Professional Documents
Culture Documents
ekbksizkslslj
MEP-660 (Ver-2.0)
ij yxs
ls lEcfU/kr
FOREWORD
Microprocessor Based Control System have been introduced
recently on Diesel Electric Locomotives.
Microprocessor
Date: 30.04.2011
CAMTECH, Gwalior
S. C. Singhal
Executive Director
Back to contents
ii
PREFACE
Micro Processor Control System is the vital part of a diesel
electric locomotive. This System is recently introduced on Indian
Railways for ensuring higher reliability and better availability of
locomotives. Proper knowledge of system and trouble shooting
is necessary to ensure reliability and availability of locomotives
in sheds as well as on line.
This book contains trouble shooting on Micro Processor based
control system MEP 660 (Ver-2.0) fitted locomotives for diesel
drivers during problems enroute. Loco pilots should understand
the steps sequentially to save time during trouble shooting.
The purpose of this book is to enhance knowledge and
competence of loco pilots in dealing with the problems of Diesel
locomotive on run. This trouble shooting guide also contains the
description of MEP660 (Ver-2.0) Micro processor system so that
loco pilot can easily understand the microprocessor system.
This book will be useful to the maintenance staff and loco
inspectors also for counselling running staff about MEP660
(Ver-2.0) Micro processor system.
It is clarified that this handbook does not supersede any existing
procedures and practices laid down in the maintenance
instructions issued by manufacturers or by RDSO/LKO.
Technological Upgradation and learning is a continuous process.
Hence feel free to write to us for any addition / modification in
this handbook or in case you have any suggestion to improve the
handbook. Your contribution in this direction shall be highly
appreciated.
30th April 2011
CAMTECH, GWALIOR
(K.P.Yadav)
Director/Mech
Back to contents
iii
CORRECTION SLIPS
The correction slips to be issued in future for this
handbook will be numbered as follows:
CAMTECH/2011/M/MPCS-TSG/1.0/C.S. # XX date --------------Where XX is the serial number of the concerned
correction slip (starting from 01 onwards).
Date of
issue
Remarks
Back to contents
iv
Contents
SNo.
Description
Page No.
Forward
ii
Preface
ii
iii
Correction Slip
iii
Contents
iv
1.0
2.0
4.0
5.0
6.0
7.0
10
8.0
14
9.0
10.0
Trouble Shootings
Code
1001
18
1002
20
3.0
3
5
15
18 to 47
21
23
v
24
1007
1008
26
1018
28
1019
31
1061
33
1074
35
1075
37
1140
40
1029
43
2000
45
2029
46
1153
47
1015
27
1.0 INTRODUCTION
SYSTEM:
OF
EXCITATION
CONTROL
Governor
Diesel
Engine
Traction
Alternator
Aux.Gen
Exciter
Rectifier
Panel
Power
Contactor
Excitation
Control
Propulsion
Control
AG
Control
Engine
Control
Traction
Motors
Control
Desk
CAMTECH/GWL
Back to contents
Traction
Alternator
Aux.Gen
Exciter
Rectifier
Panel
Traction
Motors
Power
Contactor
MICRO PROCESSOR
Propulsion
Excitation
CONTROL
SYSTEM
Control
Control
AG
Control
Engine
Control
Control
Desk
CAMTECH/GWL
Back to contents
3
MICROPROCESSOR
Back to contents
Back to contents
9.
Control Panels:
CAMTECH/GWL
Back to contents
Resistor Panels:
Wheel slip resistor panel (WSRR1& 2)
Wheel slip control resistors WR8, WR9 & WR10
Oscillator Voltage Dividing panel (OVDR)
Generator Voltage Dividing panel (GVDR/VDP)
Tacho generator load resistor panel (TGLR)
Braking limiting resistor panel (BKER1 & 2)
Relays:
12 Relays have been removed and remaining 11
relays retained.
Rotating machines:
Axle Alternator
Tacho Generator
6 TM Speed sensors
ESS
Miscellaneous items:
Transition Excitation Transformer (TET)
Armature Current control reactor (ACCR)
Stabilizing panel (Stab. Panel)
Voltage regulator current limiting shunt
Load ammeter shunt (LAS)
Engine Temperature Switches
6.0 DESCRIPTION
OF
SOME
IMPORTANT
ASSEMBLIES:
The Microprocessor based Locomotive Control System MEP
660 consists of the following sub assemblies.
6.1 CONTROL UNIT TYPE MEP 660
CAMTECH/GWL
Back to contents
CAMTECH/GWL
Back to contents
CAMTECH/GWL
Back to contents
Back to contents
10
CAMTECH/GWL
Back to contents
11
Back to contents
12
Main menu
1) Sub Menu 1
1). Sub Menu 2
1). Sub Menu 3
Display
parameters
7.1. Faults
i) View Active faults Registered faults if any will be
displayed User can navigate
through the faults using down
arrow key until 'No more
faults logged' message is
CAMTECH/GWL
Back to contents
13
displayed.
Press 'MENU' key to select
'Exit' option.
ii) Clear Active faults "Use '0' to clear faults" Message
will be displayed. After few
seconds Logged faults are
displayed one by one. After
noting down the faults, to clear
fault Press '0' key and down
arrow key to see next fault..
Continue the above till all
faults are cleared. Press
'MENU' key to select exit
option.
7.2. Display Mode
1) Excitation
2) Auxiliary
CAMTECH/GWL
Back to contents
3) Wheel Slip
4) Mixed
14
5) Driver Display
The driver/ default display has got three screens. a) IDLE
screen, b.) Motoring screen, c.) Braking screen.
Respective screens are changed automatically based on the
control stand signals while the locomotive operation is being
set by the driver. In each screen relative parameters are
displayed as shown below.
IDLE Screen
Notch
Idle
LOT
xxx.x
BAAmps +xxx
LOP
xx.x
Motoring Screen
Notch
x Engine RPM xxxx
T A Amps xxxx TA Volts
xxxxx
Kmph
xxx.x
Gross HP xxx x
CAMTECH/GWL
Back to contents
15
6) MCBG Status
Back to contents
16
4) Exit
B) Press key 1 to select Faults
The following submenu appears
1) View active Faults
2) Clear Active Faults
C) Press key 2 to select Clear Active Faults
Use 0 key to clear faults message appears first on the
screen. After some time the registered faults are shown one
by one based on the priority of the faults. Press key 0 once
and then Enter key to clear the fault displayed on the
screen. The fault is cleared and next fault is displayed.
9.0 DOS AND DONTS
DOS
1. Keep always TE Limit
switch in Normal
position unless and
until required.
2. Keep MCOS switches
always in ON position
for normal operation.
3. Make a habit to check
position of these TE
Limit
and
MCOS
switches while taking
overcharge.
4. Switch OFF Circuit
breakers MCB1 and
MCB2 on control desks
while cranking.
DONTS
1. Do not keep TE Limit
switch in Limit position
unnecessarily when not
required.
2. Do not keep MCOS in
OFF position while all
motors are working.
3. Do not start the loco with
out ensuring these switch
position.
4.
Back to contents
17
cranking
contactors
picks up. (more than 60
sec. if pre lube feature
is available.)
6. Switch ON circuit 6.
breaker CEB within 30
minutes while checking
lube oil level.
7. Switch OFF circuit 7.
breakers MCB1 &
MCB2 in case of Rear
Locomotive to avoid
VCD function.
8. Keep
EPG
cutout
Switch in OFF position
in trail / dead locos.
button
in
between.
Otherwise the time starts
again.
Back to contents
with message TM #
Excess current.
12. Apply loco brakes
when total power is
reduced at 95 deg.
Centigrade to avoid roll
back.
13. Press VCD Reset when
the VCD Lamp blinks
18
loco is moving unless and
until
warranted
by
railroad signals.
12. Do not release brakes till
the locomotive is ready to
move. (@ 90 deg.
Centigrade of engine
temperature.)
13. Do not isolate VCD
magnet valve cutout cock
unless and until the valve
is leaking.
14. Do not try to reset
penalty brakes if
1. Loco is moving, or
2. Throttle is in notch / Dy.
brake
3. VCD lamp is blinking.
CAMTECH/GWL
Back to contents
19
Fault Code
1001
Back to contents
For
Maintenance
Staff
20
Power controller
A. If both LEDS are not ON with LWS normal
position (full water),
i) Check Voltage at wire No. TO1 on
backside TB. Observe for any disconnected
wires. If so reconnect.
ii) If voltage at wire No. TO1 is zero
a) Check voltage at wire No. 51 at
backside TB. Observe for any
disconnected wires at the terminal. If
so reconnect.
b) If voltage is >65V.
i. Either LWS wiring or LWS faulty
Check wiring continuity of wire 51
from backside TB to LWS.
Check wiring continuity of wire
No. TO1 from LWS to backside
TB.
Check for any disconnected wires
at LWS.
If wire continuity is good, LWS
micro switch is defective. Replace
and check.
ii) If the Voltage at back side TB on wire
No. TO1 is > 65V
a) Check the wiring continuity of wire No.
TO1 from backside TB to MEP-660 by
removing the coupler (DI32- DI47) - (Pin.
E). If no continuity replace the cable.
b. If only Green LED is glowing, and yellow
LED is not glowing, it indicates that the LWS
feed back input is available upto digital input
card and the DI card in slot 11 is defective.
Replace the card.
CAMTECH/GWL
Back to contents
21
Action by
Loco Pilot
For
Maintenance
Staff
Back to contents
22
CAMTECH/GWL
Back to contents
23
Fault Code
Fault Message
Restrictions
Alarm Bell
Fault
Recovery
Probable
causes
Action by
Loco Pilot
For
Maintenance
CAMTECH/GWL
Back to contents
Staff
For
Maintenance
Staff
24
CAMTECH/GWL
Back to contents
25
Fault Code
1006
Alarm bell
Fault
Recovery
Probable
causes
Action by
Loco Pilot
CAMTECH/GWL
Back to contents
26
Fault Code
1007
Back to contents
Action by
Loco Pilot
27
For
Maintenance
Staff
CAMTECH/GWL
Back to contents
28
Probable
causes
Action by
Loco Pilot
CAMTECH/GWL
Back to contents
29
Fault Code
1015
Fault Message
Restrictions
Motoring prohibited.
Alarm Bell
30 Seconds.
Reset Level
Low, Manual
After manual reset if the fault still present, the
fault will be generated again.
Action by
Loco Pilot
CAMTECH/GWL
Back to contents
30
Fault code.
1018
Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes
Action by
Loco Pilot
1. Defective GF contactor.
2. GF coil burnt.
3. Defective GFCO
4. Wiring fault from MEP-660 to GF contactor
coil.
5. Positive supply to GF contactor operating
coil is missing.
1. Check wire terminal from MEPP-660 to GF
contactor coil.
2. Check operation of GF contactor
3. Check GF contactor coil
4. Check operation of GFCOs
5. Set the Display to Manual Tests for
Outputs mode through Test Mode Menu and
satisfy the initial conditions required to run
manual test as prompted on the display unit.
6. Press 13 + Enter Key+1 to energize GF
contactor.
7. If GF contactor energizes, then
A. Check up for proper closing of main contact
tips and Auxiliary contacts.
B. The status of GF Aux. Contact 1 can be
checked through 0 number Green and Yellow
LEDs on digital input card MDIP-16 in slot 11.
CAMTECH/GWL
Back to contents
Action by
Loco Pilot
For
Maintenance
Staff
31
Back to contents
For
Maintenance
Staff
32
CAMTECH/GWL
Back to contents
33
Fault code.
1019
Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes
Action by
Loco Pilot
Back to contents
Action by
Loco Pilot
34
CAMTECH/GWL
Back to contents
35
Fault code
1061
Fault
message
Restrictions
Alarm bell
Reset level
Fault
recovery
Probable
causes
Action by
Loco Pilot
For
Maintenance
Staff
Back to contents
For
Maintenance
Staff
36
CAMTECH/GWL
Back to contents
37
Fault code.
1074
Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes
Action by
Loco Pilot
For
Maintenance
staff
Back to contents
For
Maintenance
staff
38
CAMTECH/GWL
Back to contents
39
Fault code.
1075
Fault message
Restrictions
Alarm bell
Fault
recovery
Probable
causes
Action by
Loco Pilot
For
Maintenance
staff
CAMTECH/GWL
Back to contents
For
Maintenance
staff
40
Back to contents
41
CAMTECH/GWL
Back to contents
42
Fault code.
1140
Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes
Action by
Loco Pilot
CAMTECH/GWL
Back to contents
Action by
Loco Pilot
For
Maintenance
staff
43
for cranking.
6. Press start button
7. CKC contactor should pick up
C. If corresponding LED is not going OFF,
a) Check the supply voltage on the
corresponding
feedback
wire
(CK1FB/CK2FB/CK3FB) with respective to
locomotive 4 wire.
b) If the supply is zero while the auxiliary
contact is opened manually and still the
Green/Yellow LED is glowing, then the digital
input card MDIP 16 card in slot 10 is defective.
Replace the card.
c) If the supply voltage is more than 65V, then
wiring mistake. Identify from where the supply
is feeding and rectify.
5. Close the battery knife switch and prepare
the loco for cranking.
6. Pack the CK1, CK2, and CK3 contacts with
an insulating sheet so that auxiliary contacts
open when they operate and no battery supply is
going to Aux. Machines.
7. Press start button.
8. CKC should pick up.
9. If CKC is not picking up.
A. Check the voltage at the operating coil of
CKC.
B. If the voltage is more than 65 Volts and still
CKC is not picking up, then CKC is
defective. Replace the CKC.
C. If the voltage is zero, then check the voltage
at wire No. 71 with respect loco wire No. 4.
CAMTECH/GWL
Back to contents
For
Maintenance
staff
44
CAMTECH/GWL
Back to contents
45
Fault code
1029
Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes
Action by
Loco Pilot
Back to contents
Action by
Loco Pilot
For
maintenance
staff
46
CAMTECH/GWL
Back to contents
47
Fault code
2000
Fault message
Message code
Restriction
Description of
Fault
Display buzzer
ON duration
Alarm Gong
ON duration
Probable
Causes
Action by
Loco pilot
None
1. Auxiliary Generator failed to develop
voltage and batteries are not charging
1. Check AGFB circuit breaker and MB1 for
tripping.
2. Insure proper tightness of ESS Connector
on ESS.
The following faults will also be displayed
as warning since loco running on batteries.
1062--- Battery Voltage is high
1063 -- AG field drive short
1141 AG output high fault
1142 Battery charging current high .
1143 AG Output over current fault
1144 AG field over Current
1145 AG output open circuit fault.
1146 AG field circuit open or short
CAMTECH/GWL
Back to contents
48
Fault code
2029
Fault
message
Restrictions:
Description
of Fault
Displayed
message
duration
Display
buzzer ON
duration
Alarm Gong
ON duration
Fault
Recovery
Probable
causes
Action by
Loco Pilot
Cranking Prohibited.
This message is shown when operator
attempts cranking while Cranking contactor
stuck closed
Fault is already logged in the system.
5 Seconds
5 Seconds
None
Automatically recovers when feedbacks of
CK1, CK2 & CK3 main or auxiliary contacts
are comes to normal condition as sensed by
the system through their respective inputs.
Main tips of cranking contactor CK1, CK2,
CK3 might have welded.
1. Shut down the engine.
2. Open battery knife switch
3. Check for any weld condition of the
contactors. Release the main tips with a
wooden stick & clean it.
4. After the tips are separated, alarm bell
stops & the reset message is displayed
Cranking contactor stuck closed FAULT
CAMTECH/GWL
Back to contents
49
CAMTECH/GWL
Back to contents
50
Fault code.
1153
Fault
message
Restrictions
Alarm bell
Fault
recovery
Probable
causes
Action by
Loco Pilot
CAMTECH/GWL
Back to contents
OUR OBJECTIVE
To Upgrade Maintenance Technologies and
Methodologies and achieve Improvement in
Productivity and Performance of all Railway
Assets and Manpower which Interalia would
cover Reliability, Availability, Utilisation and
Efficiency.
Director (Mech)
Postal Address :
Indian Railways ,
Centre for Advanced
Maintenance Technology,
Maharajpur,Gwalior.
Pin Code
474005
Phone
0751-2470803, 2470890
Fax
0751-2470841
Back to contents