WELCOME

TO
Supervisors Training Centre

 Special course on EMU/MEMU

• A. K. Mishra
 Sr. Lecturer
Sr.no Description Number of Sessions

1 Brief introduction about EMU/MEMU. 1

2 History of developments of EMU/MEMU 1

3 Working Principle and location of Equipments of EMU/MEMU 2

3 Terminology of EMU/MEMU system and Technical details 2

4 Overview of Conventional EMU/MEMU 2

5 Demonstration in Field about Conventional EMU/MEMU 2

6 Overview of Three phase EMU/MEMU 2

7 Mechanical Equipments and their Maintenance. Shaku coupler 2

8 Braking System, Common Faults and Trouble shooting 2

9 Motor coach testing, Formation of Rake and Testing 2

10 Maintenance schedule of EMU/MEMU and Booking of Personnel 2

11 Evaluation and release 2

Total= 22
 INTRODUCTION
 The EMU stock is employed for short distance sub-urban services (up
to 150 Kms)having frequent stops and starts. MEMU stock is used for
medium distance (300 to 500 Kms) passenger transportation on the
existing track, signaling, and overhead electrical supply systems.

 Each EMU/MEMU train shall have 1 (one) driving coach at each end.
The lengths of 9- coach formation EMU/MEMU train and 12-coach
formation MEMU train presently running on Indian Railways are 195
meters (approx.) and 267 meters (approx.) respectively.

 This shall be considered as the basic train length of one EMU and
MEMU train, however, it shall be possible to add one or more basic
unit(s) to increase the length of EMU and MEMU train up to 400
meters.

 The stop time given is considered as 30 seconds.

 In the event of failure of one motor coach, the EMU / MEMU train is
able to complete the journey up to the destination.
 Conventional EMU unit

TRAIN FORMATION MEMU

8 CAR MC-TC-TC-TC-TC-TC-TC-MC

12 CAR MC-TC-TC-TC-MC-TC-TC-TC-TC-TC-TC-MC

16 CAR MC-TC-TC-TC-MC-TC-TC-TC-MC-TC-TC-TC-TC-TC-TC-MC

TRAIN FORMATION EMU:

6 CAR DMC-TC-TC-TC-TC-DMC

9 CAR DMC-TC-TC-TC-NDMC-TC-TC-TC-DMC

12CAR DMC-TC-TC-TC-NDMC-TC-TC-TC-NDMC-TC-TC-DMC
Rake Formation of EMU
Three phase EMU unit and Rake Formation
 NOMENCLATURE OF EMU/MEMU
 W – BROAD GAUGE
 A – ALTERNATING CURRENT
 U – UNIT
 4-GROUP NUMBER

 UNIT CODE:
 MOTOR COACH – (B)YZZS
 TRAILER COACH – (A)YFSY
 TRAILER COACH – (C)YSY
 DRIVING TRAILER COACH – (D)YSD
 General Data of EMU/MEMU

S/ Description EMU MEMU

no M/C T/C M/C T/C
1 Wheel arrangement Bo-Bo Bo-Bo
2 Axle Load 20.32T 13.0T 20.32T 13.0T
3 Wheel Diameter(mm) 952/877 952/857 952/877 952/857

4 Gear Ratio 20:91 20:91

5 KVA rating of Transformer 1000 1000
6 Traction Motor Rating (KW) 207/227 207/227
7 Maximum length of the 20726 21567/21337
body(mm)
8 Maximum width of the body(mm) 3658 3245
9 Floor height from rail level(mm) 1197 1278
10 Maximum height above rail to 3810 3886
top(mm)
Electrical Multiple Unit-
DTC MC TC TOTAL
Total Seating Capacity 86 86 112 284

Standing capacity in ease 90 86 116 292

Crush load 176 172 228 576

Train Normal load - 852 all seating

Crush load - 852 seating + 876 standing

Dense Crush Load - 852 seating + 1740 standing

Important Historical Events for
EMU/MEMU

 03.02.1925
• First Sub-urban Train of 4 car rakes ran between VT
and Kurla
• 1500V DC stock
• Electrical Equipments by EECo.
• Mech equipments by Metropolitan Vickers England
• 10 Feet wide stock with Cement flooring
 1951
• 12 Feet wide EMU stock with Electro Pneumatic
brake system in Mumbai Area
• Imported from EECo. England
 Contd….

14.12.1957
• 3000V DC EMU introduced in Howrah division of ER between Howrah
and Seoraphuli.
Imported from Switzerland (SIG) 1958

 1958
•12 Feet wide 1500 V DC EMU stock imported from Japan (
NSSK/Toshiba/Hitachi)
 1963-64
•BG 25kV AC EMUs were introduced in Sealdah Division in Kolkotta
Area.
•Coaches Manufactured by ICF.
• Electrical Equipments from Hitachi Japan and AEI England.
 1965-66
•ICF Manufactured MG AC EMUs.
•Electrical Equipments from Japan.
 Contd….
 1968-69
• ICF Manufactured DC and AC EMUs along with M/s Jessop,
Kolkata.
 1989-90
• ICF Manufactured Thyristor controlled 25kV MG EMU for Chennai
Area.
• Electrical Equipments by GEC England.
 1993
• Chopper control was introduced on 20 nos. BG EMU in association
with BARC.
 1995
 IR adopted 3 phase Traction Drives Equipments suitable for dual
voltage 1500V DC or 25kV AC system with Regenerative Braking
features for use in Mumbai Area. Since 2007
• 116 Energy Efficient AC/DC rakes have been introduced with 3
phase IGBT propulsion system and Regenerative Breaking feature.
(In Mumbai)
 Since Jan 2015
• 72 Energy Efficient AC rakes have been introduced in Phase II with
3 phase IGBT propulsion system and Regenerative Breaking
feature. (In Mumbai)
 Since 16-17 , 6 Energy Efficient AC rakes have been
 introduced ,Medha make. (In Mumbai).
 History of EMU services in South Eastern Railway
 Debut of EMU services :01.05.1968
 First EMU Service :HWH-PKU
 HWH-KGP Section :01.02.1969
 PKU-HLZ Section :01.05.1976
 KGP-MDN Section :25.01.1984
 AMTA Section up to Domjur :22.04.1984
• Up to AMTA :27.11.2004
 TMZ- DIGHA Section :24.06.2012
 KGP-HIJ Section :04.01.2012
 MEMU Service :15.07.1995
 Introduction of 9 Car Rake :1990
 Introduction of 12 Car Rake :29.11.2009
 Introduction of Three Phase Rake :22.03.2018
 OHE Block Diagram of EMU/MEMU

VCB

Traction
Transformer Rectifier Inverter
Motor

Only in Three
Phase

AUX-1 Radiator
Battery Blower
Oil pump Motor Compressor
266 V Charger Motors
1&2
Control Circuit

AUX-2 Head light Normal light

Auxiliary AC
141 V voltage voltage
Rectifier Stabilizer Stabilizer FANS
 Main equipments of EMU/MEMU
 Pantograph
 VCB-Vacuum circuit breaker
 EWS- Earthing switch
 Transformer
 Oil Pump
 Oil cooler
 Compressor
 Contactors/ switch group
 Battery Box
 Transition Resistor
 Field Diverter
 Silicon Rectifier/Traction Converter / Inverter / Auxiliary Converter, LCD Cubicle (LCD =
Liquid Cooled Device)
 Main Reservoir
 Auxiliary Reservoir
 After cooler
 Driving Cab (Driving Desk ,Dead man's Handle, brake controller, Indication panel, Switches,
MMI, Driver Control Switch -DCS etc.)
 Control Panel (MCB panel, Fuse panel, Rotary Switches, BA charger , Control circuit etc.)
 Traction Motors
 Bogie
 Schaku Coupler
 EP Brakes and Parking Brake
 The front end of each driving coach is provided with:

 Head light – Twin beam head lights are provided at each end, working on 110
V halogen lamps having two filaments or LED lamps.
 Headlight units are refocused, capable of giving minimum 3.2 lux at a distance
of 305 meters. The head light will work in neutral section.

 Tail light (blinking at a rate of 55-65 flashes per minute during the service)

 Flasher light: flashes at the rate of 40 +/- 5 flashes per minute.

 Two twin marker lights with suitable waterproof enclosures Fitted. Each twin
marker light is provided with one white and one red array.
 The marker lamp shall have a nominal light output of 40 LUX at 1 meter.The
marker light shall work in the neutral section.
 These shall work on the battery supply.

 A separate switch is provided in the driver’s cab to switch ON/OFF the auxiliary
head light independent of head light and tail light(Normal & blinking
operation).
 4 5 6 7
DRAVING

BOGIE-
CAB

BOGIE-1 1 2 3
2

8 9 10 11

1.Transition resistor 2. Smoothing reactor 3. Transformer 4. Battery box 5.TFP

Oil cooler 6. Silicon Rectifier 7. Switch group -2 8. Switch group -1 9. Field
diverter 10. Oil Pump 11. Main Compressor.
 Improved Performance Features of ICF EMUs
 Traction Motor Power Rating 240 kW (187 kW in conventional)

 Traction Control Microprocessor based control & Fault Diagnostics

 Resistance Control

 Auxiliary Power Supply Capacity 70 kW (12 kW in conventional)

 Passenger Information System Menu Driven Digital Audio –Visual system in

each coach

 Normal PA System

 Commuters will get information like which is the next halting station & on
which side platform will be there, on speakers as well as on LED display panels.

 Main Transformer design.

 Traction Propulsion system.

 Improved Performance Features of ICF EMUs

Features 3Phase EMUs Existing EMUs

Acceleration with super 0.54 m/s2 0.36 m/s2
dense crush loading
Deceleration 0.76 m/s2 0.84 m/s2 0.6 m/s2
(100 to 50 kmph) (50 to stand still)
Max Service Speed 100 kmph 80 kmph

Specific Energy 27 units/1000 GKTM 40 KWH/100 GTKM

Consumption

Transformer Rating 1250KVA 1000KVA

 System Requirement

• Max. Axle load < 20.32 tones

• Typical Run < 1.5 km on level tangent track in less than 113 sec

• Acceleration (average) < 0.54 m/s2.

• Deceleration < 0.76 m/s2 (100 to 50 kmph) 0.84 m/s2(50 kmph to Stand still)

Traction voltage < 25 kv AC

• Bogie suspension < Metallic springs in Primary, Air springs in Secondary.

• Brakes < Blending of Regenerative and Frictional brakes

• Main / Aux. Converter < IGBT based

• Life < 25 year

 Traction Transformer

Continuous KVA rating 1250 KVA

Continuous Secondary Voltage (at 25KV primary) 2 X 950 V

No. of secondary windings 2

Type of cooling ODAF

Type of coolant Mineral oil

Weight App. 3100 Kg

Efficiency App. 96%

 Power converter-inverter

Traction Converter Nominal Input voltage 2 x 950 V AC Nominal

DC link voltage 1800 V DC

No. of 4 quadrant choppers (4QC) 2 (IGBT based)

No. of pulse with modulated inverters (PWMI) 2 (IGBT based)

Continuous rating per 4QC 620 KW

Continuous rating per PWMI 535 KW Output

voltage 1217
(line to line, fundamental value)
Control Microprocessor control

Cooling Force air cooled

Weight App. 2200 Kg

 Traction Motor & Gear Type

3 phase AC asynchronous traction motor Axle hung nose suspended

Continuous rating 240 KW (at 2000 rpm)

One hour rating 270 KW (at 2000 rpm)

Gear ratio 5.71

Design speed 3452 rpm (fully worn wheel, 100 kmph)

Insulation system MICALASTIC T, 2.3 KV, Class 200

Cooling Force air cooled

Weight App. 1734 Kg

Efficiency App. 94%
Weight App. 2200 Kg
 RELAYS

CURRENT MECHANICAL
1. OLP VOLTAGE 1.PRESSURE
2. OL 5 & 6 1. OVR (GOVERNORS)
3. OL 1 – OL 4 2. AOVR 2.AIR FLOW
4. CLR 1&2 3. NVR (RFR)
5. CBR ‘A’ & ‘B’ 4. LTR 3.GAS
5. EFRP (BIR)
6. EFRA-II 4.TEMPERATURE
7. CR (TTR)
8. BA
9. ABR
10. ARR
11. SR
24
 Safety lights, Guard-Driver
communication and Passenger alarm
 Head light
 Tail Lamp
 Flasher Light
 Auto Warning Light
 Signal Bell/Code Bell
 Guard Driver comm. System
 Passenger alarm system
Indication Lamps
 ABB Red lamp
 Auxiliary White Light
 CHBA Failure Indication
 Rectifier Fuse Blown Indication (Blue Lamp)
 EP Green Lamp
 Motor Switch white Light
 Unit Fault Lamp
 Shaku coupler
 Provides safe and permanent connection of multiple units.
Couplability of coupler halves is ensured by adjustable cup
sleeves.

 In this couplers the coupling done manuly and the two couplers
after being aligned are secured by means of adjustable cup sleeve
joint. The pivoted joints between the couplers are designed in
such a way that even in case of maximum difference in level, the
coaches are capable of negotiating all track curves .

 This coupler can take up a compressed load of 100 Tonnes and

tensile load of 70 Tonnes. The dynamic absorption capacity of
rubber draft gear is 800 m-kg. Due to rigid connection ,there
exists negligible play between in coupling position.

 With this coupling coach permits  75 mm of vertical deflection

and 284 mm of horizontal deflection.
Shaku coupler contd….
 Main components of shaku couplers are
 Draw and buff gear
 Bearing bracket with support
 Centering device
 Air pipe coupling for BP and FP
 Intermediate tube
 Adjustable cup sleeve
Salient Features
 Prevents overriding of coaches.
 Uniform distribution of draft load.
 Cushions axial movement of coaches.
 Rigid and slack free connection.
 Enables the connection of air pipes.
Shaku coupler Parts.
 Performance requirements of EMU/MEMU Brakes
1 Main reservoir charging time To build pressure from 0 to 7 Kg/cm2 in
10 minutes.
2 Compressor governor To cut in at 6 ±0.1 Kg/cm2
To cut out at 7 ±0.1 Kg/cm2
3 Main reservoir safety valve To blow at 7.8 kg/ cm2
4 Pressure Reducing Valve 1.6 Kg/cm2 For MC ,DMC & DPC
1.2 Kg/cm2 For TC (HCC)
2.0 Kg/cm2 For TC(non HCC)
5 Brake Cylinder Safety Valve 1.8 Kg/cm2 For MC ,DMC & DPC
1.4 Kg/cm2 For TC (HCC)
2.2 Kg/cm2 For TC (non HCC)
6 Duplex Check Valve Closes at 5.0 Kg/cm2 with Drain
cock of horn reservoir opened.
7 Full EP Application 3 to 5 Seconds
8 Full EP Release 5.5 to 6.5 seconds
9 Auto Application Time 3 to 5 seconds
10 Auto Release Time 5.0 to 7.0 seconds
11 Auto Emergency application Time 3 seconds
 Leakage Test of EMU/MEMU Brakes
1 MR system (Handle EP)

1.0 Kg/ cm2 per hr. from 7 Kg/cm2 for 3

car unit 1.0 Kg/ cm2 per hr for MC
2 BP system (Handle LAP) Release & 1.0 Kg/ cm2 per Hr. from 5 Kg/cm2
Running with I.V.S. Closed.

3 Brake Cylinder (Handle 1.0 Kg/ cm2 per Hr. from 1.6 Kg/cm2
emergency) I.V.S. closed and
handle to Release & Running
4 No. of steps in EP application Minimum 4 steps
5 No. of steps in EP Release Minimum 4 steps
6 BC Piston working stroke 40 mm for MC, DMC, DPC & TC (HCC
and non-HCC, DMU/TC)
8 Charging Time of Auxiliary 50-70 sec.
Reservoir (From 0 to 4.8 Kg/cm2)
Brake Controller
 Presently two types of brake controller are used in
EMU/MEMU
 ED-6 (WSF make)
 Modular(Escorts make)
 Brake controller are provided with following positions
 Position I- Release & Running
 Position II- Full service EP
 Position III-LAP
 Position IV-Service Automatic
 Position V-Emergency
 BRAKE SYSTEM

TYPES OF BRAKE CONTROLLER

1. WSF
2. MODULAR (ESBC) -I, II, III

TYPES OF EP UNIT
1. WSF TYPE
2. EK TYPE

37
 BLOCK DIAGRAM OF E.P. BRAKE

BRAKE CONTROLLER

MCP
7Kg/cm2
MR

EPIC 7Kg/cm2

110V DC
AMV
110V DC
EP UNIT LIMITING VALVE
3.5Kg/cm2
EX
HMV

ADDITIONALLIMITING VALVE
1.5Kg/cm2
SAFTY VALVE 2Kg/cm2
RELEASE HANDLE

BIC BIC

BRAKE CYLINDER BRAKE CYLINDER

 BLOCK DIAGRAM OF AUTO BRAKE

BRAKE CONTROLLER

MCP
7Kg/cm2
MR

AIC 7Kg/cm2

TRIPLE VALVE
EP UNIT
TOP

BOTTOM EX

AUX

ADDITIONALLIMITING VALVE
1.5Kg/cm2
SAFTY VALVE 2Kg/cm2
RELEASE HANDLE

BIC BIC

BRAKE CYLINDER BRAKE CYLINDER

SELF LAPPING CYLINDER
(NO ACTION)

OPENED A B OPENED

PUPPET VALVE GROUP

A & B VALVES OPENED
C & D VALVES CLOSED

CLOSED D C CLOSED

EQUALISING
DISCHARGE VALVE

EXIT

5 KG/SQ.CM
REDUCING VALVE

7 KG/SQ.CM

ISOLATING VALVE SWITCH

M.R. GAUGE
ER

MR BC BP

DIAGRAM OF BRAKE CONTROLLER

RELEASE AND RUNNING POSITION

41
 (M AIN TAINS BC PRESSURE
CON STANTLY PROPORTIONAL TO
BCH ANGULAR M OVEM ENT DURING
EP APPLICATION)

SELF LAPPING CYLINDER

(IN ACTION)

O PENED A B OPENED

PUPPET VALVE GROUP

A & B VALV ES OPENED
C & D V ALVES CLOSED

CLOSED D C CLOSED

EQUALISING
DISCHARGE VALVE

EXIT

5 KG/SQ.CM
REDUCING VALVE

7 KG/SQ.CM

ISOLATING VALVE SW ITCH

M.R. GAUGE
ER

MR BC BP

DIAGRAM OF BRAKE CONTROLLER

E.P. APPLICATION POSITION

42
SELF LAPPING CYLINDER
(NO ACTION)

CLOSED A B CLOSED

PUPPET VALVE GROUP

A, B, C & D VALVES CLOSED

CLOSED D C CLOSED

EQUALISING
DISCHARGE VALVE

EXIT

5 KG/SQ.CM
REDUCING VALVE

7 KG/SQ.CM

ISOLATING VALVE SWITCH

M.R. GAUGE
ER

MR BC BP

DIAGRAM OF BRAKE CONTROLLER

LAP POSITION

43
SELF LAPPING CYLINDER
(NO ACTION)

CLOSED A B CLOSED

PUPPET VALVE GROUP

A , B & D VALVES CLOSED
C VALVE ONLY OPENED

CLOSED D C OPENED

EQUALISING
DISCHARGE VALVE

EX

5 KG/SQ.CM
REDUCING VALVE

7 KG/SQ.CM

ISOLATING VALVE SWITCH

M.R. GAUGE
ER

MR BC BP

DIAGRAM OF BRAKE CONTROLLER

AUTO POSITION

44
SELF LAPPING CYLINDER
(NO ACTION)

CLOSED A B CLOSED

PUPPET VALVE GROUP

A & B VALVES CLOSED
C & D VALVES OPENED

OPENED D C OPENED

EQUALISING
DISCHARGE VALVE

EX

5 KG/SQ.CM
REDUCING VALVE

7 KG/SQ.CM

ISOLATING VALVE SWITCH

M.R. GAUGE
ER

MR BC BP

DIAGRAM OF BRAKE CONTROLLER

EMEGENCY POSITION
45
 TRIPLE VALVE BULB
REGULATING CHOKE

B.P. C
TRIPLE VALVE CHARGING CHOKE
F AR
STABILISING VALVE BULB
TRIPLE VALVE
AT B
CLOSED

OPENED G A OPENED
D
H CLOSED
BRAKE PIPE

TRIPLE VALVE AUXILIARY RESERVOIR

STABILISING VALVE SAFETY VALVE
BRAKE CYLINDER
EX
SUPPLY

N
EX
OPENED
K AT P
RELEASE CHOKE

HOLDING M LIMITING VALVE

PISTON VALVE
APPLICATION
CHOKE
EX

EX EX
APPLICATION
PISTON VALVE
HOLDING APPLICATION
MAGNET VALVE MAGNET VALVE

DIAGRAM OF WESTING HOUSE E.P.BRAKE UNIT

RELEASE & RUNNING POSITION (FULLY CHARGED)
46
 TRIPLE VALVE BULB
REGULATING CHOKE

C
TRIPLE VALVE CHARGING CHOKE
STABILISING VALVE BULB F

TRIPLE VALVE
AT
B

OPENED G D A OPENED
CLOSED
H BRAKE PIPE

TRIPLE VALVE AUXILIARY RESERVOIR

STABILISING VALVE SAFETY VALVE
BRAKE CYLINDER
EX
SUPPLY

N
EX
RELEASE CHOKE AT P
L

M LIMITING VALVE

APPLICATION
CHOKE
EX

EX EX
APPLICATION
PISTON VALVE
HOLDING APPLICATION
MAGNET VALVE MAGNET VALVE
DIAGRAM OF WESTING HOUSE E.P.BRAKE UNIT
HOLDING POSITION

47
 TRIPLE VALVE BULB
REGULATING CHOKE

B.P. C
TRIPLE VALVE EMPTY CHARGING CHOKE
F AR
STABILISING VALVE BULB
TRIPLE VALVE
B CLOSED
AT

OPENED
G D A OPENED
H CLOSED
BRAKE PIPE

TRIPLE VALVE AUXILIARY RESERVOIR

STABILISING VALVE SAFETY VALVE
BRAKE CYLINDER
EX
SUPPLY

EX
RELEASE CHOKE AT P
K

HOLDING M LIMITING VALVE

PISTON VALVE
APPLICATION
CHOKE
EX

EX EX
APPLICATION
PISTON VALVE
HOLDING APPLICATION
MAGNET VALVE MAGNET VALVE

DIAGRAM OF WESTING HOUSE E.P.BRAKE UNIT

E.P. APPLICATION POSITION

48
 TRIPLE VALVE BULB
REGULATING CHOKE

B.P. C
TRIPLE VALVE CHARGING CHOKE
F
STABILISING VALVE BULB
TRIPLE VALVE
B
AT
CLOSED

CLOSED G ACLOSED
D
H OPENED
BRAKE PIPE

TRIPLE VALVE AUXILIARY RESERVOIR

STABILISING VALVE SAFETY VALVE
BRAKE CYLINDER
EX
SUPPLY

OPENED

N
EX

K AT P
RELEASE CHOKE

HOLDING
PISTON VALVE M LIMITING VALVE

APPLICATION
CHOKE
EX

EX EX
APPLICATION
PISTON VALVE
HOLDING APPLICATION
MAGNET VALVE MAGNET VALVE
DIAGRAM OF WESTING HOUSE E.P.BRAKE UNIT
AUTO POSITION

49
EP UNIT EK TYPE

50
EP UNIT EK TYPE

51
EP UNIT EK TYPE

52
EP UNIT EK TYPE

53
 Faults in Braking System

 Partial Brake Binding

 Full Train Brake Binding
 Parking Brake Binding
 Mechanical Brake Binding
 RAISE IN BP PRESSURE (MORE THAN 5 KG/CM2)
 MR PRESSURE DROP
 BP PRESSURE DROP/ LEAKAGE
 BOTH MR & BP PRESSURE DROP DUE TO
MALFUNCTION OF B.A RELAY
Inspection Schedule
periodicity/Maintenance
 STR (with pit/without pit)- at night stabling point
 Pit checking- Every 3600km or 7 days which one
earlier
 TI- 10 days
 IA- 45 days
 IC-6 months
 POH- 18months, 1st POH in 2years after
commissioning
59