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„1‟
lR;eso t;rs
GOVERMENT OF INDIA
MINISTRY OF RAILWAYS
TECHNICAL SPECIFICATION
OF
STICK TYPE MASTER CONTROLLER
FOR
25 KV AC ELECTRIC LOCOMOTIVE
Approved by Signature
Sr. EDSE
ELECTRICAL DIRECTORATE
RESEARCH DESIGNS AND STANDARDS ORGANISATION
LUCKNOW-226011
Page 2 of 20 Issued on Oct‟ 2011 Spec. No. RDSO/2011/EL/SPEC/0040 Rev. „1‟
Status of Revision
Contents
The master controller is human machine interface used by driver to drive the
locomotive. The Master controller has to perform three basic functions i.e.
Controlling the progression, regression and braking of locomotive.
This specification is intended to define the technical requirements of Stick type
Master controller (STMC) to be used in existing and new tap changer locomotives
and the interface requirements.
This revised specification supersedes the earlier technical specification No.
ELRS/SPEC/MP/0040/Rev.0 (Dec 2005).
1.1 Stick Type Master Controller (STMC) shall be based on Modular Concept for
Microprocessor type as well as Non Microprocessor type 25 KV AC Electric
Locomotives. The system should have the added advantages over the earlier
system such as:-
i) It should have substantially lesser weight (not more than 24 Kg) in
comparison to conventional wheel type Controller of 40 Kg.
ii) It should acquire lesser space not more than (400 mm length x 250 mm
width). Height of the equipment should be not more than 170 mm max
without handle making it comfortable for driver to operate master controller
in sitting posture.
iii) The operational aspects of stick type master controller should be similar to
conventional wheel type controller.
1.3 Any deviation from the standards laid down with a view to improve the
performance, utility and efficiency of the equipment will be given due
consideration provided full particulars with technical justification and adequate
data to enhance the performance of equipment is given. However no major
deviation in the specified over all dimensions of mounting, cable routing, over all
space requirement specific to depth of controller shall be allowed. The master
controller has to be cam shaft switch type only.
2.0 SCOPE:
2.1 This specification covers the manufacturing and supply of stick type master
controller for use on 25 KV, 50 Hz, single-phase electric locomotive of Indian
Railways. Master controller design should be able to interface with both
microprocessor and non-microprocessor type locomotives.
3.0 SERVICE CONDITIONS:
3.1 The Stick Type Master Controller shall operate satisfactorily under the following
climatic conditions: -
i) Ambient temperature varies from 0oC to 55oC with 100 % humidity and an
altitude 1200 meters above sea level.
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Page 5 of 20 Issued on Oct‟ 2011 Spec. No. RDSO/2011/EL/SPEC/0040 Rev. „1‟
ii) During dry whether the atmosphere is dusty. The equipment shall be
working in coastal areas with corrosive atmosphere.
3.2 The master controller and its mounting arrangement shall be of robust design
and shall withstand the shocks and vibrations satisfactorily. Following test as per
Category 1 class B of IEC 61373 for rolling stock equipment for Railway
application are to be satisfied.
i) Functional random test as per clause no. 8.0
ii) Simulated long life testing as per clause no. 9.0
iii) Shock testing as per clause no. 10.0
The key can only be inserted or withdrawn from controller at „0‟ position. Key
handle should be mechanically linked to the camshaft to actuate the cam
switches mounted on every individual cam. There should be minimum 6 NC
combination of cam switches. Cam switches should confirm to CLW drawing no
3TWD.101.138.
5.2.2 Throttle Handle (MP Handle):
Throttle handle (MP handle) shall be designed for stick type movement and
placed at the extreme right hand side. There should be Eight positions of this
handle ( + , N , - , P , 0 , - , N , +).
The Maximum degree of rotation of this handle shall be 90 0 +/- 50. The division of
all Eight positions should be placed in such a manner that driver should feel the
notch on every position. The notch formation on the wheel should have enough
depth to arrest the roller for avoiding slip of handle
There are two main divisions of this handle. Away from driver side of this handle
is used for powering the locomotive for traction. The following notches are used
for this application.
0, - , N , +,
Driver side of this MP handle is used for powering the locomotive for Braking.
The following notches are used for this application.
+,N,-,P
The „0‟ position of MP Handle is neutral position and „P‟ position is for brake set
up. This is a very critical junction in driving locomotive. When driver wants to
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Page 7 of 20 Issued on Oct‟ 2011 Spec. No. RDSO/2011/EL/SPEC/0040 Rev. „1‟
bring throttle (MP handle) from traction side to braking side to apply dynamic
braking the MP handle should not be brought to braking side instantly as this will
affect traction motors and lead to heavy jerk. To avoid this , “U” path for MP
handle is made at the crossing junction. This redirects the throttle handle (MP
handle) from traction to braking and vice-versa for Minimum Time to Change
over (MTCO) operation.
Throttle (MP handle) should be mechanically linked to the camshaft to actuate
the cam switches mounted on every individual cam. There should be minimum
14 nos. combination of cam switches. Cam switches should confirm to CLW
drawing no 3TWD.101.138.
5.2.3 Field Weakening Handle (MPS):
The Field-weakening handle shall be designed for stick type movement and
placed at the middle position of both the MPJ and MP handle. There should be
five positions of this handle 0,1,2,3 and 4. Position no.4 should be towards driver
side.
The maximum degree of rotation of this handle should be 80 0 +/- 50 . The division
of all positions should be equally placed to each other. The notch formation on
the wheel should have enough depth to arrest the roller for avoiding slip of
handle.
The handle should be mechanically linked to the camshaft to actuate the cam
switches mounted on every individual cam. There should be minimum 4-nos.
combination of cam switches. Cam switches should confirm to CLW drawing no
3TWD.101.138.
6.0 MECHANICAL INTERLOCKING BETWEEN THREE HANDLES:
6.1 All these handles shall be mechanical interlocked with each other for safety of
driving locomotive as given below:
S. Handle Position Mechanical Interlock
No.
1. Reverser Key at “0” position Throttle (MP handle) and field handle
gets locked in “0” position.
2. Reverser Key moved either “F” Throttle handle (MP handle) can be
or “R” moved towards Traction or Braking.
3. Throttle handle (MP handle) at Reverser Key can be turned from “0”
“0” position to “F” or “R”
4. Throttle handle at any position Reverser Key gets locked in either
except “0” “F“ or “R” position.
5. Throttle handle (MP handle) Field handle can be moved to all four
moved towards Traction positions as desired
6. Throttle handle (MP handle) Field handle gets locked at
moved towards Braking “0”position
7. Field weakening handles at any If the Throttle handle (MP handle) is
6.2 The cam sequence of stick type master controller would be initially tested as per
standards of WAG7 locomotives.
7.0 MOUNTING DIMENSIONS AND SPACE REQUIREMENT:
There is limited space inside driver‟s console. The overall dimensions and
mounting frame for retro fitment are defined in the annexure-2. Supplier has to
design the master controller, which can be accommodated in the space defined.
The depth of the controller has to be maintained maximum 175 mm and any
major deviation on this is not acceptable.
8.0 WIRING, CONNECTORS & CABLES:
All cam switches are to be wired with thin walled E-beam cables as per RDSO
specification and approved source. This controller will be interfaced to locomotive
through coupler. One 26 pin bayonet connector size 28-12 of Amphenol/Allied
make shall be used which is complying (MIL-C-5015) MIL standard. If any other
interface i.e. terminal board or any other couplers are required, prior approval
from RDSO has to be taken.
Wiring details of 26 pin circular connector
11.0 TESTS:
The type tests shall be carried out by RDSO representative on prototype unit
either totally or in part. Under the following conditions without any additional
cost.
11.3 ROUTINE TEST: Routine test shall be carried out in every equipment of each
order.
11.4 Tests will be carried out on the prototype unit as per relevant IEC
specification or mutually agreed test program. Manufacturer will bear the
expenses of the tests.
vi) The mechanical locking of the master controller shall be as per clause 6.0
of this specification.
11.5.6 Vibration and shocks Tests:
The vibration and shocks tests shall be carried out as per category 1,
class B of IEC 61373 for rolling stock equipment for Railway application.
The following test should be carried out.
i) Functional random test as per clause no. 8.0
ii) Simulated log life testing as per clause no. 9.0
iii) Shock testing as per clause no. 10.0
The parameters of the above testing as per category 1 of class B are
given below:-
Each Stick Type Master Controller shall be provided with a name plate or
plates legibly and indelibly marked with at least the following information: -
i) Name or trade mark of the manufacturer
ii) Type/Designation
iii) Month & Year of manufacture &.
iv) Batch No. of manufacture at a visible place.
13.1 PACKING:
Each Stick Type Master Controller will be packed in Polly Pack with
wooden crate or high density thermo coal boxes to protect the equipped
panel from any damage due to transit vibrations, rains, moisture and dust
etc. during transportation. List of equipment‟s shall also be enclosed along
with each packing.
Annexure-1
Annexure-2
Annexure-3
Testing sheet of STMC for functionally testing
1. For MP handle: