(भारत सरकार)

GOVERNMENT OF INDIA

Handbook on
Electro Pneumatic Pressurised Flushing System
Fitted in Indian Railway BG coaches

IRCAMTECH/GWL/M/Bio-Toilet
October-2022

Maharajpur, Gwalior – 474005 (MP)

Ph: 0751 -2470803 & Fax: 0751 -2470841
 Contents
1. Introduction....................................................................................................... 1
2. Purpose of Electro Pneumatic Pressurised Flushing System. .......................... 1
3. Working principle of Electro Pneumatic Pressurised Flushing System. ............ 2
4. Working of Electro Pneumatic Pressurised Flushing System. .......................... 2
5. Parts of Electro Pneumatic Pressurised Flushing System. ............................... 3
6. Installation instruction ....................................................................................... 7
6.1. Mounting ....................................................................................................... 7
6.1.1. Mounting Stud:-.......................................................................................... 7
6.1.2. Panel Mounting:- ........................................................................................ 8
6.1.3. Water Pressure Pump:- ............................................................................. 8
6.1.4. Water Main Line:-....................................................................................... 9
6.2. Measures during initial setup......................................................................... 9
6.3. CHECK POINTS BEFORE OPERATION ................................................... 10
6.4. Dismantling the System .............................................................................. 11
7. Trouble shooting. ............................................................................................ 11
8. Preventive Maintenance Plan. ........................................................................ 12
9. Line Diagram for Electro Pneumatic Water Pressuriser ................................. 15
10. List of References:- ..................................................................................... 17
Annexure: - I EPPFS Check sheet ........................................................................ 18
Annexure-II List of Emergency Spares for maintenance ....................................... 19
1. Introduction

Electro Pneumatic Pressurized Flushing System (EPPFS) is positive displacement

type having “Piston-Cylinder arrangement” type set up for creating pressurized water
supply without allowing water coming into contact with pressurized air and has been
designed to provide long trouble free service and uses standard components easily
available from globally renowned manufacturers who have been operating in India for
a long time and are well known for quality. While designing the System, safety and
convenience of the passengers have been paid special consideration. The system is
non-corrosive type and would render satisfactory performance for a long time.

This electro pneumatically operated toiletry flushing system is designed for toiletry
system in railways. By pressing the push button, the solenoid valve is energised for
pre-set time (min.5 sec), in turn making the water pump to flush the water completely
and being ready for the next cycle. On completion of every flushing cycle, the green
light provided in the Push button indicates for starting the next cycle. The cylinder
delivers 1.5 ltr of water on completion of every flushing cycle.

The System would dispense 1.5 Liter water @ pressure of 2-3 Kg/cm² each time with
light pressing the Push Button Switch having metallic body and would be ready for
next use in 7-8 Seconds.

Our system is user friendly, modular in design, durable, portable and very easy to use
install and maintain. All the electrical, electronic and pneumatic parts of the system
are shock and vibration proof and comply with IEC 61373 category -2 or equivalent
international standard.

2. Purpose of Electro Pneumatic Pressurised Flushing System.

The pressurised flushing system will transfer the fecal matter from the Indian style
bowl/Western style bowl with minimum usage of pressurised water.

Benefits of Electro Pneumatic Pressurised Flushing System:

• Positive displacement type system having ‘Piston Cylinder Arrangement.

• Clean, odour-less, hygienic, & aesthetically pleasing toilet.
• No spillage of waste on bogie parts, under gear, track, waste processing tank, or in
the depot.
• Generates high water pressure for ultimate cleanliness.
• Robust design interface valves for vast usages without failure.
• Minimal requirement of air, power, and water for the flushing of faeces & urine.

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3. Working principle of Electro Pneumatic Pressurised Flushing System.
The user presses the electric push button switch, it will activate a solenoid valve. By
the actuation of the solenoid valve, pressurizer will deliver the required pressurized
water automatically with single push of the switch to the toilet-seat to clean the faeces
& urinal matter.

The system will be readily available for next time usage immediately. Need to press
button switch to get the required pressurised water at the toilet seat. A proper
concealed tamper–proof switch is provided for easy operation & maintenance.

4. Working of Electro Pneumatic Pressurised Flushing System.

The working of the system can be explained in the following steps:-

1. Supply the air pressure 6 bar to inlet of the 1/4 - 5/2 Push Spring return valve.
2. Outlet of the 1/4 - 5/2 Push Spring return valve is connected to the cylinder
(Pressurized flushing system).
3. 1/4 - 5/2 Push Spring return valve is operated to activate the cylinder.
4. When switch ‘OFF’ the 1/4 - 5/2 Push Spring return valve, the piston moves
retract and suck the water.
5. When switch ‘ON’ the 1/4 - 5/2 Push Spring return valve, the piston rod moves
forward and discharge the water.

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5. Parts of Electro Pneumatic Pressurised Flushing System.
The parts of Electro Pneumatic Pressurised Flushing System are explained in details
as follows:-

Main Sub-assemblies of the System

(i) Water Pressure Pump.

(ii) Illuminated Push Button Switch
(iii) Preset Air Filter Regulator
(iv) Control Panel
(v) Power Convertor
(vi) Timer
(vii) Relay with Base

(i) Water Pressure Pump:

Inlet of water pump sucks the line water and amplifies the water pressure to generate
enough flow through the flushing nozzles to clean the toilet bowl. ¾” NRV on Inlet Port
and 2/2 Piston Valve (3/4”) on Outlet Port are used. It is preferred 2/2 Piston Valve to
Angle Seat Valve as the former has virtually no leakage and no NRV is, therefore,
required to be used and thus Systems becomes more reliable.

(ii) Illuminated Switch:

The Illuminated Push Button is used for starting the flushing operation. This switch is
in metallic body and operates on 24VDC. Green light is on when the System is ready
for use. No light is displayed when the Flushing operation is on. Once Flushing Cycle
is completed and the System is ready for next use, Green Light appears again. The
Switch is protected from backside by a Cover.

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(iii) Preset Air Filter Regulator:

Filter Regulator ensures clean Air and Pressure of the Inlet Air is 3 bar.

(iv) Control Panel:

The Panel houses Power Convertor (Input 110AC and Output 24VDC), Timer (24VDC)
used for controlling the flushing cycle time, Relay (24VDC), Filter and 5/2 Solenoid
Valve,

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(v) Power Convertor:

Functions at Input Voltage 110 AC/DC, converts the same to 24 VDC for control
components and Solenoid Valve, and withstands ± 30% voltage fluctuation and 30%
Ripple.

(v) Timer:-

Operates at 24 VDC and facilitates control of flushing cycle time. This item is shock
and vibration proof and comply with IEC 61373 tests. This component is also

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complying with EN 50155 for environmental protection. Item is able to withstand ±30%
voltage fluctuations.

(vii) Relay with Base:-

Operates at 24 VDC and is used at the start of the cycle. This item is shock and
vibration proof and comply with IEC 61373 tests. This component is also complying
with EN 50155 for environmental protection. Item is able to withstand ±30% voltage
fluctuations.

S NO. DESCRIPTION UNIT

BOM ELECTRO-PNEUMETIC PRESSURIZED FLUSHING SYSTEM

1 Hose Nipple 3/4" Thread 1"( For Tank) 1
2 Hex Connector 3/4" 2
3 Pipe Nipple 3/4"x50mm 1
4 Elbow 3/4" 1
5 SS Pipe Nipple 3/4"x1500 1

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6 Ball Valve 3/4" 1
7 Y Strainer 3/4" 1
8 Hose Nipple 3/4" 4
9 Hose Pipe 3/4" Thermo Plastic As Required
10 Hex Connector1/4" Brass 1
11 Hose Clamp 3/4" 6
12 NRV 3/4" Vertical 1
13 Bally Valve Female 1/4" 1
14 Push Button Plate (SS304) 1
15 Mounting Plate with Stud (SS304) 4
16 CYL MTG Bracket (SS304) 2
17 Push Button Cover 1
18 Z Mounting Stud plate with clamp 2
19 Hex Bolt M10x30 with Split Pin 4
20 SS Seal Nut M10 10
21 SS Seal Nut M8 8
22 PRESURIZER CYLINDER 1
23 PRESET REGULATOR (3 BAR) 1
24 Angle Seat Valve or 2/2 Piston Valve 1
25 VALVE 5/2 WITH MANIFOLD 1
26 STRAIGHT FITTING TUBE 10mm THREAD 1/8" 1
27 STRAIGHT FITTING TUBE 10mm THREAD 1/4" 1
28 ELBOW FITTING TUBE 10mm THREAD 1/4" 5
29 TEE FITTING TUBE 10 mm 1
30 NYLON PNEUMATIC PIPE 10 mm As Required
31 Flat Silencer 3
32 Flat Silencer 1
33 Cable Conduit metallic for Pneumatic Pipe ID = 11 mm As Required
34 Timer 1
35 Switching Power Supply 1
36 Illuminated Green Push Button (Metal Body) 1
37 NO CONTACT 1
38 RELAY 24V DC 1
39 RELAY BASE 1
40 Panel Box according to drg. 1

Specifications:
Pressurization time 7-8 Seconds
Flushing Pressure 2-3 Kg/nm²
Water Consumption 1.5 Liters
Air Consumption 3 Liters approx
Power Consumption ≤10 Watt

6. Installation instruction

6.1. Mounting

6.1.1. Mounting Stud:-

Mounting Studs are pasted on FRP using a Structural Adhesive keeping the
Control Panel Mounting Dimensions in view.

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6.1.2. Panel Mounting:-

Put Control Panel on Pasted Mounting Studs and fix the same with using M8
Nyloc Nut.

6.1.3. Water Pressure Pump:-

Water Pressure Pump is to be mounted at Coach Under Frame using 4 Nos of

M10x35 Hex Bolts, Nyloc Nuts and Split Pins

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 6.1.4. Water Main Line:-
It is to be fitted on studs fixed on FRP using C Clamps and M8 Nyloc Nuts. Main
Line is to be connected with the Main Water Tank from up side with Hose Pipe
(20mm) with SS sleeve and Hose Clamp, down side connect to NRV Port with
using Hose Pipe (20mm) and Hose Clamp.

6.2. Measures during initial setup.

Following measures are required during initial setup of system.

1. Check that the water pressurisation system is mounted with four no’s M10 bolts,
plain washer, nyloc nut and split pin arrangement.

2. Connect all the pneumatic tubes as per the airline diagram.

3. Connect 1”X3/4” OR 3/4"X3/4” (AS PER FEMALE THREAD AVAILABLE)

nozzle at the outlet of the water tank available at coach.

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4. Assemble pipeline for water line at FRP wall with c-clamp, z-clamp, nuts and
bolts.

5. Connect the hosepipes from water tank to input of pipeline (Refer WATER LINE
DIAGRAM).

6. Mount FR and panel box at FRP wall with bolts and nuts.

7. Assemble hosepipe with help of hose clamps from output of pipeline to input of
pressuriser unit as per direction shown on NRV and valve.

8. Assemble hose with the help of hose clamps from output of pressuriser unit to
the input of toilet pan.

6.3. CHECK POINTS BEFORE OPERATION

 Check all the connections with nuts and bolts are properly mounted or
tightly fixed.
 Check all air connections are correct or as mentioned in the drawing.
 Check all the water hose pipe connections are correct or as mentioned in
drawing.
 Check all the Ball Valves (for water line and airline) are in open condition.

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  Check the required Air pressure is available at Coach as specified in the
Drawing
 Check the water is there in the Main Water Tank of the coach.

6.4. Dismantling the System

For Dismantling the System, follow the following Steps

Step 1:- First of all we need to close the all supply like Water, Air, Power
Step 2:- Disconnect the power connection and Push Button connection.
Step 3:- Disconnect the all water line, which is connected 20 mm Hose Pipe.
Step 4:- Disconnect the all Pneumatic connections.
Step 5:- Dismantling the system as reverse of Mounting.

7. Trouble shooting.

GENERAL
REMEDIAL ACTIONS
PROBLEMS

 Check pneumatic connections as per assembly drawing.

 Check input pressure using pressure gauge.
Airline not working  Check air Ball Valve is open.
properly  Check the Air Line for any clogging.
 Check output pressure from pressure regulator using Pressure
gauge.

 Check water connections as per the assembly drawing.

 Check input connection from the overhead tank to the
Pressuriser unit.
Water line not working
 Check water ball valve is open
properly
 Check the water line for any clogging.
 Check output connection of water pressurization system up to
the toilet pan/bowl.

 Check the all connections as per the assembly drawing.

 Check pneumatic connections of Solenoid Valve in Penal.
Water output not  Check pneumatic connections of pressuriser unit.
available in the toilet  Check air pressure available.
pan/bowl.  Check the input N.R.V and output 2/2 valve for any Clogging.
 Check the Power Supply is Working or not
 Check the timer and Relay

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  Check Pneumatic connections on valve (Pneumatic valve of
PFS system/Solenoid valve of EPPFS system), may be
Delayed Flushing
reversed.
(Flushing after some
 Check ball valve in air is fully open
time of pressing
 Check the airline for any clogging
button)
 Check output pressure from pressure regulator using pressure
gauge

Electrical Supply not  Check electrical connection and polarity.

available  Check push button LED and timer is glowing

8. Preventive Maintenance Plan.

S. No. Name of Description

Schedule

 Cleaning the surface of the lavatory bowl/pan a regular

intervals. If water is not coming out there may be a chance
of clogging of lavatory pan nozzles.

 Clean the Y-Strainer. If water is not coming out there may

be a chance of Strainer filter Chock.

1 Trip  Activate the Push Button and check the functionality of

flushing.

 If not, corrective action to be taken as mentioned in the

general problems and their remedial actions.

 Ensure availability of Passenger Notification near the push

button. If not, to be provided.

 Check whether there is water or air leakage on Western

Style Module/ Indian Style Module.

2 D1  Check all the Hose Pipes Under frame, replace them if

necessary.

 Check for Rusting of Parts.

 Rubber Seal Kit of Water Pump to be cleaned / replaced.

3 D2
 Spool Seal Kit of Pneumatic Valve to be cleaned / replaced

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  Spring of NRV , 2/2 Valve and Piston valve to be checked /
replaced.

 NRV to be cleaned if water flow is less & quality of water

bad.

 Filling 4% lemon acid solutions into the lavatory bowl/pan.

The liquid should cover the spray nozzles. Immerse for one
hour and then clean the lavatory bowl/pan with clean water
and soft brush.

 Clean the lavatory bowl/pan nozzles.

 Check the leak tightness of the discharge valve (2/2 Piston

Valve).

 Replace the Silencer of Cylinder Middle Cover.

 Check operation of Water Locking Unit. If necessary,

replace with new spring.
 Check the ageing condition of Hose under the Coach, and
replace it if necessary.
4 SS-1
 Remove the safety Valve on the interim tank, repair or
replace it if necessary.

 Cylinder needs to be opened and check the scaling level for

operation of Piston.

 Seals of Cylinder need to be changed due to opening of

Cylinder.

 If required, Water Side Piston need to be replaced.

 Waterside cylinder Barrel to be cleaned with water arid soft

brush.

 Perforated holes of spray ring in the commode pan bowl

assembly to be cleaned with metal brush & pressurised
water jet.

 Replace all the Hoses and Rubber Joints under the Coach.
5 SS-2
 Disassemble the discharge Valve completely, replace the
seal components, and replace it completely if necessary.

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 Disassemble the nozzles, waste pipeline fittings and water
pipe fittings, and clean these components after steeping
them with 4% citric acid solution for 1 hour.

 Check the pneumatic valve and other parts, and replace

them if necessary.

 Air Side Piston & Connecting Rods needs to be changed.

 NRV to be changed.

 Front End Cover of Cylinder to be Changed.

 AFR Needs to be Changed.

 Pneumatic Tubes to be changed.

 Water Hoses to be Changed.

 Water Locking Unit to be changed, if required.

 Reassemble the system, and conduct a comprehensive test

according to the requirements of test program.

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9. Line Diagram for Electro Pneumatic Water Pressuriser

Page 15 of 19
Page 16 of 19
10. List of References:-
The references are-

1. Maintenance manual of SPAC Electro Pneumatic Pressurized Flushing System

(EPPFS).
2. Maintenance manual of National Engineering system.
3. Maintenance manual of IMI Norgen.
4. Maintenance manual of Janatics.
5. ICF specification No: - ICF/MD/Spec-340 Rev-00 Dated 09/01/2018.
6. ICF specification No: - ICF/MD/Spec-340 Rev-01 Dated 01/10/2019.
7. MCF Specification No: - MMDTS-19027 Rev-00 Dated 12/03/2020.
8. MCF Specification No: - MMDTS-19027 Rev-01 Dated 07/08/2020.
9. RDSO specification No: - RDSO/2017/CG-06 Rev-03 dated 18/12/2019 on Bio-
Vacuum Hybrid Toilet for LHB coaches.

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Annexure: - I EPPFS Check sheet
PFS/EPPFS Check sheet Date:-

Sr.No Point to be checked Lavatory Lavatory Lavatory Lavatory

No 1 No 2 No 3 No 4

1. Coach No
2. Input Power Supply Connected
3. Panel Box Firmly Closed and
Mounted on two nuts?
4. Loose Wires tied with cables tie
5. Push button Cover Firmly Tight?
(with cable gland position
downward)
6. Illumination light of Push Button
Working?
7. All Hardware Firmly Mounted ?
8. AFR Air Connection are correct?
(Input and output not
interchanged)
9. 5/2 Valve Air Connection are
correct?
(Suction Stroke Port no.2
Forward Stroke Port no.4)
10. Pressurizer Unit (Cylinder)
Mounted firmly?
11. Check the Rusting of Major parts
12. Air Inlet and outlet Connection
are correct & working properly ?
2 (Hose nipple without Angle Seat
Valve = Inlet
Hose nipple with Angle seat Valve
= Outlet)
13. Complete System Functionality ok
14. Air Quality Reading Through
Hygrometer
15. Y-Water Strainer of Coach
cleaned or not
16. Pneumatic Connection to be
checked with soap water for
leakage

Name of SSE/JE/MCM: - Signature

Page 18 of 19
Annexure-II List of Emergency Spares for maintenance

Sr.No Spares

1. Pressuriser Unit (Cylinder Unit)

2. Water locking Unit

3. Manual Push type 5/2 pneumatic valve (Purely pneumatic PFS)

4. Electric push button

5. Control panel with SMPS, Timer & Electro solenoid valve

6. Pneumatic Isolating Valve 1/4" (Both end female thread)

7. Preset Pressure regulator cum filter valve

8. Water Isolating valve 3/4" (Both end female thread)

9. NRV 3/4"

10. NRV 1/2"

11. Water Hose 20 Bore

12. Hose Clamp size 30

13. Air silencer

14. Pneumatic tubes & fittings

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