Technical seminar on

Auxiliary Power Unit

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.

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

Medha Servo Drives Pvt. Ltd.

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

Engine Air Compressor Air

intake filter inlet filters

Control Unit

Diesel Engine

Compressor Alternator

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 Diesel Engine

Water level
Fuel oil sensor
secondary filter

Water
filling cap

Expansion
tank
Air Lock
releasing pump

STARTER STOP
motor Cylinder

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 MAP 756

APU Knife
Gauge panel Switch

12V Alternator

12V Battery

Manual
Shutdown

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 Compressor

Breather Valve
HP Cylinder

Oil sight glass

LP Cylinders
Oil Fill Cap.
Unloader Valves

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 MAP 756

Regulator (AVR) FOLR

SMC
Control Unit

Alternator Diode ASC ACC

Timer Unit Panel

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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/Cm.

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 below
5.5 Kg/Cm.

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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 Trouble shooting

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

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 Trouble shooting

Code Message
1279 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 Message
2075 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

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