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Passenger Car Generator Control Systems
Phone: (503) 231-4808, Fax: (503) 230-0572, E-mail
See where our equipment is located on a typical passenger car
When a generator set is added to a passenger car, in almost all cases it is put underneath the passenger car floor, with all the other under-car equipment. This is usually an excellent location. However, if the car owner simply places a standard off-the-shelf generator skid under the passenger car, there are problems to overcome. For example: normally these generator sets come with some sort of starting control and monitoring system. All of that equipment is mounted on the generator skid, with the engine. If this is done, the generator can not be started, stopped, or monitored from inside the passenger car. This means the entire train must be stopped if there is a problem of some sort with the generator. Therefore, all sensible passenger car generator installations have some sort of in-car monitoring and control system that will allow the generator to be started, stopped, and basic engine conditions monitored from inside the passenger car.
Northwest Rail Electric has developed a number of packages to suit the needs of all manner of generator installations on railroad passenger cars. All of these controls include basic remote start and stop, remote sensing and indication of coolant temperature, oil pressure, battery voltage, and other vital engine data. Because the generator is remote, and because it is difficult to give it constant attention, even the most simple Northwest Rail Electric generator control includes automatic shut-down in the event of high water temperature, low oil pressure, and engine overspeed.
Our passenger car generator controls may be broken into several different categories:
- Generator Control Only no switchgear or other items. This type of system is only desirable if the under-car generator is used for powering systems on that particular car, and already has adequate switchgear for the purpose.
Note that in this example, the switch to feed the HEP system has been blocked out, as the customer wanted a generator control system for a single car without the ability to feed other cars. This example also features an electronic engine control with a number of electronic display features, including engine oil pressure, battery voltage, coolant temperature, and output frequency.
- Car power selection and automatic start systems These are generally used on business cars and Amtrak-operating private cars where automatic start of a generator in the event of HEP failure is desired. Our most popular package in this category is the GC-500 generator control system. One of the popular options of this package includes the ability to feed power through the HEP system to other cars.
- Power car systems These are systems that feed power from the generator directly to the HEP trainline. Our most popular system of this type is the GC-135/145 series.
Each of these is described in greater detail below. The exact specifics of each system depend on the needs of the customer and the engine of the generator in question. Certain generator engines require a completely electronic control system, while others require relay contacts, and others may use either, while others require a mixture of interface types.
An example of an NW-GC500 control from Northwest Rail Electric for an engine requiring a completely electronic interface. The display screen includes almost all engine indicators, including generator output voltage and current, coolant temperature, engine hours, and even includes a fault history log.
- Generator Control Only: This is a relatively rare case, for passenger cars that need no power source selection system. This would normally only be used in cases where the car already has some sort of existing power selection system to choose between HEP, generator, or yard power, or in cases where the car electrical system is isolated from the HEP system.
Typical Generator Engine Indicators Include:
- Hour Meter
- 12 Volt Engine Alternator Meter
- Coolant Water Temperature
- Oil Pressure
- Engine Preheat Indicator
- Engine Started Indicator
- Engine Alternator Indicator
- Engine Overcrank Indicator
The switchgear part of a NW-GC500 series generator control. HEP, power, and Yard contactors and circuit breakers are clearly visible
- Car power selection and automatic start systems: for passenger cars with an under-car generator to provide power when there isn't another source available. This system is equipped with a generator control and high-voltage switchgear that allows for the selection of a power source ( Generator, Head-End Power or Yard Power ). The generator may be set to automatic operation, which will start and operate the generator when other sources of power fail, and shut the generator off when the power source returns. This is the most common power selection system for buisness cars, private varnish, and other types of cars that may operate independently of a full train. The generator control may be set to the "automatic" position and the car can travel from place to place, operating on generator power when no other power source is available, and automatically switching to head-end power whenever it is provided.
Typical Generator Engine Indicators:
- Hour Meter
- 12 Volt Engine Alternator Meter
- Coolant Water Temperature
- Oil Pressure
- Engine Preheat Indicator
- Engine Started Indicator
- Engine Alternator Indicator
- Engine Overcrank Indicator - Indicates that an attempt to start the engine was made, but due to an engine or fuel related problem it would not start
- Engine Fault Indicators: Generator will automatically shut down when any of the following fault indicators are lit:
- Low Oil Level - Time Delay Controlled to Prevent Engine from shutting down due to sloshing caused by train motion
- Low Coolant Level - Time Delay Controlled to Prevent Engine from shutting down due to sloshing caused by train motion
- Low Oil Pressure - Time Delay Controlled to Prevent Engine from shutting down due to sloshing caused by train motion
- High Water Temperature
- Engine Overspeed
- Optional Feature: Generator Output Meters. Output current, frequency and voltage may be added to most any NW-GC-500 package or customized variant of this package.
- Optional Feature: Ground Fault Detection. Above certain generator sizes, this is a required feature. This shuts off generator feed in the event that current appears to be leaking out of the circuit being fed. Any generator control may have this feature added but it requires additional space and equipment beyond the standard models.
- Optional Feature: Overcurrent Detection and Reset. This shuts off generator feed in the event that generator output current is greater than the capacity of the generator. Unlike a circuit breaker, this method of overcurrent protection may be reset using a push button located in the car. This feature is particularly useful in cases where the circuit breakers are located under the car and are not accessible while the train is moving. Any generator control may have this feature added but it requires additional space and equipment beyond the standard models.
Basic Northwest Rail Electric power selection generator control system types are:
- GC-501: Basic power selection and automatic back-up system. The generator may be turned on and run as the power source, or HEP or yard power (yard power is optional: many customers don't need it). Generator may also be set to automatic operation, so that if the HEP or yard power source fail, the on-car generator will automatically start and keep the systems on the car operating. Timers are included for a number of operations, and these may be set by the customer if desired (see illustration at left). When the unit is shipped, however, Northwest Rail Electric has already set the timers for values that have worked well in other installations, and consultation with Northwest Rail Electric is recommended before changing these values.
- GC-500:Same features as above system, but as an additional feature, the on-car generator may be used to feed power to the HEP trainline if the generator is selected as the primary power source.
- GC-502: modification of the GC-501 scheme for fitting a particular generator voltage.
- Custom Variations: We have had to build a number of custom systems to fit certain customer needs. Examples of these systems may be seen on our Custom Controls page and our Custom Power Systems page. Most of our control systems for under-car generators are built specifically for Stadco under-car generator sets. However, some customers require special modifications to fit generator sets manufactured by several other companies.
- Small Power car systems. This type of generator control is designed to operate a generator that is only intended to feed power to the Head-End power system that runs the length of the train. This series is designed for use with Stadco Generators, which are distributed by Northwest Rail Electric
Basic Northwest Rail Electric power car generator control types are:
All of these are very similar in appearance and function, but have slight differences designed to accomodate different types of HEP trainline configurations and capacities. As all of these systems are extremely similar in appearance and function, we only have one example on our web site: The GC-130.
- Larger Power Car Systems. This type of control system is intended for a larger power car. As with the above systems, there are many different types that have been developed to suit various needs. An example of this type of system featured on our web site is the NW-PC550, which is intended to take a generator with an already existing control system and make it compatible with HEP.
- Custom generator control systems. For passenger car situations that have unique needs, we have produced an assortment of custom systems. This has included such things as fuel tank level indication, parallel controls for two under-car generators mounted under the same passenger car, large power car systems for parallel operation of two generator sets in a power car, power selection systems similar to our GC-500 that include two HEP selections for the dual-HEP systems used in parts of Canada, automatic current limiting systems, ground-fault detection systems, and battery charging and isolation systems that charge generator and emergency lighting batteries but keep them separated during discharge. Examples of these systems may be seen on our Custom Controls page.
Related Products from Northwest Rail Electric:
For those doing a complete upgrade on a railroad passenger car, we also offer:
[ HEP Connectors ] [ Parts for Amtrak HEP ] [ Generators for HEP ] [ HEP Wayside Power ] [ HEP Wire ] [ Railway Heating and Air Conditioning ] [ Complete Car Electrical Control Package ]
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