ELECTRIC LOCO TROUBLE SHOOTING TRAINER

SANKATI SRINIVAS
SSE/TRS/ELS/VSKP

MAY 2012

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

LC2. EMC: For all EMC contacts C101. ASMGR between notch.DEE/TRS/VSKP. BPP. BLCPD. MPJ reverse side close interlock. EPC CONTACTS: For all EPC contacts LC1. Q30 RELAY: Original AC coil is replaced with DU relay coil and used in conventional loco circuit. ASMGR on notch interlocks provided and used for MPCS circuit.MVSL1. QRSI2. QOP2. BLDJ. Changes made to loco equipment: MP: Conventional loco MP was taken and spare cams are modified and used in MPCS circuit. MOTORS: Instead of 30HP MVRH. SAFETY RELAYS: For all safety relays QOP1. GR 132. HVSL1. C106. QRSI1. SMGR: Apart from conventional loco interlocks spare cam’s are modified for GR’0’. PUSH BUTTON SWITCHES: All push button switches BPT. 1. CTF2. HVRH additional interlocks are provided as per requirement in MPCS circuit. RSB: Apart from interlocks used in conventional loco for switches HPH.LC3. CTF3. QOA. C105. MPS 2 interlocks for MPS-1 position close and MPS-2 position close.Purohit Sr. Srawan. BLVMT additional interlocks are provided in each switch and used in MPCS circuit. BP1DJ and BP2DJ additional interlocks are provided and used in MPCS circuit. LC4. 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. 3HP .With regards.Singh. C103. 2. 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. REVERSER1 and REVERSER2 additional interlocks are provided and used in MPCS circuit. MP Braking side close interlock. 5. HVSL2. 6. C102. BLRDJ. HMCS2. MPJ forward side close interlock. MP traction side close interlock. BLCP. BL Board: Apart from interlocks used in conventional loco for BL. C107. C108 and C118 one additional auxiliary interlock provided and used in MPCS circuit. One additional N/O interlock provided for C145 and used in MPCS circuit. DRUM CONTACTS: CTF1.LC5 and LC6 two additional N/O interlocks provided and used one in MPCS circuit and one for Ammeter and Voltmeter deviation. 3. 35HP MVMT motors motors were been used for power saving. Two interlocks MP “+” & MP “-“position close. MPH was not kept in service since TFP tank not provided. BPR. HMCS1. 4.

ALL auxiliary motors were given 415V 3phase AC supply. ARNO was not kept in service. Page-1 TFP: Transformer tank and core were removed and all other parts of transformer are provided including CGR. RPGR. . MVSI1 and MVSI2 are controlled by EMC contacts provided in panel outside of loco. conservator etc. Line voltmeter internal coil was replaced with TM voltmeter coil and 110V DC supply was given and made it to represent 25KV OHE voltage. GR SMGR. RPS. TFP bushes. RGR.MVSL2. U5 and U6 meters are modified and internal resistance was removed. CAB METERS: A4.

OPERATION 2 tripping CCPT melting. CCA melting. to make the system work both in conventional loco circuit and MPCS circuit. NR. TLTE etc. QOA dropping. QRSI2 dropping. CCLC melting. QLM dropping. Instructor can create faults in loco circuit like OPERATION ‘A’ tripping. CHOS: Changeover switch provided to change the working of loco from MPCS to Conventional type. DIMMERSTAT: One dimmer stat of 230v . CCDJ melting. QOP1 dropping. OPERATION 1 tripping.Page-2 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. . 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. OPERATION ‘O’ tripping. 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. 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. MPCS display unit and LED panel. INSTRUCTOR PANEL: Instructor panel is provided with toggle switches. QRSI1 dropping. 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. OPERATION ‘B’ tripping. QOP2 dropping.

Q6-RELAY: This relay energises after 6th notch of SMGR. Third row 2 contacts made parallel and to control all the supply which comes into the loco. For motors MVSL1. Its interlock is used is DJ control circuit. Line voltmeter circuit and signal conditioning unit 3 circuits. Its interlocks used in Q30 relay coil and QCVAR relay coil circuit. MVSI1. Page-3 EMC panel: One EMC panel with 12 EMC contacts provided outside the loco. in case any overcurrent flows in motors to minimise further damage to motors and circuit. CR-RELAY: It is time lags relay its interlocks closes after 4” after closing DJ. Its interlocks are used in QOP1. Second row 2 contacts for MVSI1 and MVSI2. Top row 2 contacts for MVSL1 and MVSL2. . MVMT2. 415v AC supply taken from main supply is controlled in this panel. MVSI2 circuit breakers are provided in EMC panel provided outside the loco. QEMS-RELAY: This is an emergency stop relay its normally closed interlocks are provided VCB circuit and Panto 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. Fourth row 2 contacts one for CP1 and one for CP2 which are provided outside the loco model room. 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. MVSL2. After closing CR-Relay Q30 and QCVAR relay energises and C118 de-energises. QDJ-Relay energises when VCB closes and its interlocks are used in contacts circuit. For motors MVMT1. CR Relay circuit. This relay energises immediately after DJ closing and only when HPH is on position 1 or 3. QDJ-RELAY: Since VCB auxiliary interlocks are limited QDJ relay is provided for extra interlocks to use in different circuits.CIRCUIT BREAKERS: Circuit breakers are provided for all motors for safety. MVRH circuit breakers are provided in TK Panel. QOP2 relay circuits and EVPHGR circuit.

this panel is provided in the trainer so that practical working of the pneumatic system can be explained to loco pilots. MPCS unit was provided and faults were generated so that loco pilots know its trouble shooting technics. Auxiliary voltage status of isolations etc. Replica of the VCD is designed in house with available relays and with all features as per original VCD and installed in this trainer.. TRIPLET PNEUMATIC PANEL: Triplet pneumatic panel is the new technology been implemented in electric locos in pneumatic circuit. MPCS: Microprocessor based FAULT DIAGNOSTICS AND CONTROL SYSTEM is latest technology implemented in WAG5. VCD: Vigilance Control Device is a microprocessor based device been provided in all locomotives and been supplied by firm..e. TM currents.SPM-RELAY: Provided under frame of loco under CAB-2. after extinguishing of LSGR. Relay gets de-energised after taking notch i. and WAG7 locomotives. Voltages. 3. Many features provided in MPCS can be explained with live demonstration like display of OHE voltage. Page-4 New Technology Equated: 1. this relay energises immediately after BL unlocked. . WAM4. 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. 2.

7. ELRS/MS/0261: Modification in DBR control circuit to prevent opening of C145 contactor with snap action in case of energisation of QF1. RDSO/WAM4/205: modification to provide AMMETER/VOLTMETER for metering on 6P combination locomotives.Page-5 Modifications included: All modifications issued by RDSO were been included. 3. 8. 5. 2. 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. QF2 and QE. B/TRS/RB/MOD/2000-2001/001: ACP circuit for auto regression and auto flasher with beep in case of chain pulling. 11. 9. 6.Provision of Oil Trap Chamber in TFP exhaust pipe. ELRS/MS/0330: provision of CTF3 contact in C145 circuit. RDSO/2009/EL/MS/0383: provision of LED indication near Q50 relay for indicating status of C145 contact. . RDSO/WAG5/32: modification in QRS feeding circuit. 12.Modification sheet no. AC MVRF: modification providing AC MVRF in place of DC MVRF. 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. Modification sheet no. Modification sheet no. 4. 10.Additional BP coc modification. 1. Modification sheet no. Modification sheet no. Modification sheet no. 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. Modification sheet no. Modification sheet no.

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. LP pedal switch provided between PSA and PVEF. SA9 and A9 pressure switch provided bottom of window shutter in cab LP side. 1. it will not work in MPCS mode hence to be put-off while working in MPCS mode. VCD works in Conventional loco mode only. The VCD unit provided in this model will be an exact replica of the real VCD and will have all functional controls. . QVCD relay provided beside HVCD switch. HVCD VCD bypass switch provided near VCD main unit. 2 3 4 5 6 7 8 VCD main unit is provided back side of relay panel near TFVT. VCD main switch is provided back side of Loco Pilot seat near HLS switch.Page-6 Working of different Equipment: VCD: An in-house designed and developed VCD unit using timers and diodes is provided in this loco model.

This Mili-volts DC supply through PC-8 relays given to TM voltmeter and Ammeter and also to signal conditioning unit of microprocessor. 5. 2Amps rating was taken and its shaft mechanically coupled to SMGR notching Wheel. Note: Circuit diagram and cable index enclosed. 2. Pressing VCD pedal switch or PSA. 7. After 8” of warning cycle if any of the resets not done warning cycle level 2 will start with buzzer sound. VCD now works and it will be in supress mode. 4. Application or release of A9/SA9. c. Note: Circuit diagram and cable index for VCD circuit enclosed. b.e. Thus ammeters and voltmeters deviate as per the SMGR notch. constant voltage tap from dimmer stat was taken and connected to a cab fan. through a relay interlock which closes when LSGR extinguish. on progression. After 60” if any of the resets not done warning cycle level 1 will start and warning led will start blinking. If the notch increases the meters show higher value and vice versa. WORKING OF SPEEDOMETER: For deviation of Speedometer.. taking first shunt. VCD vigilance cycle will automatically get reset on a. e. regression.volts using 6V-0-6V transformer and is converted to DC. For working of VCD put MP on ‘0’ apply SA9/A9 put the VCD switch (toggle switch) ON. d. Pressing acknowledge push button switch on VCD cab unit. Penalty brake will get reset by putting MP on ‘0’ and pressing Reset push button switch on driver desk. 3. The regulated voltage is fed to 230/110V TFVT transformer and the transformer output is again stepped down to milli. Page-7 DEVIATION OF TM VOLTMETERS AND AMMETERS: For deviation of TM voltmeters and Ammeter one dimmer stat of 230V. Release SA9/A9 now VCD will be in vigilance cycle. Operation of MP i. Pressing horn switch. 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. PG senor is fitted on body of cab fan and adjusted so that if the cab fan rotates comb of PG rotates and . Cab fan blades were removed and speedometer PG comb is fitted to rotor shaft.Working of VCD: 1.

and BA supply will extend to MPCS CCPT. In series to fuses CCPT. CHBA. RGCP. When BPQEMS pressed relay QEMS energises and its N/C interlocks on PT and DJ circuit will open and DJ trips and panto lowers. One governor (RGCP) provided near MR2. SWC. CCA. CCDJ. CCLS and CCDJ. P2. and CCLS toggle switches are provided. An additional weight is provided on shaft to achieve controlled speed. In this mode BA supply to Microprocessor will cut off. RGEB. CCAD and ZAD provided nearby Air dryer. CCLS. Positive feed from BA is given to QEMS relay through BPQEMS. IP electro valve. MU-2B.the speedometer deviates. P1. Working of air dryer is controlled by RGCP provided near CP’s. When these switches are switched off trouble of particular fuse melting will be experienced. CCA. BC C2relay valve. UBA. F-1 selector valve. When CHOS switch put to Conventional loco mode BA feed will extend to CCPT. Pipelines are connected from different equipment to Triplet Pneumatic Panel. The below mentioned Pneumatic equipment’s are included in Triplet Pneumatic panel. ECC and LECC are provided as per WAG5 loco circuit. CCA. airflow measuring valve. PANTO CIRCUIT: Positive feed for panto circuit is taken through change over switch (CHOS). Additional BP coc provided in CAB-2. Air Dryer is provided between MR2 and MR3. Thus the speedometer starts deviating after taking notch. R6 valve and RGAF. CCDJ will cut off. BP C2relay valve. Relay QEMS is an . Microprocessor will work. BA. Positive feed is given through QEMS relay N/C interlock. CP1 and CP2 contacts close and open as per the pressure near MR2. one on SA9 sensing circuit and one in Horn circuit. Pneumatic circuit: Two CP’s are installed outside the loco model room and MR1 and MR2 reservoirs are provided near by the CP’s. For VCD circuit 3 no’s pressure switches provided in CAB-2. VEAD. C3W distributor valve. CHOS interlock are provided in the circuit so that when CHOS put to MPCS mode supply to CCPT. VEF. Page-8 Circuit Description: CHBA BA MCPA CIRCUIT: MCPA. One on BP sensing circuit. An additional condenser is kept in parallel to original condenser using a time lag relay to achieve more starting torque with low voltage. so that feed is maintained to VEPT while working in both conventional loco mode and MPCS mode. 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.

When ZPT kept in 1 position PT-1 raises. In RB through CTF1. When ZPT kept on 2 input signal (I-6) will be high to the microprocessor. 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. Positive feed to VEPT is given through HLS switch and Toggle switches provided on Instructor panel. Thus VEF will work in both conventional loco mode and MPCS mode. CTF3 and QV64 interlocks VEF will get energise. VCB opens since QEMS relay N/C interlock provided on VCB circuit. in addition Input signal (I-5) will be high to the microprocessor when operated in MPCS mode. 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. Page-9 . HLS circuit on VEPT branch can also be explained. Note: Panto 2 not provided physically but all other circuit operations will be as is when ZPT kept on 1. 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.emergency stop relay which gets energised when Loco Pilot Press BPQEMS switch which is provided on Driver Desk. Here in MPCS mode positive feed to VEPT is not given from O-2 of microprocessor as per latest circular given by RDSO. CTF2. Two diodes one in MPCS circuit and one in Conventional loco circuit are provided to isolate the non-working circuit form getting back feed. One toggle switch provided in instructor panel when switched ON electro valve VEF will not energise. Instructor can create a trouble of rear panto not rising by switching OFF toggle switch and Loco Pilots can be asked for trouble shooting. On energising QEMS relay feed to VEPT drops thus Panto Lowers.

. QPDJ. 8. 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. 2. I-13 for QVSI1 and I-14 for QVSI2. 2. I-25 for QVSL2. QRSI1 to I-52. CP CONTROL CIRCUIT: For closing of CP contacts in conventional loco mode cable connections are given as per WAG5 loco circuit. One additional N/O interlocks for C101. 6. Other end of N/C interlocks given to inputs of Microprocessor. One spare N/O interlock in BL switch taken. O-8 for closing of C101 and C102. The following input signals are used in DJ control circuit. QVRH. QVSI1.DJ CONTROL CIRCUIT: One toggle switch provided in series with each relay QVMT1. QVMT2. 7. 5. and QVSI2. I-54 and I-65 are shorted as no QPDJ is provided in MPCS mode. QRSI2 to I-53 and QLM to I-54. QOA to I-49. Q118 relays coil circuit. 4. O-1 is connected to C118 coil through a blocking diode and a toggle switch INST C118. O-46 for closing of C103. Positive feed will extend to microprocessor and signal at I-18 will be high when any of the CP contacts closed. Positive feed from C118 N/C interlock is given to I-63. For MPCS input and output signals following modifications are: 1. O-8 and O-46 are connected through blocking diodes to HCP switch and further to C101. C102 and C103. QVSL2. 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. I-64 is given direct positive feed and no QLA relay was provided. One additional N/O interlock for both BLCP and BLCPD are provided and MPCS Positive feed is extended to I-74 of MPCS. positive feed given and is connected to I-48 of Microprocessor. I-22 for QVSL1. One additional interlock of BP2DJ and BLRDJ are connected in parallel and positive feed given to I-1 of Microprocessor. QVSL1. I-2 for QVMT1. C103 are provided and are connected in parallel. When BLCP/BLCPD are closed signal at I-74 will be high. QOP2 to I-51. C102. 3.DJ control circuit cable connections are done as per WAG5 conventional loco circuit. Both relay and Toggle switches will change to MPCS circuit or Conventional loco circuit as per position of CHOS. I-3 for QVMT2. 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. 3. Toggle switches are also provided in Q44. 1. Positive feed trough DJ N/O interlock is given to I-35 & trough BV N/O interlock is given to I-55. Q45. I-4 for QVRH. Note: In MPCS circuit cable no 073M and 074M are shorted in SB of CAB-2 as no RGCP is provided for MPCS circuit. C118. I-21 for QPH. QOP1 to I-50. For closing of contacts in MPCS mode the following changes are made. 9.

3. a. Additional two interlocks are provided in HMCS1 and HMCS2 and connected as mentioned below. Two additional Interlocks are provided in HVRH. 3. One additional N/O interlock are provided for all Line Contactors and made parallel and connected to I-61 for feedback signal for microprocessor. For closing of contacts in MPCS mode the following changes are made. C106 and C107 for feedback signal to Microprocessor. O-27 is connected to HMCS2 through blocking diode and HVSI2. In HMCS1 and HMCS2 Position 1 close interlock are provided and connected in series and connected to I-60. O-26 from MPCS is connected to HMCS through blocking diode and HVSI1. in HMCS2 position 1 and 4 close interlock are provided and parallel connected and given to I-62. 6. O-7 is connected to C105 through blocking diode and toggle switch INST C105. For feedback of C145 closing. HVMT1 and HVMT2. b. Feedback of C105 to I-23. One additional N/O interlock provided in C145 and is connected to MPCS to I-68. 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. Positive feed from N/C interlock of BPQD is given to I-44. feedback of C106 to I-56 and C107 to I-66. One additional N/O interlock is provided in BLVMT and MPCS positive feed is extended to I-15 of Microprocessor when BLVMT put on. . 1. O-6 is connected to C106 coil through blocking diode and a toggle switch INST-C106. 2. O-47 is connected to C108 coil through one Blocking diode. 1.BLOWERS CONTROL CIRCUIT: For closing of Blower contacts in conventional loco mode cable connections are given as per WAG5 loco circuit. 5. 2. LINE CONTACTOR CONTROL CIRCUIT: For closing of Line contacts in conventional loco mode cable connections are given as per WAG5 loco circuit. O-5(output of microprocessor) is connected to C107 coil through blocking diode and a toggle switch INST C107. In HMCS1 position 1 and 2 close interlock. 4. One additional N/O interlocks are provided for C105. For MPCS mode the following changes are made.

MP Running interlock. the cam is modified so that its interlock closes when MPJ put to forward position and supply extends to I-32 of Microprocessor. 4. MPCS Positive feed through BL N/O interlock is given to MP. 5. In conventional loco it gets energised only when CTF. MPJ and MPS interlocks. CTF2. 6. 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. CTF3 running side interlocks feed is extended to I-31 for feedback of CTF thrown to running side. a. . Similarly to I-33 for braking side feedback. Similarly through reverse side close interlocks feed to I-36 is given. One toggle switch in circuit of each line contactor is provided in instructor panel. Reverser. 6. d. 1. Through CTF1. the cam is modified so that its interlock closes when MPJ put to reverse position and supply extends to I-27 of Microprocessor. MPJ forward interlock. BPQD is provided on Driver desk. For MPCS mode the following additional interlocks are provided. 2. For conventional loco mode cable connections are given as per WAG5 loco circuit. 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. J2 are thrown to forward direction is given to microprocessor.5. Thus feedback of J1. MP Braking interlock. C145 are moved to proper position as per MP. 3. MPCS positive feed is connected both through J1 and J2 forward side close interlocks connected in series and to I-28 of microprocessor. Q50 CIRCUIT: Q50 relay is called supervising relay. MPJ reverse interlock. In MP 5 No’s spare cams are modified and used in MPCS circuit. BPQD is bypass switch when QD acts in MPCS loco. c. Positive feed through N/C interlock connected to I44. b.

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. From O-15 feed is extended to C145 through blocking diode and toggle switch. and CTF3 running side NC4 coil. 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. CTF2. From O-13 to CTF’s Braking side NC4 valve coil. O-17 through blocking diode is connected to EVPHGR and O-39 to SON (buzzer).From O-22 feed is extended to IP coil through QVCD and HVCD interlocks Thus supply to J1. 9. 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. J2. One spare cam of MP is modified for its interlock to close when MP put on “. c. a.7. 10. CTF1. SMGR (1-32) interlock and through toggle switch INST REG for regression of SMGR. From O-12 CTF1. . One additional N/O interlock is provided in PSA switch MPCS 700 feed is given through this interlock to I-43. O-14 from MPCS to SMGR UP coil through blocking diode. b. CTF2. SMGR CONTROL CIRCUIT: Conventional loco SMGR control circuit is given as per WAG5 circuit. SMGR (0-31) interlock and toggle switch INST PROG for progression of SMGR. O-23 and O-25 through blocking diodes connected to VESA1 and VESA2. Similarly from O-11 to J1 and J2 reverse NC4 coil. and C145 is extended and feedback to microprocessor is obtained.̎ in both traction and braking side or when BPR pressed feed extends to I-29 of Microprocessor. For MPCS circuit the following input and output signals are connected. CTF3. 8. 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. Feed from O-10 is extended to J1 and J2 forward NC4 valve coil through blocking diode and toggle switches in instructor panel.

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. . S15. The regulated milli volts supply is given through relay interlocks of QM1. 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. One Dimmer stat is mechanically coupled with SMGR nothing wheel so that tapping of dimmer stat increases with SMGR notch. 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. LSB. LSCHBA. Circuited is designed such that A2 ammeter deviates only when LC4 closes and ammeter deviates in opposite direction when in RB mode. 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. Page-12 SHUNTING CONTACTOR CIRCUIT: Only 5 No’s shunting contacts are provided in loco. and QM6. LSP and LSGR. From MPS position 1 close interlock through blocking diodes feed given to S14. QM1 and QM2 relays will energise when loco in RB and when C145 closes. And in MPCS circuit for measuring of TM volt and Ammeter.NOTCH REPEATER CIRCUIT: No changes are made in NR circuit except NR of CAB-1 is provided in instructor panel. LSRSI. The following outputs through blocking diodes connected to concern LEDs in both CAB-2 LED set and Instructor panel LED set. 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. 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. Similarly when LC5 closes QM5 relay will energise and U5 meter will deviate and U6 meter deviates through QM6 relay. The same milli volts supply is given to signal conditioning unit of microprocessor. S16 and from MPS position 2 close interlock through blocking diodes feed given to S24 and S25 shunting contacts. QM2 QM5.

these contacts closes only . I-76 and I78 are shorted Positive supply given. Relay Q30 internal coil is changed and DU coil is provided. When QOP TM1 switch closed then feed from LC1 coil will extend to QOP1 through Q6 relay and QOP1 relay target drops. Toggle switches are provided for MVSL1. These contacts are controlled by RGCP governor provided near MR2 reservoir. When HPAR switched ON auto regression will be supressed. Positive feed through QDJ interlock given to UA meter which indicates the OHE voltage. MPH. MVMT2. MVRH. When toggle switch on instructor panel switched OFF. 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. MCP1. TM3 one end of switch connected to LC1. From battery charger through CHOS switch feed is given to SCU-3 as analog input to measure charger voltage for microprocessor. and MCP2. MVMT1. QOA will not drop. MVSL motors are not provided with EMC contacts. Similarly QCVAR relay will energise after 3” of closing DJ and C118 de-energises.SIGNAL CONDITIONING UNIT 3: This circuit is designed for QCVAR. Same feed is given to signal conditioning unit -3 as input signal of Auxiliary voltage. CONTACTS FOR MVSI MVSL: In loco MVSI. TM2. Note: Relay QOP1 or QOP2 will act only after 6th notch of SMGR. Thus when a particular toggle switch switched ON. MVSI1. LC2. Both these contacts are connected parallel. TM5. Same circuit is followed for QOP2 for TM4. and TM6. When Toggle switch QOA MVMT2 put ON QOA relay energises after closing DJ and when contact C106 closes. Positive feed through HPAR switch is given to I-70 of MPCS. Page-13 QOA CIRCUIT: In loco QOA relay drops whenever any earth fault occurs in Auxiliary circuit. QOP1 AND QOP2 CIRCUIT: Toggle switches QOP TM1. these motors will not rotate causing tripping as per sequence. CR relay is a time lag relay and its interlocks close after 3” after DJ closes. After trouble shooting and when HVMT2 kept on 0. Here to create fault this circuit is modified. C111 and C222 are contacts for CP’s provided outside Model room to maintain pressure continuously. CCBA feed through 003 cable and QDJ N/O interlock is given to CR relay. Q30 and input signal to MPCS. MVRF. For MPCS mode ACP circuit not kept in service. CCPT feed through 700 and through CR N/O interlock through INST Q30 switch is given to Q30 relay. Q30 relay will energise 3” after DJ closes. Thus trouble of QOP1 dropping is created. 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. QOA relay energises and DJ opens after trouble shooting and isolation of particular motor QOA will de-energise. Toggle switch HPAR provided nearby HLS switch. MVSI2. ACP CIRCUIT: For conventional loco ACP circuit is connected as per Modification sheet no B/TRS/RB/MOD/2000-2001/001. C333 and C444 are contacts provided in 3 φ 415V AC supply. 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. MVSL2. QOA relay will be bypassed when HQOA is kept on 0.

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

For conventional loco operation remove MPCS CCPT fuse and put all other fuses intact. 5. See that all contacts in EMC panel provided outside the loco are in open condition.e. Put all the Circuit Breakers provided in EMC panel and also in TK panel to ON position. 8. 7. 2. Put the Mains Supply Switch to ON position. Switch ON Toggle Switch for CP’s provided in EMC panel. CCPT. 6. CCLS fuses. Check that all contacts are closed properly as per sequence. Put the HBA switch OFF. Put HBA switch to ON. For MPCS loco operation put MPCS CCPT fuse and remove CCA. put it to top side for conventional loco operation and bottom side for MPCS loco operation. Contacts MVSL1. . 3. MVSL2. 4.Preparation to do before energising: 1. CCDJ. MVSI1 and MVSI2 will be closed. CCLSA. CP’s will start and pressure will start building up. Put the Change-Over Switch (CHOS) handle to require position i.

Creating Faults in DJ Control Circuit: Toggle switches are provided in Instructor panel to create faults in different stages. Through N/O interlock of CR relay Q30 and QCVAR relay energises. After energising of QCVAR C118 gets de-energised. 7. 6. These motors will not work but all other operations will be normal. MVSI1. After realising of BLRDJ/BP2DJ Q45 de-energises and feed to Q44 will be maintained through Q30 N/O interlock. 3. ICDJ: Impossible to close DJ/VCB. Switch ON any of the following toggle switches to create an ICDJ trouble. Here QVSL1 and QVSL2 cables are shorted to make the system work normal even when motors circuit-breakers were switched off (for power saving). MVSL2. 2. See that RS and MR pressure are above 6Kg/cm2. 4. 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. Once VCB Closed through its N/O interlock relay QDJ energises. Further continue the operation as a normal loco. NOTE: For power saving switch OFF circuit breakers of MVMT1. QVSL2 and QMPH. 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. MVRH. Close BLDJ and press BLRDJ/BP2DJ. 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. . 5. 9.9. and MVSI2 will start rotating. Relay QMPH (sequential type) provided in place of QPH as no oil is present in transformer. Q45 energises and through its N/O interlock Q44 energises. 8. CP provided outside the room will work and builds up pressure. 1. MVMT2. Release BLRDJ/BP2DJ after extinguishing of LSCHBA. Once VCB closed blower motors MVSL1. MVSL1 and MVSL2. 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”. 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. For normal working all toggle switches are to be kept in OFF position and to create fault particular toggle switch to be switched ON. Put ZPT to position-1. When Q44 gets energised feed to Q118 is maintained through QVSL1.

Note: While checking the condition of fuse by Trainee. 5 QPDJ Fault of QPDJ not closed will be generated. 6 C118 C118 will not energise and VCB will not close. Toggle switch CCPT Page-16 . 4 Q44 Q44 will not energise. 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.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.

Fault Generated DJ trips as if QVMT1 not picked up. vanishes when Switch ON toggle switch QCVAR. Toggle Switch Fault Generated 1 QLM QLM relay energises. DJ trips as if QVSI2 not picked up. To create this fault Switch ON toggle switch Q30. QCVAR relay will not energise. 2 QVMT2 DJ trips as if QVMT2 not picked up. 3 QRSI2 QRSI2 relay will energise. Toggle Switch QVMT1 OPERATION ‘II’: VCB opens after taking 6 notches. Q30 relay will not energise. To create such fault switch ON the toggle switches as mentioned below. 1 To create this fault switch ON toggle switches mentioned below. OPERATION ‘B’: LSDJ and LSCHBA go out but LSDJ glows with in 15” and DJ open. 1 2 Toggle Switch QVSI1 QVSI2 Fault Generated DJ trips as if QVSI1 not picked up. LSDJ FLICKERS: LSDJ flickers if any of the safety relays energises.OPERATION ‘A’: LSDJ goes out but glows again before LSCHBA goes out. To create this fault switch ON toggle switches mentioned below. To create this fault switch ON toggle switches mentioned below. . C107 will not energise. 2 QRSI1 QRSI1 relay will energise. OPERATION ‘O’: VCB opens within 15” after closing BLVMT. C106 will not energise. OPERATION ‘1’: VCB opens immediately after taking one notch. Trouble HQCVAR kept on ‘0’. 3 QVRH DJ trips as if QVRH not picked up. 1 2 3 Toggle Switch MVMT1 MVMT2 MVRH Fault Generated C105 will not energise.

Page-17 .

QRS relay will not energise and SMGR does not progress. TM3 TM4. TM5. Motor MVSI1 will not work as CMVSI1 will not energise. TM5. LSB remains glowing. LC4. J1 will not be thrown to forward direction. Q49 Fault Generated. 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Toggle Switch CCA CCLC CCLS PT-1 PT-2 CHBA MPH MVSL1 MVSL2 MVSI1 MVSI2 J1(F) J2(F) J1(R) J2(R) CTF1(R). J1 will not be thrown to reverse direction. REG QOP1-TM1. Motor MVSL2 will not work as CMVSL2 will not energise.CTF3(R) CTF1(B). CCLS fuse melted. Concern CTF will not be thrown to braking position. LSB remains glowing. PT-1 will not rise.CTF3(B) C145 QD1. TM3 QOP2-TM4. QMPH will not pick up. RGEB. QOP2 drops after 6th notch. LSP glows with Auto Regression and auto sanding. MCP2 QOA-MVRF QRS SMGR-PROG. TM2.CTF2(R). No action circuit will be designed later. MVMT2. TM2. CCLC fuse melted. QOA drops after closing BLCP/BLCPD. Motor MVSL1 will not work as CMVSI2 will not energise. CCA Fuse melted. LC1. LSRSI will glow. J2 will not be thrown to reverse direction. U5. Motor MVSL1 will not work as CMVSL1 will not energise. SMGR will not progress/ regress. LSCHBA does not extinguish. LSGR will not glow. Page-18 . J2 will not be thrown to forward direction. LSB remains glowing.Toggle Switches and corresponding faults generated are mentioned in table below. LSDJ will not glow. VEF will not energise. U6 will not deviate.MVRH QOA-MCP1. Q52. TM6 TM1. TM6 LSDJ LSGR LSRSI VEF ACP. QOA drops after closing BLVMT. QOA drops after MP kept on P. Concern CTF will not be thrown to running position. QD2 QOA-MVMT1. LSB remains glowing. QOP1 drops after 6th notch. C145 will not energise and LSB remains glowing in RB. LC5. LC3 will not close. LC6 will not close and corresponding meters A4.CTF2(B). No fault since PT-2 not provided. LC2.

3. MPCS CCPT fuse intact and CHOS switch kept in down direction. HLS modification. CCDJ. 1. ACP circuit. CCLSA CCLS fuses are removed. CCA. 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. Toggle Switch CCA CCLS CCDJ CCLC Q118 Q45 Q44 QPDJ Q30 QD 1 2 3 4 5 6 7 8 9 10 Note: Here in MPCS loco mode the below mentioned modifications are not in service. 2. VCD circuit.Working and Trouble Creation in MPCS loco mode: NORMAL WORKING: See that CCPT. Page-19 .

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