Self-Powered Idling Stop Technology. LTP Heating System for Diesel Engines. A.S.T. GmbH, Energie- und Umwelttechnik

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1 Self-Powered Idling Stop Technology LTP Heating System for Diesel Engines A.S.T. GmbH, Energie- und Umwelttechnik

2 The Idling Stop Technology: A.S.T. Heating Systems for Diesel Engines A.S.T. Group has designed and installed more than 4,000 fuel operated heaters (Idling Stop Technology systems) for diesel locomotives worldwide in the last 20 years. The system is a fully autonomous and automatic diesel fired heating system that protect locomotives by heating up the coolant water system in the engine block as well as engine oil, air compressor to allow shutting down the locomotive engine, stops the locomotive idling during stopovers. A.S.T.s Idling Stop Technology system is listed as SmartWay verified technologies for locomotives by EPA, it reduces operating costs by saving approximately 95% to 97% fuel consumption compared with idling, and simultaneously reduces green house gas emission, increases the operation life of the locomotive, reduces the surrounding area noise level, and cuts down the service costs. The system is a high efficiency, isolated, rail-designed heat exchanger, equipped with a two-stage burner with integrated fuel prewarming, with two of frequency controlled circulation pumps and a temperature controlled 4-way mixing valve, designed as a Two-Circle-System to meet optimum heating strategies. The heat exchanger has its own safety controlling logic, a high- frequency-ignition and numerous built in safety features to ensure the system is stable from sea level up to mountainous areas. The system has more than 90% efficiency and meets all pollution-free requirements of industrial oil heating systems. German Rail has awarded this system as the most efficient and reliable system to avoid idling. The designed life time of the system is more than 15 years, there are numerous systems have been on duty for more than 20 years at the locomotives of German Railways.

3 Heating Circuit The drawings show the integration of Idling Stop Technology systems into the cooling circuit of diesel engines. With this configuration also the cabin, fuel tank and engine oil can be warmed by the engine heating system. Several sensors at the particular points provide the necessary process data. wet/dry cooling system like in the GP38 wet/wet cooling system like in the BR232 Example of a Fuel Saving Report This fuel saving report is a GP38-2 locomotive operating in Canada from Jan. 1st to 30th During recorded hours, locomotive has been parked for hours. The ambient temperature went down to -24ºF, the coolant water temperature was kept higher than 105ºF to 120ºF, the fuel consumption of Idling Stop Technology system in hours is 71.4 gallons. If locomotive idled during this period costs 3,184.3 gallons, so the Idling Stop Technology system saved 3,113 gallons and reduced tons of GHG emission in 412 hours.

4 Design The used system components of the Idling Stop Technology system are designed for easy service in diesel locomotives. Thus the circulation pumps have integrated inverters that improve efficiency, endurance and reliability. The boilers are extremely robust and efficient. All electronic components (e.g. process control system, mini-terminal) are insured to vibrations, temperature influences and voltage up- and downturns. The microprocessor control unit of the Idling Stop Technology system is built in an IP65 EMVprotected 19 electronic-box, equipped with an integrated wide range power supply, I/O cards to connect all external and internal I/O devices, such as temperature limiter, temperature sensors and so on. The system comes with a mini control terminal for on board service and the total system is equipped with a Built in Test Equipment (BITE) connected to an integrated I/O Modem for store, download and send relevant operation data by using the worldwide GPRS modem. The system could be installed either horizontally or vertically into locomotive to find the best optimum position. It monitors the coolant water temperature, ambient temperature, the coldest spot temperature and another reference point, also locomotive battery voltage; air pressure, oil and so on, as required. The system operates based on the present situation referring to the preset parameters. Add-On (option) Due to the low energy consumption (~ 300 W) the system can run about 2 days out of the charged main battery. For longer parking times an A.S.T. battery charger can be installed. Input 110 VAC / 220 VAC (±20%) Output 70 / 96 / 108 / 112 VDC Charging current up to 20 A Of course the Idling Stop Technology system can be also combined with an integrated thermo electric generator (TEG). AST engineers have developed this integrated TEG system to become completely independent from electrical energy and to increase the lifetime of the engine and cranking motor substantially. By using ASTs integrated TEG technology will support the battery with enough electrical power to stay fully charged, even through a long time period.

5 System components 1 Circulation pump with integrated inverter short-circuit protected, jolt-free running, high breakaway torque, safety cut-off if pump is blocked, IP 65 5 Process control system log book function, build in test equipment (BITE) for permanent self-monitoring, extremely reliable, IP 65 2 Low-pressure heat exchanger thermal output kw, kw, efficiency > 90 %, Hinged front panel for rapid access to the flue for cleaning 6 Mini-terminal handling of the system, menudriven command, any installation location in the vehicle, IP 54T 3 Two-stage oil burner autonomous process control, service-friendly construction, integrated inverter for ventilator, IP 65 7 Temperature sensors Thermostat, IP way mixing valve integrated temperature sensor in all four circuits, position indication, emergency switchover to manual operation. IP 65 8 GPRS data logger remote monitoring of the system, fuel saving reports, alarm notices, IP

6 GPRS Data Logger The on bord GPRS data logger allows remote monitoring of all parameters of the LTP system. Fuel saving reports can be displayed as well. Monitored data: battery voltage / state of charge temperatures (e.g. cooling water temperature, outside temperature, boiler temperature, etc.) system specific data (e.g. burner status, pumps, malfunctions etc.) If a malfunction occurs an alarm notice can be sent by or SMS. The microprocessor system contains a flash memory to store a few months by nearly each second, the necessary operating BITE- data that contains the status of the burner, the ambient temperature, such as air pressure and so on. The system monitors up to 16 analog and 16 digital input/output signals of the system and the locomotive. Through this it is possible to calculate the diesel fuel consumption of the Idling Stop Technology system, the fuel savings of the locomotive and emission reduction. In addition, these data will show the situation of the locomotive and the services that have been done. The microprocessor also measures the battery voltage of the locomotive, for charging the locomotive battery in relevant situations. When the locomotive is operating or staying in a GPRS- Cellular Network Area, it is possible to view them down to on line and download these data from locomotives, additionally it is possible to send out data or give a few instructions to the Idling Stop Technology system of the locomotive. The Idling Stop Technology system normally starts operating after the locomotive has been parked. After the locomotive engine is shut down, while the ambient temperature is lower than 75ºF and the coolant water of locomotive drops down to 104ºF, the 4-way valve separates the boiler water circle from engine water circle and starts working. This Two-Circle- System allows to keep a few gallons water in the boiler circle to rise the temperature quickly above the dew-point of approximately 47ºC (116ºF) to avoid condensation in the combustion chamber and reduce emissions. Once the water temperature in the boiler circle reach 122ºF (50ºC), the 4-way valve will gradually open to maintain a temperature of about 104ºF in the engine circle. There is a frequency controlled water pump in each circle, to operate with a great efficiency and keep the temperature in the locomotive water circuit at nominated levels. Additionally, the Idling Stop Technology system monitors the coldest spot of the locomotive (mostly it is the air compressor or other periphery devices) via an installed additional temperature sensor, to keep the coldest spot about 90ºF (32ºC), to avoid leaking of fittings and ensure the lubrication oil and so on within a comfortable temperature range for the locomotive. When the battery voltage drops to a certain level, the LTP system sends out a battery low output signal. For example: To restart engine via the Auto-Restart-Unit (ARU) when the battery low signal is ON. The Idling Stop Technology system only uses about 0.3kW average per hour power from locomotive s battery during system operation. In normal conditions the system could operate up to 50 hours without the battery going down below a certain level, to ensure there is enough energy for ENGINE START (for example 62V). In this case the locomotive engine could be restarted by ARU, idling about minutes to recharge the battery. Also, the engine could be restarted by ARU for any other pre-set parameters.

7 Idling Stop Technology with Integrated TEG Modules Applications Thermoelectric generators (TEG) make systems independent from main batteries and any electrical infrastructure. Special Features Maximum fuel savings due to high efficiency (>90%) Operational down to -40 C (-40 F) outside temperature Self-sustaining system Conservation, charging locomotive battery No moving parts allow >15 years of lifetime Minimal emission levels (air pollution and noise) Autonomous operation Remote monitoring via GPRS Description The Idling Stop Technology system is also a LTP system (Low temperature protection system) keeps the diesel engines coolant water and locomotive in an optimum temperature after shutdown the engine. It works even ambient temperatures drops down to -40 C (-40 F). By our Idling Stop Technology, a single locomotive can save up to 60,000 liters diesel fuel (25,000 gallons, depend on the locomotive operating cycle) yearly, to achieve a higher, rapid Return of the investment. The A.S.T. Group has contrived novel invention on the application of TEG into Idling Stop Technology system. By this cutting-edge technology as a new option of an Idling Stop Technology system, while LTP system operating, up to 1.5kW electricity power will be generated to feeding back to locomotive battery. Therefore there is no longer to consider: to restart engine for charging locomotive battery, or using sideway plug to maintaining locomotive battery. Following to the Seebeck effect, by creating the temperature difference between two sides surface of certain materials, it generates and converts the heat directly into electrical power without any moving parts. The A.S.T. Group is the First party in the World to realize it and put this principle into Idling Stop Technology.

8 Our scope of supply and services Planning and realization Our scope of work includes development, prototype construction, drawing documentation and production. In cooperation with our customers we find the optimal installation location on the locomotive and make it ready for assembling system into operation. Experience A.S.T. LTP-systems for locomotives are operating reliable for more than 20 years. Our systems were developed together with the former BZA Munich and the FTZ Dessau of German Rail. They are approved under extreme climate conditions at Rail Tec Arsenal (Vienna). Service and maintenance Due to no moving parts such as a diesel engine, our LTP systems do not require major maintenance activities. EPA (Environmental Protection Agency) verified technology Our 35 kw, 50 kw and 90 kw idling stop technologies are listed as SmartWay verified technologies for diesel locomotives in EPA of USA Government website. References More than 4,000 LTP systems in duty, e.g. at: AC 4400 BR 202, 203, 204 BR 212 BR 216/217/225 BR 218 BR 219/229 BR 232/233/234 BR 241/242 BR 290/294 BR 291/295 BR 298 BR SVT 675 BR 708/714 VT 618/619(LIREX ) 2TE116 GP9 GP10 GP38 RS1325 SD18 A.S.T. GmbH, Energie- und Umwelttechnik Hagertshausen Wolnzach Germany Telefon +49 (0) Fax +49 (0) AST

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