fdcs manual stesalit

Fault Diagnostics and Control System Stesalit Limited

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Index

1. System Overview

2. Safety Design Considerations

3. System Architecture

4. System configuration

5. System Highlights

6. Relay Logic Description

7. Hardware Description

a. Processor Module

b. Multi-function Module

c. Analog Input Module

d. Signal Conditioning Module

e. Status Input Module

f. Relay Output Module

g. Display Module

h. Power Supply Module

8. Software Architecture and Description

9. Interconnection Details

a. FDCS Unit to Terminal SB

b. FDCS Unit to Display unit

c. FDCS Unit to Signal conditioning unit

d. Signal Conditioning Unit to SB Terminal

e. FDCS Unit to PC

10. Wiring Details for FDCS-9648 of WAG-7 Locomotive

11. List of Input/Outputs

12. Trouble shooting Procedure of FDCS 9648

13. Operation of the Display panel

14. Fault Messages


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1. System Overview

Existing electric locomotives working on Indian Railways are having conventional

control and interlocking of its different circuits for its safe operation. These are

achieved through an array of Electro-mechanical and Electro-pneumatic relays

and contractors. Such relay-based control involves a large amount of cabling and

a number of interlocking contacts and interconnections, which are not only

maintenance intensive but are unreliable too.

Interlocking of relays inside the loco was used to have some predefined

sequence of operation for proper operation of the different functional blocks of

the loco. For this purpose, interlocking of the relays are used to derive some

combinatorial, sequential and delay logic circuits Other than this, the purpose of

the relays is to ensure the safety of the loco against malfunctioning of the various

electrical equipments due to their different modes of failures. Further, failure of

the relay contacts often makes the situation more complicated.

In the existing loco, in case of any fault, it is very difficult to locate the actual root

cause. This not only increases the down-time of the locos, its servicing and

maintenance also becomes difficult. Identification of the exact fault condition and

its correct maintenance is important to maintain the healthy condition of loco.

The objective of the project “MICRO PROCESSOR BASED CONTROL AND

FAULT DIAGNOSTIC SYSTEM “is primarily to locate the faults for its correct

maintenance. Another objective of the system is to replace some existing relays

and its corresponding interlocking logic with software to reduce the cost and

complexity of wiring and to add certain diagnostic features for better maintenance

of the loco.


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2. Design Considerations

The heart of the system is obviously the microprocessor, which acquires the

status of the relays and some analog parameters, processes the information and

issues control outputs to operate and control the various electrical equipments

inside the loco. The purpose of the loco is to run passenger or goods train from

one location to another. Hence, safety of the passengers is one of the prime

considerations for all the interlocking, be it derived through relays or through

electronics & software. Failure to ensure its safe operation may also lead to loss

of property.

Implementation of such protection and operational logics through electronic

hardware and software is much more critical because of the numerous failure

modes that are observed with such systems. Although the basic objective of such

system is quite simple, one needs to ensure the correctness of the input data, its

processing and the output status with a certain degree of confidence.

Components might fail as part of its inherent characteristics. But it is essential to

ensure that in case of any malfunction due to a failure, the control system does

not lead the loco to an unsafe condition.

A safety level for such systems have been designated by various international

bodies and is typically 10–7 to 10-8 / hour (Safety Integrity Level, SIL3). With

single processor system, the level that can be achieved is typically 10-6 to 10-7 /

hour or even worse depending on the design methodology. Safety level of such

system is considerably enhanced by the use of testability at various levels and

dual hardware redundancy in the hardware. Use of hot-standby processor does

not necessarily enhance the safety level since there are quite a few failure

modes, which a single processor system fails to identify and subsequently lead to

a safe condition.

Availability is another important requirement of such system since due to any

failure if the system ceases to work, there will be disruption of service, which may

lead to inconvenience to the passengers, although it may be safe.


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Thus considering both safety and availability of the equipment, the architecture

adapted in the present system is 2-out-of-2 operations with full hardware

redundancy in the input and processor level. Output drive is combined for both

since it would the same relay or contactor. However, each of the subsystem has

its own redundancy and testability to ensure its individual function. Normal

operation will be carried out based on 2-out-of-2 voting in taking all the logic

processing and vital decisions. However, in case of a failure in one set of

hardware, the second set would continue its operation but with an alarm,

ensuring a certain degree of safety.

Redundancy alone does not guarantee fail-safe operation of equipment. For a

redundant system to function properly in presence of a fault, the redundancy

must be managed properly. Redundancy management issues are closely inter-

related to ensure the reliability, availability and safety issues for such systems.

One of the key issues for such architecture is the synchronization of the two

processors so that both of them get the same data and processes the output for

the 2-out-of-2 voting process.

3. System Architecture

The basic architecture adapted for the Fault Diagnostic and Control System is

shown in Fig. I. Each individual processor has its own digital and analog input

cards. Each status input is read by each processor through two separate opto-

isolators to ensure the correctness of input data individually through dual

redundancy. Correctness of analog inputs is assured by feeding of the same

signal through multiple paths using separate hardware. Outputs of both the

processors are combined in the output card to drive the external relays.

The Multi-function card gives the synchronization pulse to run the two processors

in collusion. It also has the necessary selection logic to select the processor,

which will download all the necessary information to the display units based on

the keyboard interaction. It also drives the safety relay, which will ensure the


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safety of the system under the worst-case condition of multiple failures in the

system by withdrawing the power to drive some of the vital external relays of the

loco.

All the status inputs are available in the form of 110 VDC input for ON condition

and no voltage for OFF condition. Analog voltages are available in very high

voltage, which are attenuated in the signal-conditioning box and then fed to the

analog module. Six TM currents are sensed through the voltage drop at shunt of

Traction Motor by means of low voltage. Isolation amplifiers are used for feeding

each input to the processor after proper scaling. All the outputs are driven by

solid-state switch with short-circuit protection to drive the external relays with

110VDC. Elaborate testability at the output has been kept to ensure the integrity

of the output status.

Each of the two processors interfaces to the I/O modules through separate I/O

bus so that in case one of failure of one of the busses, the other can still continue

with the operation. Communication between the two processors is carried out

through inter-processor communication bus to carry out the voting process. The

processors have individual health lines which are also interchanged to

crosscheck the proper functioning of the system. One USB port is provided in

each CPU card to download the data to USB memory device or Pen Drive.

The system uses two display units to prompt the various status and alarm

conditions of the loco. A 40 alphanumeric character x 4 lines LCD display unit is

used for this purpose. It also has two segments 7-SEG Display to display the

current notch position. Five numbers of keys are provided to enable the user to

browse through the status and fault condition of the loco. The display unit

receives +110V power from LOCO battery i.e. from wire no. 700. This unit has a

built in power supply module to convert +110V to +5V and +12V.


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Fig.1: System Architecture

IPC Comm. Bus

CPU-A

CPU-B

Multi- Function Card.

Sync.

Display Bus A

Display Bus B

Display Unit 1

Display Unit 2

Display Bus.

PSU-A

+12V +5V

+110V DC

Analog Input

Signal Conditioning Module.

Interface A

Interface B

Output Driver.

Control Outputs.

Analog Input

Output Module

I/O Bus

A

I/O Bus

B

PSU-B

DIODE OR-ing

TM CURRENT SENSING MODULE - A

TM CURRENT SENSING MODULE - B

External Status Input

Interface A

Interface B

Input Module

Input Scanner


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4. SYSTEM CONFIGURATION

The system contains three separate sub-racks, which are fitted inside the main

cabinet. The lowest sub-rack contains two Processor cards, one Multifunction

card, one Analog Input cards and two Power Supply card. In the middle sub-rack

there are eight Input cards, out of these one is redundant card and one is spare

card. All the external input wires are routed from the backplane to the terminating

19/17 pin circular (bayonet type) connectors mounted on the cabinet. The

uppermost sub-rack houses five output cards, out of these three for 48 O/P, one

is redundant and one is s spare output card, which are common for both the A &

B processors. The uppermost sub-rack also has one card called filter card. All

the external output wires are similarly extended from the backplane to the 19 pin

circular connectors placed on the cabinet. The front side of the cabinet is a

detachable door. The door is also provided with a lock to protect the system from

unauthorized access. The rear side of the cabinet is having four M12 nuts to fit

the system to AC2 panel wall.

Normally the FDCS can accept 128 digital inputs (96 I/P for 6 I/P card, 16 I/P for

one Redundant I/P card, 16 for one spare I/P card) and 12 analog inputs and can

drive up to 80 digital outputs (48 O/P for 3 O/P card, 16 O/P for one Redundant

O/P card, 16 for one spare O/P card). The inputs enter to the FDCS through 7

no. of 19 pin allied connectors (one is redundant) and outputs goes out from the

system through 4 no of 19 pin allied connectors (one is redundant). A 3-pin

bayonet type connector is used for 110V DC power supply. The connectors are

fitted on the topside of the cabinet. The cables for inputs/outputs used are 19

core PTFE insulated 90% shielded type of 1 sq. mm. Outer jacketing of FRLS

material is of suitable grade. One end of the cables is terminated to the allied

connector and other end is terminated at 2.5 sq. mm cable lugs for M5 terminal

stud with loco cable number of ferrules. The cables used for power inputs are of

3 sq. mm are of suitable grade. The interconnection of various connectors of

FDCS main cabinet, display units, and signal conditioning box, Traction Motor


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Current Sensing box and AC 2 Panels SB terminal is described later. The

diagram of box mounting type allied connector in the control unit is shown in

figure 2A. There is a mechanical polarization difference among the bayonet type

connectors. Therefore the interchangeability among the input and output

connectors is ruled out.

Wiring details of various connectors are shown in table 1.Position of various

racks, connectors of a typical FDCS are shown in figure 2.

The display unit functions as an interface between the operator and the system.

Each FDCS system consists of two display boxes, one in master cabinet (CAB A)

and the other in rear cabinet (CAB B). In each box there is one display CPU

along with one display keyboard and a power supply card. In display unit there is

one 4X40 character LCD, two seven segment LED, one red LED, one buzzer

and eight keys. Communication is held between the display and main unit trough

RS485 serial port using 10 pin bayonet connector. The display panel diagram of

the display system is shown in figure 3.

Each FDCS system consists of one signal-conditioning box. In this box there is

one signal-conditioning card. High voltage analog inputs are terminated on the

card through 6-way M5 terminal strip, which is fitted one side of the box. The

voltages are down converted to 2.0V. These down voltage signals pass through

10-pin allied connector to FDCS main system, which is, fitted another side of the

box.

Each FDCS system consists of two traction motor current sensing box. In this

box there is one traction motor current sensing card. Low voltage (range between

45mV to 75mV) analog inputs are terminated on the card through 6-way and 2-

way M5 terminal strip, which is fitted at side of the box. The voltages are

converted to 1.0V. These voltage signals pass through 10-pin allied connector to

FDCS main system, which is, fitted another side of the box.


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Fig.2: FDCS Main Cabinet

PLACE FOR BAYONET CONNECTOR (Details in Fig. 2A)

O U T P U T R D T

O U T P U T 1

O U T P U T 2

O U T P U T 3

O U T P U T S P R

F I L T E R

I N P U T R D T

I N P U T 1

I N P U T 2

I N P U T 3

I N P U T 4

I N P U T 5

I N P U T 6

I N P U T S P R

A N A L O G

C P U 1

C P U 2

M U L T I F U N C

P S U 1

P S U 2


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Fig.2A: FDCS Main Cabinet Connector Details

INP1

INP RDT

OP1

INP2

INP5

OP2

INP3

INP6

OP3

INP4

INP SPR

OP SPR

DISP2

DISP1

SIG CON

TM2

TM1

PWR

OP RDT


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Fig.3: Display Screen Diagram

8

Fig.3A: Display Unit

Date – 27/12/07 Time – 12:30

Insert BL Key

MENU ENTER

+

-

ACK


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Dimensions of FDCS9648: -

Parameter Main Unit (in mm) Display Unit (in mm) Signal Conditioning

Unit (in mm)

TM Current Sensing Unit (in mm)

900(including connector) 160 (hole to hole) Height

785 (without connector) 180 (total) 102

62

240 (hole to hole) Width 305

265 (Total) 180

180

Breadth 385 46 210 210

Viewing Area

NA 150 X 30 NA NA

5. System Highlights

• System meets RDSO specification no. ELRS/SPEC/MPC-FDS/0001 (REV-2) Aug 2005.

• High performance Intel 80C196KC used for better performance.

• Elaborate testability and dual hardware redundancy at all levels including the processor for high degree of safety.

• Normal operation mode is in 2-out-of-2 mode, providing a safety integrity level of typically 10-12 / hour. In case of a failure in any one of the sub-system, the system continues its operation with a reduced safety integrity level of typically 10-7 / hour.

• Online system diagnostics for identification of faults.

• All Inputs and Outputs are optically isolated for protection against high voltage, surges, transients and ground faults.

• Total CMOS design for reduced power consumption and better MTBF.

• Modular construction for ease of maintenance.

• Uses 4 x 40 character alphanumeric displays status and fault conditions in lucid language for ease of understanding and the right corrective action.

• Use of large segment 7-segment LED for display of notch position.

• Non Volatile Fault Memory stores last 512 events with all back ground data, which can be retrieved sequentially through the display unit.

• Provision of USB port in the Control Unit to download fault history from system to USB storage device or pen drive.


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6. Relay Logic Description

An array of relays and contactors is currently used inside the loco for protection

of the various electrical equipments and its operation in a desired sequence. The

functional blocks that are intended to be replaced by the Microprocessor based

Fault Diagnostic and Control System are described below. The system would

realize these functional blocks through software and activate the respective

contactors and power relays to maintain the same operational condition of the

loco.

6.1 PANTO GRAPH CONTROL CIRCUIT

Current from overhead is controlled by means of two pantographs, PT-1 and PT-

2. These are operated by hand-operated switch ZPT-1 & ZPT-2.Compressed air

pressure is used to connect and disconnect the pantograph from the overhead

high tension wire.

To raise the pantograph in CAB-1 or CAB-2, the corresponding two relays VEPT-

1 or VEPT-2 are energized, depending on the status of the switch ZPT-1 or ZPT-2.

In position ‘O’ of the two switches ZPT-1 & ZPT-2, both the pantographs are

OFF, i.e. VEPT-1 & VEPT-2 are not energized.

6.2 BATTERY CHARGER OPERATION

The battery charger is fed from the supply of ARNO/Static converter. The charger

unit provides 110V DC and a load of 20 amps. A relay QV-61 has been provided

across the charger, indicating its working. As long as charger is ON, QV-61 is

energized and the signaling lamp LSCHBA remains OFF.

6.3: OPERATION OF THE HIGH VOLTAGE CIRCUIT BREAKER (MTDJ):

The electro valve MTDJ (O0) controls the high voltage circuit breaker DJ. The

breaker is closed by means of the electro-valve EFDJ. The breaker (DJ) is closed

as long as the MTDJ is closed. If MTDJ is interrupted by any of the relay contact


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in its path then DJ will be tripped resulting disconnection of power feeding from

the 25 KV HT overhead.

CONDITIONS OF CLOSSING DJ:

1. BL key in CAB-1 or CAB-2 must be inserted and switched to ON position.

2. After this, Q45 have to be ON. The conditions required for this are:

a. BP1DJ closed

b. BL1DJ/BL2DJ closed

c. ZPT1/ZPT2 closed (Alternately BV closed) and

d. BL1RDJ/BLR2DJ pressed and released as soon as LSDJ OFF.

3. A. For ARNO based Loco :-

Now Q118 is to be energized. For this, the conditions required are:

a. C118 must be de-energized,

b. Blower motors must be OFF so that C105, C106, C107 de-energized,

Q46 de-energized (between-notch relay) and

c. GR within 0 to 5 Notches.

B. For Static Converter based Loco:-

Now Q118 is to be energized. For this, the conditions required are:

a. Blower motors must be OFF so that C105, C106, C107 de-energized,

Q46 de-energized (between-notch relay) and

b. GR within 0 to 5 Notches.

4. As Q118 energized, Q44 will be ON provided Q45 closed. ASMGR full

Notch contact available and GR-0 contact is there.


As Q44 and Q45 are ON and QCVAR OFF (Arno not started), C118 will

be energized closing the Arno starting contactor and introducing the arno


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starting phase by R118 and so Q30 will be ON. And Q44 will be latched

through Q30.


As QV60 is in OFF condition, through NC contact of QV60, SI will get ON.

It causes 440V A.C feed in wire no. 991 and 993 i.e. output of SI, by which

Q30 gets on via resistance RQ30. Thus Q44 will be latched through Q30.


As C118 energized, DJ starting coil EFDJ will be energized. On opening of

C118 (after ARNO starting) EFDJ will be de-energized but DJ will be hold

by MTDJ.


As Q45 is energized, DJ starting coil EFDJ will be energized through NC

contact of DJ and N/O contact of Q45 (This N/O contact gets closed in this

condition). As EFDJ is energized, NC contact of DJ will open. Hence

EFDJ will be de-energized but DJ will be hold by MTDJ.

7. The number of protection relays, such as QOA, QLA, QLM, QOP-1, QOP-

2, QRSI-1, QRSI-2 and QPDJ should be closed.

8. When Blower motors are ON after DJ closing, C105, C106, C107 will be

energized, so the NC chain of the above 3 relays in the path of Q118 will

be opened. Since Q118 is a time lag relay, it will be dropped after 5 sec,

so that the path remains closed till the chain of protective relays QVMT-1,

QVMT-2, QVRH, QVSL-1, QVSL-2, QPH, QCVAR close the alternate

path.


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Tripping of DJ:

A) TRIPPING OF DJ INSTANTANEOUSLY.

1. Through tripping of the relay QOA for ARNO based Loco and QSIT for

SI based Loco.

2. Through tripping of the relay QLA for ARNO based Loco only.

3. Through tripping of the relay QLM.

4. Through tripping of the relay QOP-1.

5. Through tripping of the relay QOP-2.

6. Through tripping of the relay QRSI-1.

7. Through tripping of the relay QRSI-2.

8. Through tripping of the relay QPDJ.

B) TRIPPING OF DJ DELAYED BY AT LEAST 0.6 SEC.

1. If Q30 contact opens.

For ARNO based Loco: - Q30 is the ARNO voltage condition relay. It remains

picking up between 215V - 260V AC.

For SI based Loco: - Q30 is the Aux. Rectifier Side voltage condition relay of

Static Inverter. It remains picking up between 400V – 460V A.C

2. QVSI-1 and QVSI-2 (rectifier blower protection relays) relays trip.

OVERRIDING OPERATION OF DJ OVER RECTIFIER BLOWER

PROTECTION RELAYS:

For bypassing any of the contacts QVSI-1/QVSI-2, it is necessary to put the

handle of HVSI-1 and HVSI-2 in the ‘O’ or ‘3’ position.

C) TRIPPING OF DJ DELAYED BY ATLEAST 5.6 SEC.

Q118 drops out after delay of 5 seconds and opens energizing circuit of relay

Q44 which trips the main circuit breaker after a further delay of 0.6 second

following any of the following faults.


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� Upon blower motors protective relays QVMT-1, QVMT-2, QVRH and

QVSL 1-2 as well as upon failure of the oil pump via protective relay QPH

and for ARNO based Loco through relay QCVAR also.

During normal operation QVMT-1, QVMT-2, QVRH, QVSL 1-2, QPH and

QCVAR for ARNO based Loco remain closed and auxiliary contacts

(C105, C106, and C107 &Q44) remain opened.

In case of any failure the associated protections relay open, the relay

Q118 drop out in 5 sec.

� If the tap changer comes to a standstill at any particular notch while

notching down with master controller on ‘0’ position, relay Q46 is

energized (contacts opened), thereby switching off the relay Q118.

The relay Q46 is constantly switched on and off until the tap changer has

reached zero position.

Note:

It is possible to put the switch HVMT1, HVMT2, HVRH, HVSL1,

HVSL2, HPH in position ‘0’ or ‘3’ to override the contacts. In case of

HQCVAR, ‘0’ is the overriding position

6.4. A. ARNO STARTING LOGIC DESCRIPTION

SEQUENCE OF OPERATION OF ARNO STARTING: 1. BP1DJ, BL1DJ/BL2DJ and ZPT1/ZPT2 should be closed and then

BL1RDJ/BL2RDJ is pressed for a moment (and released as soon as the

green lamp LSCHBA glows OFF) to ON the relay Q45. (At this time GR

should be in ‘0’ Notch position).


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2. Normally, the relay Q44 is switched by the contact of Q45, if the GR is not

there in between two notches (stuck at notch faults) and Q118 has picked

up.

3. On closing of Q44 and Q45 the ARNO starting contactor coil C118 gets

energized to generate a phase difference between the voltage and current

for starting the ARNO which is a single phase induction motor.

4. C118 is cut by the excitation of the relay QCVAR (N/C).

6.4. B. STATIC CONVERTER STARTING LOGIC DESCRIPTION

SEQUENCE OF OPERATION OF SI STARTING: 1. BP1DJ, BL1DJ/BL2DJ and ZPT1/ZPT2 should be closed and then

BL1RDJ/BL2RDJ is pressed for a moment (and released as soon as the

green lamp LSCHBA glows OFF) to ON the relay Q45. (At this time GR

should be in ‘0’ Notch position).

2. Normally, the relay Q44 is switched on by the contact of Q45, if the GR is

not there in between two notches (stuck at notch faults) and in this

condition relay Q118 will be ON.

3. Static Inverter will be ON by the NC contact of QV60 relay when it is in

OFF condition,

6.5 BLOWER MOTOR CONTROL

NORMAL OPERATION:

The contactors of the blower motors close automatically when

MPJ1/MPJ2 puts in the forward or reverse direction and GR is at 1 or

above position and Q100 is in closed condition.

ALTERNATIVE PATH:

The contactors of the blower motors may be energized if

BL1VMT/BL2VMT switch is closed and Q100 is in closed condition.


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The starting of the motors for the traction motor blower and the

transformer oil cooler are in the following sequence.

1. Closing the BL1VMT/BL2VMT

2. Q100 is already closed (since DJ is closed and C118 is opened).

3. keeping the disconnecting switch for oil cooler blower motor HVRH

in position ‘1’ or ‘3’. Coil of C107 gets energized and transformer oil

cooling blower motor gets started.

4. When the relay C107 is energized, the time delay relay QTD105

gets energized after a time delay of 5 seconds and its contact

energized the coil C105 if the disconnecting switch for traction

motor blower no.1 HVMT-1 is in ‘1’ or ‘3’ position and also

energized the time delay relay QTD106 after a delay of 5 seconds.

The contact of QTD106 energized the relay C106 if the

disconnecting switch for traction motor blower no.2 HVMT-2 is in ‘1’

or ‘3’ position. The relay C105 & C106 latches the contacts by the

self-contact C105 and C106.

5. For WAG-7 Loco having Static Inverter has C108 relay also. If

C145 is in ON condition and C107 in OFF condition only then C108

will be energized. In WAP-4 Loco, C108 is not available.

Note:

Driver can switch off the blower motor contactors C107, C105, and C106 by

directly putting the disconnecting switches HVRH, HVMT-1 and HVMT-2 in

position ‘0’ or ‘2’ respectively.

6.6 COMPRESSOR MOTOR CONTROL

GENERAL DESCRIPTION

The compressor motor contactors C101, C102, and C103 are energized, if any of

the key BLCP and valve RGCP or BLCPD is closed, and also the relay Q100 is

closed and HCP is not in position ‘0’ (The position of HCP determines how many of

compressor motors will be started at a time). When no compressor motor has been


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started, the relay for unloaded valve Q119 is under energized condition through a

chain of NC contacts of C101, C102, C103 and the N/O contact of Q119 make

unloaded valves VEUL1-3 energized. Unloaded valves are electro-pneumatic

valves work to avoid the backpressure of the delivery pipe at the time of starting of

compressors. First C101 and C103 are energized which results opening of path for

Q119 coil. The path of C102 is closed through N/C contact of Q119. So C102 starts

after dropping of Q119. The purpose of unloaded valves is served through the 5”

time lag of Q119.

Fig. 4: Signal Diagram Un-loader Valve

6.7 TRACTION MOTOR CONTRACTORS (LINE CONTACTORS) There are six Line contactors L1, L2, L3, L4, L5, and L6 for the traction motors. NORMAL OPERATION: For closing the line contactors, the following conditions must be satisfied: 1) The running/braking drum of the master controller MP is only in running

position.

2) Q50 is closed.

3) CTF [1-3] are in running.

4) The tap-changer GR must be on notch 1 or above.

5sec

O8

VEUL


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5) The rotary switch position of HVS1-2 and HVMT1-2 must be at 1 or 3,

which determine the half or full power availability of the traction motor.

6) HMCS-1 & HMCS-2 rotary switching positions are at closed contacts.

Once traction motor contactors are closed, and GR is in notch position ‘1’ or

above the line contractor’s relays are latched by their own contacts through a

N/O contact of DJ, which bypass the MP and Q50.

6.8 TRACTION MOTOR CONTROL

The traction motor double reverser J1J2, pneumatically controlled, connects the

exciting windings of the motor in such a way that these carry current in one

direction or in the other thus enabling the locomotive to run in either direction.

6.8.1 OPERATION OF TRACTION BRAKING REVERSER IN RUNNING

POSITION

1) Main circuit breaker DJ must be closed.

2) Tap Changer GR must be in position “ O” (zero)

3) The selected position of the MP must be coincide with the corresponding

operating position of the switches CTF[R]/CTF [B]

4) Supervision takes place via the auxiliary contacts of reversers J1 J2.

6.8.2 OPERATION OF TRACTION BRAKING REVERSER IN BRAKING

POSITION


2) Tap Changer GR must be in position “O” (zero)

3) The selected position of the MP must be coincide with the corresponding

operating position of the switches CTF[R]/CTF [B]

4) Supervision takes place via the auxiliary contacts of reverser


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6.8.3 OPERATION OF TRACTION MOTOR DOUBLE REVERSER IN

FORWARD DIRECTION


2) Tap Changer GR must be in position ‘ O’ (zero)

3) The selected position of the reversing drum MPJ must be coincide with the

corresponding operating position of the switches J1J2 [F]/J1J2 [R]

4) Supervision takes place via the auxiliary contacts of reverser CTF[R]/CTF [B].

6.8.4 OPERATION OF TRACTION MOTOR DOUBLE REVERSER IN

REVERSE DIRECTION


2) Tap Changer GR must be in position “ O” (zero)

3) The selected position of the reversing drum MPJ must be coincide with the

corresponding operating position of the switches J1J2 [F]/J1J2 [R]

4) Supervision takes place via the auxiliary contacts of reverser CTF[R] CTF [B].

The traction/braking switch CTF1-3 with pneumatic control connects the

power circuits of motors for traction or braking. Both J1-2 and CTF1-3 can

be changed over the ‘0’ position of GR.

6.9 NOTCHING IN LOCO

Inside the Loco, the main transformer (primary fed by 25 KV) comprises

one autotransformer with 32 taps (called notches) and a step down

transformer with two separate secondary. The primary of the step-down

transformer is connected to one of 32 taps of the autotransformer by

means of 32-step tap changer GR, which is driven by a pneumatic

servomotor SMGR. The passage from one tap of transformer to another

takes place on load.

When GR value is increasing it is called notch-up of the loco and when

decreasing it is called notch-down. Notching is held during running


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/braking condition of loco. Running/Braking is controlled by master

controller MP called Running /Braking drum and Forward/Reverse is

controlled by reversing drum MPJ. MPJ can be operated only when MP is

at position ‘0’ (mechanically locked). In the loco there is adequate

arrangement to ensure that the tap changer always moves only one notch

at a time.

FUNCTIONALITY OVERVIEW: If Master Controller MP in ‘+’ position with RUN /BRK, SMGRVE-1 UP

valve will be activated. If it is in ‘-’ position with RUN /BRK, SMGRVE-1

DOWN valve will be activated. Instead of Master Controller push button

switch for operating GR motor in progression BPP1-2 can be used for

notching up and push button switch for GR motor in regression BPR1-2

can be used for notching down. The relay EVPHER will be ON after 5-

notch.

A) Tap changer down valve SMGRVE2 DOWN is energized both for the

running braking drum MP at running and braking position, provided

1. ZSMS must be in position 1(ON).

2. ZSMGR is ON.

3. GR is in 1 to 32 in any of the valid position.

4. Notch to notch relay Q52 and slip protection relay Q51 must

not be energized.

5. The relay Q50 must be closed.

B) Tap changer down valve SMGRVE1 UP is energized both for the

running braking drum MP at running and braking position, provided

1. ZSMS must be in position 1(ON).

2. ZSMGR is ON.

3. GR is in 0 to 31 in any of the valid position.

4. Notch to notch relay Q52 and slip protection relay Q51 must

not be energized.

5. The relay Q50 must be closed.


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To ensure safety, there exists the arrangement of auto regression i.e. tap

changer automatically comes to zero from any high notch value. Auto regression

occurs in case of ARNO over voltage or wheel slip or fall in brake

Pipe pressure monitored by air brake governor as follows:

a. In case of ARNO over voltage, auto regression occurs via Q20

b. In case of wheel slip, auto regression occurs via Q48.

c. In case of fall in brake pipe pressure, auto regression occurs via

QRS relay which causes energizing of Q51 and so auto

regression.

d. If relay Q50 is de-energized in any case then auto regression

Takes place via Q50.

6.10. BRAKE FAIL PROTECTION VALVE – IP (MECHANICAL BRAKE)

IP valve is generally used for braking when normal brake fails to work properly. It

is generally electrically operated mechanical brake. Operation of IP valve is

controlled by FDCS. It is Output22 of FDCS. If Out22 is in ON condition, IP valve

is in de-energized condition – hence no braking. If Out22 is in OFF condition, IP

valve is in energized condition – hence mechanical brake come in to work.

This Output will ON if

1. Q30 is ON or CTF is in Braking side and

2. MP in Braking side or Input73 (GR 0_5 for WAG-7, GR 11_32 for WAP-4)

is in ON condition.

6.11. SHUNTING CONTACTORS

In order to increase the balancing speed, three steps of shunting are used for

field weakening. The shunting operation is done under running condition

controlled by field weakening controller of master controller MPS1-2. Four

shunting steps, Sx1, Sx2, Sx3A, and Sx3B are introduced in MPS1-2. This

shunting is valid only in notch position 20 and onwards.


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For WAP-4 type Locomotive there are two more shunting contactor also named

Sx41 and Sx42.

By pressing switch ZQWC, the weight transfer relay QWC can be energized in

J1J2 [FOR] or J1J2 [REV] condition for notch value 0-10, thus activating O20 and

O21 (S13-S63).

6.12. SANDING LOGIC DESCRIPTION

Sanding occurs via the electro valve VESA-1 & VESA-2 for two directions

respectively.

These relays are energized by operating the pedal switches PAS-1 or PAS-2 in

two cabs or by the wheel slip relays Q48. If the pedal switch is applied and J1J2

are in the forward direction, the relay named VESA-1 will be activated; otherwise

VESA-2 will be activated if J1J2 is in the reverse direction.

On the other hand, VESA-1 & VESA-2 will be activated via Q48 (The relay Q48

can be energized only if the traction breaking switches CTF are in running

position.). If the wheel on one boogie starts slipping, the load on the motor drops

and this is detected by the relay QD1& QD2. (The HMCS-1 switch also selects

this, where we need auto sanding or pedal sanding). When the current difference

exceeds around 150A, the relay QD is energized. Operation of the relay Q48 as

a result of wheel-slip and operation of relay QD-1 or QD-2 also results in

automatic regression of the tap changer (GR) till the relay QD-1 and QD-2 drops

out to arrest of the wheel slip.

The contact of the relay Q48 are provided with a drop out delay of 5-secs. This

begins as soon as the relay has been de-energized. This means that sanding will

continue for 5-sec after wheel slip has stopped.

For MU operation of WAG-7 type Loco, if Q48 acts in any Loco i.e. leading Loco

or trailing Loco, auto-sanding and auto-regression should take place via Q51 in

its energized state at other Loco also.


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6.13. SIGNALLING LOGIC DESCRIPTION

a. LSDJ Lamp (RED):

It indicates the position of the main circuit breaker DJ. When DJ is open QV60

is energized, which turn ON the lamp LSDJ.

LSDJ DJ

ON OFF

OFF ON

b. LSCHBA (GREEN): Lamp LSCHBA will be ON as soon as the driver inserts the BL key. On

closing DJ, lamp LSCHBA extinguishes after picking up of the relays QV-61

and QCVAR on completion of starting of the ARNO.

c. LSGR (GREEN): The lamp LSGR indicates whether the tap changer GR is at position ‘0’ or

away from that position. The relay QV62 should be ON if GR is at zero

position. The lamp LSGR is switched on by the way of the contacts of QV62.

d. LSB (YELLOW): The lamp LSB is switched ON by the relay QV64, which in turn is energized

by the contact of the relay Q50, which is normally closed. The lamp will be

OFF if the Q50 is in ON condition.

e. LSP (RED): If signaling checking lamp switch BPT-1or BPT-2 switch is pressed or wheel

slip relay Q48 is closed, then LSP glows.


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f. LSRSI (YELLOW): This lamp glows when silicon rectifier RSI1-2 is ON or signaling lamp

checking switch BPT1-2 is pressed.

g. LSOL (YELLOW): This signal lamp is useful only during multiple operations of the locomotives.

For detecting defective loco in the event of fault occurring in any of the locos,

QVLSOL is ON and LSOL is also ON.

h. LS –GROUP (RED): This lamp glows when DJ is not in closed condition, or battery charger is in

OFF condition, or silicon rectifier cubicle is ON, or Q50 is in OFF condition.

This indication lamp presents only in WAG-7 type Loco.

7. Hardware Description

The system is provided with three motherboards, which are fitted at the backside

of three sub racks. The cards are plugged to the motherboard through EURO

connectors. To ensure the correct insertion of cards, mechanical polarization is

provided at the backplane by positioning the EURO connectors at different level

for different cards. The advantage with this arrangement is that the same types of

cards are interchangeable and at the same time the insertion of a card at wrong

slot is prevented.

The system consists of two processor cards with a common set of Input Cards,

both analog and digital, and common Output and Multi-function Card set. The

power supply card provides power to both the processor sub-systems.

Each of the Digital Input Cards accommodates 16 external inputs. Three such

Input cards support altogether 128 inputs. For both the processors, altogether

eight input cards are there with complete dual hardware redundancy. Out of


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these eight input card one is redundant and one is spare. The system presently

uses 80 inputs and the rest are available for future expansion of its functionality.

The analog card interfaces to 12 external analog inputs. Each of the analog

inputs have optical isolation amplifier to protect the system from harmful external

high voltage.

The system has five output cards. Out of these five output cards, one is

redundant and one is spare. Each output card drives 16 outputs through solid-

state FET switches. Each switch can drive typically 3 Amps from 110Vdc supply

for driving external relays. Again each of the switches is also provided with short

circuit protection so that in case of accidental overload or external short-circuit

the switch is tripped to protect the switches. Altogether five output cards are

provided in the system to support 80 outputs, out of which, 40 outputs are used

at present. The rest are there for future expansion.

The multifunction card provides the synchronization clock to both the processors.

It also processes the health signal of the two processors, which is used to arm

the output drives of the output module. The combined health signal is also used

to drive a safety relay, which provides 110V power to the first two output cards

driving most of the vital relays. In case of a critical fault, the processors go to a

safe state by withdrawing the health signals, which in turn trips the safety relay to

remove the power from the first two output cards for driving the corresponding

outputs.

The system has two power supply card. One is spare. User can switch on any

power supply card or both. The power supply unit produces the requisite +5Vdc

and +12Vdc power for the system from the 110Vdc power supply. It has two

separate controllers for generating those outputs. Switched-mode technology is

used to increase the efficiency of the power supply and thus produce less heat

inside the cabinet.


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Each FDCS system has two display panels; one is placed in the front cab and

the other in the rear cab. The system communicates with each panel through an

RS485 communication link. Whenever an alarm comes in the relay logic, it is

displayed to both display panels. The display unit of the cab, which contains the

BL key, will give audio annunciation to draw the attention of the driver. The audio

buzzer gets deactivated after getting acknowledgement from the user through the

key ACK. The minor alarms are displayed only for 6 sec without any audio

annunciation. The user can browse through the status of inputs and outputs

with the help of five keys on the keyboard. Also the faults (if exists) can be

viewed one by one on the display panel. The present notch value is always

displayed on the 7 segment LED.

The FDCS system has got the feature of logging of status and faults that can be

downloaded to a USB mass storage device. With the help of a history buffer in

the memory unit of CPU, the system is enabling to download last 512 faults each

with background data.

Description of each individual module is given below.

7. a PROCESSOR CARD

1. Card Name: PROCESSOR CARD

2. Card No.: P09/FDCS01

3. Card Requirement: This is the heart of the FDCS containing the CPU and

all its associated input & output interfaces. It controls the entire hardware,

processes all digital and analog data and based on input data, it issues the

corresponding output command.

4. Functional Capacity

Processor - Intel 80C196 Micro controller

RAM space - 32K bytes

EPROM space - 64K bytes

Clock Frequency - 8MHz


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Communication Speed - Main system with display at 2.1K baud

-Inter Processor communication at 9600 baud

Watchdog - Internal & external

5. Functional Description of Processor Card

• Based on high performance 16 bit Intel 80C196KC Microcontroller

• Built-in internal & external watchdog with real time task monitor to keep

the system continuously on track.

• On-line diagnostics of ROM, RAM and other utilities.

• Two processor cards per system to ensure double hardware

redundancy.

• On-line LED display ensures easy diagnostic of fault.

• Inter-processor communication interface

• Display communication interface

• USB support.

A number of alarms LED’s are there in the processor card, which display alarm

for different conditions of the processor and its related hardware. Definitions of

the alarm LED are as follows.

A. System OK. (Green)

B. PSU Alarm (Amber)

C. System working in 2-out-of-2 mode (Green)

D. Display panel not responding (Amber)

E. Error in Input module (Red)

F. Error in Output module (Red)

G. Error in Analog Input module (RED)

H. Processor sub-system SHUT DOWN (Red)

Fig.5: Facia Panel Diagram of CPU card

A

B

C

D

E

F

G

H

USB PORT


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7. b. MULTIFUNCTION CARD

1. Card Name: Multifunction Card

2. Card No.: P09/FDCS12

3. Card Requirement: This card accommodate various hardware for both the

Processor module and Interface hardware for Main

System and the Display modules.

4. Functional Capacity:

• Driver interface for Main system and Display module Communication.

• Processor synchronization hardware

• Power shutdown switch for Output card 1 and 2 where driver of the vital

outputs are exists.

5. Functional Description of the Multifunction card:

This module provides the synchronization clock to the two processors

derived from a separate crystal source. This section of hardware is common

for both the processors. It also processes the health signals received from

the two processors and derives the master health line, which enables the

output modules. It also selects the particular processor, which will

communicate to the display units to display the status and alarm

information.

7. c. DIGITAL INPUT CARD

1. Card Name: Digital Input Card 2. Card No.:- P09/FDCS02 3. Card Requirement: - This card accepts the various inputs with double

modular hardware redundancy.

4. Functional Capacity: - Each Digital Input card contains 16 digital inputs. The

System has 8 input card out of these 1 is redundant and 1 is spare card. The

system has a provision of 128 digital inputs, which are distributed to both the

Processor card.


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5. Functional Description of the Digital Input card:

Each input card contains 16 digital inputs. In the facia there are 16 green

LED to monitor the status of individual input. All inputs are protected from

surge and transient voltages by using MOVR. Each input to a processor is

acquired through two sets opto-isolators to ensure correctness of data.

In the first stage high voltage (110V) are down converted with the help of a

high wattage resistance. Optical isolation at the input side is done through

individual optical isolators. Two optical isolators with separate hardware are

used for each input.

The high wattage resistance and the MOVR part are common to both the

set for each input. Any failure in this part will be treated as a common mode

failure, which will be detected through the other processor data. Any failure

in the subsequent stages will be differential mode of failure, which can be

identified by the individual processor through testability and redundancy.

The processor collects the inputs through different hardware using chip

select and input-read logic signal. The data is read in the form of data and

inverted data, which gives a better integrity of the data, read through the

bus.

Inputs are assigned to the processor by the address of the card, which are

placed in the back plane (it is independent of the slot). To select a particular

card the address is compared with a four-bit card address and an active low

signal is generated to select a particular chip.

7. d. OUTPUT CARD

1. Card Name: Output Card 2. Card No.: P09/FDCS11


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3. Card Requirement: This card drives various high voltage relays through

P-channel MOSFET.

4. Functional Capacity: - Each Output card contains 16 outputs. The system

has five output card out of these one is redundant and one is spare. The

system has a provision of 80 outputs.

5. Functional Description of the Output card:

The system has a provision for 80 digital outputs. All outputs are optically

isolated. The system is a two out of two system i.e. two processor will work

simultaneously and in case of failure of one the other will take the whole

responsibility of the system.

Output data from the two-processor cards are first latched on individual

buffers. This is crossed checked by the individual processor through

feedback ports. The data is then passed through an OR gate to combine

the activation signals from the individual processor. A second stage of

feedback is provided from this stage. This ORed output is used to drive

opto-isolators, which in turn switch ON the MOSFET for driving the external

relay.

The driver circuit is short circuit current protected. The current protection is

achieved by considering the resistance drop due to over current flowing in

the input side, as a result a thyristor will be ON, which pulls the gate to the

high voltage towards source; hence put the FET into cut-off. A Zener diode

is used between source and gate of the FET, to protect gate to source

break down, due to some fault in the circuit.

The output latches are armed with the health line of the processors

extended through the backplane. In case of any failure in a processor sub-

system, the processor identifies the fault and goes to a safe state where it


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negates the health line. In the output card, this negation of the health line

forces the output drive of the faulty processor to the OFF state. The system

would then continue its operation with the help of the other processor sub-

system.

7. e. POWER SUPPLY CARD

1. Card Name: Power Supply Card 2. Card No.: P09/FDCS07

3. Card Requirement: This card converts power from 70V-135V input power

supply to +5V and +12V for the operation of FDCS.

4. Functional Capacity: Input Voltage - 110V nominal

(70V to 135V)

Output Voltage - +5V DC nominal, ±10%, 1Amp

+12V DC nominal, ±15%, 1.2Amp

Protection -

Input - Surge and transient voltages

Over voltage and under voltage

Output - Over voltage and short circuit

Efficiency - Better than 75% at nominal

5. Functional Description of the Output card:

The system has two Power Supply card. User can switch ON one power

supply or both for use.

The power supply unit first starts its operation from a series 10V regulator

derived from the 110V dc supply. Once the module starts to operate it will

generate an auxiliary +12V supply from which it will take the input, i.e. self-

feeding takes place.

The PSU has two separate switching power supply modules, one for +5V

and the other for +12V.The two power supplies are kept fully dc isolated


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from the 110V signal earth. They are also mutually isolated from each other.

Optically isolated feedback is used for voltage stabilization, maintaining the

ground isolation.

Elaborate alarm monitoring circuit is used to raise alarms if the voltage goes

beyond certain limits. The input voltage is also monitored to be within a

specified limit, beyond which the switching regulator is switched off raising

over voltage or under voltage alarm. The output voltages are also required

to be within a specified limit beyond which alarms would be generated. The

two CPU cards monitor all the PSU alarms.

There are four testing points and seven alarm LEDs

in the each PSU card as shown in figure.

A. PSU ON (Green)

B. I/P over Voltage Alarm (Red)

C. I/P under Voltage Alarm (Red)

D. +5V over Voltage Alarm (Red)

E. +5V under Voltage Alarm (Red)

F. +12V Over Voltage Alarm (Red)

G. +12V under Voltage Alarm (Red)

P. +5V Test Point (Red)

Q. +5V Ground Test Point (Black)

R. +12V Test Point (Red)

S. +12V Ground Test Point (Black)

Fig.7: Facia Panel Diagram of PSU card

7.3 ANALOG INPUT MODULE

The system has a provision of 12-analog inputs. Out of 12-analog inputs, four

channels are used at present and the rest is kept open for future. Out of these

four, three of them are for A.C inputs to measure the phase voltages of the

ARNO and one is DC high voltage input (1000V) coming from the traction motor.

A

B

C

D

E

F

G

P

Q

R

S


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External high voltage analog inputs, scaled down by signal conditioning unit and

low voltage analog input, scaled up by TM Current sensing unit are taken through

a differential amplifier stage in the Analog input card. Thus the effect of any

difference in analog ground potential (ANGND) would be cancelled out. The

swing of analog signals, from the output of differential amplifier, is kept within

+5V and GND. This voltage is fed to the CPU card through the analog interface

card for A/D conversion. There are pots with each analog channel to adjust the

gain to the proper value. These are accessible from the front for trimming if

required. The front panel of the analog module is shown below

7.4 SIGNAL CONDITIONING MODULE

High voltage analog inputs are terminated on the card and are down converted.

The 1000V dc is down converted to 2.0V first by simple resistance drop. The 3

inputs for 3 phases AC, high voltages are first rectified and then the rectified

output is down converted by resistance drop.

The Analog Module transfers the external analog signal through optical amplifiers

to isolate the signals from dangerous external voltages. Each of the analog

sections is powered by separate isolated power supplies so that none of the

external voltages have any mutual relationship. The isolated power supplies are

generated by four sets of switching regulators working from 12Vdc of the main

system. This power is taken with the help of the circular connector connecting the

signal-conditioning unit with the main unit.

7.5 TRACTION MOTOR CURRENT SENSING MODULE

Six Traction Motor shunt voltage are terminated on the card and are up

converted. The almost 75mV D.C voltage is up converted or amplified to a level

of almost 1V by differential amplifier.

The Analog Module transfers the external analog signal through optical amplifiers

to isolate the signals from dangerous external voltages. Each of the analog


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sections is powered by separate isolated power supplies so that none of the

external voltages have any mutual relationship. The isolated power supplies are

generated by four sets of switching regulators working from 12Vdc of the main

system. This power is taken with the help of the circular connector connecting the

TM Current Sensing unit with the main unit.

7. h. DISPLAY CARD

1. Card Name: Display Card 2. Card No.: P09/FDCS09 3. Card Requirement: This card display various faults, input output status,

notch position. By using the keyboard, which is attached with it, the user

can see the fault history, current fault, I/O status etc. In the Display

Module there is a power supply card which generates +5V and +12V from

110V.

4. Functional Capacity

Processor - Intel 80C196 Micro controller

RAM space - 32K bytes

EPROM space - 64K bytes

Clock Frequency - 8MHz

Communication Speed - Main system with display at 2.1K baud

-Inter Processor communication at 9600 baud

Watchdog - Internal & external

Input Voltage - +110V nominal

Output Voltage - +5V DC nominal, ±10%, 1Amp

- +12V DC nominal, ±10%, 1Amp

Protection -

Input - Surge and transient voltages

Output - Short circuit

Efficiency - Better than 75% at nominal


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7.7I. FILTER CARD

Filter Card is used to protect the Power Supply Card as well as the system from

surge, spike and external hazards. The raw 110V dc from LOCO battery is fed to

the power supply unit through a surge protector and filter section to protect the

system from high voltage spikes and surges coming along the power line. The

first stage is a Gas arrestor to absorb high-energy pulses. This is followed by an

LC filter and a transient protector to bring down the spikes within acceptable limit.

The primary supply is connected to earth through high voltage capacitors to

bypass AC noises but ensuring DC isolation.

7.7 DISPLAY MODULE

The card is housed in the Display Unit. In an FDCS system two display units are

required for two cabins. The main component of the card is an 80196KC

microcontroller, which actually drives two 7-segment LEDs, one 40character X

4lines LCD display and a buzzer.

Serial communication with the main controller is done in RS485 standard with

ground isolation.

8. Software Architecture

Microprocessor Based Control and Fault Diagnostic System is a dual processor

redundant system. Normally it works in 2-out-of-2 mode i.e. two processor are

working simultaneously in conjunction to each other. In case of failure of any of

the processor or its sub-system, the other processor will take up the whole

responsibility of the system, indicating an alarm that the system is working with

one processor. Integrity of the system will then be ensured through the built-in

testability with the various functional blocks.

It is a system, where apart from its basic purpose of monitoring the inputs and

controlling the outputs, safety is an important issue. A good level of safety and

reliability is achieved by managing the redundancy of both hardware and

software stage. With such a tightly coupled system, synchronization of the two

processors is a big issue. The synchronizer hardware in the multi-function card


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gives the synchronizing clock to both the CPUs. Each of the processors takes the

synchronization information from the synchronizer and does the same specified

task at a particular instant of time.

In case of two out of two system, inter processor communication at various

stages is the heart of the system to ensure the safety and reliability. Information

acquired by each processor along with its processed outputs is interchanged to

ascertain the validity. In case of any mismatch, the faulty unit is isolated from the

system by forcing the software to a fail-safe core where it switches OFF all the

corresponding outputs and withdraws the health signal. The other processor

would then carry out the processing and control the outputs individually.

All the vital and time critical jobs are performed in a 10 msec periodic task,

invoked by the synchronizer. This task is basically an 8-step state machine. The

job of reading the inputs, processing the data for validity and relay status and

outputting the data is distributed among the 8 states in such a way that the

processor gets ample time to carry out other jobs. The cycle time to complete the

state machine is thus 80 msec. which is consistent with the response time of the

external relays.

Each of the processor cards reads the inputs through two separate opto-

isolators. It also receives additional two sets of data from the adjacent processor

through inter-processor communication. Thus each processor at a certain point

of time has four data for the same input. The validity of data is derived from these

four data sets to give a very high integrity of data. The logic used to validate the

data is given in the table shown below.


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TABLE FOR VALIDATION OF INPUTS

INPUT COMBINATION. ALARM A B

DATA

SELFA /ADJ.B

SELFB /ADJ.A

FATAL ALARM

0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 0 0 1 0 0 0 1 0 0 0 1 1 0 * 0 0 1 0 1 0 0 0 1 0 0 0 1 0 1 0 * 0 0 1 0 1 1 0 0 * 0 0 1 0 1 1 1 1 1 0 0 1 0 0 0 0 1 0 0 1 0 0 1 0 * 0 0 1 1 0 1 0 0 * 0 0 1 1 0 1 1 1 1 0 0 1 1 0 0 0 * 0 0 1 1 1 0 1 1 0 1 0 1 1 1 0 1 0 1 0 1 1 1 1 1 0 0 0

=> Status of these data cannot be derived from these states. However, the output is treated as OFF which is a safer state.

In case of output, the system uses OR-ing logic to feed the particular output. A

number of hardware feedbacks are taken to ensure the correctness of the output.

The software first cross-checks the equality of the output state derived from the

input status. If the equality does not hold good for a certain time out period

(typically 400 msec.), the total system would go to a safe state, since in 2-out-of-

2 voting, the system cannot decide who is correct.

Integrity of the output is checked against three levels of feedback and in case of

any mismatch, the respective processor would go to safe state. The various

tasks that the software would perform are given below.


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A. Power On Self Test (POST)

a. Processor Initialization

b. RAM Test

c. ROM Test

d. Initialization of Analog Inputs

e. Initialization of variables and peripheral devices

f. Initialization of Interrupts

B. Base Executive

a. Display Transmit Packet Processing

b. Display Receive Packet Processing

c. Processing of External PC information

d. Self Diagnostics

C. Timer Routine

a. Scanning of Inputs and checking its local validity

b. Transmission of Input data to Adjacent Processor

c. Reading Feedback status of outputs and crosschecking with the

derived output data.

d. Validation of input with adjacent data and derive virtual outputs (Q

relays).

e. Derivation of outputs

f. Transmission of output data to Adjacent Processor for validation.

Derivation of Status Conditions for display.

g. Derivation of Fault Conditions in the Loco for display.

h. Validation of Output data with the adjacent data and issue the

outputs to the output card.


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D. Service Routine for Display Units

a. Processing of receive data to check integrity of the information

packet received from display.

b. Transmission of the information packet to display unit.

E. Service Routine for Interfacing External PC

a. Processing of information packet received from PC

b. Transmission of information of packet to PC

Each of the tasks has its own defined functionality. The architecture of the

software is build up in such a way that the overall functionality of the system is

achieved.


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9. Inter Connection Details:

6

6

10

Fig.8: Wiring Details of FDCS

Fig.9: Allied Connector diagram

3

6

LOCOMOTIVE TERMINAL SB In AC2 Panel

FDCS 9648 CONTROL UNIT

In AC 2 Panel

SIGNAL CONDITIONING UNIT in AC2 Panel

DISPLAY UNIT NO. 1 FOR CAB A

DISPLAY UNIT NO. 2 FOR CAB B

19 19 19 19 19 19 19

10 10

10

19

CSU1

CSU2


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FDCS

Fig.10: Connection diagram of Allied Connector, wire and lug of FDCS

A. FDCS Unit to Terminal SB: Signal Name No.

Of Pins

Connector type on FDCS Unit

Connector type on Cable

Cable type and length in meter

Digital Input 0 to 15 19 97B3102R-22-14P FDCS Unit side 97B3106F - 22 - 14S SB side: 2.5mm Lugs

6m length 19 Core shielded Teflon wire (1 sq. mm dia each)

Digital Input 16 to 31 19 97B3102R -22-14PW

FDCS Unit side 97B3102F -22-14SW, SB side: 2.5mm Lugs


Digital Input 32 to 47 19 97B3102R-22–14PX

FDCS Unit side 97B3106F - 22 – 14SX, SB side: 2.5mm Lugs


Digital Input 48 to 63 19 97B3102R-22-14PY

FDCS Unit side 97B3106F - 22 - 14SY , SB side: 2.5mm Lugs


Digital Input 64 to 79

19 97B3102R -22-14PZ

FDCS Unit side 97B3106F - 22 – 14SZ, SB side: 2.5mm Lugs


Digital Input 80 to I94 19 97B3102R - 20 - 29P

FDCS Unit side 97B3102F - 20 – 29S, SB side: 2.5mm Lugs


Digital Input 95 to 110 19 97B3102R-20-29PW

FDCS Unit side 97B3102F-22- 14SW,SB side: 2.5mm Lugs


Digital Input Spare 19 97B3102R-20-29PZ

FDCS Unit side 97B3102F-22- 14SZ,SB side: 2.5mm Lugs


Digital Output 0 to 15 19 97B3102F-22- 14S

FDCS Unit side 97B3102R-22- 14P,SB side: 2.5mm Lugs


Allied Connector

LUG Wire


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Signal Name No. Of Pins




Digital Output 16 to 31 19 97B3102F-22- 14SW

FDCS Unit side 97B3102R-22- 14PW, SB side: 2.5mm Lugs


Digital Output 32 to 47 19 97B3102F-22- 14SX

FDCS Unit side 97B3102R-22- 14PX SB side: 2.5mm Lugs


Digital Output 48 to 63 19 97B3102F-22- 14SY

FDCS Unit side 97B3102R-22- 14PY SB side: 2.5mm Lugs


Digital Output Spare 19 97B3102F-22- 14SZ

FDCS Unit side 97B3102R-22- 14PZ SB side: 2.5mm Lugs


110V DC Power Supply

3 97B3102R-10- SL 3P

FDCS Unit side 97B3102F-10-SL 3S SB side: 2.5mm Lugs


B. FDCS Unit to Display unit:





Transmit, Receive and Power Signals For CAB A

10 97B3102R-18-1PX FDCS Unit side 97B3102R-18-1SX Display Unit side 97B3102R-18-1S


Transmit, Receive and Power Signals For CAB B

10 97B3102R-18-1PY FDCS Unit side 97B3102R-18-1SY Display Unit side 97B3102R-18-1S

8m length 10 Core shielded Teflon wire (1.5 sq. mm dia each)

C. Display Unit to Terminal SB:





110V DC Power Supply to CAB A Display Unit

3 97B3102R-10-SL 3P

Display Unit side 97B3102F-10-SL 3S SB side: 2.5mm Lugs


110V DC Power Supply to CAB B Display Unit

3 97B3102R-10-SL 3P

FDCS Unit side 97B3102F-10-SL 3S SB side: 2.5mm Lugs



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D. FDCS Unit to Signal Conditioning Unit: Signal Name No. Of

Pins Connector type on FDCS Unit



AUX, AUX_R, Battery and TM Armature Voltage

10 97B3102R-18-1S FDCS Unit side 97B3102R-18-1P Signal Cond. Unit side 97B3102R-18-1P

2.5m length 10 Core shielded Teflon wire (1 sq. mm dia each)

E. Signal Conditioning Unit to SB Terminal:


Connector type on Sig. Conditioning Unit


Connector type on SB

Cable type and Length in meter

AUX, AUX_R Output Voltages

4 Terminals Lugs in both side Terminal provided by CLW


TM Armature Voltage, Battery



F. FDCS Unit to TM Current Sensor Unit 1:



Connector type on Cable Cable type and length in meter

Traction Motor Current 1, 2 ,3 & 4

8 97B3102R-18-8PW

FDCS Unit side 97B3102R-18-8SW , TM Current Sensor Unit1 side 97B3102R-18-8SW

19m length 8 Core Teflon shielded wire (1sq. mm dia each)

G. TM Current Sensor Unit1 to SHUNT:


Connector type on TM Current Sensor Unit 1




TM Current1, 2, 3 & 4


2.5m length Teflon Wire (3 sq. mm dia each)

H. FDCS Unit to TM Current Sensor Unit 2:



Connector type on Cable Cable type and length in meter

Traction Motor Current 5 , 6, 7 & 8

8 97B3102R-18-8PZ

FDCS Unit side 97B3102R-18-8SZ , TM Current Sensor Unit1 side 97B3102R-18-8SZ

19m length 8 Core Teflon shielded wire (1sq. mm dia each)


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I. TM Current Sensor Unit2 to SHUNT: Signal Name No. Of

Pins Connector type on TM Current Sensor Unit 1




TM Current 5, 6, 7 & 8


2.5m length Teflon Wire (3 sq. mm dia each)

2. Wire Details for FDCS-9648 of Electric Locomotive: A. Connector Number: Digital Input 1

Connector Type: 22-14P

Input No. Name Of Input Screen Display Name

Pin No. Wire No. SB No.

I-0 BP1DJ/BLDJ BLDJ N1-A 021 SB-1 I-1 BP2DJ/BLRDJ BLRDJ N1-B 024 SB-1 I-2 QVMT1 QVMT1 N1-C 025 SB-1 I-3 QVMT2 QVMT2 N1-D 026 SB-1 I-4 QVRH QVRH N1-E 027 SB-1 I-5 ZPT1_2 ZPT1_2 N1-F 030 SB-1 I-6 ZPT1_1 ZPT1_1 N1-G 029 SB-1 I-7 HVMT1_1 HVMT1_1 N1-H 036 SB-1 I-8 HVMT1_2 HVMT1_2 N1-J 037 SB-1 I-9 HVMT2_1 HVMT2_1 N1-K 038 SB-1 I-10 HVMT2_2 HVMT2_2 N1-L 039 SB-1 I-11 HVRH_1 HVRH_1 N1-M 040 SB-1 I-12 HVRH_2 HVRH_2 N1-N 041 SB-1 I-13 QVSI1/HVSI1 Q/H_VSI1 N1-P 042 SB-1 I-14 QVSI2/HVSI2 Q/H_VSI2 N1-R 043 SB-1 I-15 BLVMT BLVMT N1-S 070 SB-1


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B. Connector Number: Digital Input 2

Connector Type: 22-14PW

Input No. Name Of Input Screen Display Name Pin No. Wire No. SB No. I-16 ASMGR (B.N.) GR_BN W2-A 072 SB-1 I-17 BLCP/BLCPD BLCP W2-B 074 SB-1 I-18 C101_3 FB C101_3 FB W2-C 075 SB-1 I-19 GR-0 GR-0 W2-D 076 SB-1 I-20 GR-0_31 GR-0_31 W2-E 077 SB-1 I-21 QPH/HPH Q/H_PH W2-F 078 SB-1 I-22 QVSL1/HVSL1 Q/H_VSL1 W2-G 079 SB-1 I-23 C105_FB C105_FB W2-H 061 SB-1 I-24 ASMGR (O.N.) GR_ON W2-J 082 SB-1 I-25 QVSL2/HVSL2 Q/H_VSL2 W2-K 080 SB-1 I-26 MP+ (R, B) MP+ W2-L 093 SB-1 I-27 MPJ (FOR) MPJ FOR W2-M 091 SB-1 I-28 J1,J2 (FOR) J_FOR W2-N 095 SB-1 I-29 MP (+N-) R MP- W2-P 096 SB-1 I-30 MP- (R, B) MP_RUN W2-R 097 SB-1 I-31 CTF (RUN) CTF_RUN W2-S 100 SB-1

C. Connector Number: Digital Input 3 Connector Type: 22-14PX

Input No. Name Of Input Screen Display Name Pin No. Wire No. SB No.

I-32 MPJ (REV) MPJ_REV X3-A 092 SB-2 I-33 CTF (BRK) CTF_BRK X3-B 212 SB-2 I-34 MP (+,N,-) B MP_BRK X3-C 213 SB-2 I-35 DJ_FB DJ_FB X3-D 105 SB-2 I-36 J1,J2 (REV) J_REV X3-E 107 SB-2 I-37 ZQWC ZQWC X3-F 121 SB-2 I-38 MPS (1-4) MPS_1 X3-G 123 SB-2 I-39 MPS (2-4) MPS_2 X3-H 124 SB-2 I-40 MPS (3-4) MPS_3 X3-J 125 SB-2 I-41 MPS (4-4) MPS_4 X3-K 126 SB-2 I-42 PVEF PVEF X3-L 150 SB-2 I-43 PSA PSA X3-M 151 SB-2 I-44 BPQD BPQD X3-N 230 SB-2 I-45 RGEB RGEB X3-P 155 SB-2 I-46 SWC SWC X3-R 156 SB-2 I-47 QF & QE QF_QE X3-S 162 SB-2


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D. Connector Number: Digital Input 4

Connector Type: 22-14PY

Input No. Name Of Input Screen Display Name Pin No. Wire No. SB No. I-48 BL BL Y4-A 142 SB-2 I-49 QOA/QSIT* QOA QSIT Y4-B 017 SB-2 I-50 QOP1 QOP1 Y4-C 046 SB-2 I-51 QOP2 QOP2 Y4-D 047 SB-2 I-52 QRSI1 QRSI1 Y4-E 048 SB-2 I-53 QRSI2 QRSI2 Y4-F 049 SB-2 I-54 QLM QLM Y4-G 050 SB-2 I-55 BV BV Y4-H 122 SB-3A I-56 C106_FB C106_FB Y4-J 062 SB-3A I-57 ZSMGR ZSMGR Y4-K 128 SB-3A I-58 ZSMS ZSMS Y4-L 120 SB-3A I-59 RSI RSI Y4-M 170 SB-3A I-60 HMCS HMCS Y4-N 058 SB-3A I-61 L1 to L6_FB L1_6_FB Y4-P 028 SB-3A I-62 HMCS & QD HMCS_QD Y4-R 153 SB-3A I-63 C118 (N/C)/ QCON* C118_NC QCON Y4-S 018 SB-3A

E. Connector Number: Digital Input 5 Connector Type: 22-14PZ


I-64 QLA_FB/ SI INT FAULT*

QLA_FB SI INT FLT

N5-A 019 SB-3A

I-65 QPDJ_FB QPDJ_FB N5-B 052 SB-3A I-66 C107_FB C107_FB N5-C 060 I-67 SI EXT FAULT* SI EXT FLT N5-D 068 SB-3A I-68 C145 N/O C145 N/O N5-E 059 NOT IN WAP I-69 N5-F I-70 HQ51 HQ51 N5-G 200 I-71 CHBA CHBA N5-H 973 SB-3A I-72 BL1 BL1 N5-J 149 SB-2B I-73 SWITI/DBR SW_DBR N5-K 157 SB-3A I-74 N5-L I-75 RGAF/P2(ACP) P2_ACP N5-M 219 SB-2A I-76 BLFL BLFL N5-N 216 SB-2A I-77 BPT BPT N5-P 217 SB-2A I-78 RGPA/P1(ACP) P1_ACP N5-R 218 SB-2A I-79 BPSW1/2/ACK (ACP) BPSW_ACK N5-S 203 SB-2A


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F. Connector Number: Digital Input 6 (Spare Inputs) Connector Type: 20-29P


I-80 LOCO SEL 1 L_SEL 1 A B- I-81 LOCO SEL 2 L_SEL 2 B 700 I-82 LOCO SEL 3 L_SEL 3 C 700 I-83 LOCO SEL 4 L_SEL 4 D B- I-84 MU_FB MU_FB E 237 WAG ONLY I-85 BPEMS-1&2 BPEMS-1&2 F 067 I-86 I-87 I-88 I-89 I-90 I-91 I-92 Q49_FB N WAG ONLY I-93 I-94 I-95

G. Connector Number: Digital Input 6 (REDUNDANT INPUTS) Connector Type: 20-29P

Input No. Name Of Input Screen Display Name


I-96 (I-14) BVSI1 / HVSI1 Q/H_CSI1 A 043 I-97 (I-21) QPH / HPH Q/H_PH B 078 I-98 (I-22) QVSL1/HVSL1 Q/H_VSL1 C 079 I-99 (I-25) QVSL2/HVSL2 Q/H_VSL2 D 080 I-100 (I-49) QOA / QSIT QOA QSIT E 017 I-101 (I-50) QOP1 QOP1 F 046 I-102 (I-51) QOP2 QOP2 G 047 I-103 (I-52) QRSI1 QRSI1 H 048 I-104 (I-53) QRSI2 QRSI2 J 049 I-105 (I-54) QLM QLM K 050 I-106 (I-64) QLA/SI INT FAULT QLA L 019 I-107 (I-63) QCON / C118-N/C C118_NC/QCON* M 018 I-108 (I-48) BL BL N 142 I-109 (I-15) BLVMT BLVMT P 070 I-110 (I-17) BLCP / BLCPD BLCPD R 074 I-111 S


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I. Connector Number: Digital Output 1 Connector Type: 22-14S

Output No. Name Of Output Screen Display Name


O-0 DJ DJ A 044 SB-3 O-1 C118/BLSI* C118 / BLSI B 035 SB-3 O-2 VEPT1 VEPT1 C 055 SB-3 O-3 VEPT2 VEPT2 D 056 SB-3 O-4 DJ DJ E 044 SB-3 O-5 C107 C107 F 083 SB-3 O-6 C106 C106 G 084 SB-3 O-7 C105 C105 H 085 SB-3 O-8 C101, C103 C101_3 J 086 SB-3 O-9 VEUL VEUL K 087 SB-3 O-10 J1,J2 (FOR) J_FOR L 108 SB-3 O-11 J1,J2 (REV) J_REV M 109 SB-3 O-12 CTF (RUN) CTF_RUN N 111 SB-3 O-13 CTF (BRK) CTF_BRK P 112 SB-3 O-14 VE (UP) VE_UP R 110 SB-3 O-15 C145 C145 S 114 SB-3

J. Connector Number: Digital Output 2 Connector Type: 22-14SW

Output No. Name Of Output Screen Display Name Pin No. Wire No. SB No.

O-16 VE (DN) VE_DN A 113 SB-3 O-17 EVPHGR EVPHGR B 115 SB-3 O-18 Sx1 Sx1 C 129 SB-3 O-19 Sx2 Sx2 D 130 SB-3 O-20 Sx31 Sx31 E 131 SB-3 O-21 Sx32 Sx32 F 132 SB-3 O-22 IP IP G 166 SB-3 O-23 VESA2 VESA2 H 165 SB-3 O-24 VEF VEF J 164 SB-3 O-25 VESA1 VESA1 K 163 SB-3 O-26 L1, L2, L3 L1_3 L 143 SB-3 O-27 L4, L5, L6 L4_6 M 133 SB-4 O-28 LSDJ (R) LSDJ N 171 SB-4 O-29 LSCHBA (G) LSCHBA P 172 SB-4 O-30 LSGR (G) LSGR R 173 SB-4 O-31 LSB (Y) LSB S 174 SB-4


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K. Connector Number: Digital Output 3 Connector Type: 22-14SX



O-32 LSP (R) LSP A 175 SB-4 O-33 LSRSI (Y) LSRSI B 176 SB-4 O-34 Sx41 Sx41 C 144 WAP ONLY O-35 Sx42 Sx42 D 145 WAP ONLY O-36 LSGROUP (R) LS_GRP E 235 WAG ONLY O-37 LSOL (Y) LSOL F 210 SB-4 O-38 LSFL LSFL G 232 SB-4 O-39 SON (ALARM) SON H 177 SB-4 O-40 Q51_52 FB_MU Q51_52 FB_MU J WAG ONLY O-41 QFL QFL K 236 SB-4 O-42 LSDBR (Y) LSDBR L 234 SB-4 O-43 M SB-4 O-44 Q49_MU Q49_MU N WAG ONLY O-45 FL_LP FL_LP P SB-4 O-46 C102 C102 R WAG ONLY O-47 C108 C108 S WAG ONLY

L. Connector Number: Digital Output 4 (REDUNDANT OUTPUTS) Connector Type: 22-14SY



O-48 (O-0) DJ DJ A 044 SB-3 O-49 (O-1) C118/BLSI* C118 BLSI B 035 SB-3 O-50 (O-2) VEPT1 VEPT1 C 055 SB-3 O-51 (O-3) VEPT2 VEPT2 D 056 SB-3 O-52 (O-0) DJ DJ E 044 SB-3 O-53 (O-5) C107 C107 F 083 SB-3 O-54 (O-6) C106 C106 G 084 SB-3 O-55 (O-7) C105 C105 H 085 SB-3 O-56 (O-8) C101, C103 C101,C103 J 086 SB-3 O-57 (O-16) VE (DN) VE_DN K 113 SB-3 O-58 (O-10) J1,J2 (FOR) J_FOR L 108 SB-3 O-59 (O-11) J1,J2 (REV) J_REV M 109 SB-3 O-60 (O-12) CTF (RUN) CTF_RUN N 111 SB-3 O-61 (O-26) L1,L2,L3 L1_3 P 143 SB-3 O-62 (O-14) VE (UP) VE_UP R 110 SB-3 O-63 (O-27) L4,L5,L6 L4_6 S 133 SB-4


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Connector Number: Display for CAB A Connector Type: 18-1P X Name Of Signal

Pin No. Wire No.

TRANSMIT +VE SIGNAL A TX P TRANSMIT -VE SIGNAL B TX N RECEIVE +VE SIGNAL C RX P RECEIVE -VE SIGNAL D RX N GROUND H GROUND GROUND I GROUND GROUND J GROUND

Connector Number: Display for CAB A Connector Type: 18-1P Y Name Of Signal

Pin No. Wire No.

TRANSMIT +VE SIGNAL A TX P TRANSMIT -VE SIGNAL B TX N RECEIVE +VE SIGNAL C RX P RECEIVE -VE SIGNAL D RX N GROUND H GROUND GROUND I GROUND GROUND J GROUND

Connector Number: Analog Input (Signal Conditioning) Connector Type: 18-1S Name Of Input Pin No. Wire No.

ANG1 – TM A AI1 ANG2 – BAT B AI2 ANG3 – W C AI3 ANG4 – AUX D AI4 ANG5 – AUX® E AI5 +12V H +12V AGND J ANGND

Connector Number: TM Current Sensing Unit1 Connector Type: 18-8PW Name Of Input Pin No. Wire No.

ANG6 – TM CURRENT 1 A AI6 ANG7 – TM CURRENT 2 B AI7 ANG8 – TM CURRENT 3 C AI8 ANG9 – QE D AI9 +12V G +12V AGND H ANGND


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Connector Number: TM Current Sensing Unit1 Connector Type: 18-8PZ Name Of Input Pin No. Wire No.

ANG6 – TM CURRENT 4 A AI10 ANG7 – TM CURRENT 5 B AI11 ANG8 – TM CURRENT 6 C AI12 ANG9 - SPARE D SPR +12V G +12V AGND H ANGND

Terminal Number: 1(Signal Conditioning Unit) Terminal Type: 7 Pins H/V Terminal Name of Input Pin Number Wire Number

W 1 991 AUX 2 991 AUXR 3 991 A.C RTN 4 993 TM 5 A17 CHBA 6 D.C GND 7 SGND

Terminal Number: 2(TM Current Sensing Unit1) Terminal Type: 6 Pins H/V Terminal Name of Input Pin Number Wire Number TM1+ 1 196 TM1 GND 2 197 TM2+ 3 208 TM2 GND 4 209 TM3+ 5 206 TM3 GND 6 207

Terminal Number: 3(TM Current Sensing Unit2) Terminal Type: 6 Pins H/V Terminal Name of Input Pin Number Wire Number

TM4+ 1 214 TM4 GND 2 215 TM5+ 3 247 TM5 GND 4 248 TM6+ 5 249 TM6 GND 6 250


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b. LIST OF ELIMINATED RELAYS:

I/P NUMBER NAME I/P NUMBER NAME

I-112 Q20 I-136 QVLSOL

I-113 Q30 I-137 GR 0-1

I-114 Q44 I-138 GR 0-5

I-115 Q45 I-139 GR 0-10

I-116 Q46 I-140 GR 6-32

I-117 Q48 1-141 GR 20-32

I-118 Q49 I-142 QSVM (SI)

I-119 Q50 I-143 Q120

I-120 Q51 I-144 QD1

I-121 Q52 I-145 QD2

I-122 Q100 (ARNO) / Q101(SI) I-146 QE

I-123 Q118 I-147 QF1

I-124 Q119 I-148 QF2

I-125 Q121 I-149

I-126 QV60 I-150

I-127 QV61 I-151

I-128 QV62 I-152

I-129 QV63 I-153

I-130 QV64 I-154

I-131 QCVAR I-155

I-132 QRS I-156

I-133 QTD105 I-157

I-134 QTD106 I-158

I-135 QWC I-159


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12. Trouble shooting Procedure of FDCS 9648

YES

Check the wirings and Voltage level on the SB Terminals of the system

Are all ok? NO

Check the CPU LEDs

Is Sys Ok LED ON?

NO

Is PSU alarm LED ON?

YES

NO

Is 2/2 LED ON?

Check PSU Card

YES

Check the other CPU card

NO

Is Display LED ON?

YES One of the Display Systems is not communicating, check the display cable and if the cable is OK change the display CPU card.

A

YES SYSTEM IS OK


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Is Error in I/P LED ON?

YES

NO

Change Digital Input Card

A

Is Error in OP LED ON?

YES Change Output Card

Is Error in Analog I/P LED ON?

YES Change Analog Input Card

NO

Is Shut Down

LED ON?

YES Check for other errors indication and take corresponding action

NO

SYSTEM IS OK

NO


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Check the PSU LEDs

Is PSU ON

NO

Is IP Over voltage LED

ON?

YES

NO

Lower the Input Voltage

YES PSU IS OK

Check the PSU Card

Is IP Under voltage LED

ON?

YES Increase the Input Voltage

Is +5V Over voltage LED

ON?

NO

YES

Change the PSU card

Is +5V Under voltage LED

ON?

NO

YES

Is +12V Over voltage LED

ON?

NO

YES

Is +12V Under voltage LED

ON?

NO

YES

NO


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Check the corresponding Output Logic and then check O/P card’s LED

Is LED ON?

YES

Check Voltage at BD panel

Available

NOT AVAILABLE

Check Loco side wiring/Check the Relay

NO Change the corresponding O/P card

Output Not Coming from FDCS

Check Wiring bet. BD Panel & FDCS Coupler

NOT OK Repair the damage portion of wiring

OK


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13. OPERATION OF THE DISPLAY UNIT

There are five keys such as MENU, UP, DOWN, ENTER, and ACK Keys in the keyboard of the Display unit. The unit has also one 4X40 character LCD with backlight and a two digit seven segment LED. The default LCD screen shows the date and time. The seven segments LED shows the current notch number. By using the keyboard the current working status and information can be shown in the display screen. By pressing the MENU key at any time the following display screen will be shown

The “ “ shows the current cursor position. To select an option move the cursor UP or DOWN position.

DATE: TIME: *****************MAIN MENU******************

1. VEHICLE DIAGNOSTIC 2. PROCESS INFORMATION

Check the corresponding Input switch and then check I/P card’s LED

Is LED ON?

NO

Check Voltage at BD panel

Not Available

AVAILABLE

Check Loco side wiring/Check contact

YES Check in Display Unit. Input must ON, else change corresponding card

Input Not Coming from LOCO side to FDCS

NOT OK Repair the damage portion of wiring

OK

Check Wiring bet. BD Panel & FDCS Coupler


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To see the VEHICLE DIAGNOSTIC information, press the ENTER key, then the display screen will be shown like the follows

Now if the PROCESS INFORMATION option is selected then the display screen is shown as follows

If the INPUT-OUTPUT option is selected then the display screen is shown as follows

13.1.1 Display Digital Input (Use UP/DOWN keys to move next/previous screen)

The following information is shown if the DISPLAY DIGITAL INPUT option is selected

Here the first digit is showing the status of the Digital Input 0,the second digit is showing the Digital Input 1. A ‘1’ shows that the input is in OFF state (Low), whereas a ‘0’ shows that the input is in ON state (High). Now by scrolling the screen with the help of UP DOWN key the various input status individually can be shown.

DATE: LOCO OK TIME: 1 ISOLATION INFORMATION 2 CURRENT FAULT INFORMATION 3 FAULT HISTORY

1 Input/Output Display 2 Parameter Setting 3 Test Mode.

1. Display Digital Input 2. Display Digital Output 3. Display Eliminated Relays 4. Display Analog Parameters

DATE: LOCO OK TIME: 10101010 10101010 10101010 10101010 10101010 10101010 10101010 10101010 10101010 10101010 00000000 00000000


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One card inputs are defined in two screens. Each screen has 8 inputs like:

1st screen of card-1

1st line 2nd line 3 inputs 3rd line 3 inputs 4th line 2 inputs 2nd screen of card-1 1st line 2nd line 3 inputs 3rd line 3 inputs 4th line 2 inputs

All the digital inputs are shown in the same format for display.

13.1.2. Display Digital Output (Use UP/DOWN keys to move next/previous screen) One card outputs are defined in two screens. Each screen has 8 inputs like: 1st screen of card-1 1st line 2nd line 3 outputs 3rd line 3 outputs 4th line 2 outputs 2nd screen of card-1 1st line 2nd line 3 outputs 3rd line 3 outputs 4th line 2 outputs

All the digital outputs are shown in the same format for display.

13.1.3. Eliminated Relays Display

DIGITAL INPUT CARD-1_1 BLDJ =_ BLRDJ =_ QVTM1 =_

QVMT2 =_ QVRH =_ ZPT1_2 =_ ZPT1_1 =_ HVMT1_1 =_

ELIMINATED RELAYS Screen-1 Q20 =_ Q30 =_ Q44 =_ Q45 =_ Q46 =_ Q48 =_ Q49 =_ Q50 =_ Q51 =_ Q52 =_ Q118 =_ Q119 =_

DIGITAL INPUT CARD-1_2

HVMT1_2 =_ HVMT2_1 =_ HVMT2_2 =_ HVRH_1 =_ HVRH_2 =_ Q/H_VSI1 =_ Q/H_VSI2 =_ BLVMT =_

DIGITAL OUTPUT CARD-1_1

DJ =_ C118 /BLSI =_ VEPT1 =_ VEPT2 =_ DJ =_ C107 =_ C106 =_ C105 =_

DIGITAL OUTPUT CARD-1_2

C101_3 =_ VEUL =_ J_FOR =_ J_REV =_ CTF_RUN =_ CTF_BRK =_ VE_UP =_ C145 =_


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13.1.4. Display Analog Parameters 13.1.5. Parameter Setting Note: Once any above operation is selected system will prompt for password

which is to be entered. It should be possible to set desired parameters.

Password: 123456 Password should be in 6 digits which will be settable from left to right by the UP or DOWN keys. (UP key = incremented and DOWN key =

PARAMETER SETTING 1. Loco No. 2. Date 3. Time

1. Analog Voltages 2. TM Currents

ELIMINATED RELAYS Screen-2 Q120 =_ QBI =_ QCVAR =_ QD1 =_ QD2 =_ QF1 =_ QF2 =_ QRS =_ QTD105 =_ QTD106 =_ QV60 =_ QV61 =_

ELIMINATED RELAYS Screen-3 QV62 =_ QV63 =_ QV64 =_ QVSOL =_ QWC =_

ANALOG Voltage

CHBA Voltage =___Vdc TM Voltage = _____ Vdc ARNO Voltage =___ Vac Aux. Voltage= _____ Vac

Aux. Voltage (RDT) = _____ Vac

TM Currents

TM-1 = ____ A TM-2 = ____ A TM-3 = ____A TM-4 = ____ A TM-5 = ____ A TM-6 = ____A


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decremented). The time between operations of adjacent keys will be not more than 02 sec after next digit will STAR. All the entries should be making same as password feeded.

The following information is shown if the DISPLAY DIGITAL INPUT option is selected

Here the first digit is showing the status of the Digital Input 0,the second digit is showing the Digital Input 1. A ‘1’ shows that the input is in OFF state (Low), whereas a ‘0’ shows that the input is in ON state (High). Now by scrolling the screen with the help of UP DOWN key the various input status individually can be shown.

Fault Messages: -

S. No. Signal Condition Displayed Message on LCD Action By System

1. C118 Feedback contact found open before energizing DJ

C118 N/C Contact Fail. Ensure C118 Opening Do not Press BLRDJ

��

2. C118 Feedback contact found closed while DJ is being energized

C118 Stuck Up. Ensure opening of C118 release BLRDJ if Pressed

��

3. No OHE at the time of DJ closing (BLRDJ is ON)

No Tension, wait for OHE Voltage. Retry to close DJ

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4. OHE Power fail while Running

OHE Low / No Tension. Apply Emergency Brake

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5. DJ Tripping due to QOP 1(Earth Fault)

DJ Tripped Via QOP – 1.Reset QOP-1, Isolate faulty TM by HMCS1 follow TSD, Inform TLC

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6. DJ Tripping due to QOP 2 (Earth Fault)

DJ Tripped Via QOP – 2.Reset QOP-2, Isolate faulty TM by HMCS2 follow TSD, Inform TLC

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7. DJ Tripping due to QOA (Over Current in Auxiliary Circuit)

DJ Tripped Via QOA. Check all Auxiliary / Heater put HQOA at 0, Follow TSD

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DATE: LOCO OK TIME: 10101010 10101010 10101010 10101010 10101010 10101010 10101010 10101010 10101010 10101010 00000000 00000000


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8. DJ Tripping due to QRSI 1 (Over Current in Rectifier 1)

DJ Tripped Via QRSI – 1,reset QRSI1, Isolate faulty TM by HMCS1 follow TSD, Inform TLC

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9. DJ Tripping due to QRSI 2 (Over Current in Rectifier 2)

DJ Tripped Via QRSI – 2,reset QRSI2, Isolate faulty TM by HMCS2 follow TSD, Inform TLC

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10. DJ Tripping due to QLM (X-mer Over Current)

DJ Tripped Via QLM, Check Transformer / GR Oil splashing Loco made Dead & Inform TLC

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11. DJ Tripping due to QVSL 1 (SL 1 Blower)

DJ Tripped Via QVSL – 1,check MVSL – 1 if normal, Put HVSL-1 on 3 resume traction

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12. DJ Tripping due to QVSL 2 (SL 2 Blower)

DJ Tripped Via QVSL – 2,check MVSL – 2 if normal, Put HVSL-2 on 3, resume Traction

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13. DJ Tripping due to QVMT1 (MT 1 Blower)

DJ Tripped Via QVMT – 1,Check MVMT – 1 if normal, Put HVMT-1 on 3 resume traction

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14. DJ Tripping due to QVMT 2 (MT 2 Blower)

DJ Tripped Via QVMT – 2, Check MVMT – 2 if normal, Put HVMT-21 on 3 resume traction

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15. DJ Tripping due to QVRH DJ Tripped Via QVRH, check MVRH if normal, Put HVRH on 3 Resume Traction

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16. DJ Tripping due to QVSI 1 (RSI 1 Blower)

DJ Tripped Via QVSI – 1, check MVSI – 1 if normal, Put HVSI-1 on 3 resume traction

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17. DJ Tripping due to QVSI 2

DJ Tripped Via QVSI – 2,Check MVSI – 2 if normal, Put HVSI-2 on 3 resume traction

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18. DJ Tripping due to QPH DJ Tripped Via QPH, check TFP Oil Level Frequently, put HPH on 0 & clear block section

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19. DJ Tripping due to GR Stuck

DJ Tripped due to GR Stuck between notches bring GR to Zero manually, resume normal traction clear block section manually,

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20. DJ Tripping due to Low/ No ARNO Output

DJ Tripped due to Low/No ARNO Voltage

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21. DJ Tripping due to QLA DJ Tripped Via QLA isolate faulty auxiliary machine, If fault exists make loco dead inform TLC

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22. DJ Tripping due to QPDJ DJ Tripped Via QPDJ check RS pressure start CPA to build up pressure

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23. Insufficient Air Flow for DBR(I-73)

QVRF not working Do not use Dynamic Braking

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24. Unable to Close DJ due to QOP -1

ICDJ through QOP-1 Dropped Put HQOP-1 OFF. On running condition watch HTC

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25. Unable to Close DJ due to QOP -2

ICDJ through QOP-2 dropped Put HQOP-2 OFF. On running condition watch HTC

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26. Unable to Close DJ due to QOA

ICDJ through QOA dropped Put HQOA on 0 Check auxiliary machines

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27. Unable to Close DJ due to QLM

ICDJ through QLM Dropped Check HT Compartment for Oil Splashing inform TLC

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28. Unable to Close DJ due to QRSI -1

ICDJ through QRSI-1 Dropped ��

29. Unable to Close DJ due to QRSI -2

ICDJ through QRSI-2 Dropped ��

30. Unable to Close DJ due to QLA

ICDJ through QLA Dropped Check ARNO. Inform TLC

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31. Unable to Close DJ due to QPDJ

ICDJ through QPDJ Dropped Check MS Pressure / Leakage Start CPA to build pressure

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32. CTFs are neither in “T” nor in “B” at BL Key ON

CTFs are neither in “T” nor “B”. Set the CTFs manually on “T” side only. Resume Traction

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33. GR not in Zero at BL Key ON

GR Not in Zero. Bring GR at 0 manually. Close DJ

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34. IP coil de energizes during Dynamic Braking

Brake Applied Through IP Do not use DBR

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35. Auto regression via RGEB

Auto-regression via RGEB If not Brake applied check for Leakage

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36. Auto regression via QD Auto-regression via QD Press BPQD / Resume Traction

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37. Auto regression via TM Over voltage

Auto-regression via TM Over Voltage. Check TM Voltage, ensure TM voltage is not more than 750V

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38. Braking Fault SWC Operated

Braking Fault SWC Operated Do not use Loco Brake during DB

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39. One CPU failure Working with One CPU Note down in log book

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40. Display Communication fail with other CAB

Other CAB Display fail ��

41. HVMT 1 is in Position 0 HVMT 1 in Position 0. L1 L2 L3 Cut Off Half Power available

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42. HVMT 2 is in Position 0 HVMT 2 in Position 0. L4 L5 L6 Cut Off Half Power available

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HVSI 1 in Position 0 43. HVSI 1 is in Position 0

L1 L2 L3 Cut Off Half Power available ��

44. HVSI 2 is in Position 0 HVSI 2 in Position 0 L4 L5 L6 Cut Off Half Power available

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45. Reverser not as per MPJ Position

Reverser not as per MPJ Position. Set manually as per MPJ

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46. CTFs not as per MP Position

CTFs not as per MP Position Set manually CTF’s in traction side only

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47. C 145 open in DB mode due to HMCS1/2 not in 1

C 145 Open HMCS 1/2 not in 1 Do not use DB

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48. C145 Open in DB mode DBR Overheated

DBR Overheated or QF/QE Operated. If QE acted do not use DBR

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49. DJ Tripped via DJ Feed back Fail

DJ Tripped via DJ FB Fail ��

50. Battery Charger Output Fail

Battery Charger Output Fail Check CHBA. Clear Block Section

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51. Unable to Close DJ due to C107 Feedback Fail

ICDJ through C107 Feedback Fail. Inform TLC

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ICDJ through C106 Feedback Fail. Put HVMT-2 on 0 Clear section, Inform TLC

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ICDJ through C105 Feedback Fail. Put HVMT-1 on 0 Clear section, Inform TLC

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54. GR Stuck on notches GR Stuck up on Notches GR Bring to 0 manually

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55. DJ Tripped via C107 Feedback Fail when DJ is energized

DJ Tripped via C107 Feedback Fail. Inform TLC

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DJ Tripped via C106 Feedback Fail. Put HVMT-2 on 0 Clear Section, Inform TLC

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DJ Tripped via C105 Feedback Fail. Put HVMT-1 on 0 Clear Section, Inform TLC

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58. DJ Tripped due to C118 N/C Contact Fail

DJ Tripped Via C118 N/C Contact Fail ��

59. Communication with Display in CAB 2 Failed

Communication Link Display 2 Fail �

60. Communication with Display in CAB 1 Failed

Communication Link Display 1 Fail �

61. Auto regression via ACP ( Alarm Chain Pulling/ Train Parting)

Auto-regression via ACP ��

62. BPAR put in bypass mode

BPAR put in bypass ��

63. BPAR restored BPAR restored ��

64. Unable to close DJ due to QSIT high

ICDJ through QSIT Dropped ��

65. OHE Voltage out of Range

SI shutdown See front panel of SI

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�� Save message in Fault Memory

�� Give Buzzer Output till it is acknowledged

fdcs manual stesalit

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