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Fault Diagnostics and Control System

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Index
1.
2.
3.
4.
5.
6.
7.

8.
9.

10.
11.
12.
13.
14.

System Overview
Safety Design Considerations
System Architecture
System configuration
System Highlights
Relay Logic Description
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
Software Architecture and Description
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
Wiring Details for FDCS-9648 of WAG-7 Locomotive
List of Input/Outputs
Trouble shooting Procedure of FDCS 9648
Operation of the Display panel
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 107 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 interrelated 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 optoisolators 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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+110V DC

PSU-A

PSU-B

Analog
Input

DIODE OR-ing
+5V

Display
Unit 1

Analog
Input

+12V
TM CURRENT
SENSING
MODULE - A

Display Bus A

CPU-A

I/O
Bus
A

Display
Bus.

Signal
Conditio
ning
Module.

MultiFunction
Card.

Sync.

IPC
Comm.
Bus

TM CURRENT
SENSING
MODULE - B

Input Module

Interface
A
Input
Scanner

CPU-B
Display
Unit 2

I/O
Bus

External
Status
Input

Interface
B

B
Display Bus B

Output Module

Interface
A

Control
Outputs.
Output
Driver.

Interface
B

Fig.1: System Architecture


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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 2way 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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PLACE FOR BAYONET CONNECTOR


(Details in Fig. 2A)

O
U
T
P
U
T

O
U
T
P
U
T

O
U
T
P
U
T

O
U
T
P
U
T

O
U
T
P
U
T

R
D
T

S
P
R

F
I
L
T
E
R

I
N
P
U
T

I
N
P
U
T

I
N
P
U
T

I
N
P
U
T

I
N
P
U
T

I
N
P
U
T

I
N
P
U
T

I
N
P
U
T

R
D
T

S
P
R

A
N
A
L
O
G

C
P
U

C
P
U

M
U
L
T
I

P
S
U

P
S
U

F
U
N
C

Fig.2: FDCS Main Cabinet

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OP
RDT

OP1

OP2

OP3

OP
SPR

INP
RDT

INP5

INP6

INP
SPR

DISP
1

SIG
CON

TM
1
TM
2

INP1

INP2

INP3

INP4

DISP
2

Fig.2A: FDCS Main Cabinet Connector Details

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PW
R

Fault Diagnostics and Control System

Date 27/12/07

Time 12:30

Insert BL Key

MENU

ACK

Stesalit Limited

ENTER

Fig.3: Display Screen Diagram

Fig.3A: Display Unit

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Dimensions of FDCS9648: Parameter

Signal Conditioning
Unit (in mm)

TM Current
Sensing Unit
(in mm)

102

62

240 (hole to hole)


265 (Total)

180

180

385

46

210

210

NA

150 X 30

NA

NA

Main Unit (in mm)

Display Unit (in mm)

900(including connector)

160 (hole to hole)

785 (without connector)

180 (total)

Width

305

Breadth
Viewing
Area

Height

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 PT2. 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 VEPT1 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.

5. A. For ARNO based Loco :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.
B. For Static Converter based Loco: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.
6. A. For ARNO based Loco :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.
B. For Static Converter based Loco: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, QOP2, 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:

TRIPPING OF DJ INSTANTANEOUSLY.

A)

1.

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

B)

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.

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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Fault Diagnostics and Control System

2.

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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

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.

O8

VEUL

5sec

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.

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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 contractors 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
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 reverser

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6.8.3 OPERATION

OF

TRACTION

MOTOR

Stesalit Limited

DOUBLE

REVERSER

IN

FORWARD DIRECTION
1) Main circuit breaker DJ must be closed.
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
1) Main circuit breaker DJ must be closed.
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 5notch.
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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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 solidstate 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 LEDs 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
A. System OK. (Green)

B. PSU Alarm (Amber)


C. System working in 2-out-of-2 mode (Green)
D. Display panel not responding (Amber)

C
D

E. Error in Input module (Red)


E

F. Error in Output module (Red)


G. Error in Analog Input module (RED)

H. Processor sub-system SHUT DOWN (Red)

G
H

Fig.5: Facia Panel Diagram of CPU card

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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 subsystem, 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 subsystem.

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. selffeeding 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)


B

C. I/P under Voltage Alarm (Red)


P

D. +5V over Voltage Alarm (Red)


E. +5V under Voltage Alarm (Red)
F. +12V Over Voltage Alarm (Red)
G. +12V under Voltage Alarm (Red)

C
Q
R

P. +5V Test Point (Red)


Q. +5V Ground Test Point (Black)
R. +12V Test Point (Red)
S. +12V Ground Test Point (Black)

E
F
G

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.
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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

Efficiency

Input

- Surge and transient voltages

Output

- Short circuit
- 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 optoisolators. 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.

Page 40 of 69

Fault Diagnostics and Control System

Stesalit Limited

TABLE FOR VALIDATION OF INPUTS

INPUT COMBINATION.
A
B
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1

0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1

0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1

0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1

DATA
0
0
0
0*
0
0*
0*
1
0
0*
0*
1
0*
1
1
1

ALARM
SELFA
SELFB
/ADJ.B
/ADJ.A
0
0
0
1
0
1
0
0
1
0
0
0
0
0
1
0
1
0
0
0
0
0
1
0
0
0
0
1
0
1
0
0

FATAL
ALARM
0
0
0
1
0
1
1
0
0
1
1
0
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-of2 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.

Page 41 of 69

Fault Diagnostics and Control System

Stesalit Limited

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.

Page 42 of 69

Fault Diagnostics and Control System

Stesalit Limited

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.

Page 43 of 69

Fault Diagnostics and Control System

9.

Stesalit Limited

Inter Connection Details:

CSU1

LOCOMOTIVE TERMINAL
SB In AC2 Panel

6
CSU2

10

19

19

19

19

19

19

19

SIGNAL
CONDITIONING
UNIT in AC2
Panel

19

10

DISPLAY
UNIT NO. 1
FOR CAB A

10

FDCS 9648 CONTROL UNIT


In AC 2 Panel

Fig.8: Wiring Details of FDCS

Fig.9: Allied Connector diagram

Page 44 of 69

10

DISPLAY
UNIT NO. 2
FOR CAB B

Fault Diagnostics and Control System

Stesalit Limited

FDCS
LUG
Wire

Allied Connector

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

A. FDCS Unit to Terminal SB:


Signal Name

Connector type
on FDCS Unit

Connector type on
Cable

Cable type and


length in meter

Digital Input 0 to 15

No.
Of
Pins
19

97B3102R-22-14P

Digital Input 16 to 31

19

97B3102R -2214PW

Digital Input 32 to 47

19

97B3102R-22
14PX

Digital Input 48 to 63

19

97B3102R-2214PY

Digital Input 64 to 79

19

97B3102R -2214PZ

FDCS Unit side


97B3106F - 22 - 14S
SB side: 2.5mm Lugs
FDCS Unit side
97B3102F -22-14SW, SB
side: 2.5mm Lugs
FDCS Unit side
97B3106F - 22 14SX,
SB side: 2.5mm Lugs
FDCS Unit side
97B3106F - 22 - 14SY ,
SB side: 2.5mm Lugs
FDCS Unit side
97B3106F - 22 14SZ,
SB side: 2.5mm Lugs

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

Digital Input 80 to I94

19

97B3102R - 20 29P

Digital Input 95 to 110

19

97B3102R-2029PW

Digital Input Spare

19

97B3102R-2029PZ

Digital Output 0 to 15

19

97B3102F-2214S

FDCS Unit side


97B3102F - 20 29S,
SB side: 2.5mm Lugs
FDCS Unit side
97B3102F-22- 14SW,SB
side: 2.5mm Lugs
FDCS Unit side
97B3102F-22- 14SZ,SB
side: 2.5mm Lugs
FDCS Unit side
97B3102R-22- 14P,SB
side: 2.5mm Lugs

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

Page 45 of 69

Fault Diagnostics and Control System

Signal Name

Digital Output 16 to 31

No.
Of
Pins
19

Digital Output 32 to 47

19

Digital Output 48 to 63

19

Digital Output Spare

19

110V DC Power
Supply

Connector type
on FDCS Unit

Stesalit Limited

Connector type on
Cable

Cable type and


length in meter

97B3102F-2214SW

FDCS Unit side


97B3102R-22- 14PW,
SB side: 2.5mm Lugs
97B3102F-22FDCS Unit side
14SX
97B3102R-22- 14PX
SB side: 2.5mm Lugs
97B3102F-22FDCS Unit side
14SY
97B3102R-22- 14PY
SB side: 2.5mm Lugs
97B3102F-22FDCS Unit side
14SZ
97B3102R-22- 14PZ
SB side: 2.5mm Lugs
97B3102R-10- SL FDCS Unit side
3P
97B3102F-10-SL 3S SB
side: 2.5mm Lugs

6m length 19
Core shielded Teflon
wire (1 sq. mm dia each)
6m length 19
Core shielded Teflon
wire (1 sq. mm dia each)
6m length 19
Core shielded Teflon
wire (1 sq. mm dia each)
6m length 19
Core shielded Teflon
wire (1 sq. mm dia each)
6m length 3
Core shielded Teflon
wire (1 sq. mm dia each)

B. FDCS Unit to Display unit:


Signal Name
Transmit, Receive and
Power Signals
For CAB A
Transmit, Receive and
Power Signals
For CAB B

No. Of
Pins
10

10

Connector type on Connector type on


FDCS Unit
Cable
97B3102R-18-1PX FDCS Unit side
97B3102R-18-1SX
Display Unit side
97B3102R-18-1S
97B3102R-18-1PY FDCS Unit side
97B3102R-18-1SY
Display Unit side
97B3102R-18-1S

Cable type and length


in meter
23m length 10 Core
shielded Teflon wire (1
sq. mm dia each)
8m length 10 Core
shielded Teflon wire (1.5
sq. mm dia each)

C. Display Unit to Terminal SB:


Signal Name
110V DC Power
Supply to CAB A
Display Unit
110V DC Power
Supply to CAB B
Display Unit

No. Of
Pins
3

Connector type
on FDCS Unit
97B3102R-10-SL
3P

97B3102R-10-SL
3P

Connector type
on Cable
Display Unit side
97B3102F-10-SL
3S SB side: 2.5mm
Lugs
FDCS Unit side
97B3102F-10-SL
3S SB side: 2.5mm
Lugs

Page 46 of 69

Cable type and length in


meter
8m length 3 Core shielded
Teflon wire (1.5 sq. mm dia
each)
8m length 3 Core shielded
Teflon wire (1.5 sq. mm dia
each)

Fault Diagnostics and Control System

Stesalit Limited

D. FDCS Unit to Signal Conditioning Unit:


Signal Name

No. Of
Pins
10

AUX, AUX_R, Battery


and TM
Armature Voltage

Connector type
on FDCS Unit
97B3102R-18-1S

Connector type on
Cable
FDCS Unit side
97B3102R-18-1P
Signal Cond. Unit side
97B3102R-18-1P

Cable type and


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

E. Signal Conditioning Unit to SB Terminal:


Signal Name

No. Of
Pins

Connector type
on Cable

Connector Cable type and


type on
Length in meter
SB

Connector
type on Sig.
Conditioning
Unit
Terminals

AUX, AUX_R Output


Voltages

Lugs in both side

Terminal
provided
by CLW

TM Armature Voltage,
Battery

Terminals

Lugs in both side

Terminal
provided
by CLW

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

F. FDCS Unit to TM Current Sensor Unit 1:


Signal Name

No. Of
Pins

Traction Motor Current


1, 2 ,3 & 4

Connector
type on
FDCS Unit
97B3102R18-8PW

Connector type on Cable

Cable type and


length in meter

FDCS Unit side 97B3102R-18- 19m length 8 Core


8SW , TM Current Sensor Unit1 Teflon shielded wire
side 97B3102R-18-8SW
(1sq. mm dia each)

G. TM Current Sensor Unit1 to SHUNT:


Signal Name

No. Of
Pins

TM Current1, 2, 3
&4

Connector type on Connector type


TM Current
on Cable
Sensor Unit 1
Terminals
Lugs in both side

Connector
type on SB

Cable type and


Length in meter

Terminal
provided by
CLW

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

H. FDCS Unit to TM Current Sensor Unit 2:


Signal Name
Traction Motor
Current 5 , 6, 7 & 8

No. Of
Pins
8

Connector type
on FDCS Unit
97B3102R-188PZ

Connector type on Cable


FDCS Unit side 97B3102R-188SZ , TM Current Sensor
Unit1 side 97B3102R-18-8SZ

Page 47 of 69

Cable type and


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

Fault Diagnostics and Control System

Stesalit Limited

I. TM Current Sensor Unit2 to SHUNT:


Signal Name

No. Of
Pins

Connector type
on TM Current
Sensor Unit 1

Connector type
on Cable

Connector
type on SB

TM Current 5, 6, 7
&8

Terminals

Lugs in both side

Terminal
provided by
CLW

2.

Wire Details for FDCS-9648 of Electric Locomotive:

A.

Connector Number: Digital Input 1


Connector Type: 22-14P

Input No.

Name Of Input

I-0
I-1
I-2
I-3
I-4
I-5
I-6
I-7
I-8
I-9
I-10
I-11
I-12
I-13
I-14
I-15

BP1DJ/BLDJ
BP2DJ/BLRDJ
QVMT1
QVMT2
QVRH
ZPT1_2
ZPT1_1
HVMT1_1
HVMT1_2
HVMT2_1
HVMT2_2
HVRH_1
HVRH_2
QVSI1/HVSI1
QVSI2/HVSI2
BLVMT

Screen Display
Name
BLDJ
BLRDJ
QVMT1
QVMT2
QVRH
ZPT1_2
ZPT1_1
HVMT1_1
HVMT1_2
HVMT2_1
HVMT2_2
HVRH_1
HVRH_2
Q/H_VSI1
Q/H_VSI2
BLVMT

Page 48 of 69

Cable type
and
Length in
meter
2.5m length
Teflon Wire (3
sq. mm dia
each)

Pin No.

Wire No.

SB No.

N1-A
N1-B
N1-C
N1-D
N1-E
N1-F
N1-G
N1-H
N1-J
N1-K
N1-L
N1-M
N1-N
N1-P
N1-R
N1-S

021
024
025
026
027
030
029
036
037
038
039
040
041
042
043
070

SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1

Fault Diagnostics and Control System

B.

Connector Number: Digital Input 2


Connector Type: 22-14PW

Input No.
I-16
I-17
I-18
I-19
I-20
I-21
I-22
I-23
I-24
I-25
I-26
I-27
I-28
I-29
I-30
I-31

C.

Stesalit Limited

Name Of Input
ASMGR (B.N.)
BLCP/BLCPD
C101_3 FB
GR-0
GR-0_31
QPH/HPH
QVSL1/HVSL1
C105_FB
ASMGR (O.N.)
QVSL2/HVSL2
MP+ (R, B)
MPJ (FOR)
J1,J2 (FOR)
MP (+N-) R
MP- (R, B)
CTF (RUN)

Screen Display Name


GR_BN
BLCP
C101_3 FB
GR-0
GR-0_31
Q/H_PH
Q/H_VSL1
C105_FB
GR_ON
Q/H_VSL2
MP+
MPJ FOR
J_FOR
MPMP_RUN
CTF_RUN

Pin No.
W2-A
W2-B
W2-C
W2-D
W2-E
W2-F
W2-G
W2-H
W2-J
W2-K
W2-L
W2-M
W2-N
W2-P
W2-R
W2-S

Wire No.
072
074
075
076
077
078
079
061
082
080
093
091
095
096
097
100

SB No.
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1
SB-1

Pin No.
X3-A
X3-B
X3-C
X3-D
X3-E
X3-F
X3-G
X3-H
X3-J
X3-K
X3-L
X3-M
X3-N
X3-P
X3-R
X3-S

Wire No.
092
212
213
105
107
121
123
124
125
126
150
151
230
155
156
162

SB No.
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2

Connector Number: Digital Input 3


Connector Type: 22-14PX

Input No.
I-32
I-33
I-34
I-35
I-36
I-37
I-38
I-39
I-40
I-41
I-42
I-43
I-44
I-45
I-46
I-47

Name Of Input
MPJ (REV)
CTF (BRK)
MP (+,N,-) B
DJ_FB
J1,J2 (REV)
ZQWC
MPS (1-4)
MPS (2-4)
MPS (3-4)
MPS (4-4)
PVEF
PSA
BPQD
RGEB
SWC
QF & QE

Screen Display Name


MPJ_REV
CTF_BRK
MP_BRK
DJ_FB
J_REV
ZQWC
MPS_1
MPS_2
MPS_3
MPS_4
PVEF
PSA
BPQD
RGEB
SWC
QF_QE

Page 49 of 69

Fault Diagnostics and Control System

D.

Connector Number: Digital Input 4


Connector Type: 22-14PY

Input No.
I-48
I-49
I-50
I-51
I-52
I-53
I-54
I-55
I-56
I-57
I-58
I-59
I-60
I-61
I-62
I-63

E.

Stesalit Limited

Name Of Input
BL
QOA/QSIT*
QOP1
QOP2
QRSI1
QRSI2
QLM
BV
C106_FB
ZSMGR
ZSMS
RSI
HMCS
L1 to L6_FB
HMCS & QD
C118 (N/C)/ QCON*

Screen Display Name


BL
QOA QSIT
QOP1
QOP2
QRSI1
QRSI2
QLM
BV
C106_FB
ZSMGR
ZSMS
RSI
HMCS
L1_6_FB
HMCS_QD
C118_NC QCON

Pin No.
Y4-A
Y4-B
Y4-C
Y4-D
Y4-E
Y4-F
Y4-G
Y4-H
Y4-J
Y4-K
Y4-L
Y4-M
Y4-N
Y4-P
Y4-R
Y4-S

Wire No.
142
017
046
047
048
049
050
122
062
128
120
170
058
028
153
018

SB No.
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-2
SB-3A
SB-3A
SB-3A
SB-3A
SB-3A
SB-3A
SB-3A
SB-3A
SB-3A

Pin No.

Wire No.

SB No.

N5-A

019

SB-3A

N5-B
N5-C
N5-D
N5-E
N5-F
N5-G
N5-H
N5-J
N5-K
N5-L
N5-M
N5-N
N5-P
N5-R
N5-S

052
060
068
059

SB-3A

Connector Number: Digital Input 5


Connector Type: 22-14PZ

Input No. Name Of Input


QLA_FB/ SI INT
I-64
FAULT*
I-65
QPDJ_FB
I-66
C107_FB
I-67
SI EXT FAULT*
I-68
C145 N/O
I-69
I-70
HQ51
I-71
CHBA
I-72
BL1
I-73
SWITI/DBR
I-74
I-75
RGAF/P2(ACP)
I-76
BLFL
I-77
BPT
I-78
RGPA/P1(ACP)
I-79
BPSW1/2/ACK (ACP)

Screen Display Name


QLA_FB
SI INT FLT
QPDJ_FB
C107_FB
SI EXT FLT
C145 N/O
HQ51
CHBA
BL1
SW_DBR
P2_ACP
BLFL
BPT
P1_ACP
BPSW_ACK

Page 50 of 69

SB-3A
NOT IN WAP

200
973
149
157

SB-3A
SB-2B
SB-3A

219
216
217
218
203

SB-2A
SB-2A
SB-2A
SB-2A
SB-2A

Fault Diagnostics and Control System

F.

Connector Number: Digital Input 6 (Spare Inputs)


Connector Type: 20-29P

Input No.
I-80
I-81
I-82
I-83
I-84
I-85
I-86
I-87
I-88
I-89
I-90
I-91
I-92
I-93
I-94
I-95

G.

Stesalit Limited

Name Of Input
LOCO SEL 1
LOCO SEL 2
LOCO SEL 3
LOCO SEL 4
MU_FB
BPEMS-1&2

Screen Display Name


L_SEL 1
L_SEL 2
L_SEL 3
L_SEL 4
MU_FB
BPEMS-1&2

Q49_FB

Pin No.
A
B
C
D
E
F

Wire No.
B700
700
B237
067

SB No.

WAG ONLY

WAG ONLY

Connector Number: Digital Input 6 (REDUNDANT INPUTS)


Connector Type: 20-29P

Input No.

Name Of Input

I-96 (I-14)
I-97 (I-21)
I-98 (I-22)
I-99 (I-25)
I-100 (I-49)
I-101 (I-50)
I-102 (I-51)
I-103 (I-52)
I-104 (I-53)
I-105 (I-54)
I-106 (I-64)
I-107 (I-63)
I-108 (I-48)
I-109 (I-15)
I-110 (I-17)
I-111

BVSI1 / HVSI1
QPH / HPH
QVSL1/HVSL1
QVSL2/HVSL2
QOA / QSIT
QOP1
QOP2
QRSI1
QRSI2
QLM
QLA/SI INT FAULT
QCON / C118-N/C
BL
BLVMT
BLCP / BLCPD

Screen Display
Name
Q/H_CSI1
Q/H_PH
Q/H_VSL1
Q/H_VSL2
QOA QSIT
QOP1
QOP2
QRSI1
QRSI2
QLM
QLA
C118_NC/QCON*
BL
BLVMT
BLCPD

Page 51 of 69

Pin No.

Wire No.

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S

043
078
079
080
017
046
047
048
049
050
019
018
142
070
074

SB No.

Fault Diagnostics and Control System

I.

Connector Number: Digital Output 1


Connector Type: 22-14S

Output No.

Name Of Output

O-0
O-1
O-2
O-3
O-4
O-5
O-6
O-7
O-8
O-9
O-10
O-11
O-12
O-13
O-14
O-15

DJ
C118/BLSI*
VEPT1
VEPT2
DJ
C107
C106
C105
C101, C103
VEUL
J1,J2 (FOR)
J1,J2 (REV)
CTF (RUN)
CTF (BRK)
VE (UP)
C145

J.

Stesalit Limited

Screen Display
Name
DJ
C118 / BLSI
VEPT1
VEPT2
DJ
C107
C106
C105
C101_3
VEUL
J_FOR
J_REV
CTF_RUN
CTF_BRK
VE_UP
C145

Pin No.

Wire No.

SB No.

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S

044
035
055
056
044
083
084
085
086
087
108
109
111
112
110
114

SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3

Pin No.
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S

Wire No.
113
115
129
130
131
132
166
165
164
163
143
133
171
172
173
174

SB No.
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-4
SB-4
SB-4
SB-4
SB-4

Connector Number: Digital Output 2


Connector Type: 22-14SW

Output No.
O-16
O-17
O-18
O-19
O-20
O-21
O-22
O-23
O-24
O-25
O-26
O-27
O-28
O-29
O-30
O-31

Name Of Output
VE (DN)
EVPHGR
Sx1
Sx2
Sx31
Sx32
IP
VESA2
VEF
VESA1
L1, L2, L3
L4, L5, L6
LSDJ
(R)
LSCHBA (G)
LSGR
(G)
LSB
(Y)

Screen Display Name


VE_DN
EVPHGR
Sx1
Sx2
Sx31
Sx32
IP
VESA2
VEF
VESA1
L1_3
L4_6
LSDJ
LSCHBA
LSGR
LSB

Page 52 of 69

Fault Diagnostics and Control System

K.

Stesalit Limited

Connector Number: Digital Output 3


Connector Type: 22-14SX

Output No.

Name Of Output

O-32
O-33
O-34
O-35
O-36
O-37
O-38
O-39
O-40
O-41
O-42
O-43
O-44
O-45
O-46
O-47

LSP
(R)
LSRSI
(Y)
Sx41
Sx42
LSGROUP (R)
LSOL
(Y)
LSFL
SON (ALARM)
Q51_52 FB_MU
QFL
LSDBR
(Y)

Screen Display
Name
LSP
LSRSI
Sx41
Sx42
LS_GRP
LSOL
LSFL
SON
Q51_52 FB_MU
QFL
LSDBR

Q49_MU
FL_LP
C102
C108

Q49_MU
FL_LP
C102
C108

Pin No.

Wire No.

SB No.

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S

175
176
144
145
235
210
232
177

SB-4
SB-4
WAP ONLY
WAP ONLY
WAG ONLY
SB-4
SB-4
SB-4
WAG ONLY
SB-4
SB-4
SB-4
WAG ONLY
SB-4
WAG ONLY
WAG ONLY

236
234

L. Connector Number: Digital Output 4 (REDUNDANT OUTPUTS)


Connector Type: 22-14SY
Output No.

Name Of Output

O-48 (O-0)
O-49 (O-1)
O-50 (O-2)
O-51 (O-3)
O-52 (O-0)
O-53 (O-5)
O-54 (O-6)
O-55 (O-7)
O-56 (O-8)
O-57 (O-16)
O-58 (O-10)
O-59 (O-11)
O-60 (O-12)
O-61 (O-26)
O-62 (O-14)
O-63 (O-27)

DJ
C118/BLSI*
VEPT1
VEPT2
DJ
C107
C106
C105
C101, C103
VE (DN)
J1,J2 (FOR)
J1,J2 (REV)
CTF (RUN)
L1,L2,L3
VE (UP)
L4,L5,L6

Screen Display
Name
DJ
C118 BLSI
VEPT1
VEPT2
DJ
C107
C106
C105
C101,C103
VE_DN
J_FOR
J_REV
CTF_RUN
L1_3
VE_UP
L4_6
Page 53 of 69

Pin No.

Wire No.

SB No.

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S

044
035
055
056
044
083
084
085
086
113
108
109
111
143
110
133

SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-3
SB-4

Fault Diagnostics and Control System

Stesalit Limited

Connector Number: Display for CAB A


Connector Type: 18-1P X
Name Of Signal

Pin No.

Wire No.

TRANSMIT +VE SIGNAL


TRANSMIT -VE SIGNAL
RECEIVE +VE SIGNAL
RECEIVE -VE SIGNAL
GROUND
GROUND
GROUND

A
B
C
D
H
I
J

TX P
TX N
RX P
RX N
GROUND
GROUND
GROUND

Connector Number: Display for CAB A


Connector Type: 18-1P Y
Name Of Signal

Pin No.

Wire No.

TRANSMIT +VE SIGNAL


TRANSMIT -VE SIGNAL
RECEIVE +VE SIGNAL
RECEIVE -VE SIGNAL
GROUND
GROUND
GROUND

A
B
C
D
H
I
J

TX P
TX N
RX P
RX N
GROUND
GROUND
GROUND

Connector Number: Analog Input (Signal Conditioning)


Connector Type: 18-1S
Name Of Input

Pin No.

Wire No.

ANG1 TM
ANG2 BAT
ANG3 W
ANG4 AUX
ANG5 AUX
+12V
AGND

A
B
C
D
E
H
J

AI1
AI2
AI3
AI4
AI5
+12V
ANGND

Connector Number: TM Current Sensing Unit1


Connector Type: 18-8PW
Name Of Input

Pin No.

Wire No.

ANG6 TM CURRENT 1
ANG7 TM CURRENT 2
ANG8 TM CURRENT 3
ANG9 QE
+12V
AGND

A
B
C
D
G
H

AI6
AI7
AI8
AI9
+12V
ANGND
Page 54 of 69

Fault Diagnostics and Control System

Connector Number: TM Current Sensing Unit1


Connector Type: 18-8PZ
Name Of Input

Pin No.

Wire No.

ANG6 TM CURRENT 4
ANG7 TM CURRENT 5
ANG8 TM CURRENT 6
ANG9 - SPARE
+12V
AGND

A
B
C
D
G
H

AI10
AI11
AI12
SPR
+12V
ANGND

Terminal Number: 1(Signal Conditioning Unit)


Terminal Type: 7 Pins H/V Terminal
Name of Input
W
AUX
AUXR
A.C RTN
TM
CHBA
D.C GND

Pin Number
1
2
3
4
5
6
7

Wire Number
991
991
991
993
A17
SGND

Terminal Number: 2(TM Current Sensing Unit1)


Terminal Type: 6 Pins H/V Terminal
Name of Input
TM1+
TM1 GND
TM2+
TM2 GND
TM3+
TM3 GND

Pin Number
1
2
3
4
5
6

Wire Number
196
197
208
209
206
207

Terminal Number: 3(TM Current Sensing Unit2)


Terminal Type: 6 Pins H/V Terminal
Name of Input
TM4+
TM4 GND
TM5+
TM5 GND
TM6+
TM6 GND

Pin Number
1
2
3
4
5
6

Wire Number
214
215
247
248
249
250

Page 55 of 69

Stesalit Limited

Fault Diagnostics and Control System

Stesalit Limited

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

Page 56 of 69

Fault Diagnostics and Control System

Stesalit Limited

12. Trouble shooting Procedure of FDCS 9648


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

NO
Are all ok?

YES
Check the CPU LEDs

YES

SYSTEM IS
OK

Is Sys Ok
LED ON?
NO
YES

Check PSU
Card

Is PSU alarm
LED ON?
NO

Is 2/2
LED ON?

NO

Check the other


CPU card

YES

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.

Page 57 of 69

Fault Diagnostics and Control System

YES
Is Error in I/P
LED ON?

Change Digital
Input Card

NO
YES
Is Error in OP
LED ON?

Change Output
Card

NO

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

Page 58 of 69

Stesalit Limited

Fault Diagnostics and Control System

Stesalit Limited

Check the PSU Card

Check the PSU LEDs

YES

Is PSU
ON

PSU IS
OK

NO

Is IP Over
voltage LED
ON?

YES

Lower the
Input Voltage

YES

Increase the
Input Voltage

NO

Is IP Under
voltage LED
ON?

NO
Is +5V Over
voltage LED
ON?

YES

NO

Is +5V Under
voltage LED
ON?

YES

Change the
PSU card

NO

Is +12V Over
voltage LED
ON?

YES

NO

Is +12V Under
voltage LED
ON?

YES

NO

Page 59 of 69

Fault Diagnostics and Control System

Stesalit Limited

Output Not Coming from FDCS

Check the corresponding Output Logic and then check O/P cards LED

Is
LED ON?

NO

Change the
corresponding O/P card

Available

Check Loco side


wiring/Check the Relay

NOT OK

Repair the damage


portion of wiring

YES

Check Voltage
at BD panel

NOT AVAILABLE

Check Wiring
bet. BD Panel &
FDCS Coupler

OK

Page 60 of 69

Fault Diagnostics and Control System

Stesalit Limited

Input Not Coming from LOCO side to FDCS

Check the corresponding Input switch and then check I/P cards LED

Is
LED ON?

YES

Check in Display Unit. Input must ON,


else change corresponding card

Not Available

Check Loco side


wiring/Check contact

NOT OK

Repair the damage


portion of wiring

NO

Check Voltage
at BD panel

AVAILABLE

Check Wiring
bet. BD Panel &
FDCS Coupler

OK

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
DATE:

TIME:
*****************MAIN MENU******************
1. VEHICLE DIAGNOSTIC
2. PROCESS INFORMATION

The shows the current cursor position. To select an option move the cursor
UP or DOWN position.
Page 61 of 69

Fault Diagnostics and Control System

Stesalit Limited

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

LOCO OK
1 ISOLATION INFORMATION
2 CURRENT FAULT INFORMATION
3 FAULT HISTORY

TIME:

Now if the PROCESS INFORMATION option is selected then the display screen
is shown as follows
1 Input/Output Display
2 Parameter Setting
3 Test Mode.

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


follows
1.
2.
3.
4.

Display Digital Input


Display Digital Output
Display Eliminated Relays
Display Analog Parameters

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
DATE:
10101010
10101010
10101010

LOCO OK
10101010 10101010
10101010 10101010
10101010 00000000

TIME:
10101010
10101010
00000000

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.
Page 62 of 69

Fault Diagnostics and Control System

Stesalit Limited

One card inputs are defined in two screens. Each screen has 8 inputs like:
1st screen of card-1
DIGITAL INPUT
BLDJ
=_
QVMT2
=_

1st line
2nd line 3 inputs
3rd line 3 inputs
4th line 2 inputs

ZPT1_1

=_

BLRDJ
QVRH

=_

CARD-1_1
QVTM1

=_
HVMT1_1 =_

ZPT1_2

=_

=_

2nd screen of card-1


DIGITAL INPUT

1st line
2nd line 3 inputs
3rd line 3 inputs
4th line 2 inputs

HVMT1_2
HVRH_1
Q/H_VSI2

CARD-1_2

=_
=_
=_

HVMT2_1
HVRH_2
BLVMT

=_
=_
=_

HVMT2_2 =_
Q/H_VSI1 =_

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
DIGITAL OUTPUT

1st line
2nd line 3 outputs
3rd line 3 outputs
4th line 2 outputs

DJ
VEPT2
C106

CARD-1_1

=_
=_
=_

C118 /BLSI =_
DJ
=_
C105
=_

VEPT1
C107

=_
=_

2nd screen of card-1


1st line
2nd line 3 outputs
3rd line 3 outputs
4th line 2 outputs

DIGITAL OUTPUT

C101_3
J_REV
VE_UP

CARD-1_2

=_
=_
=_

VEUL
=_
CTF_RUN =_
C145
=_

J_FOR
=_
CTF_BRK =_

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

13.1.3. Eliminated Relays Display


ELIMINATED RELAYS
Q20
=_
Q30
=_
Q46
=_
Q48
=_
Q51
=_
Q52
=_

Q44
Q49
Q118

Page 63 of 69

=_
=_
=_

Screen-1
Q45
=_
Q50
=_
Q119
=_

Fault Diagnostics and Control System

ELIMINATED RELAYS
Q120
=_
QBI
=_
QD2
=_
QF1
=_
QTD105 =_ QTD106 =_
ELIMINATED RELAYS
QV62
=_
QV63
QWC
=_

=_

Stesalit Limited

QCVAR =_
QF2
=_
QV60 =_
QV64

Screen-2
QD1
=_
QRS
=_
QV61
=_

Screen-3
=_ QVSOL =_

13.1.4. Display Analog Parameters


1. Analog Voltages
2. TM Currents

ANALOG Voltage

CHBA Voltage =___Vdc


TM Voltage = _____ Vdc
ARNO Voltage =___ Vac
Aux. Voltage= _____ Vac
Aux. Voltage (RDT) = _____ Vac

TM Currents

TM-1 = ____ A
TM-4 = ____ A

TM-2 = ____ A
TM-5 = ____ A

TM-3 = ____A
TM-6 = ____A

13.1.5. Parameter Setting


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

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 =
Page 64 of 69

Fault Diagnostics and Control System

Stesalit Limited

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
DATE:
10101010
10101010
10101010

LOCO OK
10101010 10101010
10101010 10101010
10101010 00000000

TIME:
10101010
10101010
00000000

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.


1.

2.
3.
4.

Signal Condition
C118 Feedback contact
found open before
energizing DJ
C118 Feedback contact
found closed while DJ is
being energized
No OHE at the time of DJ
closing (BLRDJ is ON)
OHE Power fail while
Running

Displayed Message on LCD

Action By
System

C118 N/C Contact Fail.


Ensure C118 Opening Do not Press
BLRDJ



C118 Stuck Up. Ensure opening of


C118 release BLRDJ if Pressed



No Tension, wait for OHE Voltage. Retry



to close DJ
OHE Low / No Tension. Apply

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

5.

DJ Tripping due to
QOP 1(Earth Fault)

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



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



Page 65 of 69

Fault Diagnostics and Control System

S. No.

Signal Condition

Stesalit Limited

Displayed Message on LCD

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

9.

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

10.

DJ Tripping due to QLM


(X-mer Over Current)

11.

DJ Tripping due to
QVSL 1 (SL 1 Blower)

12.

DJ Tripping due to
QVSL 2 (SL 2 Blower)

13.

DJ Tripping due to
QVMT1 (MT 1 Blower)

DJ Tripped Via QRSI 2,reset QRSI2,


Isolate faulty TM by HMCS2 follow TSD,
Inform TLC
DJ Tripped Via QLM, Check
Transformer / GR Oil splashing
Loco made Dead & Inform TLC
DJ Tripped Via QVSL 1,check MVSL
1 if normal, Put HVSL-1 on 3 resume
traction
DJ Tripped Via QVSL 2,check MVSL
2 if normal, Put HVSL-2 on 3, resume
Traction
DJ Tripped Via QVMT 1,Check MVMT
1 if normal, Put HVMT-1 on 3 resume
traction

14.

DJ Tripping due to
QVMT 2 (MT 2 Blower)

15.

16.

17.

18.

DJ Tripped Via QVMT 2, Check


MVMT 2 if normal, Put HVMT-21 on 3
resume traction
DJ Tripped Via QVRH, check MVRH if
DJ Tripping due to QVRH normal, Put HVRH on 3
Resume Traction
DJ Tripped Via QVSI 1, check MVSI
DJ Tripping due to
1 if normal, Put HVSI-1 on 3 resume
QVSI 1 (RSI 1 Blower)
traction
DJ Tripped Via QVSI 2,Check MVSI
DJ Tripping due to
2 if normal, Put HVSI-2 on 3 resume
QVSI 2
traction
DJ Tripped Via QPH, check TFP Oil
DJ Tripping due to QPH
Level Frequently, put HPH on 0 & clear
block section

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,

20.

DJ Tripping due to Low/


No ARNO Output

DJ Tripped due to Low/No ARNO


Voltage
Page 66 of 69

Action By
System


























Fault Diagnostics and Control System

S. No.

Signal Condition

Stesalit Limited

Displayed Message on LCD

Action By
System

DJ Tripping due to QLA

DJ Tripped Via QLA isolate faulty


auxiliary machine, If
fault exists make loco dead inform TLC



22.

DJ Tripping due to QPDJ

DJ Tripped Via QPDJ check RS


pressure start CPA to build up pressure



23.

Insufficient Air Flow for


DBR(I-73)

24.

Unable to Close DJ due


to QOP -1

25.

Unable to Close DJ due


to QOP -2

26.

Unable to Close DJ due


to QOA

27.

Unable to Close DJ due


to QLM

21.

28.
29.
30.

Unable to Close DJ due


to QRSI -1
Unable to Close DJ due
to QRSI -2
Unable to Close DJ due
to QLA

34.
35.





ICDJ through QRSI-2 Dropped



Auto-regression via RGEB


If not Brake applied check for Leakage

CTFs are neither in T


nor in B at BL Key ON



ICDJ through QRSI-1 Dropped

Auto regression via


RGEB

32.





GR not in Zero at BL Key


ON
IP coil de energizes
during Dynamic Braking

Unable to Close DJ due


to QPDJ



ICDJ through QLM Dropped


Check HT Compartment for Oil
Splashing inform TLC

ICDJ through QLA Dropped


Check ARNO. Inform TLC
ICDJ through QPDJ Dropped
Check MS Pressure / Leakage
Start CPA to build pressure
CTFs are neither in T nor B.
Set the CTFs manually on T side only.
Resume Traction
GR Not in Zero. Bring GR at 0 manually.
Close DJ
Brake Applied Through IP
Do not use DBR

31.

33.

QVRF not working


Do not use Dynamic Braking
ICDJ through QOP-1 Dropped
Put HQOP-1 OFF. On running condition
watch HTC
ICDJ through QOP-2 dropped
Put HQOP-2 OFF. On running condition
watch HTC
ICDJ through QOA dropped
Put HQOA on 0 Check auxiliary
machines

Page 67 of 69









Fault Diagnostics and Control System

S. No.

Signal Condition

Stesalit Limited

Displayed Message on LCD


Auto-regression via QD
Press BPQD / Resume Traction
Auto-regression via TM Over Voltage.
Check TM Voltage,
ensure TM voltage is not more than
750V

Action By
System

36.

Auto regression via QD

37.

Auto regression via TM


Over voltage

38.

Braking Fault SWC


Operated

Braking Fault SWC Operated


Do not use Loco Brake during DB



39.

One CPU failure

Working with One CPU


Note down in log book



40.

Display Communication
fail with other CAB

Other CAB Display fail



41.

HVMT 1 is in Position 0

42.

HVMT 2 is in Position 0

43.

HVSI 1 is in Position 0

44.

HVSI 2 is in Position 0

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



45.

Reverser not as per MPJ


Position

Reverser not as per MPJ Position. Set


manually as per MPJ



46.

CTFs not as per MP


Position

CTFs not as per MP Position


Set manually CTFs in traction side only



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



48.

C145 Open in DB mode


DBR Overheated

DBR Overheated or QF/QE Operated. If


QE acted do not use DBR



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



51.

Unable to Close DJ due


to C107 Feedback Fail

ICDJ through C107 Feedback Fail.


Inform TLC



HVMT 1 in Position 0. L1 L2 L3 Cut Off


Half Power available
HVMT 2 in Position 0. L4 L5 L6 Cut Off
Half Power available
HVSI 1 in Position 0
L1 L2 L3 Cut Off Half Power available

Page 68 of 69









Fault Diagnostics and Control System

S. No.

Signal Condition

52.

Unable to Close DJ due


to C106 Feedback Fail

53.

Unable to Close DJ due


to C105 Feedback Fail

54.

GR Stuck on notches
DJ Tripped via C107
Feedback Fail when DJ
is energized
DJ Tripped via C106
Feedback Fail when DJ
is energized

Stesalit Limited

Displayed Message on LCD


ICDJ through C106 Feedback Fail. Put
HVMT-2 on 0
Clear section, Inform TLC
ICDJ through C105 Feedback Fail. Put
HVMT-1 on 0
Clear section, Inform TLC
GR Stuck up on Notches
GR Bring to 0 manually

Action By
System





DJ Tripped via C107 Feedback Fail.


Inform TLC



DJ Tripped via C106 Feedback Fail. Put


HVMT-2 on 0
Clear Section, Inform TLC



57.

DJ Tripped via C105


Feedback Fail when DJ
is energized

DJ Tripped via C105 Feedback Fail. Put


HVMT-1 on 0
Clear Section, Inform TLC



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

Auto-regression via ACP



BPAR put in bypass



BPAR restored



ICDJ through QSIT Dropped



SI shutdown
See front panel of SI



55.

56.

Auto regression via ACP


( Alarm Chain Pulling/
Train Parting)
BPAR put in bypass
mode
BPAR restored
Unable to close DJ due
to QSIT high
OHE Voltage out of
Range

61.
62.
63.
64.
65.

 Save message in Fault Memory

  Give Buzzer Output till it is acknowledged

Page 69 of 69