LOCOMOTIVE TESTING

WAP7/WAG9

WAP7/WAG9 LOCOMOTIVE TESTING AND ELECTRICAL

PANELS LAYOUT & INTERCONNECTION
 INTRODUCTION TO 3-PHASE TECHNOLOGY

Three phase technology

➢ Induction motors
➢ Operates at 4000 RPM in contrast to 2500 RPM in DC motors.
➢ DC propulsion rated for 750V,1000A whereas 3 phase propulsion(3-phase
propulsion.docx) configured for 2800V,300A. resulting in reduction of size of
power cables and losses concerned.
➢ Power to weight ratio high than DC machine.
➢ Torque Speed characteristics much steeper.(TS curve.png)
➢ Microprocessor control
➢ VVVF inverter and converter control.
➢ Supervision of all the functions and operations.
➢ Driving & braking control with automatic speed regulation.
➢ DC Link
➢ Supplies periodic and non-periodic energy requirement of load.
➢ Supplies reactive power to induction motor
GTO, IGBT Comparison

Parameter GTO IGBT

Efficiency Low High
Gate Signal Current Voltage
Gate current High Low
Gate control Component High Low
required
Voltage rating High Medium
Switching loss High Low
Switching speed Low High
Snubber parts required Many Few
 Power flow in WAP7

VCB Pantograph

FB Hotel
BUR
Pan SR2 Blow
ers Load
el 2,3 2

Hotel Blow
ers BUR
Load SR1
1 1

Main Transformer
 CONTROL CIRCUIT TESTING
Control Circuit Testing
➢ Battery Circuit and Lighting
➢ Battery voltage capacity ----- 110V.
➢ Voltage of correct polarity fed for lighting and control system.
➢ Machine room light, cab light, Head light, classification light, flasher light.
➢ Logic Box Testing
➢ Four number each logic box connected with VCU1, 2.
➢ Logic box testing done on 110 V battery supply
➢ All control circuit wiring is tested through Logic box testing.
➢ As per procedure in Para . 3.6 in Doc. No. 3EHX610279
➢ Sheet 4
➢ Sheet 5
➢ Sheet 6
➢ Sheet 7
➢ Sheet 8
➢ Sheet 9
➢ Sheet 10
➢ Sheet 11
➢ Sheet17
 TRANSFORMER-POLARITY, RATIO
Polarity and Ratio test
▪ Equipments required
▪ Variac (Autotransformer)
▪ Oscilloscope

▪ Main transformer polarity

▪ Apply 140 Vrms to the primary w inding and measure output (4.2-7.1 Vrms) of secondary, compare phase
sequence(should be same) of following winding:
▪ Line converter
▪ Auxiliary converter
▪ Hotel load

▪ Harmonic filter

▪ Auxiliary Transformer
▪ Apply 100 Vrms to the input and measure output (41.5Vrms,11.0Vrms), compare phase sequence (should be
opposite) of follow ing cable:
▪ Cable 1218-1200

▪ Cable 1218-6500
 SOFTWARE UPLOADING
Software loading:
▪ VCU,SR,BUR software loading
▪ S/w version as shown for
different propulsion system
 Vehicle Control Unit(VCU)
Vehicle Control Unit(VCU)VCU.jpg
➢ Top level Automation system controls Various systems like Traction converter, DDU, Auxiliary converter, etc.

➢ MICAS based VCU with GTO based Traction & auxiliary converter.

➢ TCN based VCU with IGBT based Traction & auxiliary converter.
➢ VCU1 , VCU2 functionally interchangeable except in MEDHA propulsion system.

➢ Technical details:

➢ Operating voltage – 110V DC

➢ SMPS input voltage 110V DC converts to 5V,15V,24V DC Schematic Architecture of VCU

➢ Operating temperature range – (-25 to 70 C)

MVB
(Electrical)
➢ 32-bit IO & application processor LOCAL CAN BUS

SUPPLY

➢ CAN based CPU IO interface

BUS

➢ VCU cards detail:

APPLICATION PROCESSOR(HBB_DDA)
APPLICATION PROCESSOR(FLG_STB)

PASSIVE TEMPERATURE SENSOR

ANALOG ROUTING CARD
RACK POWER SUPPLY

RACK POWER SUPPLY

MVB ADMINISTRATOR
ANALOG I/O CARD

DIGITAL I/O CARD

DIGITAL I/O CARD

DIGITAL I/O CARD

DIGITAL I/O CARD

MVB COUPLER
SPARE SLOT

SPARE SLOT
SPARE SLOT

SPARE SLOT

SPARE SLOT
SPARE SLOT
SPARE SLOT

SPARE SLOT

SPARE SLOT

SPARE SLOT
SPARE SLOT
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

FAN
 Vehicle Control Unit(VCU)
VCU cards detail:
➢ Power supply cardpower supply card.jpg
➢ 160W DC-DC conv erter control and monitoring

➢ Analog Routing card analog routing card.jpg

 It interfaces the analog signals originating from EMC polluted peripheral to rear edge connector

➢ Application processor cards application processor PCB.jpg

➢ I/O interface v ia CAN 2.0

➢ TCN process data and message data communication

➢ Digital I/O cards Digital IO PCB.png

➢ The digital I/O cards acts as the interface for digital signals between the process zone of the locomotive and
the VCU processors.

➢ Analog I/O cards analog card.jpg

➢ Conv erts analog signal to digital and sav e to memory, conv erts digital signal to analog.

➢ The corresponding digital data from Analog Card is interfaced with processor card v ia back plane through
Controller Area Network (CAN ).

➢ Temperature Sensor Interface card & interface thermostat.jpg

➢ MVB administrator & coupler card MVB Coupler PCB.jpg
➢ Conv erts electrical signal to optical signal

➢ Communication with DDU

➢ CAN, WTB bus & card wtb admin card.jpg

➢ Fan Assembly & heat exchanger heat exchanger.jpg, fan assembly.jpg
➢ PCB rack And accessories VCU rack.jpg
 Vehicle Control Unit(VCU)
Funct ional Architecture of VCU
➢ TCN-Train Communication Network

➢ WTB-Wire Train Bus

➢ MVB-Multifunction Vehicle Bus

➢ Electronic signal transmitted via BUS & FOC
➢ Application Processor process IO signals (Logic based)
➢ VCU controls SR,BUR,DDU through MVB

CAN Gateway CAN Coupler

WTB
Interface MVB Administrator

Ethernet Hub
WTB Dev elopment
Administrator Computer

Analo
g IO
Application CAN
Processor

Digital
Application IO
Processor MVB

MVB Coupler
Redundant FO M VB t o VCU2
VCU2
 Vehicle Control Unit(VCU)

➢ FOC Connection on MVB Coupler card

➢ VCU communicates with SR,BUR through FOC

➢ A, C, E,G and I are FOC transmitters on Coupler

➢ B, D, F,H and J are FOC receivers on Coupler

➢ Advantages:

➢ Immunity to electromagnetic interference

➢ Electrical insulation

➢ High bandwidth & high speed data transmission

➢ Light weight & high durability

BUR1 BUR2

SLG1 SLG2

BUR3

Display Display
CAB1 CAB2

VCU1 Bus Coupler VCU2 Bus Coupler

 Vehicle Control Unit(VCU)
Digital IO Card Signals (VCU1)

Sl. No. Card Type Card Name Functions concerned

MCB compressor 1 Tripped, Parking brake, Hotel load supply, C & D

1 Digital Input J
cab activation, F/R direction, Vigilance, Sanding, BPCS

Indication (wheel slip, parking brake, hotel load, train parting,BPCS),

2 Digital Output J
hotel load contactor,Air dryer, Antispin
Failure mode,configuration mode,bogie cutout, simulation, VCB
3 Digital Input L
ON,Hotel Load contactor,CE ON
CE OFF, self hode mode, VCB ON pulse, VCB disable,Indication
4 Digital Output L
configuration, MCB Compressor 1

Emergency stop LOW, Max TE Limit, Banking operation, Main

5 Digital Input O compressor OFF or direct, F/R direction, TE/BE demand, BPFL push
button

Fault indication, Cab1 Buzzer (Black/Red), Self hold CE, compressor 1

6 Digital Output O
contactor

MCB(active low)-TMB1&scavenge,MRB1 & scavenge,Oil pump

7 Digital Input Q converter & transformer,OCB1,Aux Fuse, EF relay-415/110V, hotel
load, control, harmonic, VCB ON command

8 Digital Output Q Control circuit self hold contactor, VCB ON pulse, VCB disable
 MVR,MCR,CURRENT SENSOR
Minimum Voltage Relay (MVR) settingmvr.jpg

➢ Relay setting for minimum operating v oltage (OHE - 17.5KV) below which VCB should
open.

Maximum current relay (MCR)settingmcr.jpg

➢ Tune the MCR and resistor 78.1 for correct v alue of maximum current permissible to be
drawn.
Current Sensor test IMG_20191108_180857_6.jpg,IMG_20191108_181027_1.jpg
➢ Equipments required
➢ DC Source
➢ Loop box
➢ Operation
➢ Supply DC current to sensor plug pin 7(+) & 8(-), VCB should trip at specified
v oltage
➢ Primary return current sensor (297mA DC)
➢ Auxiliary winding current sensor (333mA DC)
➢ Harmonic filter current sensor (342mA DC)
➢ Hotel Load current sensor (1242mA DC)
 HIGH VOLTAGE TESTING
High voltage Charging Preparation
➢ Roof (roof layout.mp4) inspection (for any conducting
material in touch with roof line or pantograph, roof
grounding, loose connections, equipment grounding).
➢ Fibre optics and all Sub-D connected properly.
➢ Traction converter(SR) (sr insp.jpg), auxiliary converter(BUR),
harmonic filter panel(FB), auxiliary transformer inspection
(for any foreign material, loose connections, grounding) .
➢ Transformer oil level (conservator.jpg)
➢ Traction converter coolant level (sr coolant.jpg) check.
➢ Panel and Blowers/equipments grounding .
➢ Break down voltage (BDV of transformer oil,>50KV).
➢ Earth return brush (ERB) continuity(resistance<0.3ohms).
 HIGH VOLTAGE TESTING
High voltage Testing
➢ High Voltage Charging
➢ All Safety Checks (ZPT, BLDJ, Emergency switch)
➢ Open ZPT,BLDJ switches pantograph should drop down.
➢ Press emergency switch pantograph should drop down.

➢ Loco First High Voltage charging( C & D Mode).

➢ ZPT switch UP-Pantograph connected to OHE, PT sense OHE v oltage (17.5KV-
30KV), if v oltage out of limit Pantograph drops down.
➢ BLDJ Switch UP-Current Flows from 25KV OHE to Main Transformer primary
winding than to Earth return brush (Through Pantograph, VCB).
➢ Check for Humming sound from Main Transformer.
 HV TESTING-MAIN TRANSFORMER
Main TransformerTransformer.jpg
➢ Rated Voltage: Min-17.5KV,Normal-25KV, Max-30KV.
➢ Oil cooled Transformer. BDV of oil >50KV
➢ 6-GOD for BUR and 2 SOD for SR to filter harmonics
➢ Voltage, Current, Power rating of primary &
secondary windings:
Power (KVA) Voltage (V) Current(A)
Winding
WAG9 WAP7 WAG9 WAP7 WAG9 WAP7
HV
6531 7775 25000 25000 261 311
(1U &1V)
Traction
(2U1&2V1,2U2&2V2, 4X1449 4X1449 4X1269 4X126 4X1142 4X1142
2U3&2V3, 2U4&2V4)
BUR
334 334 1000 1000 334 334
(2UB&2VB)
Filter
400 400 1154 1154 347 347
(2UF&2VF)
Hotel load
(2UH1&2VH1, - 1245 - 960 - 1296
2UH2&2VH2)
 HV TESTING-MAIN TRANSFORMER
25KV FROM OHE

1U 1V
XB(11,12),(13,14),(21,22),(23,24),(31,32),(33,
(X11,X12),(X21,X22)
34)

2UB
2U1 BUR
1,2,3
S 2V1 SOD GOD 2VB

R
1 2U2 2UF

FB
2V2 2VF

2U3 2UH1
HOTEL
CORE 1 CORE 2 LOAD
2VH
S 2V3 1 1
R
2 2U4 2UH2 HOTEL
LOAD
2V4
2VH 2
2
 HV TESTING-MACHINE ROTATION
Auxiliary machine rotation
➢ Verify Pressure(SR Coolant & TF oil) : In case pressure out of limit VCB will
open
➢ Close MCB of all auxiliary machine (1000V &415V) in sequence and
check for:
➢ Clockwise rotation
➢ Starting current
➢ Continuous running current
➢ No abnormal sound

➢ Auxiliary machine details:

➢ Oil cooling blower
➢ Traction motor blower and scav enge to blower
➢ Machine room blower and scav enge to blower
➢ Main Compressor
➢ Transformer pump and SR pump
➢ Cab fan, Cab heater/Ventilation
 HV TESTING-AUXILIARY CONVERTER
Auxiliary converter( 1,2,3), BUR1,2,3 aux conv erter circuit.PNG

➢Auxiliary converter 1 Cubicle-1 Box, Auxiliary converter 2&3 cubicle-

1Box. bur 1.PNG, BUR2,3.PNG
➢Each converter rated for 100KVA Output.
➢Parts of Auxiliary converter:
➢Half controlled Rectifier: Asymmetrical type IGBT rectifier output 630-670V
DC.GTO_IGBT.JPG, igbt 1.JPG
➢Intermediate DC- Link filter- Reactor & Capacitor.
➢3-phase inverter: Coverts DC to 3-phase 415V AC output fed to
Blowers.Inverter module 1.JPG
➢3-phase inductor: attenuates harmonics in 3-phase output supply.
➢Battery Charger: Diode bridge rectifier, voltage supplied from Auxiliary
Converter 3. Output Voltage 110V DC.
➢Auxiliary converter control unit : Communicates with VCU via MVB optical
Bus.
➢BUR1,2 gives variable output frequency 0-50Hz,BUR3 gives fixed
frequency 50Hz output. Output voltage 415V three phase AC.
➢Redundancy exist- In case of failure of any one auxiliary converter,
load will be shifted to other and normal operation can be continued.
 HV TESTING-AUXILIARY CONVERTER
Ac supply

Input circuit
rectifier

DC link Control
Unit VCU
filter (FLG)

Output circuit
inverter

Battery
Charger

415V 3-phase AC to:

OCB1,OCB2, TMB1 &scavenge, TMB2 & scavenge, TFP1, TFP2, SRP1, SRP2
 Simplified Schematic of IGBT Based Auxiliary Converter

30mH DC Choke

Input
700-1200V,
50Hz

Rectifier Module
DC
Capacitor
Assembly

Voltage Indicator 50.X4

3-phase IGBT Inv erter Sine W av e Filter

Module
 DC to 3 phase AC
3+5+6 2+5+6 1+2+5 1+2+4 1+3+4 3+4+6 3+5+6 2+5+6 1+2+5 1+2+4 1+2+4 3+4+6 100 V

1 3 5
U

W
6 2 4
U

0V

UV
UV=U-V

VW
VW =V-W

WU
W U=W -U
 HV TESTING-BUR REDUNDANCY
BUR redundancy
▪ In case of any BUR goes out (fault condition), auxiliary machine load will
shift on remaining 2 BUR for normal operation of locomotive

Loads on BUR2 Loads on BUR3

Conditions of BURs Loads on BUR1

Scavenge TMB
TMB 1&2,TFP 1&2, 1&2,Compressor
All BUR ok OCB1 & 2
SRP 1&2 1&2, Battery
Charger

OCB1 & 2 , TMB Compressor 1&2,

1&2, Battery Charger,
BUR 1 out -----
Scavenge TMB 1&2 TFP 1&2,SRP 1&2

OCB1 & 2 , TMB

Compressor 1&2,
1&2,
BUR 2 out ----- Battery Charger,
Scavenge TMB 1&2
TFP 1&2,SRP 1&2

OCB1 & 2 , TMB

Compressor 1&2,
1&2,
BUR 3 out Battery Charger, -----
Scavenge TMB 1&2
TFP 1&2,SRP 1&2
 HV TESTING- TRACTION CONVERTER
Traction Converter/Line Converter/SR traction converter.JPG
➢ Line Converter: Two pulse controlled single phase full bridge rectifier, IGBT switching takes place
at much higher frequency than line voltage Rectifier module.jpg
➢ I GBT
➢ Charging contactor & conv erter contactor
➢ Charging resistor
➢ Current transducer
➢ DC Link: Functions to cater non-periodic power differences between line and motor side of
converter, overvoltage limiting resistor connected across DC link by firing of IGBT & afterwards
IGBT turned off DCLink.jpg
➢ DC Link Capacitor bank
➢ Series resonant circuit capacitor bank
➢ Series resonant choke
➢ DC Link & earth fault Voltage transducer
➢ Earthing & ov ervoltage limitation resistor
➢ Motor Converter: Pulse controlled 3 phase bridge inverter circuit generating 3 phase VVVF
supply fed into stator winding of traction motor Inverter module 2.jpg, Inverter module 3.jpg
➢ I GBT for motor conv erter
➢ Current transducer

➢ Traction converter is controlled by VCU(FLG),converter control module(SLG), Drive control

unit(ALG)
➢ SLG compares the demand torque from FLG w ith effective load torque calculated in ALG.
➢ ALG determines firing and turn off pulse for I GBT on the basis of demand torque.
AC LINE
VCU

P
T 250V 5V Temperat ure/Speed

Primary Volt age Det ect ion

Mot or Current Sensor

ALG SLG
Prot ect iv e Turn-off
Firing Feedback Cont rol
Line Current Sensor

Pow er Fail
Charging/Ma Firing
in Cont act or Feedback
signal DC-Link Volt age
Charging/fee Det ect ion Gat e U nit Supply
dback
GU SP

EF Monit oring

S
e Line Motor
P
c
r
w Conve Conve
i r-ter rter
d
m g
a TM
r
y
w
Intermediate DC-
i
n link
d S
i e Line Motor
n c
g Conve Conve
W
r-ter rter
d
g

TRACTION CONVERTER/SR
 HV TESTING- TRACTION/BRAKING
Traction and Braking in High Voltage

➢ Traction motor correct rotation

➢ Traction motor speed & temperature
➢ Failure mode operation (photo\rotary switch.jpg)
➢ During fault in angle transmitter normal operation can be continued
with operating in failure mode.
➢ Configuration mode operation
➢ Restrict loco speed below 15 Kmph.
➢ Bogie cut-out operation
➢ In case of fault condition bogie can be cutout from rotary switch for
normal operation with half power available.
➢ BPCS operation
➢ Constant speed operation over 5Kmph
➢ Inching mode operation
DC to 3 phase AC
➢ DC Link acts as constant DC voltage source
➢ 3 phase controlled inverter for conversion
 HV TESTING- TRACTION/BRAKING
Traction and Braking in High Voltage

➢ Regenerative braking
➢ Electric power generated (approx 12% of total power
consumed) and fed back to Overhead lines.
➢ Alarm chain pulling (Safety Device)
➢ Emergency stop operation
➢ Vigilance Control Device operation.
➢ VCD Indication and alarm
➢ VCD reset/ Acknowledge
➢ Foot Switch
➢ BPVR switch
➢ Emergency brake application if VCD not reset (brake can be
reset after 3 min of application).
HV TESTING- EARTH FAULT, HOTEL LOAD, AC
Earth Fault detection:
Check for locomotive operation during earth fault developed in
following circuits:
➢ Control circuit
➢ Power circuit
➢ Auxiliary circuit(1000V/415V)
➢ Hotel load
➢ Harmonic filter

Hotel Load operation (only in WAP7)

➢ Check hotel load converter 1,2 output voltage(750V), frequency (50Hz),
operating through BLHO switch at ‘C’ panel

Air Conditioner (ac.jpg)

➢ Check for proper ventilation/cooling/heating.
➢ Cab selector switch in HB2 panel.
 SHOWER TEST/PDI
Shower Test

▪ To check for water leakage inside Cab, Machine room and

Traction motors. (VID-20191113-WA0069.mp4)

Pre-delivery Inspection
▪ All lighting check
▪ All SR, BUR, Panels cover applied
▪ Loco Running, regenerative braking
▪ Check for any abnormal sound from rotating machines
▪ Cab heater, blower, AC
▪ SR coolant and Transformer oil level
▪ Check for any fault messages in archive, delete all
▪ All keys applied at appropriate position (Key multiplier, panels)
 LOCOMOTIVE DISPATCH
Final Dispatch of locomotive
 VID-20191113-WA0002.mp4