Loco Model Booklet 2003

ELECTRIC LOCO TROUBLE SHOOTING TRAINER

SANKATI SRINIVAS SSE/TRS/ELS/VSKP

MAY 2012

Introduction "We learn by example and by direct experience because there are real limits to the adequacy of verbal instruction." – Malcolm ladwell Loco troubleshooting and quick remedial action is one of the prime objectives of loco pilots. I on behalf of Mr P.K.JAIN CEE/BBS and Mr.KASINATH DRM/WAT take pride in producing and presenting this “ELECTRIC LOCO TROUBLE SHOOTING TRAINER”. Designed and fabricated in-house with most of released equipment from condemned loco as a process of recycle. The objective of the project “ELECTRIC LOCO TROUBLE SHOOTING TRAINER “is primarily to give practical training to loco pilots in troubleshooting loco defects experienced on line. Another objective of the system is to educate loco pilots about the new technology equated in electric loco. The loco troubleshooting trainer is used to train loco pilots in troubleshooting techniques and thereafter take remedial actions. This User Documentation is an overview of the features and operation techniques. Considering all modifications and new technology equated in electric loco we have designed this loco trouble shooting trainer. One of the salient feature of this “ELECTRIC LOCO TROUBLE SHOOTING TRAINER” it is equipped with both conventional type (relay based) and Microprocessor(MPCS) equipment, and works in either mode .Faults can be generated in both the modes, thus loco pilots can get practical training and troubleshooting technics for both conventional and microprocessor equipped locos simultaneously. Recently introduced Vigilance Control Device in electric loco has also been provided in this trainer for training loco pilots about its features, operating system and isolating procedure. Recent upgradation in pneumatic circuit in electric loco is “Triplet pneumatic panel”. “ELECTRIC LOCO TROUBLE SHOOTING TRAINER” was also been provided with triplet pneumatic panel for training loco pilots its operating system location of isolating coc etc.., “ELECTRIC LOCO TROUBLESHOOTING TRAINER” has an Instructor Panel from where any fault in the loco sub-system can be generated. It simulates the faulty symptoms and the trainee should identify the corrective action by following a systematic process, thus experience gained will be helpful in future for taking corrective action while working on train.

Hopping this “ELECTRIC LOCO TROUBLE SHOOTING TRAINER” is more worthwhile in teaching better driving and troubleshooting technics for loco pilots and Asst loco pilots.

With regards, Srawan.Singh.Purohit Sr.DEE/TRS/VSKP.

Changes made to loco equipment: MP: Conventional loco MP was taken and spare cams are modified and used in MPCS circuit. 1. MP traction side close interlock. 2. MP Braking side close interlock. 3. MPJ forward side close interlock. 4. MPJ reverse side close interlock. 5. Two interlocks MP “+” & MP “-“position close. 6. MPS 2 interlocks for MPS-1 position close and MPS-2 position close.

BL Board: Apart from interlocks used in conventional loco for BL, BLDJ, BLRDJ, BLCPD, BLCP, BLVMT additional interlocks are provided in each switch and used in MPCS circuit. RSB: Apart from interlocks used in conventional loco for switches HPH, HVSL1, HVSL2, HMCS1, HMCS2, HVRH additional interlocks are provided as per requirement in MPCS circuit. DRUM CONTACTS: CTF1, CTF2, CTF3, REVERSER1 and REVERSER2 additional interlocks are provided and used in MPCS circuit. PUSH BUTTON SWITCHES: All push button switches BPT, BPP, BPR, BP1DJ and BP2DJ additional interlocks are provided and used in MPCS circuit. SAFETY RELAYS: For all safety relays QOP1, QOP2, QOA, QRSI1, QRSI2, QLM internal coil was changed and DU relay coil provided and one N/C interlock used in conventional loco circuit and one N/C interlock for each relay is used in MPCS circuit. Q30 RELAY: Original AC coil is replaced with DU relay coil and used in conventional loco circuit. QCVAR RELAY: DC coil is used and relay supplied with 110V DC supply through CR relay N/O interlock which energises after 3” after DJ is closed. EMC: For all EMC contacts C101, C102, C103, C105, C106, C107, C108 and C118 one additional auxiliary interlock provided and used in MPCS circuit. EPC CONTACTS: For all EPC contacts LC1, LC2,LC3, LC4,LC5 and LC6 two additional N/O interlocks provided and used one in MPCS circuit and one for Ammeter and Voltmeter deviation. One additional N/O interlock provided for C145 and used in MPCS circuit. SMGR: Apart from conventional loco interlocks spare cam’s are modified for GR’0’, GR 132, ASMGR between notch, ASMGR on notch interlocks provided and used for MPCS circuit. MOTORS: Instead of 30HP MVRH, 35HP MVMT motors motors were been used for power saving. MPH was not kept in service since TFP tank not provided.MVSL1,

3HP

MVSL2, MVSI1 and MVSI2 are controlled by EMC contacts provided in panel outside of loco. ALL auxiliary motors were given 415V 3phase AC supply. ARNO was not kept in service.

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TFP: Transformer tank and core were removed and all other parts of transformer are provided including CGR, GR SMGR, TFP bushes, RGR, RPGR, RPS, conservator etc.

CAB METERS: A4, U5 and U6 meters are modified and internal resistance was removed. Line voltmeter internal coil was replaced with TM voltmeter coil and 110V DC supply was given and made it to represent 25KV OHE voltage.

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New equipment’s provided: Original loco circuit was been modified to create different tripping’s and also to make the system work as a loco since no OHE (25KV) provided and also to minimise the power consumption, to make the system work both in conventional loco circuit and MPCS circuit. CHOS:

Changeover switch provided to change the working of loco from MPCS to Conventional type. One reverser was taken its drum and fixed contacts are removed and 96 auxiliary interlocks are provided for changeover of input signals from MPCS circuit to conventional loco circuit and vice versa.

DIODE PANNEL: All the output signals of MPCS and conventional loco are fed to diodes in diode panel provided behind MPCS UNIT and a common output is taken to equipment’s, thus output from both circuits are separately fed to equipment’s and are made to work in either mode.

INSTRUCTOR PANEL: Instructor panel is provided with toggle switches, NR, MPCS display unit and LED panel. Instructor can create faults in loco circuit like OPERATION ‘A’ tripping, OPERATION ‘B’ tripping, OPERATION ‘O’ tripping, OPERATION 1 tripping, OPERATION 2 tripping CCPT melting, CCA melting, CCDJ melting, CCLC melting, QOA dropping, QOP1 dropping, QOP2 dropping, QLM dropping, QRSI1 dropping, QRSI2 dropping, TLTE etc.

DIMMERSTAT: One dimmer stat of 230v , 2AMPS rating is provided and mechanically coupled to SMGR to achieve regulated voltage as per SMGR notches and this regulated voltage is used for simulation of TM Voltmeter and Ammeter deviation. This regulated voltage is further stepped down using step-down transformer to get millivolts power for TM voltmeter and Ammeter. Another tapping from dimmer stat is given to a cab fan motor which drives the PG sensor of SPEEDOMETER thus speedometer made to work.

CIRCUIT BREAKERS: Circuit breakers are provided for all motors for safety, in case any overcurrent flows in motors to minimise further damage to motors and circuit. For motors MVSL1, MVSL2, MVSI1, MVSI2 circuit breakers are provided in EMC panel provided outside the loco. For motors MVMT1, MVMT2, MVRH circuit breakers are provided in TK Panel.

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EMC panel: One EMC panel with 12 EMC contacts provided outside the loco. 415v AC supply taken from main supply is controlled in this panel. Top row 2 contacts for MVSL1 and MVSL2. Second row 2 contacts for MVSI1 and MVSI2. Third row 2 contacts made parallel and to control all the supply which comes into the loco. Fourth row 2 contacts one for CP1 and one for CP2 which are provided outside the loco model room.

QDJ-RELAY: Since VCB auxiliary interlocks are limited QDJ relay is provided for extra interlocks to use in different circuits. QDJ-Relay energises when VCB closes and its interlocks are used in contacts circuit, CR Relay circuit, Line voltmeter circuit and signal conditioning unit 3 circuits. CR-RELAY: It is time lags relay its interlocks closes after 4” after closing DJ. Its interlocks used in Q30 relay coil and QCVAR relay coil circuit. After closing CR-Relay Q30 and QCVAR relay energises and C118 de-energises. Q6-RELAY: This relay energises after 6th notch of SMGR. Its interlocks are used in QOP1, QOP2 relay circuits and EVPHGR circuit. QMPH-RELAY: This relay is used in place of QPH as no tank and core is provided for TFP and MPH is not made to work. This relay energises immediately after DJ closing and only when HPH is on position 1 or 3. Its interlock is used is DJ control circuit. QEMS-RELAY: This is an emergency stop relay its normally closed interlocks are provided VCB circuit and Panto circuit. After pressing of BPQEMS switch on DRIVER DESK this relay energises opens its contacts on VCB circuit and panto circuit thus VCB opens and panto lowers.

SPM-RELAY: Provided under frame of loco under CAB-2, this relay energises immediately after BL unlocked. Relay gets de-energised after taking notch i.e., after extinguishing of LSGR. Its normally close interlocks are used in Speedometer circuit after relay de energises a single phase AC motor gets feed and it rotates thus speedometer deviates.

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New Technology Equated: 1. MPCS: Microprocessor based FAULT DIAGNOSTICS AND CONTROL SYSTEM is latest technology implemented in WAG5, WAM4, and WAG7 locomotives. MPCS unit was provided and faults were generated so that loco pilots know its trouble shooting technics. Many features provided in MPCS can be explained with live demonstration like display of OHE voltage, TM currents, Voltages, Auxiliary voltage status of isolations etc.,

2. VCD: Vigilance Control Device is a microprocessor based device been provided in all locomotives and been supplied by firm. Replica of the VCD is designed in house with available relays and with all features as per original VCD and installed in this trainer.

3. TRIPLET PNEUMATIC PANEL: Triplet pneumatic panel is the new technology been implemented in electric locos in pneumatic circuit, this panel is provided in the trainer so that practical working of the pneumatic system can be explained to loco pilots.

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Modifications included: All modifications issued by RDSO were been included. 1. AC MVRF: modification providing AC MVRF in place of DC MVRF. 2. Modification sheet no. ELRS/MS/0261: Modification in DBR control circuit to prevent opening of C145 contactor with snap action in case of energisation of QF1, QF2 and QE. 3. Modification sheet no. ELRS/MS/0298-2000: Introduction of delay in the starting of 3rd compressor motor in order to improve the reliability of Arno as well as compressor motors. 4. Modification sheet no. ELRS/MS/0330: provision of CTF3 contact in C145 circuit. 5. Modification sheet no. ELRS/MS/0336: Provision of auxiliary interlock no 9-10 of SMGR in series with existing interlock no 89-90 on QV62 branch to avoid RGR overheating/burning due to closing of DJ/VCB in case of GR in between 1 and ‘0’ notches. 6. Modification sheet no. RDSO/2009/EL/MS/0383: provision of LED indication near Q50 relay for indicating status of C145 contact. 7. Modification sheet no. RDSO/WAG5/32: modification in QRS feeding circuit. 8. Modification sheet no. RDSO/WAM4/205: modification to provide AMMETER/VOLTMETER for metering on 6P combination locomotives. 9. Modification sheet no. B/TRS/RB/MOD/2000-2001/001: ACP circuit for auto regression and auto flasher with beep in case of chain pulling. 10.Modification sheet no. WAT/TRS/MOD/1/84: Provision of HLS switch to isolate the signalling circuit to leading loco when trailing loco or middle loco made dead. 11.Additional BP coc modification. 12.Provision of Oil Trap Chamber in TFP exhaust pipe.

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Working of different Equipment: VCD: An in-house designed and developed VCD unit using timers and diodes is provided in this loco model. The VCD unit provided in this model will be an exact replica of the real VCD and will have all functional controls. 1. VCD main switch is provided back side of Loco Pilot seat near HLS switch. 2

VCD main unit is provided back side of relay panel near TFVT.

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One LED is provided beside VCD cab unit, it blinks when VCD vigilance cycle resets to zero and will glows continuously when VCD is in supress mode.

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HVCD

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QVCD relay provided beside HVCD switch.

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LP pedal switch provided between PSA and PVEF.

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SA9 and A9 pressure switch provided bottom of window shutter in cab LP side.

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VCD works in Conventional loco mode only, it will not work in MPCS mode hence to be put-off while working in MPCS mode.

VCD bypass switch provided near VCD main unit.

Working of VCD: 1. For working of VCD put MP on ‘0’ apply SA9/A9 put the VCD switch (toggle switch) ON, VCD now works and it will be in supress mode. 2. Release SA9/A9 now VCD will be in vigilance cycle. 3. VCD vigilance cycle will automatically get reset on a. Operation of MP i.e., on progression, regression, taking first shunt. b. Pressing VCD pedal switch or PSA. c. Pressing acknowledge push button switch on VCD cab unit. d. Pressing horn switch. e. Application or release of A9/SA9. 4. After 60” if any of the resets not done warning cycle level 1 will start and warning led will start blinking. 5.

After 8” of warning cycle if any of the resets not done warning cycle level 2 will start with buzzer sound.

6. Finally after 8” of warning cycle level 2 Penalty brake will be applied by energising QVCD relay resulting auto-regression of SMGR and de-energising of IP valve. 7. Penalty brake will get reset by putting MP on ‘0’ and pressing Reset push button switch on driver desk. Note: Circuit diagram and cable index for VCD circuit enclosed. Page-7

DEVIATION OF TM VOLTMETERS AND AMMETERS: For deviation of TM voltmeters and Ammeter one dimmer stat of 230V, 2Amps rating was taken and its shaft mechanically coupled to SMGR notching Wheel. The regulated voltage is fed to 230/110V TFVT transformer and the transformer output is again stepped down to milli- volts using 6V-0-6V transformer and is converted to DC. This Mili-volts DC supply through PC-8 relays given to TM voltmeter and Ammeter and also to signal conditioning unit of microprocessor. Thus ammeters and voltmeters deviate as per the SMGR notch. If the notch increases the meters show higher value and vice versa. Note: Circuit diagram and cable index enclosed. WORKING OF SPEEDOMETER: For deviation of Speedometer, constant voltage tap from dimmer stat was taken and connected to a cab fan, through a relay interlock which closes when LSGR extinguish. Cab fan blades were removed and speedometer PG comb is fitted to rotor shaft. PG senor is fitted on body of cab fan and adjusted so that if the cab fan rotates comb of PG rotates and

the speedometer deviates. An additional condenser is kept in parallel to original condenser using a time lag relay to achieve more starting torque with low voltage. An additional weight is provided on shaft to achieve controlled speed. Thus the speedometer starts deviating after taking notch.

Pneumatic circuit: Two CP’s are installed outside the loco model room and MR1 and MR2 reservoirs are provided near by the CP’s. One governor (RGCP) provided near MR2. CP1 and CP2 contacts close and open as per the pressure near MR2. Air Dryer is provided between MR2 and MR3. Working of air dryer is controlled by RGCP provided near CP’s. CCAD and ZAD provided nearby Air dryer. Pipelines are connected from different equipment to Triplet Pneumatic Panel. The below mentioned Pneumatic equipment’s are included in Triplet Pneumatic panel. C3W distributor valve, BP C2relay valve, BC C2relay valve, VEF, RGCP, RGEB, P1, P2, SWC, MU-2B, F-1 selector valve, IP electro valve, VEAD, airflow measuring valve, R6 valve and RGAF. Additional BP coc provided in CAB-2. For VCD circuit 3 no’s pressure switches provided in CAB-2. One on BP sensing circuit, one on SA9 sensing circuit and one in Horn circuit.

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Circuit Description: CHBA BA MCPA CIRCUIT: MCPA, BA, CHBA, UBA, ECC and LECC are provided as per WAG5 loco circuit. CHOS interlock are provided in the circuit so that when CHOS put to MPCS mode supply to CCPT, CCLS, CCA, CCDJ will cut off, and BA supply will extend to MPCS CCPT. Microprocessor will work. When CHOS switch put to Conventional loco mode BA feed will extend to CCPT, CCA, CCLS and CCDJ. In this mode BA supply to Microprocessor will cut off. In series to fuses CCPT, CCDJ, CCA, and CCLS toggle switches are provided. When these switches are switched off trouble of particular fuse melting will be experienced. Relay output from CHBA is given through CHOS switch to QV61 and I-71 of microprocessor and signal conditioning unit of microprocessor. QEMS is an emergency stop relay; Positive feed from BA is given to QEMS relay through BPQEMS. When BPQEMS pressed relay QEMS energises and its N/C interlocks on PT and DJ circuit will open and DJ trips and panto lowers. PANTO CIRCUIT: Positive feed for panto circuit is taken through change over switch (CHOS), so that feed is maintained to VEPT while working in both conventional loco mode and MPCS mode. Positive feed is given through QEMS relay N/C interlock. Relay QEMS is an

emergency stop relay which gets energised when Loco Pilot Press BPQEMS switch which is provided on Driver Desk. On energising QEMS relay feed to VEPT drops thus Panto Lowers, VCB opens since QEMS relay N/C interlock provided on VCB circuit. When ZPT kept in 1 position PT-1 raises, in addition Input signal (I-5) will be high to the microprocessor when operated in MPCS mode. When ZPT kept on 2 input signal (I-6) will be high to the microprocessor. Note: Panto 2 not provided physically but all other circuit operations will be as is when ZPT kept on 1. Positive feed to VEPT is given through HLS switch and Toggle switches provided on Instructor panel. Instructor can create a trouble of rear panto not rising by switching OFF toggle switch and Loco Pilots can be asked for trouble shooting. HLS circuit on VEPT branch can also be explained. Here in MPCS mode positive feed to VEPT is not given from O-2 of microprocessor as per latest circular given by RDSO. When trainer is working as conventional loco signal at I-5 and I-6 will be low as changeover switch interlocks will be in open condition. VEF CIRCUIT: Additional interlock is provided in PVEF switch and when working in MPCS mode positive feed will extend to microprocessor through PVEF interlock and signal at I-42 will be high when PVEF is pressed. While working as conventional loco positive feed through CCPT fuse and BL interlock and PVEF interlock and QRS N/O interlock electro valve gets energise. In RB through CTF1, CTF2, CTF3 and QV64 interlocks VEF will get energise. Two diodes one in MPCS circuit and one in Conventional loco circuit are provided to isolate the non-working circuit form getting back feed. Thus VEF will work in both conventional loco mode and MPCS mode. One toggle switch provided in instructor panel when switched ON electro valve VEF will not energise.

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DJ CONTROL CIRCUIT: One toggle switch provided in series with each relay QVMT1, QVMT2, QVRH, QVSL1, QVSL2, QVSI1, and QVSI2. Toggle switches are also provided in Q44, Q45, QPDJ, C118, Q118 relays coil circuit. Both relay and Toggle switches will change to MPCS circuit or Conventional loco circuit as per position of CHOS.DJ control circuit cable connections are done as per WAG5 conventional loco circuit. For MPCS input and output signals following modifications are: 1. One spare N/O interlock in BL switch taken, positive feed given and is connected to I-48 of Microprocessor. 2. One additional N/C interlock in BP1DJ provided positive feed is connected through BP1DJ N/C interlock further BLDJ N/O interlock and given to I-0 of Microprocessor. 3. One additional interlock of BP2DJ and BLRDJ are connected in parallel and positive feed given to I-1 of Microprocessor. 4. Positive feed trough DJ N/O interlock is given to I-35 & trough BV N/O interlock is given to I-55. 5. Positive feed from C118 N/C interlock is given to I-63. 6. I-64 is given direct positive feed and no QLA relay was provided. 7.

Feed from O-0 and O-4 is connected to additional N/C interlock of QOA and to all Safety relays additional interlocks in series. Other end of N/C interlocks given to inputs of Microprocessor. QOA to I-49, QOP1 to I-50, QOP2 to I-51, QRSI1 to I-52, QRSI2 to I-53 and QLM to I-54. I-54 and I-65 are shorted as no QPDJ is provided in MPCS mode. Further O-1 feed after safety relays N/C interlocks is connected to VCB through N/C interlock of QEMS and N/O interlock of C118 and toggle switch INST QPDJ.

8. O-1 is connected to C118 coil through a blocking diode and a toggle switch INST C118. 9. The following input signals are used in DJ control circuit. I-2 for QVMT1, I-3 for QVMT2, I-4 for QVRH, I-22 for QVSL1, I-25 for QVSL2, I-21 for QPH, I-13 for QVSI1 and I-14 for QVSI2. CP CONTROL CIRCUIT: For closing of CP contacts in conventional loco mode cable connections are given as per WAG5 loco circuit. For closing of contacts in MPCS mode the following changes are made. 1. One additional N/O interlock for both BLCP and BLCPD are provided and MPCS Positive feed is extended to I-74 of MPCS. When BLCP/BLCPD are closed signal at I-74 will be high. 2. O-8 and O-46 are connected through blocking diodes to HCP switch and further to C101, C102 and C103. O-8 for closing of C101 and C102, O-46 for closing of C103. 3. One additional N/O interlocks for C101, C102, C103 are provided and are connected in parallel. Positive feed will extend to microprocessor and signal at I-18 will be high when any of the CP contacts closed. Note: In MPCS circuit cable no 073M and 074M are shorted in SB of CAB-2 as no RGCP is provided for MPCS circuit.

BLOWERS CONTROL CIRCUIT: For closing of Blower contacts in conventional loco mode cable connections are given as per WAG5 loco circuit. For closing of contacts in MPCS mode the following changes are made. 1. One additional N/O interlock is provided in BLVMT and MPCS positive feed is extended to I-15 of Microprocessor when BLVMT put on. 2. One additional N/O interlocks are provided for C105, C106 and C107 for feedback signal to Microprocessor. Feedback of C105 to I-23, feedback of C106 to I-56 and C107 to I-66. 3. Two additional Interlocks are provided in HVRH, HVMT1 and HVMT2. Switc h HVM T1 HVM T2 HVRH

Interlock Closes in switch position 1 and 3 0 and 3 1 and 3 0 and 3 1 and 3 0 and 3

MPCS input signal high I-7 I-8 I-9 I-10 I-11 I-12

4. O-5(output of microprocessor) is connected to C107 coil through blocking diode and a toggle switch INST C107. O-6 is connected to C106 coil through blocking diode and a toggle switch INST-C106. O-7 is connected to C105 through blocking diode and toggle switch INST C105. 5. One additional N/O interlock provided in C145 and is connected to MPCS to I-68. For feedback of C145 closing. 6. O-47 is connected to C108 coil through one Blocking diode. LINE CONTACTOR CONTROL CIRCUIT: For closing of Line contacts in conventional loco mode cable connections are given as per WAG5 loco circuit. For MPCS mode the following changes are made. 1. One additional N/O interlock are provided for all Line Contactors and made parallel and connected to I-61 for feedback signal for microprocessor. 2. Additional two interlocks are provided in HMCS1 and HMCS2 and connected as mentioned below. a. In HMCS1 position 1 and 2 close interlock, in HMCS2 position 1 and 4 close interlock are provided and parallel connected and given to I-62. b. In HMCS1 and HMCS2 Position 1 close interlock are provided and connected in series and connected to I-60. 3. Positive feed from N/C interlock of BPQD is given to I-44. 4. O-26 from MPCS is connected to HMCS through blocking diode and HVSI1. O-27 is connected to HMCS2 through blocking diode and HVSI2.

5. One toggle switch in circuit of each line contactor is provided in instructor panel. 6. BPQD is provided on Driver desk. Positive feed through N/C interlock connected to I44. BPQD is bypass switch when QD acts in MPCS loco. Q50 CIRCUIT: Q50 relay is called supervising relay. In conventional loco it gets energised only when CTF, Reverser, C145 are moved to proper position as per MP. For conventional loco mode cable connections are given as per WAG5 loco circuit. For MPCS mode the following additional interlocks are provided. 1. MPCS Positive feed through BL N/O interlock is given to MP, MPJ and MPS interlocks. 2. In MP 5 No’s spare cams are modified and used in MPCS circuit. a. MPJ forward interlock, the cam is modified so that its interlock closes when MPJ put to forward position and supply extends to I-32 of Microprocessor. b. MPJ reverse interlock, the cam is modified so that its interlock closes when MPJ put to reverse position and supply extends to I-27 of Microprocessor. c. MP Running interlock, the cam is modified so that its interlock closes when MP put to traction position and remains close until MP is put back to ‘0’ positions and feed extends to I-30 of microprocessor. d. MP Braking interlock, one spare cam is modified so that interlock remains closed in all positions in braking side of MP and the feed extends to I-34 of Microprocessor. 3. MPCS positive feed is connected both through J1 and J2 forward side close interlocks connected in series and to I-28 of microprocessor. Thus feedback of J1, J2 are thrown to forward direction is given to microprocessor. 4.

Similarly through reverse side close interlocks feed to I-36 is given.

5. Through CTF1, CTF2, CTF3 running side interlocks feed is extended to I-31 for feedback of CTF thrown to running side. 6. Similarly to I-33 for braking side feedback.

7. Feed from O-10 is extended to J1 and J2 forward NC4 valve coil through blocking diode and toggle switches in instructor panel. 8. Similarly from O-11 to J1 and J2 reverse NC4 coil. From O-12 CTF1, CTF2, and CTF3 running side NC4 coil. From O-13 to CTF’s Braking side NC4 valve coil. 9. From O-15 feed is extended to C145 through blocking diode and toggle switch. 10.From O-22 feed is extended to IP coil through QVCD and HVCD interlocks Thus supply to J1, J2, CTF1, CTF2, CTF3, and C145 is extended and feedback to microprocessor is obtained. SMGR CONTROL CIRCUIT: Conventional loco SMGR control circuit is given as per WAG5 circuit. For MPCS circuit the following input and output signals are connected. INPUT signal: One spare cam of MP is modified so that its interlock closes when MP put on “O” in both traction and braking side or BPP pressed and feed extends to I-26 of Microprocessor. One spare cam of MP is modified for its interlock to close when MP put on “- ̎ in both traction and braking side or when BPR pressed feed extends to I-29 of Microprocessor. Four numbers spare cams of SMGR are modified to get the feedback signals to Microprocessor: SMGR INTERLOCKS 1 2 3 4 5 6

GR-0 GR(0-31) ASMGR-BETWEEN notch ASMGR-On Full notch ZSMS N/O Interlock ZSMGR N/C interlock

MPCS FEEDBACK/INPUT I-19 I-20 I-16 I-24 I-58 I-57

OUTPUT Signal: O-16 from MPCS is feed to SMGR Down coil through blocking diode, SMGR (1-32) interlock and through toggle switch INST REG for regression of SMGR. O-14 from MPCS to SMGR UP coil through blocking diode, SMGR (0-31) interlock and toggle switch INST PROG for progression of SMGR. O-17 through blocking diode is connected to EVPHGR and O-39 to SON (buzzer). SANDERS AND QRS CIRCUIT: Conventional loco sander and QRS circuit is connected as per WAG5 circuit with a minute change of provision of toggle switch INST RGEB in QRS relay branch. For MPCS circuit the following changes are done. a. In MPCS circuit RGEB is not provided instead MPCS 700 is shorted to 155/1M and through toggle switch INST RGEB connected to I-45. b. One additional N/O interlock is provided in PSA switch MPCS 700 feed is given through this interlock to I-43. c. O-23 and O-25 through blocking diodes connected to VESA1 and VESA2.

NOTCH REPEATER CIRCUIT: No changes are made in NR circuit except NR of CAB-1 is provided in instructor panel.

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SHUNTING CONTACTOR CIRCUIT: Only 5 No’s shunting contacts are provided in loco. For conventional loco circuit CCPT feed through SMGR (20-32) interlock given to MPS interlocks one closes in MPS position 1 and other in MPS position 2. From MPS position 1 close interlock through blocking diodes feed given to S14, S15, S16 and from MPS position 2 close interlock through blocking diodes feed given to S24 and S25 shunting contacts. For MPCS circuit 2 additional interlocks in MPS are provided and MPCS 700 feed through these interlocks and through blocking diodes given to shunting contacts. Signalling circuit: Signalling circuit for conventional loco operation is connected as per WAG5 circuit with minute change of providing one blocking diode in path of LSDJ, LSRSI, LSB, LSCHBA, LSP and LSGR. For MPCS circuit MPCS 700 feed through additional N/O interlock of BPT is given to I-77 and through Tell-tale fuse and change over switch is given to I-59. The following outputs through blocking diodes connected to concern LEDs in both CAB-2 LED set and Instructor panel LED set. 1 2 3 4 5 6

Output Signal O-28 O-29 O-30 O-31 O-32 O-33

LED Indication LSDJ LSCHBA LSGR LSB LSP LSRSI

SIGNAL CONDITIONING UNIT CIRCUIT: This circuit is designed for deviation of CAB meters as per SMGR notch. And in MPCS circuit for measuring of TM volt and Ammeter. One Dimmer stat is mechanically coupled with SMGR nothing wheel so that tapping of dimmer stat increases with SMGR notch. This regulated AC supply is given to a 6-0-6 volts step down transformer and is converted to DC using diodes and this Milli Volts is given to TM voltmeter and Ammeter. The regulated milli volts supply is given through relay interlocks of QM1, QM2 QM5, and QM6. Circuited is designed such that A2 ammeter deviates only when LC4 closes and ammeter deviates in opposite direction when in RB mode. The same milli volts supply is given to signal conditioning unit of microprocessor. Similarly when LC5 closes QM5 relay will energise and U5 meter will deviate and U6 meter deviates through QM6 relay. QM1 and QM2 relays will energise when loco in RB and when C145 closes.

SIGNAL CONDITIONING UNIT 3: This circuit is designed for QCVAR, Q30 and input signal to MPCS. CCBA feed through 003 cable and QDJ N/O interlock is given to CR relay. CR relay is a time lag relay and its interlocks close after 3” after DJ closes. CCPT feed through 700 and through CR N/O interlock through INST Q30 switch is given to Q30 relay. Relay Q30 internal coil is changed and DU coil is provided. Q30 relay will energise 3” after DJ closes. Similarly QCVAR relay will energise after 3” of closing DJ and C118 de-energises. Positive feed through QDJ interlock given to UA meter which indicates the OHE voltage. Same feed is given to signal conditioning unit -3 as input signal of Auxiliary voltage. From battery charger through CHOS switch feed is given to SCU-3 as analog input to measure charger voltage for microprocessor. Page-13

QOA CIRCUIT: In loco QOA relay drops whenever any earth fault occurs in Auxiliary circuit. Here to create fault this circuit is modified. One toggle switch for each motor is provided and one end of toggle switch is connected to particular motor EMC contact cable and second end of all toggle switches are looped and connected to QOA relay through HQOA switch. Thus when a particular toggle switch switched ON, QOA relay energises and DJ opens after trouble shooting and isolation of particular motor QOA will de-energise. QOA relay will be bypassed when HQOA is kept on 0. Toggle switches are provided for MVSL1, MVSL2, MVSI1, MVSI2, MVMT1, MVMT2, MVRH, MVRF, MPH, MCP1, and MCP2. When Toggle switch QOA MVMT2 put ON QOA relay energises after closing DJ and when contact C106 closes. After trouble shooting and when HVMT2 kept on 0, QOA will not drop.

QOP1 AND QOP2 CIRCUIT: Toggle switches QOP TM1, TM2, TM3 one end of switch connected to LC1, LC2, LC3 NC4 valve coil cable and other end of switch are looped and through Q6 N/O interlock and HQOP switch connected to QOP1 relay. When QOP TM1 switch closed then feed from LC1 coil will extend to QOP1 through Q6 relay and QOP1 relay target drops. Thus trouble of QOP1 dropping is created. Same circuit is followed for QOP2 for TM4, TM5, and TM6. Note: Relay QOP1 or QOP2 will act only after 6th notch of SMGR. ACP CIRCUIT: For conventional loco ACP circuit is connected as per Modification sheet no B/TRS/RB/MOD/2000-2001/001. For MPCS mode ACP circuit not kept in service. I-76 and I78 are shorted Positive supply given. Toggle switch HPAR provided nearby HLS switch. Positive feed through HPAR switch is given to I-70 of MPCS. When HPAR switched ON auto regression will be supressed. CONTACTS FOR MVSI MVSL: In loco MVSI, MVSL motors are not provided with EMC contacts, but create a fault of these motors not working EMC contacts are provided and are controlled through toggle switch provided on instructor panel and for MPH QMPH relay provided. When toggle switch on instructor panel switched OFF, these motors will not rotate causing tripping as per sequence. C111 and C222 are contacts for CP’s provided outside Model room to maintain pressure continuously. These contacts are controlled by RGCP governor provided near MR2 reservoir. C333 and C444 are contacts provided in 3 φ 415V AC supply. Both these contacts are connected parallel, these contacts closes only

after DJ closes and 3 φ AC supply will extend to the Motors, TFVT, Battery Charger and Dimmer stat. thus 3 φ AC supply will extend to loco only after closing DJ. QLM QRSI1 QRSI2: In loco these relays energise when over current flows. Here to create a fault through these relays some modifications are done. The coil inside the relay is replaced with DU type coil. Battery positive feed through QDJ relay is given to Toggle switches INST QLM, INST QRSI1, INST QRSI2 and directly connected to concern relays. When any of these switches switched ON, concern relay energises and DJ trips. QDJ RELAY: This relay energises when DJ closed and its N/O interlocks are used in different circuit. Q6 RELAY: this relay energises when SMGR in between 6 to 32 notch. Its interlocks are used in EVPHGR circuit QOP1 and QOP2 circuit. Page-14

Preparation to do before energising: 1. Put the HBA switch OFF. See that all contacts in EMC panel provided outside the loco are in open condition. 2.

Put the Change-Over Switch (CHOS) handle to require position i.e. put it to top side for conventional loco operation and bottom side for MPCS loco operation. Check that all contacts are closed properly as per sequence.

3. For conventional loco operation remove MPCS CCPT fuse and put all other fuses intact. For MPCS loco operation put MPCS CCPT fuse and remove CCA, CCPT, CCLSA, CCDJ, CCLS fuses.

4. Put the Mains Supply Switch to ON position. 5.

Put all the Circuit Breakers provided in EMC panel and also in TK panel to ON position.

6. Put HBA switch to ON. 7. Contacts MVSL1, MVSL2, MVSI1 and MVSI2 will be closed. 8. Switch ON Toggle Switch for CP’s provided in EMC panel. CP’s will start and pressure will start building up.

9. Further continue the operation as a normal loco.

NOTE: For power saving switch OFF circuit breakers of MVMT1, MVMT2, MVRH, MVSL1 and MVSL2. These motors will not work but all other operations will be normal. Page-15

Normal Working and Trouble Creation in conventional loco mode: Normal working: See that CHOS switch is in UPWARD direction and MPCS CCPT removed condition. See that RS and MR pressure are above 6Kg/cm2. 1. Put ZPT to position-1. 2. Close BLDJ and press BLRDJ/BP2DJ. 3. Q45 energises and through its N/O interlock Q44 energises. Through N/O interlock of Q44 on VCB coil branch C118 energises and through its N/O interlock and through all safety relays N/C interlocks feed extends to VCB coil and VCB closes. 4. Once VCB Closed through its N/O interlock relay QDJ energises. Through N/O interlock of QDJ positive feed extends to CR relay (time-lag relay) and CR relay energises but its N/O interlock closes after 3”. Through N/O interlock of CR relay Q30 and QCVAR relay energises. After energising of QCVAR C118 gets de-energised. 5. When the relay QDJ closes through its N/O interlock EMC contacts C333 and C444 closes and 415V AC supply extends to CHBA and QV61 relay energises and LSCHBA extinguishes. 6. Release BLRDJ/BP2DJ after extinguishing of LSCHBA. After realising of BLRDJ/BP2DJ Q45 de-energises and feed to Q44 will be maintained through Q30 N/O interlock. 7. When Q44 gets energised feed to Q118 is maintained through QVSL1, QVSL2 and QMPH. Here QVSL1 and QVSL2 cables are shorted to make the system work normal even when motors circuit-breakers were switched off (for power saving). Relay QMPH (sequential type) provided in place of QPH as no oil is present in transformer. 8. Once VCB closed blower motors MVSL1, MVSL2, MVSI1, and MVSI2 will start rotating. 9. Switch ON BLCP/BLCPD CP contacts C101 and C102 will close and after 5” contact C103 closes. Note: Only one defective CP is provided inside trainer which will not work and it is provided only to show the trainee location of CP. CP provided outside the room will work and builds up pressure. Creating Faults in DJ Control Circuit: Toggle switches are provided in Instructor panel to create faults in different stages. For normal working all toggle switches are to be kept in OFF position and to create fault particular toggle switch to be switched ON. ICDJ: Impossible to close DJ/VCB. Switch ON any of the following toggle switches to create an ICDJ trouble.

Toggle switch CCPT

Fault Generated 1 Fault of CCPT melting will be generated 2 CCDJ Fault of CCDJ melting will be generated 3 Q118 Q118 will not energise. 4 Q44 Q44 will not energise. 5 QPDJ Fault of QPDJ not closed will be generated. 6 C118 C118 will not energise and VCB will not close. Note: While checking the condition of fuse by Trainee, instructor may switch ON the LECC switch so that LECC will not glow and trainee will assume that Fuse melted and will take necessary action.

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OPERATION ‘A’: LSDJ goes out but glows again before LSCHBA goes out. Switch ON toggle switch QCVAR. QCVAR relay will not energise. Trouble HQCVAR kept on ‘0’.

vanishes when

LSDJ FLICKERS: LSDJ flickers if any of the safety relays energises. To create such fault switch ON the toggle switches as mentioned below. Toggle Switch Fault Generated 1 QLM QLM relay energises. 2 QRSI1 QRSI1 relay will energise. 3 QRSI2 QRSI2 relay will energise. OPERATION ‘B’: LSDJ and LSCHBA go out but LSDJ glows with in 15” and DJ open. To create this fault Switch ON toggle switch Q30. Q30 relay will not energise.

OPERATION ‘O’: VCB opens within 15” after closing BLVMT. To create this fault switch ON toggle switches mentioned below. Fault Generated DJ trips as if QVMT1 not picked up. 2 QVMT2 DJ trips as if QVMT2 not picked up. 3 QVRH DJ trips as if QVRH not picked up. OPERATION ‘1’: VCB opens immediately after taking one notch. 1

Toggle Switch QVMT1

To create this fault switch ON toggle switches mentioned below. 1

Toggle Switch QVSI1

2

QVSI2

Fault Generated DJ trips as if QVSI1 not picked up. DJ trips as if QVSI2 not picked up.

OPERATION ‘II’: VCB opens after taking 6 notches. To create this fault switch ON toggle switches mentioned below. 1 2 3

Toggle Switch MVMT1 MVMT2 MVRH

Fault Generated C105 will not energise. C106 will not energise. C107 will not energise.

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Toggle Switches and corresponding faults generated are mentioned in table below. 1 2 3 4 5 6 7 8 9 10 11 12

Toggle Switch CCA CCLC CCLS PT-1 PT-2 CHBA MPH MVSL1 MVSL2 MVSI1 MVSI2 J1(F)

12

J2(F)

13

J1(R)

14

J2(R)

15 16 17 18 19 20 21 22

CTF1(R),CTF2(R),CTF3(R) CTF1(B),CTF2(B),CTF3(B) C145 QD1, QD2 QOA-MVMT1, MVMT2,MVRH QOA-MCP1, MCP2 QOA-MVRF QRS

23 24 25 26 27

SMGR-PROG, REG QOP1-TM1, TM2, TM3 QOP2-TM4, TM5, TM6 TM1, TM2, TM3 TM4, TM5, TM6

28 29 30 31 32

LSDJ LSGR LSRSI VEF ACP, RGEB, Q52, Q49

Fault Generated. CCA Fuse melted. CCLC fuse melted. CCLS fuse melted. PT-1 will not rise. No fault since PT-2 not provided. LSCHBA does not extinguish. QMPH will not pick up. Motor MVSL1 will not work as CMVSL1 will not energise. Motor MVSL2 will not work as CMVSL2 will not energise. Motor MVSI1 will not work as CMVSI1 will not energise. Motor MVSL1 will not work as CMVSI2 will not energise. J1 will not be thrown to forward direction. LSB remains glowing. J2 will not be thrown to forward direction. LSB remains glowing. J1 will not be thrown to reverse direction. LSB remains glowing. J2 will not be thrown to reverse direction. LSB remains glowing. Concern CTF will not be thrown to running position. Concern CTF will not be thrown to braking position. C145 will not energise and LSB remains glowing in RB. LSP glows with Auto Regression and auto sanding. QOA drops after closing BLVMT. QOA drops after closing BLCP/BLCPD. QOA drops after MP kept on P. QRS relay will not energise and SMGR does not progress. SMGR will not progress/ regress. QOP1 drops after 6th notch. QOP2 drops after 6th notch. LC1, LC2, LC3 will not close. LC4, LC5, LC6 will not close and corresponding meters A4, U5, U6 will not deviate. LSDJ will not glow. LSGR will not glow. LSRSI will glow. VEF will not energise. No action circuit will be designed later.

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Working and Trouble Creation in MPCS loco mode: NORMAL WORKING: See that CCPT, CCDJ, CCA, CCLSA CCLS fuses are removed, MPCS CCPT fuse intact and CHOS switch kept in down direction. Working and faults creation for MPCS loco mode is same as is for conventional loco mode except that there will be no effect by switching ON the below mentioned toggle switches.

1 2 3 4 5 6 7 8 9 10

Toggle Switch CCA CCLS CCDJ CCLC Q118 Q45 Q44 QPDJ Q30 QD

Note: Here in MPCS loco mode the below mentioned modifications are not in service. 1. ACP circuit. 2. VCD circuit. 3.

HLS modification.

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