VCW VIBHU COMPOSITE WORKS - Integral Coach Factoryicf.indianrailways.gov.in/works/MECHANICAL/PDF/cdts... · like a Non CDTS in the event of no air, no power. VIBHU COMPOSITE WORKS.

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VCW

Belongs to the Pragati Group situatedat Yamuna Nagar which are the leadersin export of Engineered wood productsfrom India. Pragati Group is working since the last 45 years. We are a Government recognised export housesince last ten years. We are also registered as a ISO – 9001 Company.We have offices in Germany, Kuwaitand USA .

INTRODUCTIONINTRODUCTION

Vibhu Composite

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Pragati Group is the receipent of number of Export Awards from the Govt. of India for their excellent performance in the field of new items in Export. We are also the recipients of the Golden America Award, 1999 for quality in New York. Pragarti High-tech Products Pvt. Ltd. , have a technical collaboration with M/S Geta Interior, Germany for the manufacture of folding Plywood products especially for railway and furniture applications.

Mr. Ved Parkash receiving the GOLDEN AMERICA 99for quality and Excellence Award in Madrid, Spainfrom Mr. Craig Miller on the 15th of October, 1999

Mr. B.R.Gupta, Chairman, PRAGATI GROUP signingtechnology Transfer Agreement with Mr. Robert Buhmann,Chairman, GETA INTERIER at Germany

INTRODUCTIONINTRODUCTION

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It is easily programmable and reprogrammable .

Less Air, water and electricity consumption.

Effective cleaning with minimum water quantity.

Fully P.L.C Controlled.

System remains operative during air and power failure.

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It is robust, reliable and requires low maintenance.

It works under extreme operating conditions.

Technical DataTechnical Data

Controller

Water Consumption

Air Consumption

The system consumes about 2.5 liters of water for oriental and 1.5 liters of water for European CDTS. At the moment there is post flush.

Primary air pressure : Min. 5.0 bar. Air consumption per cycle : About 6.7 NL.

The standard system operates on 24V DC / 110V DC.

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Technical DataTechnical Data

Material Selection

Fail-safe Mode

All components of the systems are made of Abrasion Proof, Non Corrosive materials.

The passengers can continue to use this system like a Non CDTS in the event of no air, no power.

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Proven DesignThe system can be installed in the toilet module as an integrated system providing for conventional facilities along with provision of CDTS.

Technical DataTechnical DataVI

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Operating ConditionAll the subparts are designed and manufactured keeping in mind heavy duty cycle required for CDTS and extreme operating conditions.

The Euro Toilet SystemThe Euro Toilet SystemVI

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The Euro Toilet SystemThe Euro Toilet SystemThe Euro Toilet system are provided with the followingmain components :-

1. European toilet basin with flush nozzles.

2. Control panel with valve block,water separator and controller.

3. Flapper valve (inlet).

4. Intermediate tank.

5. Slide valve (outlet).

6. Flush button.

7. Pressurizer.

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The Oriental Toilet SystemThe Oriental Toilet SystemVI

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The Oriental Toilet SystemThe Oriental Toilet SystemThe Oriental Toilet system is provided with the followingcomponents :-

1. Oriental Toilet basin with flush nozzles.2. Control panel with valve block separator and controller.3. Flush valve 4. Flapper valve (inlet)5. Intermediate tank6. Slide valve (outlet)

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7. Flush Button8. Pressurizer

Control PanelControl PanelVI

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ControllerController

PLC ( Programmable Logic Controller ) :-- PLC is Made by Siemens/ Crozet. PLC works on 24 VDC / 110V DC having 8 inputs & 4 outputs. The permissible Input voltage range for Logo is 20.4 to 26.4 VDC.

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Valve BlockValve BlockVI

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Flapper ValveFlapper ValveVI

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Outlet Valve:- it is programmed to open at moment when the train

reaches a pre deter mend speed.

Outlet ValveOutlet ValveVI

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Cylinder of Outlet Valve:-

The cylinder(SPDK-8125) is made by NORGREN.

Cylinder of Outlet ValveCylinder of Outlet ValveVI

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Parts of Slide ValveParts of Slide ValveVI

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Water PressurizerWater Pressurizer

It is the arrangement of Rubber diaphragm and Spring.

The steel housing is designed to give maximum water pressure.

The flush valve is provided to adjust the quantity of water.

Operating Time 8.0 Sec.

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S Water Pressurizer PartsWater Pressurizer Parts

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S Water PressurizerWater Pressurizer

Flush ValveFlush ValveVI

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Intermediate TankIntermediate Tank

It designed to store maximum 50 lts. When outlet valve is closed.

In case of extra flush, overflow is provided. 316 L SS material is used.

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Design Improvement in CDTSDesign Improvement in CDTS

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Shuttle ValveThe same has been replaced by flush valve. As the shuttle valve had sliding movement and required higher maintenance in comparison to flush valve (needs very low maintenance) .

Water PressurizerThe pressurizing capacity of the same has been increased to ensure water flow at higher pressure in the toilet bowl for effective cleaning

Design Improvement in CDTSDesign Improvement in CDTS

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Inlet Slide ValveThe same has been replaced with flapper valve. Due to sliding movement of the valve which requires regular maintenance. Flapper valve needs low maintenance.

Flapper ValveSpeed controller has been introduced to regulate the closing speed of flap so as to minimise the sound created by the flap while closing..

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Problem Identification & RemediesProblem Identification & Remedies

PROBLEM CAUSE REMEDY

Valve Y3 on the control panel is defective or non- operational

The control panel fails to transmit signals (the red light is not illuminated)

An air hose may be bent

The shut-off cock on the water tank is closed

No water in the tank

Activate valve Y3 on the control panel manually

Check the electric signals and connections

Check the air hoses ( activate Y3 manually )Open the cock

Fill the tank

No flush water

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Some foreign particles in water can obstruct the flush valve operation.

Remove the flush valve and clean it with a soft cloth and again put it into the line.

Continuous water falling from nozzles

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1. The inlet valve fails to open.

2. Valve Y2 on the control panel is defective or non- operational.

3. The controller (PLC) fails to transmit signals

4. An air hose may be bent

Flapper valve not open during flushing.

Activate the push button “Inlet” on the control panel

Activate valve Y2 on the control panel manually.

Check the electrical signals and connections.

Check the air hoses ( activate Y2 manually )

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1. The outlet valve fails to open.

2. Valve Y1 on the control panel is defective or non- operational.

3. The controller (PLC) fails to transmit signals

4. An air hose may be bent

The outlet valve fails to open

Activate the push button “outlet” on the control panel

Activate valve Y1 on the control panel manually.

Check the electrical signals and connections.

Check the air hoses ( activate Y1 manually )


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The ball valve of Pressurizer closed

There is a failure signals in the controller.

Valve Y3 on the control panel is defective or non operational.

Open the ball valve

Check the electric signals and connections

Activate valve Y3 on the control panel manually

No activity by the Pressurizer

Presenter

Presentation Notes

Service & Maintenance ScheduleService & Maintenance Schedule

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FLAPPER VALVE( INLET)

The Flapper valve should be cleaned with soap water once in a month.The speed controller should be properly adjusted The nuts should be tightened properlyThe Rubber sheet gasket should be suitable placed on flapper

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Presentation Notes


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PRESSURIZERThe spring inside the pressurizer should be fitted properly.

The pressurizer can be opened by opening the side nuts and can be properly cleaned.

Tighting of nuts & bolts should be checked daily.

The pressurizer should be properly fitted at define position.

Presenter

Presentation Notes


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SOLENOIDVALVES

The solenoid valve can be checked by pushing the button present on Y1,Y2&Y3 valves.The solenoid valves operates at 5 bar pressure.It needs filtered compressed air for long time working.If it is not working simply open it and after cleaning its spool by a soft cloth reinstall it at its position.

Presenter

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CONTROLLER (P.L.C.)

The P.L.C. should be fitted properly at control panel plate, not be loose fitted.

Avoid any impact or shock on P.L.C. that may crack upper surface.

Presenter

Presentation Notes

SLIDE VALVE

( OUTLET)


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The Slide valve should be cleaned with soap water once in a month.The nuts should be tightened properlyThe gasket should be suitably placedat grooves.


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FLUSH NOZZLESThe flush nozzle should be cleaned daily with toilet brush & soap water.


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FLUSH VALVEFlush valve should be opened by pressing its lock

(as shown in the picture) to clean it by a simple clothGenerally it needs maintenance when you see the

water is coming continuously through nozzles.


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AIR FILTER

Air Filter can be opened, cleaned & can be fitted.

Avoid any impact on Air Filter that may crack the air filter.

Presenter

Presentation Notes

VCW VIBHU COMPOSITE WORKS - Integral Coach Factoryicf.indianrailways.gov.in/works/MECHANICAL/PDF/cdts... · like a Non CDTS in the event of no air, no power. VIBHU COMPOSITE WORKS.

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