Introductory Handbook On Microprocessorcontrolled Electric Locomotives

CAMTECH/E/10-11/MPC-Loco/1.
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(For Official Use Only)
Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS
INTRODUCTORY HANDBOOK
ON
MICROPROCESSOR CONTROLLED
ELECTRIC LOCOMOTIVES (MBFDS)
TARGET GROUP: TRS Maintenance Staff
CAMTECH/ E/ 10-11/ MPC-Loco/ 1.0
July 2010
egkjktiqj, Xokfy;j & 474 005

Maharajpur, GWALIOR - 474 005
Introductory Handbook on Microprocessor Controlled Electric Locomotives (MBFDS)
July 2010
CAMTECH/E/10-11/MPC-Loco/1.0
INTRODUCTORY HANDBOOK
ON
MICROPROCESSOR CONTROLLED
ELECTRIC LOCOMOTIVES
(MBFDS)
QUALITY POLICY
To develop safe, modern and cost
effective Railway Technology complying
with Statutory and Regulatory
requirements, through excellence in
Research, Designs and Standards and
Continual improvements in Quality
Management System to cater to
growing demand of passenger and
freight traffic on the railways.
July 2010
FOREWORD
In the conventional electric locomotives, control is achieved through a large number of
relays, switches and auxiliary contacts. This type of control mechanism has mechanical moving
parts and a large number of contacts, thus result into malfunction during service.
To overcome these problems microprocessor based control and fault diagnostic system has
been developed and is being used in electric locomotives. Since this technology is comparatively
new, need has been felt for a handbook to disseminate basic knowledge about the system among the
user.
CAMTECH has prepared this handbook which describes important features of the system,
various sub-assemblies and input/ output logics etc.
I am sure this document will be very useful for our maintenance staff in electric loco sheds
and workshops.
CAMTECH, GWALIOR
DATE : 30TH JULY 2010
S.C. SINGHAL
EXECUTIVE DIRECTOR
July 2010
PREFACE
Improved technology in the field of microprocessor based digital control systems has made
the application of control and fault diagnostic system possible in conventional locomotives.
The microprocessor based control and fault diagnostic system has been developed for
conventional electric locomotives including locos provided with static converter. It performs logical
control of the locomotive by continuously monitoring various digital/ analog inputs and checks for
any abnormality in the operation. It also displays/ announces the fault condition on the display units
provided in both cabs of the locomotive. The system is equipped with Real Time Clock (RTC) and
a non volatile memory to record the faults in the real time with date, time and fault type.
This handbook on Microprocessor based control and fault diagnostic system has been
prepared by CAMTECH with the objective to disseminate basic knowledge of the system.
It is clarified that this handbook does not supersede any existing provisions laid down by
RDSO or Railway Board/ Zonal Railways. The handbook is for guidance only and it is not a
statutory document.
I am sincerely thankful to all field personnel who helped us in preparing this handbook.
Technological upgradation and learning is a continuous process. Hence feel free to write us
for any addition/ modification in this handbook. We shall highly appreciate your contribution in this
direction.
CAMTECH, GWALIOR
DATE: 26TH JULY 2010
JAIDEEP GUPTA
DIRECTOR ELECTRICAL
July 2010
CONTENTS
Item No.
Description
Page No.
Foreword
Preface
Contents
Correction Slip
iii
iv
v
vi
1.0
INTRODUCTION
01
2.0
ABBREVIATIONS
02
3.0
ADVANTAGES
02
4.0
RELAYS/ FUSES REMOVED
03
5.0
ADDITIONAL SWITCHES PROVIDED
03
6.0
SYSTEM SUB-ASSEMBLIES
03
6.1
CONTROL UNIT
04
6.2
SIGNAL CONDITIONING UNIT
07
6.3
INTELLIGENT SIGNAL CONDITIONING UNIT
08
6.4
DISPLAY UNIT
08
7.0
SYSTEM BLOCK DIAGRAM
09
8.0
TECHNICAL SPECIFICATIONS (MEDHA MCS 657)
11
8.1
CONTROL UNIT
11
8.2
DISPLAY UNIT
11
8.3
INTELLIGENT SIGNAL CONDITIONING UNIT
11
8.4
SIGNAL CONDITIONING UNIT
11
9.0
PRINCIPAL OF OPERATION
12
9.1
CONTROL UNIT
12
9.2
DISPLAY UNIT
12
10.0
OPERATIONAL BLOCK DIAGRAM
14
11.0
DIGITAL INPUT DETAILS
15
12.0
DIGITAL OUTPUT DETAILS
20
13.0
OUTPUT TO INPUT LOGIC
23
14.0
DOS
27
15.0
DONTS
27
16.0
GENERAL GUIDELINES
27
REFERENCES
28
July 2010
ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows :
CAMTECH/E/10-11/MPC-Loco/C.S. # XX date--------Where XX is the serial number of the concerned correction slip (starting from 01
onwards).
CORRECTION SLIPS ISSUED
Sr. No.
Date of issue
Page no. and Item

no. modified
Remarks
July 2010
MICROPROCESSOR BASED
CONTROL AND FAULT DIAGNOSTIC SYSTEM
OF
ELECTRIC LOCCOMOTIVES
1.0
INTRODUCTION
There are essentially three main circuits in an electric locomotive viz. power circuit,
auxiliary circuit and control circuit. The control circuit is the heart of the locomotive
controlling both power as well as auxiliary circuits. The control circuit can be further subdivided into three parts:
Traction power control

Auxiliary machine control
Light and fan control
There are a large number of relays in control circuit of the locomotive, each relay
having multiple contacts. In the conventional locomotives, control is achieved by
permutation & combinations of relay contacts, switches and auxiliary contacts of the
contactors. As these relays have mechanical moving parts and large number of contacts
which creates malfunction of the control system during service.
To overcome these problems microprocessor based control and fault diagnostic
system has been developed and is being used in electric locomotives. This fault diagnostic
and control system is suitable for all types of electric locomotives including locos provided
with static converter.
This system is designed to work with electric locomotives in accordance with RDSO
specification no. ELRS/ SPEC/ MPC-FDS/ 001 (REV.2) August 2005.
It performs logical control of the locomotive by continuously monitoring various
digital and analog inputs. It also checks for any abnormality in the operation and displays/
announces the fault condition on the display units provided in both cabs of the locomotive.
The system is equipped with Real Time Clock (RTC) and a non volatile memory to
record the faults in the real time with date, time and fault type.
Any fault is logged in data packs with event logging of 5 seconds prior and
3 seconds after the occurrence of fault at 1 second interval. The following parameters are
recorded in data packs.
Status of all 128 Digital inputs

Status of all 80 Digital outputs
Analog input voltages and currents
Status of notch position and eliminated relays
July 2010
2.0
3.0
ABBREVIATIONS
CU
Control Unit
SCU
Signal Conditioning Unit
ISCU
Intelligent Signal Conditioning Unit
CSU
Current Sensing Unit
CPU
Central Processing Unit
LED
Light Emitting Diode
LCD
Liquid Crystal Display
USB
Universal serial Bus
IF
Interface
ARNO
Single phase to 3 phase AC converter
SI
Static inverter
TM
Traction motor
RTC
Real time clock
PC
Personal computer
ADVANTAGES
This system has the following advantages over the conventional control system:
Elimination of a numbers of relays (Time delay relays, sequential relays, indication

relays, no volt relay Q30 and over voltage relay Q 20)
Elimination of notch indication system
Enhancement of availability of locomotive
Reduction in numbers of interlocks required
Reduction in size of master controller
Reduction in control wiring
Fault diagnosis, indication and recording
Easier trouble shooting as status/ fault massages are displayed to crew in the cabs
Easier to identify recurring problems by error log and event recording analysis
Easier and least maintenance
Improved reliability
Vigilance control and flexibility
July 2010
4.0
5.0
6.0

CIRCUITS
DJ Control circuit
Q44, Q45, Q118, Q30, QCVAR/QSVM, Q46
Aux circuit
Q100, QTD105, 106, Q119
Signaling circuit
QV60 to 64, QVLSOL
Other circuit
Q50,51,52, QD-1,2, QRS, QWC, QF-1,2, Q48, Q49, Q20
Fuses
CCDJ, CCLSA, CCA
ADDITIONAL SWITCHES PROVIDED

SWITCH
LOCATION
FUNCTION
TSACP
TR panel
For ACP circuit
TSFL
TR panel
For AFL circuit
HPAR / HQ-51
TB panel
For bypassing Q-51 function.
BPQD
Driving Desk
For Sanding during wheel slip.
SYSTEM SUB-ASSEMBLIES
There are two types of systems mostly in use in electric locomotives. One is of
Medha make Ver.2, type MCS 657 and the other one is Stesalit make type FDCS 9648.
These systems comprise of the following sub-assemblies:
S.No. Description of Sub-Assembly
MEDHA
(MCS 657)
STESALIT
(FDCS 9648)
1.
Control unit mounted in AC 2 panel
01 no.
01 no.
2.
Signal conditioning unit mounted above the

control unit
01 no.
01 no.
3.
Intelligent signal conditioning unit/ Current

sensing unit
02 nos.
02 nos.
4.
Display unit (1 in each cab)
02 nos.
02 nos.
5.
Potential transformer
--
01 Nos.
6.
VCD reset unit (optional)
02 nos.
--
July 2010
6.1
Control Unit
This unit is housed in a powder coated MS enclosure and mounted in AC 2 panel. It
consists of the following cards:
S.No.
Control Unit
MEDHA (MCS 657)
STESALIT (FDCS 9648)
1.
Digital input cards
08 nos.
08 nos.
2.
Digital output cards
05 nos.
05 nos.
3.
Analog input card
01 no.
01 no.
4.
Interface card
01 no.
--
5.
Control cards
02 nos.
02 nos.
6.
Power supply cards
02 nos.
02 nos.
7.
Filter card
--
01 Nos.
8.
Multi Function Card
--
01 No.
19 Nos.
20 Nos.
Total Cards
It also consist necessary Bayonet connectors for all input, outputs, communication and
power connections.
BAYONET
CONNECTORS
INPUT CARDS
(08 Nos.)
OUTPUT CARDS
(05 Nos.)
ANALOG INPUT CARD
POWER SUPPLY CARDS

(02 Nos.)
INTERFACE CARD
CONTROL CARDS
(02 Nos.)
MEDHA CONTROL UNIT

July 2010
BAYONET
CONNECTORS
OUTPUT CARDS
(05 Nos.)
FILTER CARD
INPUT CARDS
(08 Nos.)
ANALOG INPUT
CARD
POWER SUPPLY CARDS
(02 Nos.)
CONTROL CARDS
(02 Nos.)
MULTI FUNCTIONAL
CARD
STESALIT CONTROL UNIT
6.1.1
Digital Input Card

These cards convert the high voltage input
signals of 110 V DC received from the locomotive
circuits into isolated low voltage 5 V DC signals
which are required for the microprocessor system.
All the inputs are protected from surge and reverse
polarity. Each card can process 16 input signals.
The green colour LEDs provided on the card
indicate presence of 110 V DC voltage on that
particular channel and the yellow LEDs indicate status of signal read by microprocessor
after isolation and signal conditioning. Both the LEDs of a particular channel should be
either OFF or ON to indicate the correct functioning of card. Out of 8 digital input cards 1
card is redundant and 1 is spare. These cards are interchangeable.
July 2010
6.1.2
Digital Output Card

These cards convert low voltage 5 V digital
signals which are generated by the microprocessor
system to the high voltage signals of 110 V DC to
drive relays, contactors, indication lamps etc. in the
locomotive. All the outputs are protected from
surge, over load, short circuit and reverse polarity.
Each card can process 16 output signals. The green
colour LEDs provided on the card indicate presence
of 110 V DC voltage on that particular channel and the yellow LEDs indicate status of
signal given by microprocessor. Both the LEDs of a particular channel should be either OFF
or ON to indicate the correct functioning of card. Out of 5 digital output cards 1 card is
redundant and 1 is spare. These cards are interchangeable.
6.1.3
Analog Input Card

This card accepts low voltage analog signals
given by the signal conditioning unit. These signals
are isolated and then taken to the CPU card for
processing. LED is provided on each channel for
indication and rate of blinking of LED indicates the
level of input voltage given to SCU.
6.1.4
Interface Card
This card communicates with both
display units. The communication signals are
optically isolated from rest of the circuit. The
communication signal lines are protected by
surge absorbers. This card is also provided
with non-volatile memory and real time clock.
The fault data is recorded in the non-volatile
read write memory with date, time and type of fault. This card is provided with type A USB
connector for down loading data to the pen drive and type B miniature connector for
configuration of various parameters as well as down loading fault data directly on to PC/
laptop. This card is provided with an USB LED to know the status of working with pen
drive and blinking of Card Status (CS) LED indicates healthiness of card. Glowing of Watch
Dog (WD) LED indicates failure abnormality of CPU card.
6.1.5
Control Card
There are 2 identical Control cards each
with 16 bit microcontroller. At a time only one
control card is active and other remains in
standby mode. This card is provided with Watch
Dog Timer Circuit to detect failure of
microcontroller or crashing of software, in such
condition standby card takes over automatically
and system continues to work. Active card is
recognized by blinking of LED. It communicates with both intelligent signal conditioning
units and the communication signals are again optically isolated from rest of the circuit.
July 2010
The communication signal lines are protected by surge absorbers. The control card
reads analog voltages from Signal Conditioning Unit as well as Configuration information
from IF card which can be set by the laptop. It also sends the status of digital inputs, digital
outputs, output feedback, eliminated relay status, analog voltages, traction motor currents,
diagnosis information, notch position and fault information to the IF card for event logging
purpose in case of any fault generated.
6.1.6
Power Supply Card

This module supplies regulated low
voltage DC supply to the various cards from
locomotive battery. This power supply is
protected from reverse polarity, surges, RFI &
EMI through suitable devices. This module
comprises another card of same type to take
over functions of failed card. The following
voltages are generated in the power supply card and LED indication is provided for each
output.
6.2
+9VI
Isolated DC supply for control circuit
+12VE
Isolated DC supply for digital output card
+18VE
Isolated DC supply for signal conditioning unit
-18VE
Isolated DC supply for signal conditioning unit
+9VE
Isolated DC supply for communication circuit

This unit is enclosed in a powder coated MS enclosure. It consists of 5 cards and
necessary Bayonet connectors for sending low voltage signals to control unit. Out of these 5
cards, 3 cards are used for AC voltage processing and 2 cards are used for DC voltage
processing. These cards are interchangeable with in a group. It accepts locomotive HV
inputs of auxiliary supply, ARNO/ SI output, battery charger voltage and TM voltage (of
only one Bogie). It has one redundant channel for auxiliary supply.
MEDHA
STESALIT
July 2010
Analog Inputs
A11
A12
A13
A14
A15
A16
6.3
ARNO - U
ARNO V
ARNO W
ARNO - M
RQ -20
HO- 1
965
966
967
960
A17
H0 1

This unit is enclosed in a powder coated MS enclosure. It consists of two cards i.e.
power supply & control cards along with necessary Bayonet connectors for communication
and power connections. Power supply card converts locomotives 110 V DC to low level
working voltage for other cards. Further the control card comprises of three child cards per
ISCU for processing of individual TM current. There are two ISCUs on a locomotive to
process 6 TM currents; one each mounted in BA1 and BA2 panels. TM shunt voltages are
inputs to this unit. Each unit receives 3 TM shunt voltages and processed output is sent to
controller unit via communication link. The pick up and drop out currents for auto
regression due to wheel slip can be set through configuration settings in the control unit.
The power supply input is protected from reverse polarity, surges, RFI & EMI through
suitable devices. In Stesalit System TM current sensing unit is used in place of ISCU.
MEDHA
ISCU 1
Traction Motor 1 Current
6.4
STESALIT (TM current sensing unit)

ISCU - 2
Display Unit
This unit is enclosed in a powder coated MS enclosure and mounted in each cab of
the locomotive. The unit has a 40 character by 4 lines back lit type LCD, a 2 digit 7 segment
LED display of one inch height and a 8 keys keyboard with hooter. This unit receives data
from control unit. The default LCD screen shows date, time and loco configuration settings.
The 7 segment LED display shows current notch no. Any fault is announced with a fault
massage on LCD with hooter (if configured to announce). The LCD displays the current
status, earlier logged faults, isolation conditions, digital/ analog inputs and digital outputs
etc. depending on the option selected through the key board. This unit takes 110 V DC from
July 2010
locomotive battery and provides regulated DC low voltages for functioning of display unit.
The power supply is protected for reverse polarity, surges, RFI/ EMI, under and over
voltages of supply through suitable devices.
MEDHA
DISPLAY UNIT
LCD SCREEN
UP ARROW KEY
MENU KEY
DOWN ARROW KEY
NOTCH INDICATOR
ENTER KEYS
LCD SCREEN
UP ARROW KEY
STESALIT
DISPLAY UNIT
MENU KEY
DOWN ARROW KEY
7.0
SYSTEM BLOCK DIAGRAM

6
CSU 1
Locomotive Terminal
SB in AC2 Panel
6
CSU 2
19
19
19
19
19
19
19
19
Signal
conditioning
unit in AC 2
Panel
10
10
Display unit 1
in CAB 1
10
FDCS 9648 Control Unit

In AC 2 Panel
10
Display unit 2
in CAB 2
STESALIT FDCS 9648

July 2010
10
Locomotive SB
Digital Inputs
128 Numbers
Digital Outputs
80 Numbers
ISC Unit 1
Type MSC804
Display Unit 1
Type MDS736
in BA 1
TM-1-3
Currents
TM Shunts
110 V DC
ISC Unit 2
Type MSC804
RS485 Communication
RS485 Communication
TM shunts
110 V DC
110 V DC
in CAB 1
Display Unit 2
Type MDS736
in BA 2
110 V DC
in CAB 2
TM-4-6
Currents
Control Unit
Type MCS657
Locomotive SB
In AC2 panel
SC Unit 2
Type MSC805
VCD Reset Unit 1

Type MSA709
in AC 2
in CAB 1
Analog
Inputs
110 V DC
VCD Reset Unit 2

Type MSA709
in CAB 2
MEDHA MCS 657
July 2010
11
8.0
TECHNICAL SPECIFICATIONS (MEDHA MCS 657)
8.1
Control Unit
8.2
8.3
8.4
Supply Voltage
60V to 140V DC
Power consumption
25 W approximately
Suitable for locomotives
WAG5, WAG7, WAP4 and WAM4
I/O couplers
Reverse Bayonet connectors
Number of Digital Inputs
128 Nos. with LED indication on fascia
Number of Digital Outputs
80 Nos. with LED indication on fascia
Number of Analog Inputs
5 Nos. provision for 8 nos. with LED indication

on fascia
Number of TM Current Inputs
6 Nos.
Weight
55 Kgs approximately
Display Unit
Supply Voltage
60V to 140V DC
Power consumption
10 W approximately
I/O couplers
LCD
40 x 4 line alphanumeric with back lit provision
Notch Indicator
Two digit 7 segment indication
Back lit
ON/OFF control
Contrast
Adjustable through keyboard
Keyboard
8 keys of sealed membrane keyboard
Weight
2 Kgs approximately

Supply Voltage
60V to 140V DC
Power consumption
10 W approximately
I/O couplers
Number of TM Current Inputs
3 Nos.
Weight
3 Kgs approximately

Supply Voltage
18V DC from Control Unit
Power consumption
10 W approximately
I/O couplers
Number of Analog voltage channels
5 Nos. (3 for AC voltage and 2 for DC voltage)
Weight
3 Kgs approximately
July 2010
9.0
PRINCIPLE OF OPERATION
9.1
Control Unit
12
After the power is switched ON to the Control Unit, Display Unit and ISCU, one of
the CPU cards becomes active, it checks for healthiness of various sub systems. Any
abnormally found is sent to both Display Units for announcement. The Control Unit reads
the Digital and Analog input signals and debounces them through software. Depending on
the state of various inputs logical condition of Digital Outputs is worked out based on the
predefined logic. Digital outputs are set to high (+ve of Battery supply voltage) or low (Off)
state through the Digital output cards. Also the initial status of certain inputs e.g. Reverser is
checked at BL key switch ON.
Any abnormality is immediately announced on display Units. The monitoring of
inputs and calculation of outputs is done at a very high rate to ensure a prompt action. If any
feedback input does not match with the output driving status during running of locomotive,
then also an appropriate message is sent to Display Units. If the set limit of TM voltage,
OHE voltage, ARNO voltage etc. is crossed, then either Auto regression or DJ tripping is
done or any other appropriate action is taken as per the defined logic.
Faults are logged in a Non Volatile Memory with date, time and type of fault and
background data. When the fault data is to be downloaded, the USB port of PC/Laptop/ Pen
drive is connected to the USB connector of interface card. The downloaded data can be
analyzed using the data extraction and analysis software on the PC/Laptop.
For every normal DJ opening with BLDJ, the standby CPU card becomes active and
active CPU card becomes standby. If at any stage active CPU card fails, the other healthy
CPU card takes over with a message on Display Units and logging of fault. Once a CPU
card is found faulty the role change over does not take place. The system works only with
the healthy CPU. If both the CPU cards fail, then all the outputs will go into safe mode i.e.
de-energized condition (0V).
9.2
Display Unit
On powering up, each Display Unit checks for communication from Control Unit. If
no communication is received within 10 seconds the respective Display announces a
communication fail message. The system can continue to work even if one or both Display
Units fail. The default screen on the LCD shows date, time and loco configuration which
were set. The 2 digit 7 segment LED indicator shows the current notch position. When
Control Unit is unable to find out the current notch position e.g. after power up of any of the
control unit the tap changer is not at 0, manual operation of GR etc. the display shows
Er.
Any fault message received from control unit is announced by displaying of message
on LCD and sounding of hooter (If configure). For messages which need compulsory
acknowledgement, the hooter continues to sound till acknowledge key is pressed in the cab
where BL key is made ON. For other messages and display in the other cab, the hooter
stops sounding after 10 seconds irrespective of the type of message. The keyboard provided
on the Display Unit can be used to get the information and current working status of the
system. There are 8 membrane keys. These are MENU, , , ENTRE, ACK,
Back light ON/OFF, Contrast increase and Contrast decrease.
July 2010
052
050
051
BL2SN
BL1SN
049
048
047
(B-)
046
045
BL1DJ
I 65 I-0
I 64
I 54
I 53
I 52
I 51
I 50
I 49
700
BL2DJ
BP2DJ
I-1
BLR2DJ
MTDJ(VCB)
QLA
QLM
QOSI 2
QOSI 1
QOP2
QOP1
QOA
BLR1DJ
BP1DJ
DJ
QVMT1
I-3
QVMT2
EPDJ
DJ
C118
QPDJ
I-2
QVRH
I-4
I-6
C118
I-5
BL2SN
BL1SN
102
ZPT1
BL2SN
VEPT1
CPU
I-7
I-8
0 1 2 3
HVMT1
0 1 2 3
BL1SN
102
ZPT2
VEPT2
I-9
0 1 2 3
I-10
I-11
0 1 2 3
0 1 2 3
HVMT2
I-12
0 1 2 3
HVRH
QVSI1
(B-)
QVSI2
I-13
HVSI1
0 1 2 3
700
I-14
-(N)
+(P)
HVSI2
0 1 2 3
POWER SUPPLY
003
(B-)
110V
DC
SUPPLY
13
PANTO & DJ CONTROL CIRCUIT
July 2010
10.0
14
OPERATIONAL BLOCK DIAGRAM
Power
Supply
Display
Unit
Inputs
Display
Unit
Microprocessor
Control Unit
Outputs
Contactors
DJ
Valves
Contactors
MP
GR
Relays
Valves
July 2010
11.0
15
DIGITAL INPUT DETAILS

Total No of Digital inputs
128 ( I 0 I 127 )
Channels per card
16
Main inputs ( Cards 1 6 )
I 0 I 95
Redundant inputs ( Card 7 )
I 96 I 111
Spare inputs ( Card 8)
I 112 I 127
Card No 1
Bayonet Connector: Type - MG06F 22-14 S,
Ferrule I0 I15
Signal
Pin No
Ferrule on Core
Legend
Name
I-0
BP1DJ/BLDJ
021
I1
BP2DJ/BLRDJ
024
I2
QVTM1
025
I3
QVTM2
026
I4
QVRH
027
I5
ZPT1_2
030
I6
ZPT2_1
029
I7
HVMT1_1
036
I8
HVMT1_2
037
I9
HVMT2_1
038
I 10
HVMT2_2
039
I 11
HVRH_1
040
I 12
HVRH_2
041
I 13
QVSI1/HVSI1
042
I 14
QVSI2/HVSI2
043
I - 15
BLVMT
070
NC
NC
NC
NC
BN
BN
July 2010
16
Card No 2
Bayonet Connector: Type - MG06F 22-14 SW,
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Ferrule I 16- I 31
Signal
Legend
I 16
I 17
I 18
I 19
I 20
I 21
I 22
I 23
I 24
I 25
I 26
I 27
I 28
I 29
I 30
I - 31
Name
ASMGR (BN)
BLCP/ BLCPD
C101_3FB
GR-0
GR-0_31
QPH/HPH
QVSL1/ HVSL1
C105_FB
ASMGR (ON)
QVSL2/ HVSL2
MP + (R,B)
MPJ (FOR)
J1, J2 (FOR)
MP-(R,B)
MP (+,N,-) R
CTF (RUN)
NC
NC
BN
Ferrule on Core
072
074
075
076
077
078
079
061
082
080
093
091
095
096
097
100
NC
NC
BN
Card No 3
Bayonet Connector: Type - MG06F 22-14 SX,
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Ferrule I 32-I 47
Signal
Legend
I 32
I 33
I 34
I 35
I 36
I 37
I 38
I 39
I 40
I 41
I 42
I 43
I 44
I 45
I 46
I 47
Name
MPJ (REV)
CTF (BRK)
MP (+,N,-) B
DJ_FB
J1, J2 (REV)
ZQWC
MPS (1-4)
MPS (2-4)
MPS (3-4)
MPS4
PVEF
PSA
BPQD
RGEB
SWC
QF & QE
NC
NC
BN
Ferrule on Core
092
212
213
105
107
121
123
124
125
126
150
151
230
155
156
162
NC
NC
BN
July 2010
17
Card No 4
Bayonet Connector: Type - MG06F 22-14 SY,
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Ferrule I 48 I 63
Signal
Legend
I 48
I 49
I 50
I 51
I 52
I 53
I 54
I 55
I 56
I 57
I 58
I 59
I 60
I 61
I 62
I 63
Name
BL
QOA/ QSIT
QOP1
QOP2
QRSI1
QRSI2
QLM
BV
C106_FB
ZSMGR
ZSMS
RSI
HMCS
L1 TO L6_FB
HMCS & QD
C118N/C/QCON
NC
NC
BN
Ferrule on Core
142
045
046
047
048
049
050
122
062
128
120
170
058
028
153
018
NC
NC
BN
Card No 5
Bayonet Connector: Type - MG06F 22-14 SZ,
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Ferrule I 64 - I 79
Signal
Legend
I 64
I 65
I 66
I 67
I 68
I 69
I 70
I 71
I 72
I 73
I 74
I 75
I 76
I 77
I 78
I 79
Name
QLA_FB/SI INT FAULT
QPDJ_FB
C107_FB
SI EXT FAULT
C 145 N/O
Ferrule on Core
019
052
060
068
059
HQ51
CHBA
BL1
SWITI/ DBR
200
973
149
157
RGAF (ACP)
P2
BPT
RGPA/P1 (ACP)
BPSW1/2/ACK (ACP)
NC
NC
BN
219
216
217
218
203
NC
NC
BN
July 2010
18
Card No 6
Bayonet Connector: Type - MG06F 20-29 S,
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
Ferrule I 80 - I 95
Signal
Legend
I 80
I 81
I 82
I 83
I 84
I 85
I 86
I 87
I 88
I 89
I 90
I 91
I 92
I 93
I 94
I 95
Name
LOCO SEL 1
LOCO SEL 2
LOCO SEL 3
LOCO SEL 4
MU_FB
ES_DJ
Ferrule on Core
SEL 1
SEL 2
SEL 3
SEL 4
067
BN
BN
Card No 7
Bayonet Connector: Type - MG06F 20-29 SW,
Ferrule I 96 I 111
Signal
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
Legend
I 13
I 21
I 22
I 25
I 49
I 50
I 51
I 52
I 53
I 54
I 64
I 63
I 48
I 15
I 17
I 65
Name
QVSI1/ HVSI1
QPH/HPH
QVSL1/HVSL1
QVSL2/HVSL2
QOA/ QSIT
QOP1
QOP2
QRSI1
QRSI2
QLM
QLA
C118N/C/QCON
BL
BLVMT
BLCPD
QPDJ FB
BN
Ferrule on Core
042
078
079
080
045
046
047
048
049
050
051
059
142
070
074
052
BN
July 2010
19
Card No 8
Bayonet Connector: Type - MG06F 20-29 SZ,
Pin No
Ferrule I 112 - I 127
Signal
Legend
Name
Ferrule on Core
I 112
I 113
I 114
I 115
I 116
I 117
I 118
I 119
I 120
I 121
I 122
I 123
HORN
HORN
I 124
A9
A9
I 125
SA9
SA9
I 126
RESET
RESET
I 127
LOW SPEED
LOW SPEED
BN
BN
July 2010
12.0
20
DIGITAL OUTPUT DETAILS

Total No of Digital outputs
80 ( O 0 O79 )
Total No of Output cards
Channels per Card
16
Main Outputs ( Cards 1 3 )
O 0 O 47
Redundant Outputs ( Card 4 )
O 48 O 63
Spare Outputs ( Card 5 )
O 64 O 79
Card No.1
Bayonet Connector: Type - MG06F 22-14 P, Ferrule O 0 O 15
Signal
Pin No
Ferrule on Core
Legend
Name
O-0
DJ
044
O 1
C118 BLSI
035
O2
VEPT1
055
O3
VEPT2
056
O4
DJ
044
O5
C107
083
O6
C106
084
O7
C105
085
O8
C101, C103
086
O9
VEUL
087
O 10
J1, J2(FOR)
108
O 11
J1, J2 (REV)
109
O 12
CTF (RUN)
111
O 13
CTF (BRK)
112
O 14
VE (UP)
110
O - 15
C 145
114
BP
BP
BP
BP
BN
BN
July 2010
21
Card No.2
Bayonet Connector: Type - MG06F 22-14 PW,
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Ferrule O 16 O 31
Signal
Legend
O 16
O 17
O 18
O 19
O 20
O 21
O 22
O 23
O 24
O 25
O 26
O 27
O 28
O 29
O 30
O 31
Name
VE (DN)
EVPHGH
SX 1
SX2
SX31
SX32
IP
VESA2
VEF
VESA1
L1, L2, L3
L4, L5, L6
LSDJ (R)
LSCHBA (G)
LSGR (G)
LSB (Y)
BP
BP
BN
Ferrule on Core
113
115
129
130
131
132
166
165
164
163
143
133
171
172
173
174
BP
BP
BN
Card No. 3
Bayonet Connector: Type - MG06F 22-14 PX,
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Ferrule O 32 O 47
Signal
Legend
O 32
O 33
O 34
O 35
O 36
O 37
O 38
O 39
O 40
O 41
O 42
O 43
O 44
O 45
O 46
O 47
Name
LSP (R)
LSRSI (Y)
SX 41
SX 42
LSGROUP (R)
LSOL (Y)
LPAR (R)
SON (ALARM)
Q49/MU
B1, B2 (CPA)
LSDBR (Y)
LSFL
QFL
FL_LP
C102
C108
BP
BP
BN
Ferrule on Core
175
176
144
145
235
210
179
177
231
234
232
236
BP
BP
BN
July 2010
22
Card No.4
Bayonet Connector: Type - MG06F 22-14 PY,
Ferrule O 48 O 63
Signal
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Legend
O 48
O 49
O 50
O 51
O 52
O 53
O 54
O 55
O 56
O 57
O 58
O 59
O 60
O 61
O 62
O 63
Name
DJ
C118/BLSI
VEPT 1
VEPT 2
DJ
C 107
C 106
C 105
C101, C 103
VE (DN)
J1, J2 (FOR)
J1, J2 (REV)
CTF (RUN)
L1, L2, L3
VE_UP
L4, L5, L6
BP
BP
BN
Ferrule on Core
044
035
055
056
044
083
084
085
086
113
108
109
111
143
110
133
BP
BP
BN
Card No. 5
Bayonet Connector: Type - MG06F 22-14 PZ,
Pin No
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Ferrule O 64 O 79
Signal
Legend
O 64
O 65
O 66
O 67
O 68
O 69
O 70
O 71
O 72
O 73
O 74
O 75
O 76
O 77
O 78
O 79
Name
WORKING
FAULT
EM VALVE
BUZZER
WARNING
BP
BP
BN
Ferrule on Core
WORKING
FAULT
EM VALVE
BUZZER
WARNING
BP
BP
BN
July 2010
13.0
23
OUTPUT TO INPUT LOGIC
O0 & O4
(DJ closing)
O1
(C118 Closing)
I0=I(BLDJ-on, Wire no-021),

I1=1(BLRDJ-on, Wire no-024)
I5,I6 or i55=1(ZPT1-on,WireNo-029, or ZPT2-0n Wire no-030 or BVon Wire no-122),
I16=1(ASMGR IL Between notches-off, Wire no-072),
I19=1(ASMGR IL 41/42-on,Wire no-076 ),I20=1(ASMGR IL 61/62
on Wire no-077),
I23=0(C105 Feedback-off, Wire no-061),
I24=1(ASMGR on notch-on, Wire no-082),
I48=1(BL1/2-on,Wireno-142),
I72=1(BL1-on,Wire no-149 For working from Cab1),
I49=1(QOA-off, Wire no-045),
I50=1(QOP1-off,Wire no-046),
I51=1(QOP2-off,Wire no-047),
I52=1(QRSI1-off,Wire no-048),
I53=1(QRSI2-off,Wire no-49),
I54=1(QLM-off, Wire no-050),
I56=0(C106FB-off,Wire no-062),
I63=1(C118-off,Wire no 059/018),
I64=1(for QLA-off & for SI int. flt.I64=0),
I65=1(QPDJ-on, Wire no-052),
I66=0(C107FB-off Wire no-068 & Analogue Input Voltage-Aux.
Voltage-215Volt & Arno Voltage-157Volt
IO=1,I1=1,I5orI6orI55=1I19=1,I48=1,I63=1
I0-BLDJ-on wire no-021
I1-BLRDJ-on wire no024
I5,I6&I55-Any one on wire no-029,030&122 respectively
I19-ASMGR-on wire no-076
I48-BL-on wire no-142
I63-C118-off wire no-059/018
I35-DJ feedback-off wireno-155
O2 (VEPT1)
I6=1 ZPT-on wire no029&I55=0 BV-off wire no122
O3 (VEPT2)
I5=1 ZPT-on wire no-030& I55=0 BV-off wire no-122
O5 (C107 Coil)
I15=1BLVMT-on wire no-070,

I11=1HVRH(1or3) wire no-040,
I35=1 DJ feed back wire no105,
I68=0 C107 feed back wireno-080
July 2010
O6
(C106 Coil)
I15=1BLVMT-onwire no070,
I9=1HVMT2-on (1or3) wire no-038,
I56=0(C106) feedback wire no-062
O7
(C105Coil)
I15=1BLVMT-onwire no-070,
I7=1HVMT1-on (1or3) wire no-036,
I23=0(C106) feedback wire no-081
O8
(C101&C103)
Coil
I19=1BLCP&RGCP or BLCPD on wire no-074,

I35=1DJ feedback wire no-105,
I18=0 C101,102,103 feedback wireno-075,
I63-1QCON/CII8 on wire no-059/018
O9
(VEULCoil)
O8=0-1 wire no086 or I18=1-0 wire no-075
O10
(J1&J2 Up
Coil)
I48=1BLon wire no-142,

I19=1 SMGR on-0 wire no- 076,
I27=1(MPJ1-F or MPJ2-R) wire no-091
O11
(J1&J2 Dn
Coil)
I48=1Blon wire no-142,

I19=1 SMGR on-0 wire no- 076,
I32=1(MPJ1-R or MPJ2F) wire no-092
O12
(CTF1,2,3Up
Traction)
O13
(CTF1,2,3Dn
Braking)
O14
(VE1 UP
Coil)
O15
(C145 Coil)
24

I30=1MP on Traction wire no-097
I34=1MP on Braking wire no-213
I48=1BL-on wire no-142,
I35=1DJ feedback wire no105,
I20=1SMGR on 0to31 wire no-077,
I26=1(MP on+ Tr or Br)wire no-093,
O31=0 LSB-off wire no-174,
I55=1 RGEB on wire no -155,
I16=0SMGR Dn-off wire no-113
I35=1DJ feedback wire no-105,
I34=1MP on Braking wire no-213,
I33=1CTF1,2,3 on Braking feedback wire no-212,
I27&I28=1or I32&I36=1Reversar F/R,
I60=1Both HMCS on-1wire no-058,
I61=0L1-6 feedback wire no-028,
I47=1QE feedback wire no-162,
I73=1QVRF on/SMGR up to5 notch wire no-159,
I46=1SWC on wire no -156,
I57=1ZSMGR on wire no-128,
I58=1ZSMS on 1 (On MP)wire no-120
July 2010
O16
(SMGR
DnVE2)
O17
(EVPHGR
Coil)
O18
(Shunting
Contactors1)
O19
(Shunting
Contactor2)
O20
(S13,S23,S33)
O21
(S43,53,63)
In running- I35=1DJ feedback wire no-105,

I19=0SMGR not on 0 wire no-076,
I29=1MP on-( Tr or Br) wire no-096,
O31=1LSB off wire no-174,
I45=0RGEB off wire no-155,
On other condition(Auto Regression),
I45=0RGEB-off wire no-155,
I35=0 DJ feedback wire no-105,
O38=1(ACP actuated),
QD Operated(Current difference between TM2&TM3 Or TM4&TM5,
TM Over voltage ,Tm Voltage Above 810 Volt
SMGR above 5notches

I38=1MPS1-onwire no-123,
SMGR above20 notch
SMGR above20 notch
SMGR above20 notch,
I37-1BPQWC-on(MPJ-FOR)
SMGR above20 notch,
I37-1BPQWC-on(MPJ-REV)
O22
(IP Valve)
I35=1,
O22 Will be off when I35=0 In Braking Mode
O23
(VESA-2)
I36=1J1J2 on Rev I48=1 or QD on
O24(VEF)
I35=1
I42=1PVEF-onwireno-150&BP more than 3.5Kg,
In Braking Mode O24 Will not be High
O25
(VESA-!)
I28=1J1J2 on FORI48=1 or QD on
O26
(L1,L2,L3)
O27
(L4,L5,L6)
O28
(LSDJ Off)
25
I35=1DJ feedback-on wire no 105,

I7=1 HVMT1 on1/3 wire no -036,
I30=1 MP on run wire no097,
O31=0 LSB-off
I35=1DJ feedback-on wire no 105,
I9=1 HVMT2 on1/3 wire no -038,
I30=1 MP on run wire no097,
O31=0 LSB-off
I35=1
July 2010
O29
(LSCHBA
Off)
O30
(LSGR Off)
O31
(LSB Off)
O32
(LSP)
O33
(LSRSI)
O34
(S14,24,34)
Shunting4
O35
(S44,54,64)
Shunting4
O38
(LED ACP)
O39 (SON)
O44 (QFL)
O46
(C102)(081)
O47 (C108)
26
I71=1CHBA Voltage above-85 Volt,

I63=1QCON-on for STC loco
I19=0 SMGR not on 0
(1) Running mode
I35=1DJ feedback-on,
Either I27 with I28=1 Or I32with I36=1(J1&J2 Both are in for or Rev),
I68=0C145FB-off,
I31=1 CTF on run,
I30=0=0or1,
I34=0 MP on braking
(2) Braking Mode
I35=1DJ feedback-on,
Either I27 with I28=1 Or I32with I36=1(J1&J2 Both are in for or Rev),
I68=1C145FB-on,
I31=0CTF on braking,
I30=0=0or1,
I34=1MP on braking,
I46=1SWC-on,
I33=1 CTF on braking,
I47=1QE-off,
I60=1 Both HMCS on1,
I61=0 Line contactor-open,
I68=1 C145 close,
I73=I QVRF on,
I48=1 BL on
I77=1 BPT-on,
QD1orQD2 operated (Current difference more than 170Amp(WAG7),
125Amp(WAP4) inTM2&TM3 or TM4&TM5
I48=1 BL on,
I59=1 RSI micro switch on
I41=1MPS3-onwire no125
I41=1MPS3-onwire no125
I76=1
TM voltage above 810 Volt
I76=1 But I79 should not go high
5 second after O8=1
O15=1 C145 close &O31=0
July 2010
14.0
15.0
16.0
27
DOs
1.
Check all connections at input/ output connectors & ensure they are not interchanged.
This will lead to system malfunction and may lead to accident.
2.
Simulation test is mandatory after every change of cables/components, new program

loading etc. to avoid any malfunction incident on line.
3.
Use trained/ confident staff only to attend these locos as the trial and error methods
are not at all acceptable and may lead to major fire or such fatal things.
4.
Ensure dust proof covering for all the system components as it will avoid malfunction
and extend useful life of the equipment.
5.
Always ensure vibration free fitment of the equipment.
6.
Download the fault data and analyze carefully to take corrective action.
DONTs
1.
Never try to bypass any input/ output cards by using external cables without properly
studying the repercussions after such bypassing.
2.
Never try to modify the main configuration settings of the system without proper
knowledge of the software/ hardware.
3.
Never switch OFF the battery supply while the system displaying Busy with USB
communication.
4.
Never do any Hammering, Welding, Gas cutting in the vicinity of the CPU as it may
lead to malfunctioning or permanently damage the system.
GENERAL GUIDELINES
1.
Encourage all concerned staff to always follow systematic approach while working on
the sophisticated equipment.
2.
Make available all related information like trouble shooting and maintenance manuals
3.
Use proper tools & handling equipment.
4.
Record all activities carried on a particular system.
5.
Maintain good understanding with firms service personnel to give and take the
information as and when required.
July 2010
28
REFERENCES
1.
IRIEEN Journals Vol.II, July Sept. 1992, Vol.14 No.2, April June 2004.
2.
Operation, Trouble Shooting and Maintenance manual of Microprocessor Based

Controlled and Fault Diagnostic System Type MCS 657 of Medha Servo Drives Pvt.
Ltd., Hydrabad.
3.
Field study and Literature collected from various electric loco sheds/ workshops.
4.
Presentations given by participants from various Electric Loco Sheds during seminar
conducted on 16TH July 2010 at IRCAMTECH/ Gwalior.
*****
July 2010
29
OUR OBJECTIVE
To upgrade maintenance technologies and

methodologies and achieve improvement in
productivity, performance of all Railway
assets and manpower which inter-alia would
cover reliability, availability, utilisation and
efficiency.
If you have any suggestions and any specific Comments

please write to us.
Contact person
Director (Elect.)
Postal Address
Indian railways
Centre for Advanced
Maintenance technology,
Maharajpur, Gwalior.
Pin code 474 005
Phone
0751 2470740
0751 2470803
Fax
0751 - 2470841
July 2010

Introductory Handbook On Microprocessorcontrolled Electric Locomotives

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Introductory Handbook On Microprocessorcontrolled Electric Locomotives

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What is the quality policy of CAMTECH?

What is the quality policy of CAMTECH?

What are the key features of microprocessor based control system introduced in locomotives?

What are the key features of microprocessor based control system introduced in locomotives?

CAMTECH/E/10-11/MPC-Loco/1.

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Hkkjr ljdkj GOVERNMENT OF INDIA

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Introductory Handbook on Microprocessor Controlled Electric Locomotives (MBFDS)

Introductory Handbook on Microprocessor Controlled Electric Locomotives (MBFDS)

Introductory Handbook on Microprocessor Controlled Electric Locomotives (MBFDS)

RELAYS/ FUSES REMOVED

ADDITIONAL SWITCHES PROVIDED

SIGNAL CONDITIONING UNIT

INTELLIGENT SIGNAL CONDITIONING UNIT

SYSTEM BLOCK DIAGRAM

TECHNICAL SPECIFICATIONS (MEDHA MCS 657)

INTELLIGENT SIGNAL CONDITIONING UNIT

SIGNAL CONDITIONING UNIT

OPERATIONAL BLOCK DIAGRAM

DIGITAL INPUT DETAILS

DIGITAL OUTPUT DETAILS

OUTPUT TO INPUT LOGIC

Introductory Handbook on Microprocessor Controlled Electric Locomotives (MBFDS)

ISSUE OF CORRECTION SLIPS

Page no. and Item

Introductory Handbook on Microprocessor Controlled Electric Locomotives (MBFDS)

Traction power control

Status of all 128 Digital inputs

Introductory Handbook on Microprocessor Controlled Electric Locomotives (MBFDS)

Signal Conditioning Unit

Intelligent Signal Conditioning Unit

Current Sensing Unit

Central Processing Unit

Light Emitting Diode

Liquid Crystal Display

Universal serial Bus

Single phase to 3 phase AC converter

Real time clock

Elimination of a numbers of relays (Time delay relays, sequential relays, indication

Elimination of notch indication system

Enhancement of availability of locomotive

Reduction in numbers of interlocks required

Reduction in size of master controller

Reduction in control wiring

Fault diagnosis, indication and recording

Easier and least maintenance

Vigilance control and flexibility

Introductory Handbook on Microprocessor Controlled Electric Locomotives (MBFDS)

RELAYS/ FUSES REMOVED

RELAYS/ FUSES REMOVED

Q44, Q45, Q118, Q30, QCVAR/QSVM, Q46

Q100, QTD105, 106, Q119

QV60 to 64, QVLSOL

Q50,51,52, QD-1,2, QRS, QWC, QF-1,2, Q48, Q49, Q20

CCDJ, CCLSA, CCA

ADDITIONAL SWITCHES PROVIDED

For ACP circuit