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Summary of Contents for Medha MAS 696
- Page 1 Operator’s Manual AC-AC T RACTION YSTEM MAS 696 MEDHA SERVO DRIVES PVT. LTD. IM - 70 rev 3...
- Page 2 Web documentation—is expressly forbidden. Medha logo is trademark of Medha Servo Drives Pvt. Ltd. Any other trade- marks are the property of their respective owners.
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Page 3: Table Of Contents
Contents Chapter 1 - System Overview...........5 Introduction..............5 Major Features of MAS 696 System........8 Chapter 2 - General Safety Precautions........11 WDG4/WDP4 Locomotive Safety Precautions......11 Automatic Discharge............12 Chapter 3 - Starting the Engine..........14 Chapter 4 - Stopping Procedure for WDG4/WDP4 Diesel Engine............18 Engine Stopping System..........18... - Page 4 Contents Chapter 10 - Operation Section..........40 Preparation for Service............40 Starting Lead Locomotive Engine........43 Starting Trailing Locomotive Diesel Engine......45 Setting Locomotives on Line..........45 Precautions before Moving Locomotive......46 Handling Light Locomotive..........46 Coupling Locomotive Together..........47 Dynamic Braking for Locomotive in Tandem......47 Engine on Train (Coupling Locomotive to Train)....47 Pumping Up Air...............48 Double Heading Service...........48 Helper Service..............48...
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Page 5: Chapter 1 - System Overview
DC-AC Power Transmission system. Medha Servo Drives Pvt. Ltd. has designed and developed indigenously the AC-AC Traction System type MAS 696 suitable to the above said series of locomotives delivering up to 4500 HP. MAS 696 is a comprehensive solution... - Page 6 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual windings. Overview block diagram is given in Fig. 1.2. The Diesel Engine drives the main Generator Assembly. The Main Generator assembly has two Alternators which are MAIN ALTERNATOR and COMPANION ALTERNATOR. The Traction Alternator converts the Diesel Engine mechanical power into 3 phase AC electrical power.
- Page 7 Chapter 1 - System Overview Medha Servo Drives Pvt Ltd. contacts with the help of DC Motor controlled by Locomotive Control Computer (LCC) which is housed in Electrical Control Cabinet 1 (ECC#1). Traction Control Cabinet (TCC) consists of six Traction Computers, 6 DCL switch gears, 6 IGBT based Inverters, DC link Capacitors and Crow bar circuit.
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Page 8: Major Features Of Mas 696 System
Main Alternator field through SCR Assembly and Power fed to the Radiator Fans 1 & 2, Inertial Blower motor and Traction Inverter Blowers. 1.2 Major Features of MAS 696 System Major Features of the System in operation point of view are explained hereafter. - Page 9 Chapter 1 - System Overview Medha Servo Drives Pvt Ltd. respect to the time or phase relationship. The phase relationship depends on the speed of the Rotating Field with respect to the Rotating speed of the Rotor. If Rotor speed lags Field speed, Voltage and Currents are nearly in phase and Power flows into the Motor most of the time.
- Page 10 Drives Pvt. Ltd., is implemented on WDG4 and WDP4 Locomotives. 1.2.4 Blended Brake System The MAS 696 system Locomotives are equipped with blended brake system. It is simultaneously applying Dynamic Brake and Air Brake, when the driver operates the Automatic Air brake handle in the service zone. The KNORR...
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Page 11: Chapter 2 - General Safety Precautions
GENERAL SAFETY PRECAUTIONS This manual provides guidelines and cautions for Locomotive operating personnel. Though enough care is taken while designing MAS 696 system developed by M/S MEDHA SERVO DRIVES PVT. LTD, which is implemented on WDG4/WDP4 Locomotive, the Microprocessor based... -
Page 12: Automatic Discharge
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual Gen. Voltage. These capacitors operate at the DC LINK Voltage between 600 to 3400 V DC. When the Locomotive shutdowns, these capacitors could remain high Voltage causing severe injury or death to the operating and maintenance personnel. - Page 13 Chapter 2 - General Safety Precautions Medha Servo Drives Pvt Ltd. RUN digital Input signal), the parallel Brake Grid path is connected to the DC LINK by four Braking contactors (B1, B2, B3, B4). This method discharges the DC LINK capacitors in less than ONE second.
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Page 14: Chapter 3 - Starting The Engine
Chapter 3 STARTING THE ENGINE The WDG4/WDP4 Locomotive is equipped with dual STARTOR MOTORS for cranking the Diesel Engine, at left side near the Engine Ring gear. Diesel Engine fuel oil must be circulated through fuel system before the Engine starts. - Page 15 TC-3 CB, TC-4 CB, TC-5 CB and TC-6 CB. All Traction Computers Initializes and power ON self check is done. 6. Switch ON COMP. CONTROL Circuit Breaker. The MAS 696 System Initializes and Power ON self check is done. If any abnormality is found, the same message is informed through Display Unit for correction, otherwise the MAIN MENU is displayed.
- Page 16 Chapter 3 - Starting the Engine Medha Servo Drives Pvt Ltd. Ÿ If the Governor Booster pump is not provided on Locomotive, Advance the Governor linkage Lay shaft gently while cranking, till the Engine is running. Ÿ Verify that the Ground Relay CUTOUT Switch is closed (lever up) and sealed properly.
- Page 17 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual Ÿ Keep the Engine at Low Idle for 6 minutes. Don't shift the ISOLATION switch to RUN position immediately to avoid automatic shutdown due to low water and low LUBE OIL Pressure.
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Page 18: Chapter 4 - Stopping Procedure For Wdg4/Wdp4 Diesel Engine
Chapter 4 STOPPING PROCEDURE FOR WDG4/WDP4 DIESEL ENGINE 4.1 Engine Stopping System The normal way to shutdown a Diesel Engine is to cause the Engine Governor to bring the fuel injector to the NO FUEL position. There are several ways to cause the Governor to bring the fuel injectors to NO FUEL position including operating the following switches: 1. - Page 19 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual Fig. 4.2 MU Engine Stop Fig. 4.1 EFCO Engine Stop 6. After shutdown of the Locomotive let the COMP. CONTROL and TURBOLUBE PUMP Circuit Breakers remain in ON position. These two CB's are required to perform POST LUBRICATION for TURBO...
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Page 20: Chapter 5 - Electrical Control Cabinets
Chapter 5 ELECTRICAL CONTROL CABINETS As mentioned in Chapter 1, MAS 696 AC AC Traction System comprises of four Cabinets, viz. ECC#1, ECC#2, ECC#3 and TCC. The three Electrical Control Cabinets are explained in detail in the following sections: 5.1 ECC#1 High voltage and current are present within this cabinet. -
Page 21: Ecc#2
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual ECC#1 is modified for MAS 696 system. The following changes are made in the MAS 696 system: 1. Locomotive Control Computer (LCC) called MLC 691 is shifted to top portion of ECC#1. - Page 22 Chapter 5 - Electrical Control Cabinets Medha Servo Drives Pvt Ltd. 3. TB 61A & TB 62 A Fig. 5.2 Electrical Control Cabinet#2 ECC#2 consists of two interfaces. One is for battery charging and another one is for starting motors circuit.
- Page 23 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual Aux Gen Battery Charger AGAV Sensor AGAI Sensor Fig. 5.3 Internal View of ECC#2 Staring Circuit: Two starting contactors (ST and STA) with resistors (RE ST1 & RE ST2) have been provided in this cabinet, as shown in Fig. 5.4, for the following...
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Page 24: Ecc#3
Chapter 5 - Electrical Control Cabinets Medha Servo Drives Pvt Ltd. motors to crank the diesel engine. Starting motor torque increases and the diesel engine cranking speed increases until the engine starts. 5.3 ECC#3 The Electrical Control Cabinet#3 mainly consists of Two Circuit Breakers and 6 contactors, as shown in Fig. - Page 25 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual operator for necessary corrective action. The Radiator Blower CB’s is shown in Fig. 5.6. FCF1B FCF2B FCS1 FCS2 FCF1A FCF2A Fig. 5.6 Radiator Blower CB’s in ECC#3 It also consists of MRPR sensor to measure MR pressure and accordingly to control compressor loading and unloading control by LCC to maintain required MR pressure.
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Page 26: Driver Accessible Panels
Chapter 5 - Electrical Control Cabinets Medha Servo Drives Pvt Ltd. 5.4 Driver Accessible Panels These are the various Driver Accessible Panels: 1. Circuit Breaker Panel 2. Engine Control Panel 3. Ground Relay Cutout switch and Test panel 4. MDS 737 Display Unit for TM Cutout, viewing of Crew messages and Fault Archive and to Enter Driver ID, Train no. - Page 27 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 8. FILTER BWR MTR Circuit Breaker: This 30A circuit Breaker protects the Inertial Filter Blower Motor circuit. If the Filter Blower Motor breaker trips, continue Locomotive operation to the nearest maintenance point.
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Page 28: Test Panel
Chapter 5 - Electrical Control Cabinets Medha Servo Drives Pvt Ltd. 14. DCL 1 to 6 Circuit Breakers: This 10A circuit Breaker protects the DC LINK contactor Motor and control circuits. 15. A safety guard over the Breaker lever helps to prevent accidental operation. -
Page 29: Engine Control Panel On Ecc#1
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 5.7 Engine Control Panel on ECC#1 The Engine Control panel has the following control Equipments for setting up Locomotive operation: 1. ISOLATION Switch: This Rotary switch has two settings. START/STOP/ISOLATE are in ONE position. RUN is in SECOND position. - Page 30 Chapter 5 - Electrical Control Cabinets Medha Servo Drives Pvt Ltd. operation and does not effect the Air Brake system. This lever of this switch is normally safety wired in the CUT IN (lever up) setting to prevent accidental Dynamic Brake CUTOUT.
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Page 31: Control And Operating Switch Panel
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual seconds. When the Alerter sounds, the driver must acknowledge it within the next 17 seconds to avoid a penalty Brake application. 10. RAPB: Restricted Air Penalty Brake switch is provided on Engine Control Panel to enable the AEB system. - Page 32 Chapter 5 - Electrical Control Cabinets Medha Servo Drives Pvt Ltd. power to key Low Voltage control circuit and it enables the Loco computer to pickup Fuel Pump Control Relay FPR and it enables Diesel Engine starting. 4. DYNAMIC BRAKE CONTROL CB: Circuit Breaker protects against a faulty operating or test setup.
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Page 33: Chapter 6 - Speedometer
Chapter 6 SPEEDOMETER An analog Speedometer is mounted on both the control console Instrument panel. The Analog Speedometer receives analog signals from LCC, these resultant signals are based on TM speed sensors speed signals. The speedometer scale is 0 to 120 kilometers per hour (km/h) 6.1 Speedometer... -
Page 34: Chapter 7 - Tractive Effort/Dynamic Brake Effort Meter
Chapter 7 TRACTIVE EFFORT/DYNAMIC BRAKE EFFORT METER The TE/BE meters are mounted on both control console instrument panel just at the right of the Speedometer. This meter indicates sum of all active Traction Motors Torque. When Locomotive is not in Power mode or in Dynamic Brake mode, meter pointer is centered (indicates zero). -
Page 35: Chapter 8 - Indicating Lights Panel
Chapter 8 INDICATING LIGHTS PANEL These panels are mounted on both Control console just at the right of the instrument panel. It has six indicating lights that indicates operation of various Locomotive system. 8.1 Indicating Lights Panel Each of the following indicator lights has the Push-to-test feature, which allows testing the light circuit alone. - Page 36 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 2. SAND LIGHT: It indicates that a sanding request has been made to the Locomotive Computer by means of a MANUAL SAND switch actuation on this Locomotive or any Train lined to this Locomotive.
- Page 37 Chapter 8 - Starting Fuse and Battery Switch Box Medha Servo Drives Pvt Ltd. Ÿ Yes - go to 4 point Ÿ No - go to 5 point Ÿ Take appropriate action specified by Railways rules and regulations concerned Locked Wheel fault.
- Page 38 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual stops Traction Alternator excitation, interrupting Locomotive Power/Dynamic Brake operation. To restore Locomotive Power after safety control or Emergency Brake conditions end and to reset PCR, set throttle handle in IDLE, then set Automatic Brake handle in Emergency for 60 seconds, then move it to Release position.
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Page 39: Chapter 9 - Starting Fuse And Battery Switch Box
Chapter 9 STARTING FUSE AND BATTERY SWITCH BOX Starting Fuse and Battery knife switch box is located on the left side of the Locomotive. The Box includes the equipment described in the following paragraphs: 1. BATT SWITCH (Battery Knife Switch): When this switch is closed, it connects the Locomotive Batteries to the Locomotive low voltage electrical system. -
Page 40: Chapter 10 - Operation Section
Chapter 10 OPERATION SELECTION This section includes recommended procedure for setup, service operations and General Locomotive operation. The procedures are brief and do not contain detailed descriptions of equipment location or function. See the Locomotive service manual for more specific descriptions. Always comply with Railway rules and instructions regarding Locomotive operation or Inspection. - Page 41 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 2. Proper Installation of Electrical cables and Air Brake house connections in multiple Unit tandem and to train. 3. Proper setting of angle cocks and shutoff valves 4. Air cut into boogie brake cylinder 5.
- Page 42 Chapter 10 - Operation Section Medha Servo Drives Pvt Ltd. 1. CIRCUIT BREAKER PANELS a. The following Circuit Breakers must be ON for Locomotive running: Ÿ AC CONTROL Ÿ CONTROL Ÿ LOCAL CONTROL Ÿ AUX.GEN.FLD Ÿ FUEL PUMP Ÿ COMP.CONTROL Ÿ...
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Page 43: Starting Lead Locomotive Engine
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual AIR BRAKE EQUIPMENT: 1. Set Air Brake controller Automatic Brake Handle in FS (full service). This nullifies any safety control brake application. 2. Set Air Brake controller Independent Brake valve Handle in FULL (full application) 3. - Page 44 Chapter 10 - Operation Section Medha Servo Drives Pvt Ltd. ENGINE STARTING PROCEDURE: After the preceding inspections have been completed, the Diesel Engine may be started. Engine should be Pre-Lubricated, if it has been shut down for more than 48 hrs. See Engine Maintenance Manual for Pre- Lubrication procedure.
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Page 45: Starting Trailing Locomotive Diesel Engine
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 6. In case the Low Lube Oil shutdown is noticed immediately after cranking, check Low water Pressure detector (EPD) for trip. If the water pressure is less, the Engine shuts down after a short time delay. -
Page 46: Precautions Before Moving Locomotive
Chapter 10 - Operation Section Medha Servo Drives Pvt Ltd. Brake commands from the LEAD Locomotive. The Locomotive Computer changes Diesel Engine speed in response to certain operating conditions, such as low Main Reservoir pressure, causes PCS OPEN by Air Brake Computer or Hot Engine-extended time and TH limit to 6 notch. -
Page 47: Coupling Locomotive Together
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 10.7 Coupling Locomotive Together Use the following procedure when coupling Locomotives together for Multiple Unit operation: 1. Couple and stretch Locomotive to ensure the couplers are locked properly. 2. Install 27 conductor electrical control cable between Locomotives. -
Page 48: Pumping Up Air
Chapter 10 - Operation Section Medha Servo Drives Pvt Ltd. 3. Slowly open Air valves on the Locomotive and the train to cut in brakes. 4. Pump up Air using the procedure given in the next section. 10.10 Pumping Up Air After cutting in Air brakes on train, note the reaction on the control console MAIN RESERVOIR pressure gauge. -
Page 49: Changing Operating Ends
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 10.13 Changing Operating Ends Use the following procedures to change the Lead from the Locomotive on one end of a tandem to the Locomotive on the opposite end: ON END BEING CUTOUT 1. -
Page 50: Stopping Engines
Chapter 10 - Operation Section Medha Servo Drives Pvt Ltd. 10.14 Stopping Engines There are six ways to Stop the Engine: 1. On the Engine Control Panel, set the Isolation switch in START/STOP/ISOLATE, then press the EMERGENCY FUEL CUT OFF & ENGINE STOP push button switch (this switch is also known by its electrical reference designator, EFCO/STOP). -
Page 51: Chapter 11 - Display Unit And Navigation Through Menus
Chapter 11 DISPLAY UNIT AND NAVIGATION THROUGH MENU The Display unit is the main interface between the user and the Control System. It has an alphanumerical Keyboard and a VFD through which it interacts with the user. It gets the information requested by the user from the Control system (Locomotive Control Computer) through the Serial Communication Interface and Displays it on the VFD. -
Page 52: Locomotive Control Computer Display Panel Details
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 11.1 Locomotive Control Computer Display Panel Details Fig. 11.1 Display Panel Keypad The Locomotive control computer is equipped with Alphanumeric keyboard containing 29 keys. They are defined below: F1, F2, F3, F4 keys are called function (Soft) keys. These keys perform the operations as displayed on the screen in the space directly above them at any particular moment. -
Page 53: Menu Screens, Sequential Flow And Key Actions For Display
Chapter 11 - Display Unit and Navigation through Menu Medha Servo Drives Pvt Ltd. HOTEL LOAD Key is required for Hotel Load Feature and is presently unused. DRIVER ID key is used to enter driver name or identification. TRAIN NO. Key is used to enter Train number. -
Page 54: How To Select Self Tests
Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual 11.3 How to Select SELF TESTS Press No. 2 key or keep cursor on SELF TEST and press F3 key. The screen appears as shown in Fig. 11.2. E n t e r... - Page 55 Chapter 11 - Display Unit and Navigation through Menu Medha Servo Drives Pvt Ltd. Auto Test Page:1 The Auto Test has three screens. The first screen for Auto Test is shown in Fig. 11.4. A U T O T E S T S P A G E : 1 / 3 / 1 .
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Page 56: Tm Cutout
Fig. 11.6 11.4 TM CUTOUT The TM's CUTOUT Function in the MAS 696 system through Display Unit replaces the Traction Inverter #n CUTOUT system in the WDG4 & WDP4 Locomotives. The existing system in WDG4 & WDP4 can be able to... - Page 57 Chapter 11 - Display Unit and Navigation through Menu Medha Servo Drives Pvt Ltd. M A I N M E N U P A G E : 1 / 2 / 1 . D A T A M E T E R S...
- Page 58 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual Press F3 key for change the Traction Motors status. Keep cursor on the defective TM and press F3 key to select TM cut out. Exp:- If you want to select TM No.3 Brining the Cursor on TM 3 CUTIN (Item No.3) and press F3 to CUTOUT TM3.
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Page 59: Crew Messages List
Chapter 11 - Display Unit and Navigation through Menu Medha Servo Drives Pvt Ltd. E N T E R T H E P A S S W O R D 1 2 3 4 5 D E L E T E C H A N G E Fig. - Page 60 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual Message Message Text Code 5094 FDB Power supply failure. 2060 B1 contactor failed to pickup. 2062 B2 contactor failed to pickup. 2051 B3 contactor failed to pickup. 2049 B4 contactor failed to pickup.
- Page 61 Chapter 11 - Display Unit and Navigation through Menu Medha Servo Drives Pvt Ltd. Message Message Text Code 1672 Fuel Pump Circuit Breaker is not closed. 5001 Filter Vacuum switch tripped. 5002 Fire Engine shutdown. Ground Fault – Grid path 1 Ground Fault –...
- Page 62 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual Message Message Text Code No Engine Start – Turbo pump not running Run pump for 15 1081 minutes. No Load – Locomotive is Isolated. No Load – Improper GFC contactor status – Cycle Computer Control CB.
- Page 63 Chapter 11 - Display Unit and Navigation through Menu Medha Servo Drives Pvt Ltd. Message Message Text Code Reduced Dynamic Brake/Load Test – No Grid Blower 2 current 2655 imbalance. Reduced Dynamic Brake/Load Test – High Grid Blower 1 current 2656 imbalance.
- Page 64 Chapter 12 DOS & DON’TS Don'ts Keep LEAD/TRAIL switch in Do not Keep LEAD/TRAIL switch in LEAD position on working control LEAD position on non working console. control console. Always keep TELM and RAPB Do not keep TELM and RAPB toggle toggle switches in Normal position switches in ENABLE position Unless Unless and Until required.
- Page 65 Medha Servo Drives Pvt Ltd. MAS 696 Operator’s Manual Don'ts Press Alerter Reset button when Do not Disable the Alerter system the Alerter light is flashing or unless and until the system is Audio bell is sounding to avoid malfunctioning.
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Page 66: Chapter 12 - Dos And Dont's, Display Menu Screens And Parameters
Chapter 12 - Dos and Don’ts, Display Menu Screens and Parameters Medha Servo Drives Pvt Ltd. 16. TM4 PARAMETERS 17. TM5 PARAMETERS 18. TM6 PARAMETERS 19. DIGITAL INPUTS 20. DIGITAL OUTPUTS 21. CREEP CONTROL 22. TI STATUS 23. DC LINK PARAMETERS 24. - Page 67 Operator’s Manual AC-AC T RACTION YSTEM MAS 696 Medha Servo Drives Pvt. Ltd. P- 4/5 B, I.D.A., Nacharam, Hyderabad - 500076. India. www.medhaindia.com...
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