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Handbook On CCB-II of Diesel Locomotives PDF
Handbook On CCB-II of Diesel Locomotives PDF
of India)
(Ministry of Railways)
Hand Book on CCB-II
of
Diesel Locomotives
I hope that this Hand book will definitely enhance the knowledge of
concerned staff to do faster restoration of troubles pertaining to brake
system while working on line.
April- 2015
(K.P.Yadav)
Director/Mech
CAMTECH/ Gwalior
CORRECTION SLIPS
1. General Description:
CCB II-IR is a microprocessor based electro-pneumatic
brake control system. A CCB II-IR equipped locomotive
can LEAD or Trail a multiple unit consist and can be
operated as a Helper unit. CCB II-IR is comprised of
distributed electronics for improved reliability,
serviceability and failure analysis. CCB II-IR includes
modular LRU’s for ease of trouble shooting & repairs.
2. Component Description
The EBV is the “Man Machine” interface to the CCB II-IR Brake
System. The EBV communicates ER and BCEP commands (handle
movements) by the driver to the Air Brake System via the LON
network.
EBV communicates via an intelligent ‘Node’. The EBV is designed
for installation as a desktop mount. It is used by the Engineer to
control the Independent Brake, Automatic Brake and Bail-off.
The EBV includes a “Target Display” that allows the Engineer to
know, immediately, how much reduction is requested when the
handle is moved. Faults are annunciated to the operator via an LCD
screen mounted on the Driver’s Brake Valve (EBV). This screen is
also used for routine advisory instructions such as penalty reset and
emergency reset.
Selector switch on EBV’s have four Positions
2.6 Direct Brake Handle:-The Direct Brake Handle has two positions
namely ‘Release’ and ‘FULL’.
Automatic brake Handle: - Automatic brake Handle has five positions
1. Release position.
IRCAMTECH/M/GWL/15-16/CCB-II 7
2. Run position.
3. Minimum reduction brake application.
4. Full service application.
5. Emergency application position.
3.0 System Back-ups:-
Brake Cylinder Back-up – If the computer controlled BC pilot
controller (16CP) fails, the system will automatically switch over to
using the KE valve output for BC pilot.
Independent Handle Back-up – If the BCE pipe controller (20CP)
fails, the system will automatically switch to a back-up mode
wherein the 16CP develops locomotive brake cylinder pressure in
response to the independent handle.
Pneumatic ER Back-up (Optional) – The system is provisioned to
optionally allow use of a back-up pneumatic ER controller and
switchover cock.
4.0 Modes of Operation of CCB II:-
There are six modes of operation for the CCB II-IR system.
They are:
LEAD CUT-IN or SINGLE UNIT - Independent brake control is
available via the (EBV) Independent handle. Equalizing reservoir
(ER) control is available via the EBV Automatic handle. The brake
pipe pressure is ‘Cut-In’ and follows equalizing reservoir pressure
increasing and decreasing.
IRCAMTECH/M/GWL/15-16/CCB-II 8
Direct Brake Handle –FULL When Stopped & REL for Moving the
Locomotives
Mode selector switch on EBV- Lead
EBV Setting in Trailing Loco on Both Control Stands .
(Both EBV are Non Working)
Auto Brake handle - Full service application.
Direct Brake Handle – Release
Mode selector switch on EBV- Trail
(c) EBV Setting in Banker Loco Operation:
1. Non Working Control Stand:-
Auto Brake handle - Full service application.
Direct Brake Handle – Release
Mode selector switch on EBV- Trail
Once, BP is charged from Leading loco, PCS in the Banker loco will
reset automatically and loco is ready for operation.
(i) If The Auto Brake Handle in the Banker loco is left in RUN
then while moving the loco ,PCS will knock-out when the
speed reaches3kmph (No development of BC pressure).But ,
Message on LCC-“NO LOAD – PCS OPEN, RECOVER
THE AIR BRAKE SYSTEM TO RESET PCS” will appear.
(ii) Stop the Locomotive, Bring Throttle Handle to IDLE LCC
message will change as “AIR BRAKE PENALTY –PLACE
HANDLE IN FULL SERVICE FOR 10 SECONDS”
(iii) Place Auto Handle in FS for 10 Seconds, PCS resets and the
LCC message changes as: “TO RESTORE NORMAL AIR
BRAKE OPERATION –PLACE AUOTMATIC HANDLE
IN “RUN”
(iv) Bring the AUTO Handle to RUN once & immediately move
the Auto Handle to FS which is a strict legitimate handle
position for Banker operation.
.
5.0 Operating Pressure -HHP LOCO
Other Pressures
• Dead Engine Regulator 1.8±0.1 Kg/cm²
• Main Reservoir- 8 to 10 Kg/cm²
IRCAMTECH/M/GWL/15-16/CCB-II 24
EBV ER BP BCEP BC
Handles
Kg/cm² Kg/cm² Kg/cm² Kg/cm²
Positions
Automatic
brake
Release 5.5±.07 5.5±.07 0 0
Run 5.0±.07 5.0±.07 0 0
MIN 0.4 reduction 0.4 reduction 0.4±.14 0.4±.14
Other Pressures
• Dead Engine Regulator 1.8±0.1 Kg/cm²
• Main Reservoir - 8 to 10 Kg/cm²
6.0 Additional Features:
Includes Real Time Clock in EBV
“Smart” LRUs include logs
Includes crew advisory on EBV display
IRCAMTECH/M/GWL/15-16/CCB-II 25
(1) Power cutoff switch (PCS) does not clear or cannot release
brakes:
(i) Place Automatic brake handle in Full
Service (FS) and wait for penalty to clear. If a ’Fault XX Active’
message appears, it will be necessary to reset the source of the
penalty (cab signal, ATP, alerter, etc.). Check Main Reservoir Gauge
to insure air is being supplied to the brake system. After any
penalties are reset, move the Automatic brake handle to RUN. Check
to see if both ER and BP pressures rise. If ER rises and BP does not,
see symptom ‘Cannot charge brake pipe’. If ER and BP rise, but PCS
still does not reset, go to step (ii).
(ii).Ensure throttle handle is in ‘IDLE’ position and reverser handle
is centered. Place the Automatic handle in Full Service (FS). Power
cycle the Electro- Pneumatic Control Unit (EPCU). If problem
persists, an ‘Emergency’ or ‘Penalty’ source is active and must be
cleared. If BP can be charged but PCS cannot reset, replace the RCP.
If problem persists, replace BPCP.
ii) Isolate locomotive (close end angle cocks) and repeat step (i). If
BP charges now but wouldn’t before, check train for leakage or de-
coupling.
iii) Place Electronic Brake Valve (EBV) Automatic handle ‘sharply’
into and out of emergency ‘EMER’ position at least ten times. Reset
emergency and move Automatic brake handle to RUN. If BP
pressure rises, the problem was a stuck 21 vent valve on the EBV.
iv) If BP rises partially toward ER but fails to reach ER (and a blow
of air is heard at EPCU), replace BPCP (there may be contamination
in the relay or emergency valve). If problem persists, replace
locomotive vent valve.
other special BC
controls will be
active. Replace
16CP at Shed.
039 MV16 16 Output Automatic BC
Fault Feedback pressure may be
indicates direct release only.
MVfault. No blending or
other special BC
controls will be
active. Replace
16CP at shop.
052 16CN RCP,20 Loss of Inspect LON cable
Fault 16heartbe is positively seated
at for 5 at 16CP. Cycle AB
seconds circuit breaker. If
not corrected,
automatic BC
pressure may be
direct release only.
No blending or
other
special BC
controls will be
active. Replace
16CP at
Shed.
055 20CP 20 Pressure Place Mode switch
AW4 not to TRAIL,
FAULT within +/- Automatic handle
5 psi in EMER, and
in 10 Independent
IRCAMTECH/M/GWL/15-16/CCB-II 34
node. If steady or
blinking,
reprogram
or replace EBV. If
red light remains
on after power
cycle, replace
EBV.
108 Cab RCP Both Cab Correct setup,
Mismat switches recover penalty. If
ch are set to not corrected, must
Fault switch be used in Trail
position Mode until repair.
and one of replace EBV
them is
not in the
TRAIL
position.
118 RCP BP,20, Loss of Must be used in
CN EBV RCP Trail Mode until
Fault heartbeat repair. Replace
for 5 RCP.
seconds
125 MV26 ER Output Must be used in
De- feedback Trail Mode until
energiz indicates repair. Replace
ed MV ERCP
fault
IRCAMTECH/M/GWL/15-16/CCB-II 36
• If one EBV faults are logged and are not clearing, work from
other EBV (may be operated to clear the section till the other
EBV is attended duly observing safety)
• While Auto Handle at FS position while changing LT switch
position (other than Test position selection –CCB will apply
FS penalty if not followed.
• Recycle CCB Circuit Breaker to clear any faults logged. If
not cleared then please contact respective shed.
• Ensure proper working of Air Dryer and MR Drain valves.
• In case the Air Dryer is by passed, then manually drain MR
Auto Drain Valves when times permits and inform shed.
• If Air Dryer by passed inform to shed and also pass the
remarks in loco repair book.
DON’Ts
• Do not spill liquid like tea, coffee, water on the Brake Valve
Controller
• Do not keep Non-working Auto handle beyond FS position.
11.0 ABBREVIATIONS
ABCB.................... AIR BRAKE CIRCUIT BREAKER
ALR ..................... ALARM RELAY
BO ........................ BAIL OFF
BC.................... BRAKE CYLINDER
BCCO................ BRAKE CYLINDERCUT-OUT PIPE
BP......................... BRAKE PIPE
BPCN................... BRAKE PIPE CONTROL NODE
BPCO................... BRAKE PIPE CUT-OFF VALVE
BPCP.................... BRAKE PIPE CONTROL PORTION
CN........................ CONTROL NODE
COC..................... CUT OFF COCK
COMM................. COMMUNICATION
COS...................... CUTOFF SWITCH
EAB...................... ELECTRONIC AIR BRAKE
EBV...................... ELECTRONIC BRAKE VALVE
EMER................... EMERGENCY
ER........................ EQUALIZING RESERVOIR
ERCP................... EQUALIZING RESERVOIR CONTROL
PORTION
ERCN................... EQUALIZING RESERVOIR CONTROL NODE
FV ......................... FEED VALVE
IND ....................... INDEPENDENT
LON ...................... LOCAL OPERATING NETWORK
LRU ...................... LINE REPLACEABLE UNIT
MIN ...................... MINIMUM
MR ........................ MAIN RESERVOIR
MREP ...................MAIN RESERVOIR EQUALIZING PIPE
IRCAMTECH/M/GWL/15-16/CCB-II 40
OUR OBJECTIVE