Total Population 365

Converter Under Warranty Converter Out of Warranty 264 110

Converter Under Warranty 264

Under warranty Failure 65 Performance after ELD Modification No of Failure 25

FRPCPY 32.8

Modified Converter 241

FRPCPY 24.9

Failure Analysis of 180 KVA ConverterUnder Warranty

Rly Shed name Loco SIV No. Type DOC RIP Failure Fault Reported Failure Analysis Action Taken Remark No. of SIV MOD Date CR ELS / AQ 27838 OB1800610021 GC 06.01.07 05.12.0706.07.08 Converter tripping and FAN_FT 3 phase cooling fan producing 3 phase cooling fan replaced. AAL fault recorded. abnormal sound ECOR ELS/VSKP 27785 OB1800706002 GC 09.07.07 25.01.0828.02.08 Battery charger not working. Battery charger GDU card Same tighten properly AAL ECoR ELS/VSKP 27886 OB1800706006 GC 10.07.07 01.03.0818.05.08 SIV sometime tripping on DC_LV SIV tripping on DC_LV fault on full Sheiled wire between TGDU to AAL fault . load . On full load the DC link Thyristor replaced. voltage drop to less than 450 volts. one of sheiled wire between TGDU to Thyristor was open causing no gate pulse to one Battery charger blocking diode AAL Battery charger blocking diode ECoR ELS/VSKP 27978 OB180080314 GC 20.05.08 FM 31.05.08 Battery Charger not working ECoR ELS/VSKP 27887 OB1800706004 ECoR ELS/VSKP 27977 OB1800803105 ECoR ELS/VSKP 27980 ER ER ER ER OB1800 GC GC GC GC GC GC GC GC 20.07.07 23.01.0801.07.08 Convertor tripping on DC_LVD TGDU card to Thyristor , sheilded Defective cable replaced. fault cable found open. Only one 20.05.08 FM 11.07.0 Converter tripping and GDU_WF Thyristor triggering . GDU card GDU card replaced W Phase inverter 8 fault recorded . defective FM Converter tripping and GDU_WF W Phase IGBT burst and IGDU W Phase IGDU card and IGBTs fault recorded card defective replaced. 19.06.07 23.02.0829.08.08 Converter tripping on GDU_WF W phase GDU card defective. GDU card replaced 31.01.08 FM 15.03.08 Converter not working and CCINV Power supply card MOV (surge Power supply card replaced. MOV fuse melting suppressor RV 1 short) is used to protect the card against 31.01.08 FM 21.04.08 Battery charger not working. One wire of molex connector of surge voltage. Replaced the lug. battery charger GDU card found lug. 09.06.07 27.11.0724.01.08 Battery charger sometime tripping broken from 1500 Capacitor f /400 V Capacitor and 27 K resistor and BCHGDU_FT fault . defective replaced MCU card replaced. 04.03.08 FM 20.09.08 Converter working but battery charger MCU card defective. not working when MVRF is turn ON. 21.01.08 FM AAL AAL AAL AAL AAL AAL AAL AAL

ELS/ASN 27879 OB1800703055 ELS/ASN 23349 OB1800708026 ELS/ASN 23349 OB1800708026 ELS/ASN 27877 OB1800703061

NCR ELS / CNB 27955

OB18008010 69

NCR

30.06.08 Battery charger working but Battery charger blocking diode Blocking diode replaced LSCHBA OFF evenwhen battery short. charger is in OFF condition. NCR ELS / JHS 27939 OB1800712049 GC 21.01.08 FM 17.04.08 Converter tripping frequently No problem found during testing. However MCU card replaced as precautionary NCR ELS / JHS 27939 OB1800712049 GC 21.02.08 FM 20.04.08 Converter tripping frequently ACPT-1 defective Replaced ACPT-1 and provided original MCU card NCR ELS / JHS 27939 OB1800712049 GC 21.01.08 FM 02.05.0 SIV tripping frequently and input SIV was tripping due to low input Pin and connector replaced 8 low voltage showing on display voltage sensing . Loose panel. connection found in lug of pin no. 38 found of Power supply card .Due to this MCU was reading input voltage half of actual. Actual voltage was 1050V but MCU sense it 525 volts. NR ELS / LDH 22691 OB1800610026 GC 01.03.07 04.12.0729.08.08 Converter tripping on GDU_UF Converter make three times DJ All the OFC connectors clean and fault. open through QSIT relay at line . refit. U phase and W phase GDU During testing at ELS / JHS no card interchanged. tripping observed. NR ELS / LDH 27679 OB1800701048 GC 05.06.07 03.12.0724.08.08 Converter tripping on DC_LVD MCU card defective. MCU card replaced. file:///opt/scribd/conversion/tmp/scratch32326/62235800.xls

ELS / JHS 27939 OB1800712049

GC

AAL

AAL AAL AAL

AAL

AAL

Rly Shed name Loco No. NR ELS / LDH 27662

SIV No. OB1800701051

Type DOC RIP Failure Fault Reported of SIV MOD Date GC 06.5.07 07.12.07 16.09.08 Battery charger not working

Failure Analysis

Action Taken

Remark AAL

Battery charger MCCB was in tripped No action taken condition. No abnormality found in charger.

NR NR NR

ELS / LDH 27624 OB1800701047 ELS / LDH 27848 OB1800612034 ELS / LDH 22692 OB180061203 7 ELS / LDH 27851 OB1800612033 ELS / KZJ 27830 OB1800609017 ELS / KZJ 27853

GC GC GC

NR SCR SCR

GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC

OB18006110 31 SCR ELS / LGD 22747 OB180071205 4 SCR ELS / LGD 22716 OB1800706012

3 Phase MCCB found in tripped MCCB switched ON again and no condition problem observed 09.02.07 25.10.0731.03.08 Converter not working and DC_OV One DC link filter capacitor DC link filter capacitor replaced fault recorded defective 27.03.07 29.02.0807.08.08 Converter tripping on transient No problem found in SIV. MCU Card, Fault Card, Logger fault Microprocessor control system Card and PSAD Card , Card malfunctioning causing DOL replaced as precautionary basis. starting of MVMT's sometimes. 23.02.07 08.12.0716.07.08 Converter tripping and FAN_FT 3 Phase Axial fan defective . 3 phase Axial fan replaced. fault recorded. 5.12.0620.02.0816.09.08 Converter not working and W phase one Inverter IGBT W phase both Inverter IGBT and GDU_WF fault recorded. defective. GDU card replaced. MCU card connection tighten 28.02.07 22.01.08 22.09.08 Converter tripping on GDU_WF fault. MCU card connection was loose. 31.03.073.02.08 03.02.08 Battery charger not working
properly.

AAL AAL AAL

AAL AAL AAL AAL AAL AAL AAL

SECR ELS / BIA 27844 OB180061002 3 SER ELS / BNDM 27970 OB18008031 02 SCR SR SR SR SR WCR WCR WCR WCR WCR ELS / KZJ 27853 OB180061103 1 ELS / ED ELS / ED ELS / ED ELS / ED ELS/TKD ELS/TKD ELS/TKD ELS/TKD ELS/TKD 27497 OB1800806020 22671 OB18006060 27906 OB1800706016 22671 OB1800606003 27635 27635 27635 27635 R & D -1 R&D-I R & D -1 R&D - 1

01.06.0 Converter sometimes tripping on U phase CT burden value CT burden resistor replaced 8 IN_OC1 and Sphase _FT fault detoriorated . 29.09.07 21.01.0818.02.08 Converter tripping sometime on M 15 wire lug broken on DCPT end New lug provided DC_LVD fault. Secondary side of battery charger High frequency transformer 28.01.07 27.12.07 02.09.0 Battery charger not working high frequency transformer burnt. replaced. 8 03.05.08 FM 22.09.08 Converter working but battery charger Two diode of input rectifier section of Input rectifier section diode replaced. battery charger open circuit. not working. 28.02.07 2..01.08 2 11.08.08 Converter not working, 13.09.08 FM Chopper IGBT, Thyristor CHGDU card defective

and Chopper IGBT, both thyristor and AAL CHGDU card replaced AAL AAL AAL AAL AAL AAL AAL AAL AAL

15.09.08 Converter not working and Thyristor defective . Input fuse Thyristor and Input fuse yet to be FUSE_FT fault recorded. ( 630 A ) blown. replaced. W phase GDU card replaced 29.07. 14.09.07 24.09.08 Converter tripping on GDU_WF fault. W phase GDU card defective. 16.11.07 FM 28.04.08 Inverter working but fan producing 3-Phase axial fan defective. 3phase cooling fan replaced abnormal sound Bearing producing abnormal sound charger IGBT and Diode IGBT 100A and diode 56A (03 Battery 29.07.06 14.09.0729.07.08 Battery charger not working defective nos. ) replaced 23.07.05 05.07.0710.03.08 Inverter working but fan producing 3-Phae cooling fan defective. 3 phase cooling fan replaced abnormal sound Bearing producing abnormal sound 23.07.05 04.09.08 Battery charger sometime not working DC capacitor 4700f/1000Volt & High DC capacitor 1500f/1000 volt & Main
frequency transformer defective. transformer provided.

23257 OB1800612040

23.07.05 05.07.0711.01.08 Smoke reported from Converter, U Phase both IGBT defective GDU_UF fault recorded 16.06.05 14.06.08 Converter not working, DC_LV DCPT defective . fault recording. 01.10. 22.09.07 03.08.0 Converter tripping and GDU_ VF V Phase IGDU card defective 07 8 fault recorded

U Phase both IGBT replaced DCPT replaced. V Phase IGDU card replaced.

file:///opt/scribd/conversion/tmp/scratch32326/62235800.xls

Rly Shed name Loco No. WCR ELS/TKD 27635

SIV No. R & D -1

Type DOC RIP Failure Fault Reported of SIV MOD Date GC 23.07.05 28.10.0706.08.08 Battery charger not working GC GC

Failure Analysis

Action Taken

Remark AAL AAL AAL

WCR ELS/TKD 27635 R & D -1 WR ELS / BRC 22675 OB1800608006

Molex pin was come out from Same insert properly conector of BCHGDU card Battery charger IGBT 100A 23.07.05 28.10.0711.08.08 Battery charger not working Battery charger IGBT defective 39002 02.01.08 27.09.08 Converter working but fan producing 3 phase cooling fan bearing defective. 3 phase cooling fan replaced. abnormal sound. Fan undergone service life of 2 years. 07.06.07 20.12.0724.03.08 Battery charger not working. Battery charger blocking diode Blocking diode replaced 12.10. 02.01.0 09.05.0 SIV working but battery charger Battery charger GDU card OFC Battery charger GDU 06 8 8 somtime not working. female socket ( RX2 ) pin replaced 13.10.06 09.07.0808.07.08 Abnormal sound coming from SIV desoldered at fan defective . 3 Phase Axial PCB end. 3 phase Axial fan replaced.

WR WR WR

ELS / BRC 22704 OB1800703053 ELS / BRC 22675 OB1800608006 ELS / BRC 22676 OB1800608008

GC GC GC

AAL card AAL AAL

file:///opt/scribd/conversion/tmp/scratch32326/62235800.xls

Date : 10.11.08

Performance of Modified Static Converter ( AAL make ) As on date total modified converter = 241
SI No . SHED NAME LOCO INVERTER NO. NO.
22692 GC

DOC

DOM

DOF

DEFECT REPORTED

DEFECT ANALYSIS

1 ELS/NR/LDH

Inverter tripping on transient No problem found regarding faults like DC_OC and transient faults in Converter. OB18006120 27.03.0 05.08.0 AC_OC1 07.08.08

37

2 ELS/SR/ED 3 ELS/NR/LDH

22671 OB18006060 29.07.0 18.07.0 Smoke emission observed SIV found tripped on ELD_FT & 20.08.08 from SIV. GC 03 AC_OC1 faults . MVRH burnt. 6 8 27679 OB18007010 05.06.0 20.08.0 Inverter tripping 24.08.08 DC_LVD fault. GC 48 7 8 on MCU card defective.

4 ELS/ER/ASN

27879 Converter sometimes not Converter tripping somtiomes GC OB18007030 19.06.0 07.08.0 29.08.08 working. on GDU_WF fault. W phase 55 7 8 GDU card defective.
Converter 22691 OB18006100 01.03.0 02.08.0 GC 29.08.08 sometimes . 26 7 8 tripping No problem observed during testing. The Converter might have tripped due to transient fault.

5 ELS/NR/LDH

27453 Converter tripping OB18002020 29.03.0 10.08.0 6 ELS/WCR/TKD KIT - 2 05.09.08 FAN_FT fault. 16 3 8 27853 GC
Converter working . sometime

on Main blower defective. ( Service life undergone 5.5 years).

not No problem found in the Converter. However the insulation OB18006110 28.02.0 10.08.0 of the Wire connected between ELS/SCR/KZJ 11.08.08 Equalizing Resistor to A0 Terminal 31 7 8 of main transformer was found cut . This has caused sparking Converter tripping on Single and finally, the wire is opened. No problem observed during 23251 Phasing fault . testing in Converter. This KIT - 2 problem might have raised to due OB18002020 21.08.0 04.08.0 ELS/WCR/TKD 24.08.08 malfunctioning / chattering of 11 2 8 CP's / MVMT's contactors.

27635 GC 9 ELS/WCR/TKD R&D-1 06.08.08 16.06.0 17.05.0 11.08.08 5 8 01.09.08

Battery charger sometime not The value of DC capacitor was working. deteriorated ( 4000 if instead of 4700 f/1000Volt

ELS / LDH 10 11 12 13 ELS / KZJ ELS / BIA ELS / ED ELS / TKD 14

27662OB180070105106.5.07 15.09.0816.09.08 Battery charger GC working

not Battery charger MCCB was in tripped condition. No abnormality found in charger. 27830OB18006090175.12.06 31.07.0816.09.08 Converter not working and W phase one Inverter IGBT GC GDU_WF fault recorded. defective. not Secondary side of battery charger high frequency transformer burnt. 27497OB1800806020 13.09.08 FM 15.09.08 Converter not working and Thyristor defective and Input GC FUSE_FT fault recorded. fuse ( 630 A ) blown. 23251OB1800202011 21.08.02 04.08.0805.09.08 Converter tripping on External fault LAMP glow when KIT -2 ELD_FT and SPHASE_FT battery turn ON. ELD control fault. card defective. 27844 OB18006100 28.01.07 06.07.0802.09.08 Battery charger GC 23 working

15 16 17 18 19

ELS / ED ELS / JHS ELS / LDH ELS / TKD ELS / MGS

ELS / NKJ 20 ELS / MGS

21

22224 OB18008060 29.08.08 FM 03.10.08 Battery Charger not Battery Charger IGBT GC 23 working defective. 28005 OB18008020 05.09.08 FM 04.10.08 Converter tripping on One Thyristor gate - emitter GC 89 rectifier fault on full load. open . 22691OB1800610026 01.03.07 02.08.0805.10.08 Converter tripping on MCU card defective. GC GDU_UF fault 23132 OB18006010 14.12.07 17.09.0806.10.08 Converter tripping on U Phase inverter GDU card KIT -3 72 GDU_UF fault defective. 27007OB1800201006 27.11.03 27.09.0810.10.08 Converter not working CCINV fuse of Loco was KIT -2 melting , (+15 and +110 V supply shorted in cable tray . 27694 OB18004020 27.09.08 18.09.0810.10.08 Converter not working, U-Phase was not generating KIT -2 08 FAN_FT recorded. due to MCU card problem causing over heating of fan winding (FAN fault). 22939OB1800801060 12.02.08 27.09.0810.10.08 Converter tripping on No problem observed in GC S_ Phasing fault Converter .

22

ELS / MGS ELS / CNB

23 ELS / MGS 24

27331OB1800201009 08.04.02 05.09.0811.10.08 Converter Tripping on KIT -2 ELD fault 27475 OB18040301 26.06.04 07.09.08 12.10.08 Converter Tripping on KIT -2 6 GDU_UF fault

MCU Card defective . GDU_UF faults were recorded but during testing ,No problem found . MCU Card defective. Replaced the same on precautionary measures . ELD card defective. & One Thyrister was not getting pulse from TGDU card .

22939OB1800801060 12.02.08 27.09.0816.10.08 Converter tripping on GC S_ Phasing fault

26

ELS / TKD ELS / TKD

27 ELS / ED 28 29 ELS / MGS

23640OB1800201003 26.06.04 13.07.08 17.10.08 KIT -2 21107 OB18003110 28.08.0 27.08.08 19.10.08 KIT -2 07 4

Converter tripping on ELD fault Converter tripping showing rectifier fault.

27904 OB18007080 18.11.07 13.08.08 17.10.08 Smoke reported GC 20 Battery charger 27522 OB18002100 11.02.03 20.08.08 20.10.08 Converter tripping KIT -2 16 ELD_FT (Internal)

from 10 ohm resistor of snubber card of Blocking Diode burnt. on ELD card defective.

Date : 10.11.08

e)

ACTION TAKEN
During IB, all Contactors of MVMT's and CP's were cleaned and after that no tripping observed.

MVRH replaced by shed. MCU card replaced. The card is under investigation. W phase GDU card replaced. Further , power test to be done in the card.
The loco is kept under observation for 10 day but no problem found.

Main blower replaced.

Wire replaced. It is a workmanship problem from AAL side. M/s AAL will take care of this point. No action taken in Converter. However the contactors were cleaned and loco was kept under observation for 10 days but no problem has been noticed.

Both the old Capacitors were replaced with new DC Capacitors of 1500f/1000 volt. However it has nothing to do with modification & AAL felt that the value of the Capacitors to be verified in AOH.

No action taken

W phase both Inverter IGBT and GDU card replaced. High frequency replaced. transformer

Thyristor and Input fuse replaced. ELD control card replaced. Battery charger load and battery connection point interchanged. Battery charger Ammeter also changed as it is defective. Battery charger IGBT and GDU card replaced Thyristor replaced. MCU card replaced U Phase inverter GDU card replaced Dressed cables properly after providing insulation tap . MCU card replaced.

Loco Escorted from MGS to Gaya ,no problem reported.

Replaced MCU Card. Escorting Loco from NKJ to Sagar.No problem observed during escorting ,given fit for service. Since this Loco was failed second time with same problem with in 3 days. Loco kept under observation in shunting for two days. ELD card replaced After removing & cleaning , reinserted all connectors. Converter working normal on full load. Value of Resitance & Capacitor ok ,.but due to over heating , resistor become blackish. ELD card replaced.