Hey, good find. Thanks for that.
I've just had a quick read and it is a bit of a "mind f**k" but, whether you understand the technical information or not, it does neatly illustrate the follies of attempting to design something in a laboratory.
As the report says, all these EMUs coming into service on the Glasgow, Manchester and London Eastern Region suburban networks (including those ER units converted from 1500V DC operation) were effectively a huge experiment in rail electrification, as no other network had at that time attempted to create a dual high voltage system of AC overhead electrification. Therefore unreliability was bound to follow, especially on lines where trains would be expected to use both the dual voltages of 6.25kV and 25kV AC. Components were designed and built based on experimental parameters and did not sufficiently take into account the actual demands made on them in operation. Therefore failures occurred that could not have been predicted, the precise nature of which depended largely on the design and construction of individual components from contractors used to equip the traction for individual routes.
However, it seems that the causes were fairly common, at least where they weren't down to poor component design. Pan bounce, which could lead to "chopping" of the Air Blast Breaker (we now use Vacuum Breakers which do not "chop"), and incorrect operation of the APC Voltage Selection Equipment which, under certain conditions, could occasionally malfunction and apply 25kV to the 6.25kV circuits imposed large transient over-voltages onto the electrical equipment, especially on the 6.25kV AC lines where they could reach voltages as high as 6 times the normal operational maximum as well as generating very high currents.
On the AEI equipped Glasgow units this lead to overheating and distortion of the secondary windings due to electro-magnetic force which, in at least two instances, caused the transformer oil to gasify and resulted in an explosion in the guards compartment. On the EE equipped London North Eastern units these over-voltages took their toll on the tertiary circuits, blowing out battery chargers as well as traction motors instead of the transformers, which were of a more robust design. The LNE units did also suffer with problems associated with the mercury arc rectifiers, some of which was down to "chopping" of the ABB and some due to the cooling arrangements for the anodes and cathodes.
History shows that they got there in the end, although the removal of the 6.25kV sections helped enormously. The various upgrades and modifications to both the trains and the fixed lineside equipment ironed out all these problems, and lessons learned were applied to later generations of EMUs.
O L Leigh