In 2017, because to the inability to repair the air compressors type 3EC2 / EC2M – manufactured by Timpuri Noi, at the request of SCRL Brasov, the management of SNTFC CFR Călători SA approved the experimental installation of an oil-free compressor (lubricating oil free) on a locomotive that was going to perform a RR type repair.

The terms and stages of installation were specified in the Minute of the Locomotive Modernization Service no. D31 / 3/54 / 13.01.2017.

After organizing the legal procurement measures, the FEROM Solution was declared the winner. The proposed solution is shown in the block diagram (see Fig. 2).

Fig.2 - Operating block diagram

Convertizorul 1 (Fig. 3)

designed to transform the single-phase voltage into three-phase voltage and to supply the compressor electric motor (m.e.).
Main characteristics:

  • input voltage: 386 Vac + 18 / -24% single phase;
  • rated output voltage: 3 x 0… 400 Vac;
  • rated output voltage frequency: 1… 500Hz;
  • rated output current: 65A ± 10%;
  • rated control voltage: 110 Vdc ± 30%;
  • size: 600 x 650 x 100.
Fig.3 – Interior converter panel

designed to transform the single-phase voltage into three-phase voltage and to supply the compressor electric motor (m.e.).
Main characteristics:

  • input voltage: 386 Vac + 18 / -24% single phase;
  • rated output voltage: 3 x 0… 400 Vac;
  • rated output voltage frequency: 1… 500Hz;
  • rated output current: 65A ± 10%;
  • rated control voltage: 110 Vdc ± 30%;
  • size: 600 x 650 x 100.
Fig.4 - Compressor WP 222LON
Fig.5 - Oil-free compressor WP 222 LON during operation tests
Fig. 6 - WP222LON compressor and ECC3 minicontroller

Compressor 2 (Fig. 4, 5, 6) designed to generate compressed air. Its main features are the following:

  • type: WP222LON – SAUER;
  • number of cylinders: 4;
  • number of compression steps: 2;
  • speed range 1000 – 1800 rpm;
  • maximum working pressure: max. 15 bar / 217.5 ps;
  • direction of rotation (looking from the motor to the compressor): clockwise;
  • set pressure of safety valves:
    – Stage 1 compression (6 bar / 87 ps);
    – Stage 2 compression (10% over working pressure);
  • net weight: 460 kg.

The WP 222 LON compressor was assessed by AFER (Romanian Railway Authority) and certified (railway technical approval series AT no.363/2019) to comply with the conditions for use in the railway transport.

Minicontroller 3 ECC3 type (Fig. 6) designed to command and control of the entire operating block. By means of the possible settings, the controller checks, monitors and protects the entire electric motor-compressor assembly (supply voltage, overvoltage protection, air discharge protection, automatic start/stop provision, complete sensor control).

It has built-in purchasing systems: operating hours, troubleshooting guide for damage, maintenance schedule. The ECC3 mini-controller allows the integration of the entire air production assembly in the general locomotive diagnostic system.

The main settings of the ECC3 are: network address (where the electric motor is powered), communications for the rotation function, activation of the compressor in the Lead/lag function, setting the priorities, adjusting the suction pressure, remote start of the compressor, manual operating module, maintenance interval reset, error display (operating errors, which cause the compressor to stop immediately, alarms, deactivated shut off, maintenance alarms. An ECC3 minicontroller can coordinate several compressors at the same time if necessary!

The drying and cooling system 4 is of Atlas Copco type (SD 7N + automatic purge type WSD25).

Fig. 7 - EA 562 at network tests

Conclusions and benefits:

  • The final tests for the operation of the compressor on the EA 562 locomotive were performed on 17.01.2019. The required filling time of the air tanks from 0… 10 bar was 3 minutes and 40 seconds. It was proved that the compressor can supply the discharge capacity of two 3EC2 type compressors.
  • By eliminating oil losses, the danger of fire, degradation of the installation and environment is reduced.
  • The life of a compressor of WP222LON – SAUER type is 20 years or 50,000 operating hours.
  • So far, the EA 562 locomotive has run for over 183,500 km, and the compressor has recorded 2562 hours. No malfunction / damage was recorded in the operation of the compressor.
  • According to the maintenance schedule, a R1 type overhaul was performed after 2000 hours. The next overhaul is scheduled at 4000 hours or after 4 years of operation.
  • Because of the lack of specialized maintenance personnel, robustness in operation is a substantial advantage.
  • Possibility to integrate the air generation, cooling and drying system in the locomotive diagnostic system. With two power supplies for the electric motor (from phase 123 and the redundant one), the locomotive (train) will not run out of compressed air.
  • The Ferom solution is more advantageous also financially than other variants, taking into account the total cost of the operating life of 20 years;
  • Most international transport operators promote oil-free installations on railway vehicles.

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