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Course 203

Inspection and Maintenance of Propulsion and Dynamic Braking Systems

Module 3: DC Propulsion

INSTRUCTOR GUIDE

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203 Inspection and Maintenance Propulsion & Dynamic Braking Module 3 Instructor Guide

Intended For Use by Rail Car Training Consortium Members Only ● ©Transportation Learning Center

Table of Contents

CHECKLIST FOR INSTRUCTION ................................................................................................................................ 3

SUPPLIES, AUDIO-VISUAL EQUIPMENT, INTERNET ACCESS .................................................................................... 3

BEST PRACTICES FOR DELIVERING TRAINING ......................................................................................................... 4

OVERVIEW TO COURSE 203 ................................................................................................................................... 5

MATERIALS FOR INSTRUCTION .............................................................................................................................. 5

OVERVIEW TO MODULE 3 ...................................................................................................................................... 6

Order of Instruction for Module 3 ........................................................................................................................ 6 Demonstrations and Take-aways ......................................................................................................................... 6 Outline of PowerPoint Presentation ..................................................................................................................... 7 Learning Objectives for Module 1 ........................................................................................................................ 7

SLIDE-BY-SLIDE INSTRUCTION ................................................................................................................................ 9

Overview .............................................................................................................................................................. 9 Master Controller and Propulsion Blower .......................................................................................................... 18 Switching and Filtering ....................................................................................................................................... 20 Traction Control and Dynamic Braking .............................................................................................................. 27 DC Traction Motors ............................................................................................................................................ 37 Summary and Quiz ............................................................................................................................................. 39

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Intended For Use by Rail Car Training Consortium Members Only ● ©Transportation Learning Center Page 5

Overview to Course 203 Course 203: Inspection and Maintenance of Propulsion and Dynamic Braking Systems provides participants with an overview of principles of maintenance of rail car propulsion and dynamic braking systems. This course is organized into three modules:

1. General Inspection and Maintenance 2. AC Propulsion 3. DC Propulsion

Materials for Instruction Check that you have the following materials for instruction:

Instructor Guide for each instructor PowerPoint Presentation Participant Guide or Coursebook for each participant – each class participant gets

their own copy Pre-course Assessment – each participant gets one copy Module 3 Quiz – each participant gets one copy Propulsion Controls Periodic Inspection and Maintenance Recommended Practice

-- LearnApp 3A APTA RT-VIM-RP-018-03 Rev 1.pdf Denver RTD LRV Maintenance Bulletin

-- LearnApp 3C and its ANSWER SHEET OEM maintenance manuals should be made available for participants during this

course. See Demonstrations and Take-aways for reference. With the exception of your agency-specific materials, all can be downloaded from www.transittraining.net.

• Click on the Resource Library tab.

• In lower right under Useful & Helpful Links click on Courseware.

• Under Quick Links click on Rail Courseware.

• Click on Rail Vehicle Maintenance.

• Scroll down to Course 103: Introduction and Overview to Propulsion & Dynamic Braking

• Follow relevant links to download files.

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http://www.transittraining.net/



Slide-by-slide Instruction Overview

Slide 1


Module 3DC Propulsion

INSTRUCTIONAL ACTIVITY: This is the opening slide for Course 103 Module 1

TIME: 1 minute

SAY: Welcome to Module 3 of Course 203: Inspection and Maintenance of Propulsion and Dynamic Braking. The purpose of this module is to provide participants with framework of the steps involved in inspecting, maintaining, and testing major components of an DC propulsion system on rail cars used in major U.S. transportation agencies.

DO: Leave this slide up until all participants are settled in the room.

PHOTOS: Rail cars representing in this slide are LA Metro (Los Angeles), Denver RTD, NFTA (Niagara Frontier Transportation Authority, Buffalo, NY), VTA (Santa Clara Valley Transportation Authority), Cleveland RTA, Maryland MTA (Baltimore, MD)

ADVANCE SLIDE

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Slide 3


Objectives

3

• Inspect and maintain chopper• Inspect and maintain cam control • Inspect and maintain master controller • Inspect and maintain propulsion logic control unit• Inspect and maintain ventilation system• Inspect and maintain high speed circuit breaker• Inspect and maintain contactor/arc chutes• Inspect and maintain resistance banks• Inspect and maintain knife switch • Inspect and maintain overcurrent protection

INSTRUCTIONAL EVENT: Inform learners of learning objectives of this module.

TIME: 2 minutes

SAY: This module has many learning objectives and at the end you will be able to ..

DO: Advance through slide’s animations to show each learning objective. Ask a volunteer to read each objective as it is displayed.

PARTICIPANT GUIDE PAGE REFERENCE: 14

OTHER:

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Slide 6


Recall

6

INSTRUCTIONAL EVENT: Recall of prior learning

TIME: 2 minutes

SAY: Can you recall this diagram of the DC propulsion system? We’re going to look at the inspection, testing, and maintenance of the components illustrated here and some! We’re also going to reinforce our classroom learning with hands-on demonstrations.

DO: Using a laser pointer or its equivalent, point out the major components such as HSCB, Line Contactor, Line Reactor, Cam Controller or Chopper Circuits, Reverser, DC Traction Motors


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Slide 9


Learning Application 3APropulsion Periodic Inspection and Maintenance

9

Read case study

Answer all 8 questions

30 minutes in group

Report back!

INSTRUCTIONAL EVENT: Provide learning activity

TIME: 35-40 minutes

SAY: We’re going to do this exercise in small groups. [Allow participants to divide themselves in groups of 2 or 3]. Turn to page 16 in the Participant Guide. Each group will read the case study that I’ve placed at your station [or you can hand out a copy to each participant at this time] the APTA Propulsion Controls Periodic Inspection and Maintenance Recommended Practice document. I want to point out that to answer Question 4, you to look at the OEM manuals on the ______________ rail car which you will be working. I’ve copied the relevant pages of the manual [or participants can access it via manuals or other ways the instructor has made available]. There will be 30 minutes for this activity and I will be walking around to answer questions or guide you through the process.

DO: Circulate to assist and answer any questions regarding the activity. After 30 minutes, call time. Have each team report back by question. For example, when Team A reports on Question 1, ask “Which other team has anything to add to this?”


MATERIALS: APTA is the American Public Transportation Association. You can also download the document from APTA’s website here

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www.apta.com/resources/standards/Documents/APTA%20RT-VIM-RP-018-03%20Rev%201.pdf

Master Controller and Propulsion Blower

Slide 10


Master Controller and Propulsion BlowerTime for Team Work!

10

INSTRUCTIONAL EVENT: Provide learning activity on new content.

TIME: 30 minutes

SAY: We’re going to divide into two teams. [Have participants count off by twos. The 1s and 2s assembly in their teams at opposite ends of the classroom]. Each team will read up about inspecting and maintaining an area of the DC propulsion system. You will have a case study on that component. You can choose to read that case study or, for bonus points, you can consult with the OEM manuals in the room. Each team will have 15 minutes to verify the steps outlined in your Participant Guide and compare them to the requirements at our agency. Ready? OK, Team #1 you get to look at the Master Controller on pages 44-45. Team #2 you will look at the Propulsion Container Blower which you’ll find on pages 46-47. You have 10 minutes to do this exercise in teams and then you will present your findings to the other team.

DO: Circulate to assist and answer any questions regarding the activity. After 10 minutes, call time. Have each team report back their findings. Each team is to address the other team, i.e. not the instructor. After each team has presented to the other team, you may add new information if they’ve overlooked any aspect of inspection and maintenance of these components.

PARTICIPANT GUIDE PAGE REFERENCE: 44-47

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Switching and Filtering

Slide 11


Switching and Filtering

11

• High Speed Circuit Breaker

• Line contactor

• Line Reactor

• Pre-charge resistor and pre-charge contactor

Major Components

INSTRUCTIONAL EVENT: Introduce new content.

TIME: 2 minutes

SAY: We’ve now come to the inspection and maintenance of the switching and filtering components on the rail car’s AC propulsion system. The four components we’re going to look at are…

DO: Read the four components as you advance the slide animations.


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Slide 19


9

Traction Control and Dynamic BrakingPropulsion Control Unit

• Housing for the propulsion logic controller

• Solid state electronics and therefore requires little maintenance.

• Mechanical elements that most often show wear are the connectors

INSTRUCTIONAL EVENT: Provide learning guidance.

TIME: 3 minutes

SAY: The propulsion control unit (PCU) is the housing for the propulsion logic controller. It is mainly solid state electronics and therefore requires little maintenance. The mechanical elements that most often show wear are the connectors

DO: Read the four subsystems as you advance the slide animations. Note that it is either cam controller OR chopper circuits so really it should be four subsystems. Please make the distinction of which is application to your rail transportation agency.

NOTE: Illustrations is of a propulsion logic box on a Niagara Frontier (NFTA) light rail vehicle.


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Slide 24


14

Traction Control and Dynamic BrakingBrake Choppers

Learning App 3C, p.58-60

Answer all 7 questions

20 minutes in group

Report back!

INSTRUCTIONAL EVENT: Introduce new content – IF APPLICABLE

SAY: We’re going to do this exercise in small groups. [Allow participants to divide themselves in groups of 2 or 3]. Beginning on page 58 in the Participant Guide, each group will read the case study that I’ve placed at your station [or you can hand out a copy to each participant at this time] the APTA Propulsion Controls Periodic Inspection and Maintenance Recommended Practice document. There will be 20 minutes for this activity and I will be walking around to answer questions or guide you through the process.

DO: Circulate to assist and answer any questions regarding the activity. After 20 minutes, call time. Have each team report back by question. For example, when Team A reports on Question 1, ask “Which other team has anything to add to this?”


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Slide 26


16

Traction Control and Dynamic BrakingBraking Resistors

• Inspect• Clean• Test

INSTRUCTIONAL EVENT: Provide learning guidance.

TIME: 3 minutes

SAY: The many steps in servicing braking resistors can be summarized as [ADVANCE] inspection, [ADVANCE] cleaning, and [ADVANCE] testing

DO: Ask participants what testing do you think they will be doing on braking resistors? Hint = Resistors and RESISTANCE


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Slide 29


DC Traction Motors

19

Three groups

Look up inspection procedures in manuals

Compare

20 minutes in group

Report back!

Motor, Brush, Commutator

INSTRUCTIONAL EVENT: Provide learning activity

TIME: 30 minutes

SAY: We’re going to do this exercise in small groups. [Divide all participants into three groups by having participants count off by threes. The 1s, 2s, and 3s should assemble in their groups]. Turn to page 65-66 in the Participant Guide. I’ve copied the relevant pages of the manual or standard operating procedures for inspection and maintenance of AC motors [or participants can access it via manuals or other ways the instructor has made available]. Group 1 will focus on inspection and maintenance of the motor outlined on page 65. Group 2 will focus on inspection and maintenance of motor brushes outlined on page 66. Group 3 will focus on inspection and maintenance of commutators outlined on page 66. There will be 20 minutes for this activity. Each group should create a summary on flip chart paper – be creative! I will be walking around to answer questions or guide you through the process. Remember that we will be learning more during the hands-on demonstration portion of this class.

DO: Circulate to assist and answer any questions regarding the activity. After 20 minutes, call time. Give participants more time if they are really into this activity. Have each team report back on their findings.


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Summary and Quiz

Slide 30


Summary• Inspect and maintain chopper• Inspect and maintain cam control• Inspect and maintain master controller• Inspect and maintain propulsion logic control unit• Inspect and maintain ventilation system• Inspect and maintain high speed circuit breaker• Inspect and maintain contactor/arc chutes• Inspect and maintain resistance banks• Inspect and maintain knife switch • Inspect and maintain overcurrent protection

20

INSTRUCTIONAL EVENT: Closure

TIME: 2 minutes

SAY: This module provided a framework for rail car technicians to approach inspection and maintenance of the major components of an AC propulsion system. Much of our learning and understanding of the AC propulsion system will occur during our hands-on demonstration in the field and on-the-job. Let’s review what we covered in this module:

DO: Review slide. For each objective, briefly review what was learned in this module or ask participants to share what they have learned for each learning objective and briefly discuss as a class.

PARTICIPANT GUIDE PAGE REFERENCE: _________________

OTHER: N/A

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