing to Don Her Hard Hat courtesy CATS .. 5 Figure Employer and Worker Responsibility Regarding PPE Source OSHA Standards Pertaining to PPE.

4 6 Figure PPE Signage Displayed in Rail Car Maintenance Facility courtesy 6 Figure Electrical Hazard Warning in OEM Manual courtesy PATCO .. 7 Figure Capacitor Voltage Hazard Warning in OEM Manual courtesy NFTA .. 7 Figure Propulsion Containers Located on top of Rail Vehicle courtesy SDMTS .. 8 Figure T-Box Propulsion Containers on A and B Cars courtesy Denver RTD .. 8 Figure LA Metro Rail Car on Hoists from .. 9 Figure Master Controller Configuration Used on PATCO Transit Cars .. 12 Figure Block Diagram of Functional Propulsion and Dynamic Braking system .. 13 Figure Track Brake on LRV in Denver RTD Maintenance Facility.

5 15 Figure Banks of Braking Resistors on Rail Car-courtesy MBTA .. 16 Figure DC Motor Driving Rail Car Axle Through Pinion and 17 Figure DC Traction Motor courtesy NFTA .. 18 Figure AC Traction Motor Major Components .. 19 Figure Location of Main Propulsion Equipment on Siemens Light Rail Vehicle courtesy CATS .. 20 Figure Location of Main Propulsion Equipment on Bombardier Heavy Rail Vehicle courtesy BART .. 21 Figure Schematic Overview of AC Propulsion Functional Areas .. 24 Figure Knife Switch Mechanism Under Rail Car courtesy WMATA .. 26 Figure Front and Side Views of HSCB courtesy PATCO.

6 27 Figure Line Contactor and Pre-charge Resistor courtesy MBTA .. 27 Figure Line Contactor and Zero Voltage Relay courtesy PATCO .. 28 Figure Line Reactor courtesy MBTA .. 28 Figure Under Car View of Brake Resistor Grids courtesy PATCO .. 35 Figure Rear View of Brake Resistors Showing Electrical Cabling courtesy PATCO .. 35 Figure Brake Chopper Module courtesy PATCO .. 36 Figure IGBT Device .. 36 Figure GTO Devices source ABB .. 36 Figure Encoder Assembly Showing Location of Speed Sensor Assembly courtesy 37 Figure Inverter installed on Rail Car courtesy MBTA .. 38 Figure Propulsion Inverter and PCU Control Unit Awaiting Installation courtesy MBTA 39 Figure Stator with Insulated Windings courtesy CATS.

7 42 Figure Rotor Components courtesy CATS .. 43 PREVIEW ONLYCOURSE 103: Introduction AND Overview TO PROPULSION AND DYNAMIC Braking MODULE 1: GENERAL PRINCIPLES AND TERMINOLOGY DRAFT Intended For Use by Rail Car Training Consortium Members Only Transportation Learning Center Page 1 MODULE 1 GENERAL PRINCIPLES AND TERMINOLOGY Outline 1-1 Safety Review 1-2 Overview to Rail Car Propulsion system 1-3 DC and AC Motors 1-4 Overview to Rail Car Dynamic Braking system 1-5 Summary Purpose and Objectives The purpose of this module is to provide participants with an Overview of the principles of maintenance of rail car propulsion and dynamic Braking Systems .

8 Following the completion of this module, the participant should be able to complete the objectives with an accuracy of 75% or greater: Recall safety procedures when working on rail car including: o Lockout tagout (LOTO) o Proper use of PPE Identify hazards specific to work around propulsion and dynamic Braking Explain basic theory of operation of a rail car s propulsion system Explain basic theory of operation of a rail car s dynamic Braking system Describe principles of motor theory Compare AC and DC motors with respect to rail cars Recall the theory of grounding circuits with respect to rail cars PREVIEW ONLYCOURSE 103: Introduction AND Overview TO PROPULSION AND DYNAMIC Braking MODULE 1.

9 GENERAL PRINCIPLES AND TERMINOLOGY DRAFT Intended For Use by Rail Car Training Consortium Members Only Transportation Learning Center Page 8 Figure Propulsion Containers Located on top of Rail Vehicle courtesy SDMTS For propulsion containers located under the rail vehicle, such as illustrated in Figure , these are accessed either from inside a pit in the repair shop or when the vehicle is hoisted on lifts (Figure ). Figure T-Box Propulsion Containers on A and B Cars courtesy Denver RTD Learning Application With guidance from your instructor, write down the ways in which you will access the propulsion containers on the rail cars in your maintenance facility.

10 PREVIEW ONLYCOURSE 103: Introduction AND Overview TO PROPULSION AND DYNAMIC Braking MODULE 1: GENERAL PRINCIPLES AND TERMINOLOGY DRAFT Intended For Use by Rail Car Training Consortium Members Only Transportation Learning Center Page 9 Figure LA Metro Rail Car on Hoists from Pit areas are confined spaces which present special challenges including proper ventilation, lighting, and access. OSHA defines confined spaces as those spaces while they are not necessarily designed for people, they are large enough for workers to enter and perform certain jobs. A confined space also has limited or restricted means for entry or exit and is not designed for continuous occupancy.