TROUBLE SHOOTING DIRECTORY FOR - 25 kV AC EMU/ MEMU

TROUBLE SHOOTING DIRECTORY FOR - 25 kV AC EMU/ MEMU
CAMTECH/E/2009/TSD-AC DC EMU                               1



                               lR;eso t;rs

                 Hkkjr ljdkj GOVERNMENT OF INDIA
                 jsy ea=ky; MINISTRY OF RAILWAYS
                        dsoy dk;Zky;hu mi;ksx gsrq
                        (For Official Use Only)

   TROUBLE SHOOTING DIRECTORY
                                FOR
              25 kV AC EMU/ MEMU
  TARGET GROUP: Motorman & Running Maintenance Staff




               CAMTECH/2009/E/TSD/AC EMU/1.1
                      December 2009




                 egkjktiqj, Xokfy;j & 474 005
               Maharajpur, GWALIOR - 474 005
Trouble Shooting Directory for 25 kV AC EMU/MEMU       Draft
TROUBLE SHOOTING DIRECTORY FOR - 25 kV AC EMU/ MEMU
CAMTECH/2009/E/TSD/AC EMU                              2




  TROUBLE SHOOTING DIRECTORY
              FOR
      25 kV AC EMU/ MEMU




                  QUALITY POLICY

   “To develop safe, modern and cost
     effective Railway Technology
     complying with Statutory and
   Regulatory requirements, through
  excellence in Research, Designs and
        Standards and Continual
 improvements in Quality Management
 System to cater to growing demand of
  passenger and freight traffic on the
                railways”.

Trouble Shooting Directory for 25 kV AC EMU/MEMU   Draft
CAMTECH/2009/E/TSD/AC EMU                                           3




                       FOREWORD

      With increasing passenger traffic in Metropolitans and
their connected cities, reliability of AC EMU/ MEMUs has
become very important to provide punctual and safe journey to
our valued passengers.

       As a step towards achieving the above, CAMTECH has
prepared this Trouble Shooting Directory which covers
essential aspects of various procedures, troubles and their
rectification in a brief and systematic manner.

       I hope this TSD will be very useful to our motormen
and running maintenance staff of EMU/ MEMUs.




CAMTECH, GWALIOR                                S. C. SINGHAL
Date:                                          Executive Director




Trouble Shooting Directory for 25 kV AC EMU/MEMU               Draft
CAMTECH/2009/E/TSD/AC EMU                                          4




                          PREFACE

        This Trouble Shooting Directory for AC EMU/
MEMUs is prepared for the guidance of Motorman and running
maintenance staff. This will be useful for motorman to rectify
the faults in least time in section which will avoid
inconvenience to the passengers.

        This TSD covers common electrical, pneumatic and
mechanical failures, occurring on line with their rectification
measures in a stepwise manner. This TSD also covers
important procedures.

         It is clarified that this TSD does not supersede any
existing provisions laid down by RDSO or Railway Board. The
TSD is for guidance only and it is not a statutory document.

          I am sincerely thankful to Director (PS & EMU)/
RDSO/ LKO for his valuable suggestions. I am also thankful to
all field personnel who helped us in preparing this TSD.

        Technological upgradation & learning is a continuous
process. Please feel free to write to us for any addition/
modification in this TSD. We shall highly appreciate your
contribution in this direction.



CAMTECH, GWALIOR                                 JAIDEEP
Date:                                        Director Electrical



Trouble Shooting Directory for 25 kV AC EMU/MEMU               Draft
CAMTECH/2009/E/TSD/AC EMU                                           5


                           CONTENTS


Chapter           Description                         Page No.
                 Foreword                                     iii
                 Preface                                      iv
                 Contents                                     v
                 Correction Slip                              ix
1.      GENERAL DESCRIPTION                                   01
        1.1      Introduction                                 01
        1.2      Abbreviations                                02
        1.3      Fuses and MCBs in Relay Panel                05
        1.4      Do’s and Don’ts for Motorman                 09

2.      GENERAL PROCEDURES                                    11
        2.1      Preparation of EMU                           11
        2.2      Driving EMU on Line                          18
        2.3      Procedure for Stabling EMU/ MEMU             20
        2.4      Procedure to Raise Front Pantos Only         20
        2.5      Procedure to Raise Rear Pantos Only          21
        2.6      Procedure for Rear Motor Coach Driving       21
        2.7      Procedure for CAB Changing                   21
        2.8      Procedure for Removing Jumper                22
        2.9      Procedure for Detaching the Coach            22
        2.10     Procedure for Operating Earthing
                 Switch (EAS)                                 23
        2.11     Procedure for Joint Brake Continuity Test    23
        2.12     Procedure to Negotiate Neutral Section       25
        2.13     Use of Fire Extinguishers                    26

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Chapter           Description                      Page No.
3.      TROUBLE SHOOTING                              28
        3.1  ABB/ VCB Trips on Run                    28
        3.2  ABB/VCB not Closing                      29
        3.3  ABB/VCB Closes and Opens Immediately 32
        3.4  ABB/VCB not Holding When OHE Supply
             Available                                32
        3.5  No OHE Supply Indication                 33
        3.6  Traction Failures                        36
             3.6.1 Total Loss of Tractive Effort      36
             3.6.2 Partial Loss of Tractive Effort    37
             3.6.3 All MCs not responding beyond
                     shunt                            42
        3.7  Battery Voltage Indicates ‘Zero’ or
             Less Than 85V                            42
        3.8  Auxiliary Compressor not Working         44
        3.9  Auxiliary Compressor Working but
             Pressure not Building up                 46
        3.10 All Pantographs not Raising              46
        3.11 Main Compressors not Working             49
        3.12 Main Compressor Working but Pressure
             not building up                          50
        3.13 BP pressure not Charging                 50
        3.14 Air Pressure Leaking from Panto/ ABB/VCB
             Pipeline                                 51
        3.15 Air Pressure Leaking from Switch
             Group 1, Switch Group 2, Control
             Reservoir and Tap Changer Pipelines      51
        3.16     Head light not Glowing                 52


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Chapter           Description                          Page No.
        3.17     Normal Lights not Glowing                  53
        3.18     Signal Bell not Working                    53
        3.19     Alarm Bell not Working                     54
        3.20     BCFR Lamp Glowing on Run                   54
        3.21     PFD Lamp Glowing                           56
        3.22     EP Brake not Working                       56
        3.23     Brake Binding                              56
                 3.23.1 Partial Brake Binding               56
                 3.23.2 Full Train Brake Binding            57
                 3.23.3 Parking Brake Binding               58
                 3.23.4 Mechanical Brake Binding            58
        3.24     Raise in BP Pressure
                 (More than 5 kg/cm2)                       59
        3.25     MR Pressure Drop                           60
                 3.25.1 Between Main Compressor and
                        CIC in Leading Motor Coach          60
                 3.25.2 In Driving Motor Coach after CIC    60
                 3.25.3 In any of Trailer Coach             61
                 3.25.4 In Rear Motor Coach                 61
                 3.25.5 In Middle Motor Coach               62
        3.26     Air Spring Burst in MC/TC                  62
        3.27     Pneumatic Suspension Air Pipe Line
                 Broken in MC/TC                            63




Trouble Shooting Directory for 25 kV AC EMU/MEMU           Draft
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Chapter           Description                         Page No.
        3.28     BP Pressure Drop/ Leakage                 63
                 3.28.1 In Leading Motor Coach             63
                 3.28.2 In Middle Motor Coach              64
                 3.28.3 In any of the Trailer Coach        64
                 3.28.4 In Rear Motor Coach                65
        3.29     Both MR and BP Pressure Drop due
                 to Malfunction of B.A. Relay              66
        3.30     Parting of Train                          66
        3.31     Hot Axle                                  68
        3.32     Wheel Locking                             68
        3.33     Skid/ Flat Wheel                          70




Trouble Shooting Directory for 25 kV AC EMU/MEMU          Draft
CAMTECH/2005/E/TSD/AC EMU/1.1                                   0




          ISSUE OF CORRECTION SLIP

       The correction slips to be issued in future for this
Trouble Shooting Directory will be numbered as follows:

CAMTECH/ 2009/ E/ TSD/ AC EMU/1.1/ C.S. # XX date---

        Where “XX” is the serial number of the concerned
correction slip (starting from 01 onwards).

CORRECTION SLIPS ISSUED


  Sr. No.       Date of        Page no. and Item   Remarks
                 issue           no. modified




Trouble Shooting Directory for 25 kV AC EMU/MEMU    December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                      1


                              CHAPTER 1



               GENERAL DESCRIPTION


1.1      INTRODUCTION

                 AC EMU/MEMU rakes are running for sub-
         urban as well as short distance main line services in
         different areas of Indian Railways to cater to growing
         demand of passenger traffic. As these trains run in high
         density routes, even a small failure can cause a big
         disturbance in smooth flow of traffic. Quick and correct
         trouble shooting is of great relevance in case of any
         failure on line.

                 This trouble shooting directory is prepared for
         the guidance of Motorman and running maintenance
         staff to help him in quick trouble shooting on line. It is
         presumed that the user is well aware about the
         equipments, switches and all other accessories of
         EMU/MEMU and the locations.

                 This TSD consists of various procedures and
         trouble shooting of both electrical as well as pneumatic
         failures which generally occur on line.




Trouble Shooting Directory for 25 kV AC EMU/MEMU       December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                              2


1.2      ABBREVIATIONS
         ABB                 -     Air blast circuit breaker
         ABR                 -     Air blast circuit breaker relay
         AF 1 to 4           -     Auxiliary fuses
         AIC                 -     Auto isolating cock
         ARR                 -     Air blast circuit breaker reset relay
         ASR                 -     Auxiliary supply rectifier
         BCC1, 2             -     Battery charging contactor
         BCFR                      Battery charger failure relay
         BCH                 -     Brake controller handle
         BIC 1& 2            -     Bogie isolating cocks
         BIR                 -     Buchholz indication relay
         BIS                 -     Battery isolating switch
         BIVS                -     Brake isolating valve switch
         BUD                 -     Buchholz device
         CBAR                -     Current balance auxiliary relay
         CBR                 -     Current balance relay
         CC1                 -     Main compressor contactor
         CC 2                -     Auxiliary compressor contactor
         CCB                 -     Control circuit breaker
         CCOS                -     Control changeover switch
         CF                  -     Control fuse
         CG1, 2              -     Compressor governor
         CIC                 -     Compressor isolating cock
         CLR1, 2             -     Current limit relay
         CR                  -     Compressor relay

Trouble Shooting Directory for 25 kV AC EMU/MEMU              December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                          3


         DL                  -     Dropping reactor
         EAS                 -     Earthing switch
         EFRP                -     Power circuit earth fault relay
         EFRA II             -     Aux –II circuit earth fault relay
         ELR                 -     Emergency lighting relay
         EPIC                -     EP isolating cock
         ESMON               -     Energy –cum speed monitoring unit
         FC                  -     Fan contactor
         FN2                 -     50 % Lights off relay
         GS1 to 5            -     Governor cut-out switch
         HOBA                -     Changeover switch for battery
                                   earthing device
         HEFRA II            -     Changeover switch for Aux –II
                                   circuit earth fault relay
         HEFRP               -     Changeover switch for Power circuit
                                   earth fault relay
         K1, 2               -     Reverser switches
         KF1, 2              -     Radiator fan motor
         LA                  -     Lightning arrester
         LC                  -     Light contactor
         LTR                 -     Low Tension Proving relay
         M1 to 4             -     Traction motor contractors
         MCB                 -     Miniature circuit breaker
         MCS1,2              -     Motor cut-out switches
         MPT                 -     Master controller
         MSTWL               -     Motor switch trip warning lamp
         NC1 to 4            -     Traction motor negative contactors

Trouble Shooting Directory for 25 kV AC EMU/MEMU           December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                         4


         NR1, 2              -     Notching relays
         NVR                 -     No-volt relay
         OL1 to 4            -     Traction motor overload relays
         OL5                 -     Rectifier overload relay
         OL6                 -     Tap changer overload relay
         OLP                 -     Primary-overload relay
         OP                  -     Oil-pump motor
         PAS                 -     Passenger announcement system
         PB                  -     Parking brake
         PFD                 -     Permanent field diverter
         PRV                 -     Pressure release valve
         RBFR1, 2            -     Rectifier bridge failure relays
         RF                  -     Rectifier fan motor
         RFAR                -     Rectifier-fan auxiliary relay
         RFR                 -     Rectifier-fan relay
         SPM                 -     Speedometer
         SL                  -     Smoothing reactor
         SR                  -     Starting relay
         T1 to 9             -     Tap-changing contactors
         TL                  -     Tap-changing reactor
         TSS                 -     Test sequence switch
         TT                  -     Transformer thermostat
         TTR                 -     Transformer thermostat relay
         VCB                 -     Vacuum circuit breaker
         W1, 2               -     Winding grouping switch contacts
         WGR                 -     Winding grouping relay


Trouble Shooting Directory for 25 kV AC EMU/MEMU          December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                      5


1.3      FUSES AND MCBs IN RELAY PANEL

         1st Row (Left to right) (266V) Fuses
         1.     Aux. I main                                   50A
         2.     Spare                                         50A
         3.     Battery charger input                         32A
         4.     Oil pump & rectifier blower motor return      32A
         5.     Spare                                         32A
         6.     Radiator motor 1 & 2 return                   16A
           st
         1 Row (Left to right) (266V) MCBs
         1.     Battery charger                               35A
         2.     Spare                                         15A
         3.     Oil pump                                      15A
         4.     Rectifier motor                               10A
         5.     Radiator motor – I                            5A
         6.     Radiator motor – II                           5A
         7.     NVR                                           2.5A
           nd
         2 Row (Left to right) (141V ac) Fuses
         1.     Aux. II Main                                  100A
         2.     Spare                                         100A
         3.     Fan phase                                     63A
         4.     NL phase                                      63A
         5.     Spare                                         63A
         6.     Fan neutral                                   63A
         7.     NL neutral                                    63A

Trouble Shooting Directory for 25 kV AC EMU/MEMU      December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                  6


         8.     HL stabilizer input                        10A
         9.     HL stabilizer input                        10A
         10. Spare                                         10A
           nd
         2 Row (Left to right) (141V ac) MCBs
         1.     Fan phase I                                 35A
         2.     Fan phase II                                35A
         3.     Spare                                       35A
           rd
         3 Row (Left to right) (110V dc) Fuses
         1. Control                                        32A
         2. DC negative main                               63A
         3. DC positive main                               63A
         4. Main compressor                                160A
         5. Spare                                          160A
         3rd Row (Left to right) (110V dc) MCBs
         1. NL I                                            6A
         2. NL II                                           6A
         3. Spare                                           10A
         4. Fan I                                           10A
         5. Fan II                                          10A
         6. Em. Hc. HL. TL Relay                            2.5A
         7. Em. Relay I                                     2.5A
         8. Em. Relay II                                    2.5A
         4th Row (Left to right) (110V dc) Fuses
         1. Aux. compressor negative                        16A
         2. Spare                                           16A
         3. Em. Light                                       10A
         4. Cab, Em., Inst., HLs.                           10A


Trouble Shooting Directory for 25 kV AC EMU/MEMU   December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                  7


          4th Row (Left to right) (110V dc) MCBs
          1. Battery positive                                35A
          2. Spare                                           15A
          3. Aux. compressor positive                        15A
          4. ABB/VCB fault                                   5A
          5. HLS                                             5A
          6. Em. Light I                                     2.5A
          7. Em. Light II                                    2.5A
          8. Main compressor control                         2.5A
          9. LT Relay                                        2.5A
          10. Aux. compressor control                        2.5A
          11. Compressor Sys.                                2.5A
          12. 50% Lights off                                 2.5A
          13. Light latch                                    2.5A
          14. Light trip                                     2.5A
          15. Spare                                          2.5A
          16. Fan latch                                      2.5A
          17. Fan trip                                       2.5A

          MCBs panel in Driver’s desk
          1.     Spare                                    10A dc
          2.     Panto/ ABB/VCB control                   10A dc
          3.     Master controller                        15A dc
          4.     Flasher light                            2.5A dc
          5.     Guards supply                            5A dc
          6.     EP brake                                 10A dc
          7.     Main compressor                          5A dc
          8.     Fault indicator                          5A dc
Trouble Shooting Directory for 25 kV AC EMU/MEMU   December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                  8


          9.     Light control                            5A dc
          10. Fan control                                 5A dc
          11. Bell bush                                   5A dc
          12. Alarm bell                                  5A dc
          13. NL, cab, LT & Eq. Compt.                    2.5A ac
          14. EL, cab, LT & Eq. Compt.                    2.5A ac
          15. Spare                                       2.5A dc
          16. HLS, Inst. Light                            2.5A dc
          17. HL & TL Em.                                 2.5A dc
          18. Voltmeter                                   2.5A dc
          19. Speedometer                                 2.5A dc
          20. Spare                                       2.5A dc
          21. Cab fan                                     2.5A dc
          22. Head code normal                            2.5A ac
          23. Tail light normal                           2.5A ac
          24. Voltmeter                                   2.5A ac
          25. Spare                                       2.5A ac
          26. Head light                                  10A ac
          27. Head light stabilizer                     5A DP ac




Trouble Shooting Directory for 25 kV AC EMU/MEMU   December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                   9


1.4      DO’S AND DON’TS FOR MOTORMAN
1.4.1 Do’s
      1. Check the authority to proceed.
      2. Ensure full release of brakes.
      3. Start the train after obtaining proper Guard signal/
           flag.
      4. Keep MPT handle at shunt position for few
           seconds and then move straight to full power
           position.
      5. Operate BCH to brake application position and
           feel the application of brakes and release the BCH.
      6. Obey the signal till you pass.
      7. Switch on flasher light immediately when BP
           drops on run.
      8. Follow speed restrictions meticulously.
      9. Observe the rules as per GR & SR while passing
           automatic/ gate signal at ‘ON’.
      10. Observe the coasting/ powering boards strictly.
      11. Switch on compressor after passing neutral
           section.
      12. Apply brakes judiciously.
      13. Reset DMH in MPT ‘OFF’ position.
      14. Coast well in advance, once booked speed is
           achieved.
      15. Frequently look for OHE, track, gauges and
           indication lamps.
      16. Ensure both cab operations before starting from
           shed/ siding.
      17. Use portable flasher light in case of flasher fails to
           work.

Trouble Shooting Directory for 25 kV AC EMU/MEMU    December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                     10


      18. Assess the brake power and work the train within
          your control.
      19. Repeat the remarks made by the previous
          Motorman instead of writing ‘refer previous
          remarks’.
1.4.2 Don’ts
         1.     Don’t bring the reverser handle to neutral position
                while the unit is on motion.
         2.     Avoid trouble shooting in mid section for partial
                loss of tractive effort.
         3.     Don’t reset ‘OLP/OL 5 & 6’ second time.
         4.     Don’t close BIC without ensuring full release of
                brakes.
         5.     Don’t forget to switch ‘OFF’ control switch while
                operating OL reset switch.
         6.     Don’t over shoot the EMU stop board in platform
                and avoid rolling back.
         7.     Don’t turn ‘ON’ BIVS, on both sides when BP line
                continuity is good.
         8.     Don’t start the train without ensuring BP pressure
                at 5kg/cm2 after auto brake application.
         9.     Don’t be hasty while troubleshooting.
         10.    Do not test brakes by applying brake and moving
                MPT to powering position. This will cause failure
                of TMs and bogie crack.
         11.    Don’t forget to put HOBA in ‘fault’ position in all
                MCs when MCB of MPT is not able to reset.
         12.    Don’t release ‘ABB/VCB close’ switch
                immediately.
         13.    Don’t forget to ensure working of auxiliary motors
                when relays are packed.
         14.    Don’t pack the SR.
Trouble Shooting Directory for 25 kV AC EMU/MEMU       December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                 11


                              CHAPTER 2

              GENERAL PROCEDURES


2.1     PREPARATION OF EMU

             Before starting from shed or stabling line, the
        following sequence of operations shall be carried out
        from leading motor coach.

2.1.1 Preliminary Checks
        1. Ensure the following keys are available along with
           EMU logbook and refer logbook for any remarks.
           a. Reverser key
           b. Brake isolating valve key - 2 Nos.
           c. BL key
           d. Guard’s key
       2. Ensure EMU is standing on an OHE wired track.
       3. Check all the wheels on the rails.
       4. Check the position of the drain cocks and close
           them if open.
       5. Check all the isolating cocks are kept in ‘Open
           position’.
       6. Ensure all the jumpers, inter coach coupler and hose
           connections are intact.
       7. Ensure intermediate driving cabs, HT room and LT
           room doors are in locked condition.
        8. Check buffers, cattle guards and other under frame
           equipments for any abnormality.
Trouble Shooting Directory for 25 kV AC EMU/MEMU   December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                   12


         9. Ensure BIVS is in turned ‘OFF’ position and BCH
             is in released position in the rear motor coach.
         10. Ensure availability of head-code boards.
         11. Check for availability of fire extinguishers,
             emergency telephone and two numbers of iron/
             wooden wedges.
         12. Check hand brakes are released.
2.1.2 Energisation of 110 Volts Control Circuit

         1. Ensure necessary MCBs are ‘ON’ and all relay
            targets are normal.
         2. Check any governor is not bypassed.
         3. Check any bypass switch is not in ‘fault’ position
            i.e. HEFRA II, HEFRP and HOBA.
         4. Open the contactor panel with reverser key and turn
            the battery switch to ‘ON’.
         5. Ensure battery voltage indicated by the voltmeter to
            90 volts.
         6. Insert the reverser key, BL key and BIVS key in
            their respective places.
         7. Ensure TSS in RUN position.
         8. Ensure MCS-1 and MCS-2 are in normal position.
            If any one of the traction motors is found isolated,
            report the matter to the TLC.
2.1.3 Starting of Auxiliary Compressor
      1. Turn BL key to ‘ON’ position and ensure
         ‘ABB/VCB Trip’ lamp glowing.
      2. Start auxiliary compressor by pressing ‘HVCB
         close’ switch.
2.1.4 Raising Pantograph

Trouble Shooting Directory for 25 kV AC EMU/MEMU     December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                 13


         1. Check the air pressure in the Panto reservoir.
            Minimum pressure required for raising the
            pantograph is 6 kg/cm2.
         2. Operate ‘Panto Raise’ switch to ‘ON’ position.
         3. Ensure visually that all motor coach pantographs
            have touched the OHE contact wire.
2.1.5 Closing of ABB/VCB
      1. Check the Panto reservoir pressure and ensure that
         it is above 5.6 kg/cm2.
      2. Press ‘HVCB Close’ switch and ensure:
           a. ABB/VCB trip lamp extinguishes.
           b. ASR and BCFR lamp glows and extinguishes.
           c. Line volt meter deviates.
         Now release ‘HVCB close’ switch.
2.1.6 Starting of Main Compressor
         1. Press ‘Main Comp. start’ switch and listen to the
            rotating noise of compressor.
         2. Check the MR pressure in dual pressure gauge for
            creating of the MR pressure up to 7 kg/cm2.
         3. Watch the cutting out and cutting in of MCP at 7.0
            kg/cm2 and 6.0 kg/cm2 respectively.
2.1.7 Charging of BP
         1. Keep the brake controller handle in release &
            running position.
         2. Operate brake isolating valve switch (BIVS) to
            ‘ON’ position.
      3. Watch the BP pressure raising to 5 kg/cm2 in dual
         pressure gauge.
2.1.8 EP Brake Testing

Trouble Shooting Directory for 25 kV AC EMU/MEMU   December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                  14


         1. Switch ‘ON’ EP supply switch in BL box and
            ensure the EP supply green lamp is glowing.
         2. Place the BCH between 1 and 2 position in step by
            step and check the BC pressure raises gradually up
            to 1.6 kg/cm2.
         3. Keep the BCH on ‘release’ position and ensure BC
            pressure comes to ‘0’.

2.1.9 Auto Brake Testing

         1. Switch ‘OFF’ EP supply switch and quickly move
            the BCH to position ‘4’ (Auto) and check the
            dropping of BP pressure and raising of BC pressure
            to 1.6 kg/cm2.
         2. Bring back the BCH to position ‘3’ (LAP) and
            check the BC pressure remains steady.
         3. Bring back the BCH to position ‘1’ and ensure the
            brakes are released (BC gauge reads ‘0’ and BP
            gauge reads 5kg/cm2).
         4. During auto brake application if BCH moved
            towards EP/ release position auto brakes are
            released fully.

2.1.10 Emergency Brake Testing

         1. Quickly move the BCH from position ‘1’ to
            position ‘5’ and watch the BP pressure drops to ‘0’
            and BC gauge reads 1.6 kg/cm2.
         2. Return the BCH from position ‘5’ to ‘1’. Check BP
            raises to 5 kg/cm2 and BC drops to ‘0’.




Trouble Shooting Directory for 25 kV AC EMU/MEMU    December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                  15


2.1.11 Guard’s Emergency Valve Testing

         1. Ensure MR pressure is 6 to 7 kg/cm2, BP pressure is
            5 kg/cm2 and BC pressure is 0 kg/cm2.
         2. Turn the Guard’s emergency valve to ‘ON’ position
            and check BP is dropping and BC pressure reads 1.6
            kg/cm2.
         3. Release Guard’s brake valve and check the charging
            of BP and releasing of BC pressure to ‘0’.

2.1.12 Dead man Handle Testing

         1. Press MPT (DMH) and operate the reverser handle
            to forward keeping MPT (DMH) pressed.
         2. Then release the DMH which will actuate a pilot
            valve under the MPT and in turn open BP to
            atmosphere.
         3. Ensure BP pressure is dropping and BC raises to 1.6
            kg/cm2.
         4. Press the DMH after moving MPT to ‘OFF’
            position.

2.1.13 Traction Test

         1. Ensure MCB for MPT is ‘ON’ and put the control
            switch ‘ON’.
         2. Keep BCH on release position. Press DMH and
            operate the reverser handle to ‘Forward’ position.
         3. Move the MPT to ‘Shunt’ and ensure motor
            contactors trip light extinguishes.
         4. Feel the unit moves freely and check the deviation
            of traction motor ammeter.
         5. Move back MPT to ‘OFF’ position, stop the train by
            applying brake.

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         Note :
            1.         This test shall be conducted only when
                       taking over charge from shed/ siding.
              2.       Do not move MPT to shunt for testing
                       traction with brake in applied condition.

2.1.14 Normal Lights & Fans Testing

         1. Unlock Guard’s control switch and ensure Guard’s
            supply ‘ON’ indication lamp glows.
         2. Switch ‘ON’ normal lights and fans and check their
            working.
         3. Switch ‘OFF’ lights and fans whenever not
            necessary.

2.1.15 Testing of head light, tail light, head code light,
       flasher light, bell and wiper.
         1. Ensure head light MCBs on driver’s desk are ‘ON’.
         2. Ensure head light ‘dim/ bright’ toggle switch is in
            bright position.
         3. Switch ‘ON’ head light; by operating head light
            switch to ‘HL ON’ position. Ensure headlight is
            glowing brightly.
         4. Put HL dim/bright toggle switch to ‘dim’ position;
            ensure head light is glowing in dim condition.
         5. Switch ‘ON’ tail light by operating tail light switch.
            Ensure taillight is glowing.
         6. Operate the head code rotary switch to ‘ON’ and
            check the head code light is glowing.




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         7. Ensure flasher light MCB is ‘ON’ in desk panel.
            Operate flasher toggle switch to ‘ON’, check flasher
            light is flickering.
         8. By keeping the Guard’s rotary switch ‘ON’, check
            the code bell is in working condition on both sides
            of the cab. Also ensure the alarm bell is in working
            condition.
         9. Ensure the pneumatic wiper is in working condition.
         10. Ensure foot operated horns are sounding properly.
         11. Ensure all destination boards pertaining to entire
             link of working are available and change the
             ‘destination board’ according to the direction of
             working.

2.1.16 Checking the Auxiliary
         1. Get down from the motor coach.
         2. Ensure visually and audibly for normal working of
            all auxiliaries (RF, OP, KF1, KF2 and MCP).

2.1.17 Testing of Pantograph
         1. Press the ‘Main Comp. trip’ switch and then HVCB
            trip switch.
         2. Check the glowing of ABB/VCB red pilot lamp and
            press the ‘Panto Lower’ switch.
         3. Check that whether the Panto lowers normally.
         4. Press the ‘Panto Raise’ switch and check the Panto
            raises normally and touching the OHE properly.
         5. Re-close the ABB/VCB and start MCP.


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2.2      DRIVING EMU ON LINE
         1. Place the BCH in release/ running position and
            ensure the brake cylinder pressure is released.
         2. Check the BP pressure. It shall be 5 kg/cm2. Ensure
            other normal conditions according to GR and SR
            rules are full filled for starting the train.
         3. Close the control and EP supply ‘ON’ switches and
            ensure the glowing of ‘green’ lamp for EP supply
            indication.
         4. The motorman shall move the MPT to ‘Shunt
            position’ to obtain slow movement initially and
            watch the free moving of unit. During run the
            motorman shall move MPT to full power position
            to attain service speed and release it to ‘OFF’
            position at the appropriate coasting board to keep
            up the running time.
         5. The motorman shall not operate the reverser handle
            when the unit is in motion.
2.2.1 Slowing Down and Stopping
         1. The motorman shall slow down the train normally
            by EP brake.
         2. If EP brake fails, motorman should apply Auto or
            Emergency brake as the case may be.
         3. The motorman should apply the brake gradually and
            stop the EMU at the stop board or stop mark
            provided (with less number of applications) duly
            making use of self lapping.




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2.2.2 Observing Speed Restrictions
             The motorman shall observe all the speed
         restrictions and acknowledge the Guard with applicable
         bell code (0 – 0) after passing the site of speed
         restrictions.

2.2.3 In case of Alarm Bell Ringing

         1. The motorman must immediately stop the train.
         2. The Guard of the train shall verify the reason for the
            inter communication chain pulling and he shall reset
            the disc, the motorman shall restart the train after
            ascertaining the Guard’s signal.

2.2.4 Dead man’s Handle Made Inoperative

             When the DMH is made inoperative due to any
         reason, the Guard shall be called to travel along with
         the motor-man in the driving cab.

2.2.5 Observation on Run

             In addition to road and signals, the motorman shall
         observe the following on run frequently.
         1. Observe BP pressure, MR pressure, speedometer,
            line voltmeter, battery voltmeter and traction
            ammeters.
         2. Keep a good watch on OHE. Lower the pantographs
            immediately, whenever there is any abnormality
            noticed in OHE. Also observe adjacent line, OHE
            for any abnormality.



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2.3      PROCEDURE FOR STABLING EMU/ MEMU
         1. Stop the train at the stabling line.
         2. Trip ABB/VCB & lower all Pantos.
         3. Apply emergency brake; ensure BP drops to ‘0’ and
            BC raise to 1.6 kg/cm2.
         4. Turn ‘OFF’ BIVS.
         5. Place BCH on release position.
         6. Ensure that BP is not charging further.
         7. Remove BL key.
         8. Switch ‘OFF’ battery in all MCs.
         9. Ensure wheels wedges are provided on the wheels
            towards down gradient.
         10. Apply parking brake, if parking brake is provided.


2.4      PROCEDURE               TO      RAISE     FRONT   PANTOS
         ONLY
         1. Trip ABB/VCB and lower all the Pantos.
         2. Keep TSS on ‘Test’ position.
         3. Press ‘HVCB close’ switch (do not release).
         4. Press and release Panto raise switch.
         5. Release HVCB close switch
         6. Ensure front Panto only raised.
         7. Normalize TSS to RUN position.




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2.5      PROCEDURE TO RAISE REAR PANTOS ONLY
         1. Trip ABB/VCB and lower all the Pantos.
         2. Latch ABR relay manually.
         3. Press ARR (do not release).
         4. Press and release Panto raise switch.
         5. Release ARR.
         6. Ensure rear Pantos only raised.

2.6      PROCEDURE FOR REAR MOTOR COACH
         DRIVING
         1. Call the Guard to the leading motor coach.
         2. Apply auto brakes and turn ‘OFF’ BIVS.
         3. Keep BCH on release position.
         4. Take out the reverser key, BIVS key and BL key.
         5. Go to the rear motor coach, unlock BL.
         6. Turn ‘ON’ BIVS and charge BP pressure.
         7. Work the train up to the next block station duly
            observing GR & SR rules.
         8. Contact TLC and seek advice.

2.7      PROCEDURE FOR CAB CHANGING
            The following procedure is to be followed
         whenever the motorman is required to change the cab:
         1. Stop the train.
         2. Apply AUTO brakes by dropping BP to 3.5 kg/cm2.
            Ensure BC pressure is 1.6 kg/cm2.
         3. Turn ‘OFF’ BIVS and keep BCH on release
            position.
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         4. Ensure that BP is not charging further.
         5. Take all the keys and go to the rear MC.
         6. Unlock BL.
         7. Turn ‘ON’ BIVS until a click/ cut sound is heard
            and ensures BP is charged to 5 kg/cm2.
         8. Check the operation of EP, Auto & DMH in
            working cab.

2.8      PROCEDURE FOR REMOVING JUMPER
         1. Stop and secure the train as per procedure laid down
            in GR & SR rules.
         2. Call the Guard to leading MC before leaving the
            cab.
         3. Open ABB/VCB and lower pantographs in all MCs.
         4. Remove the jumper and secure in dummy socket.

2.9      PROCEDURE FOR DETACHING THE COACH
         1. Stop & secure the train as per procedure laid down
            in GR & SR rules.
         2. Call the Guard to leading MC before leaving the
            cab.
         3. Close BP and MR end cocks both sides of the
            coach.
         4. Remove the jumpers and secure in dummy socket.
         5. Open MR & BP pipe and secure in dummy socket.
         6. First slack the check nut, then slack the wing nut
            and move the front portion.


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2.10 PROCEDURE FOR OPERATING EARTHING
     SWITCH (EAS)
         1. Stop & secure the train as per procedure laid down
            in GR & SR rules.
         2. Open ABB/VCB, lower pantograph, switch ‘OFF’
            BIS and ensure personally pantograph is lowered.
         3. Take BL, reverser key and enter into the HT room.
         4. Close PT COC.
         5. Slack the rotating handle (rotate anti-clock wise)
         6. Move the EAS handle from 6 O’ clock position to 9
            O’ clock position.
         7. Rotate the handle fully to clockwise to lock EAS in
            operated condition.
         Note:
         Before entering into HT room follow the points 1, 2, 3
         positively.

2.11 ROCEDURE FOR JOINT BRAKE CONTINUITY
     TEST
             Joint brake continuity test shall be conducted by the
         Guard and Motorman before commencement of first
         trip from shed/ stabling line or on platform as given
         below:
         1. The motorman shall start the main compressors and
            build up 7 kg/cm2 pressure in MR and turn ‘ON’ the
            BIVS and ensure the following:
              •    Brake pipe pressure is 5 kg/cm2
              •    Brake cylinder pressure is ‘0’.
              •    EP supply lamp is glowing.
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         2. Motorman shall give 5 bells to indicate the Guard to
            be ready for brake test.
         3. Guard shall ensure the following:
              •    Brake pipe pressure is 5 kg/cm2.
              •   Brake cylinder pressure is ‘0’
         4.   Guard shall acknowledge by giving 5 bells and
              watch brake cylinder pressure gauge.
         5.   Motorman shall move BCH between ‘1’ and ‘2’
              position and hold the brake cylinder pressure to 0.7
              kg/cm2. Guard will note the brake cylinder pressure,
              which will be about 0.7 kg/cm2 and will confirm by
              giving one bell.
         6.   Motorman shall move BCH to position ‘2’ and
              observe that brake cylinders gauge reads 1.6
              kg/cm2. Guard will note 1.6 kg/cm2 pressure
              accordingly in the brake cylinder gauge and confirm
              by giving one bell.
         7.   Motorman shall return BCH to release position ‘1’
              and observe that the brake cylinder pressure returns
              to ‘0’. Guard will note that brake cylinder pressure
              returning to ‘0’ and confirm by giving one bell.
         8.   Guard shall open the emergency valve by means of
              the Guard’s emergency brake handle to destroy BP
              pressure to ‘0’ kg/cm2. Motorman shall observe BP
              pressure rapidly dropping towards ‘0’ and will
              move BCH to emergency position ‘5’. The Guard
              after observing the brake cylinder gauge indicating
              1.6 kg/cm2 and BP gauge showing ‘0’ kg/cm2 shall
              close the emergency valve. Motorman shall return
              the brake handle to position. ‘1’ and check BC
              pressure drops to ‘0’. The Guard will confirm by
              giving one bell.
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         9. The motor man shall wait till BP pressure is built up
            to 5 kg/cm2 and then move the brake handle
            between position ‘3’ and ‘4’ to reduce BP pressure
            to 3.5 kg/cm2 and ensure BC pressure raises to 1.6
            kg/cm2.
         10. Place the handle in LAP position ‘3’ and observe
             BP pressure remain steady. Guard will observe BP
             pressure dropping to 3.5 kg/cm2 and BC pressure
             raises to 1.6 kg/cm2 and will confirm by giving one
             bell.
         11. The motorman shall put the brake handle to release
             position. BP pressure shall raise to 5 kg/cm2 and BC
             pressure comes to ‘0’. The motorman will indicate
             the completion of joint brake test by giving 5 bells.
         12. After ensuring BP pressure restored to 5 kg/ cm2
             and BC pressure comes to ‘0’, Guard shall also
             acknowledge the completion of the joint brake test
             by giving 5 bells.

2.12     PROCEDURE TO NEGOTIATE NEUTRAL
         SECTION
         1. While approaching 500m board at neutral section,
            the Motorman shall check the air pressure and
            maintain appropriate speed to pass over neutral
            section without stalling.
         2. While approaching 250m board, bring the MPT to
            ‘OFF’ position and be prepared to open ABB/VCB
            at open DJ board.
         3. Operate the main compressor trip switch.
         4. On reaching the DJ open board, press HVCB trip
            switch.

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         5. Ensure glowing of ABB/VCB open red lamp.
         6. There are two DJ closing boards after neutral
            section. First one is provided for AC Locos and
            second one is provided for EMU/ MEMU.
            Motorman shall close ABB/VCB only after passing
            ‘EMU DJ close board’.
         7. Start the main compressor without fail. Check BP &
            MR pressure and resume traction.

2.13     USE OF FIRE EXTINGUISHERS

2.13.1 General
         1. Motorman shall ensure that locking clip, nozzle,
            spring valve and seal of fire extinguishers provided
            on the EMU are intact before leaving shed.
         2. Check that the fire extinguisher is not due for re-
            filling.

2.13.2 How to use
             Whenever any smoke or fire is noticed on any
         equipment on EMU, motorman shall take the following
         actions:
         1. Open ABB/VCB, lower all Pantos, stop the train
            and switch ‘OFF’ BIS.
         2. Remove the DCP type fire extinguishers from the
            bracket, take it nearer to the equipment on fire and
            cover your nose with a wet cloth.
         3. Break the seal and remove the locking clip.
         4. Stand opposite direction to the smoke, press the
            spring valve and face the nozzle towards the base of
            fire.
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         5. Strike the knob by hand.
         6. Direct the jet towards the base of fire with a
            sweeping action.
         7. If the fire is not able to put out with one fire
            extinguisher, use the other one in the same way.
         8. If the fire is uncontrollable, inform the section
            controller or station master to arrange fire engine
            and follow GR & SR rules.
         9. Isolate the affected equipment, inform TLC and
            work onwards if possible. Make a remark in the
            logbook regarding use of fire extinguisher and
            affected equipment.




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                              CHAPTER 3

                  TROUBLE SHOOTING


        Whenever any major fault occurs in the equipment on
any unit of the rake, it is indicated in the driver’s cab by
glowing of one or more fault lamps. Which unit in the train is
faulty will be indicated by the glowing of red unit fault light of
faulty unit.

        There are three classes of faults which have different
effects as following:
         1.     The motor contactors open and the unit looses
                either half or full traction power.
         2.     The air blast circuit breaker (ABB)/ vacuum
                circuit breaker (VCB) opens and the unit looses
                full traction power.
         3.     Auxiliaries are only affected except rectifier fan
                motor and traction is not lost.

3.1      ABB/ VCB TRIPS ON RUN
         Indication:         ABB/VCB OFF red light lit.
         Action:
         1. Bring MPT to OFF position and trip MCP.
         2. Try to close ABB/VCB by pressing HVCB close
            switch.
         3. Ensure MCB for MPT is ‘ON’.
         4. Ensure MR pressure is above 6 kg/cm2.
         5. Check EFRP & OLP if found acted, reset the same.
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         6. Open control switch, press ‘Over load reset’ switch.
            Re-close ABB/VCB (Press HVCB close switch).
         7. Start MCP.
         8. Put ‘ON’ control switch.
         9. Move MPT from ‘OFF’ to ‘shunt/ half/ full’ power.
            If unit is moving, resume traction even though
            ABB/VCB trip lamp is glowing. Trouble shoot for
            the defective unit after stopping at a convenient
            place if time permits.
         10. If unit is not moving, trouble shoot in leading MC
             first.

3.2      ABB/VCB NOT CLOSING
         Indication:        On pressing ‘HVCB close switch’,
                            ABB/VCB OFF lamp remains glowing.
         Action:
         1. Check battery voltage is above 85V. If battery
            voltage is less than 85V, place CCOS on E1 or E2
            position. If battery voltage is zero or less, trouble
            shoot for the same.
         2. Ensure air pressure is above 6 kg/cm2. If it is less,
            start auxiliary compressor and buildup pressure.
         3. Check Panto/ ABB/VCB MCB at Driver’s desk.
            Check ABB/VCB Fault MCB at Relay panel. If
            found tripped, reset the MCBs.
         4. If unable to reset, put HOBA in fault position in all
            motor coaches and reset the MCB. Enter the same
            in the logbook. If still trips, contact TLC.




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         5. Ensure ABR in latched condition and ARR is
            getting energized while pressing HVCB close
            switch.
         6. If not energized operate them manually and close
            ABB/VCB in defective MC.
         7. Check EFRP in relay panel.
              a. If EFRP is tripped, try to reset through OL reset
                 switch.
              b. If unsuccessful, put HEFRP (in LT room) in
                 fault position, reset EFRP and close ABB/VCB.
              c. Watch for any smoke or smell.
              d. Stop at a convenient place and normalize the
                 HEFRP. Then isolate the traction motors one by
                 one through MCS and try to reset EFRP.
              e. If EFRP is reset while isolating any of the
                 traction motor, isolate that particular traction
                 motor. Close ABB/VCB and work onwards.
         8. Check EFRA-II in relay panels
              a. If EFRA-II is tripped, reset the relay manually.
                 Try to reset the relay even the target is not
                 dropped/ red lamp is not glowing.
              b. If not able to reset, put HEFRA II (in relay
                 panel) in “fault” position, reset EFRA II and
                 close ABB/VCB.
              c. Work onwards duly watching for any
                 abnormality in ASR, MCP, NLVS, FAN
                 circuits.    NLVS (Normal light voltage
                 stabilizer)


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              d. If any abnormality is noticed stop at a
                 convenient place and isolate the defective
                 equipment.
              e. Inform TLC and record in the logbook.
         9. Check BIR in relay panel
              a. If BIR is in tripped condition, reset BIR
                 manually and close ABB/VCB and resume
                 traction.
              b. If BIR trips again or trips frequently, after taking
                 safety measures, enter in the HT room and check
                 transformer oil level and colour in conservator
                 tank. If they are normal, remove the cap and
                 release the gas by operating BUD slow and fast
                 valves.
              c. Reset BIR manually and close ABB/VCB and
                 resume traction.
              d. If any abnormality found, make the unit dead
                 and proceed with other MC duly informing TLC
                 and record in the logbook.
         10. If PRV lamp is glowing, make the MC dead. Work
             with other MC.
         11. Ensure MR pressure is above 6 kg/cm2, bypass the
             ABB governor by the spare 16A fuse (provided in
             relay panel in 4th row). This bypass fuse is not
             provided in VCB provided MCs.
         12. Ensure TSS is in ‘RUN’ position.




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               ABB/ VCB closing circuit




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3.3      ABB/VCB CLOSES AND OPENS IMMEDIATELY
         Indication:         ‘ABB/VCB OFF’ red lamp extinguishes
                             and glows immediately.
         Action:
         1. Check relays OLP (in relay panel), OL5 & OL6 (in
            tap changer box).
         2. If any one of the relay is acted, reset once and close
            ABB/VCB. If trips again make the particular motor
            coach dead and work with other MCs.
         3. Inform the same to TLC and make record in
            logbook.

3.4      ABB/VCB NOT HOLDING WHEN OHE SUPPLY
         AVAILABLE
         Indication:
         On pressing ‘HVCB close’ switch, ABB/VCB OFF
         lamp extinguishes, line volt meter deviates, ASR
         glowing and ABB/VCB OFF lamp will glow
         immediately on releasing ‘HVCB close’ switch.
         Action:
         1. Check LTR in relay panel after pressing ‘HVCB
            close’ switch.
         2. If LTR not energizing, check MCB for LTR in fuse
            panel (4th row).
         3. If tripped, reset the MCB. If unsuccessful, pack
            LTR and work the train. Inform TLC and record in
            the logbook.



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         Precautions to be followed after packing ‘LTR’
         1. Watch line voltmeter frequently and if line
            voltmeter showing below 17.5 kV, trip ABB/VCB
            immediately.
         2. After closing ABB/VCB, switch ‘ON’ main
            compressor after 30 seconds and ensure the working
            of main compressor.
         3. Switch ‘OFF’ main compressor before tripping
            ABB/VCB.

3.5      NO OHE SUPPLY INDICATION
         Indication:
         On pressing HVCB close switch, ABB/VCB ‘OFF’
         lamp extinguishes, ASR & BCFR lamp glows and line
         voltmeter will not deviate. ABB/VCB trip lamp will
         glow immediately on releasing HVCB close switch.
         Probable causes:
         1. No supply in OHE.
         2. Panto not touching the OHE properly.
         3. OHE supply is earthed through roof equipment or
            foreign body.
         4. Train formation derailed and infringing with the
            OHE.




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         Action:
         1. If the tripping is transient, the motorman shall
            resume normal traction and keep sharp lookout
            including on the adjacent line for any abnormality/
            obstruction.
         2. During ‘No Tension’, the motorman shall
            immediately switch on Flasher light and stop the
            train. Communicate with the TPC/ controller to
            know the reason for NO Tension and act
            accordingly.
         3. Check BP pressure. If BP pressure is normal,
            motorman should check the OHE, train and track
            for any abnormality.
         4. If there is any abnormality, lower Panto and contact
            to TLC for advice.
         5. If no abnormality is noticed, raise Panto and
            observe any heavy spark coming at the time of
            Panto making contact with OHE. If so, lower Panto
            immediately and close Panto COC and try to work
            with other MC.
         6. If the power is still not resumed, after securing the
            train and lowering Pantos, contact TPC & TLC.
            Ensure auxiliary compressor is working for
            energizing EMU whenever OHE power is restored.
         7. In case of BP pressure drops rapidly, switch ON
            flasher light, lower the pantograph and stop the
            train.
         8. Check the vehicles for any derailment or capsize
            and infringing with OHE.

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         9. Inform TPC & TLC and wait for OHE staff to come
            and rectify the same after taking power block. If
            pantograph is in damaged condition, it should be
            secured properly and isolate the damaged
            pantograph by closing Panto COC and work with
            healthy unit.
         10. If the detention exceeds 5 minutes on Automatic
             block system or 15 minutes on Absolute block
             working territory, the train should be protected as
             per GR & SR rules.




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3.6      TRACTION FAILURES

3.6.1 Total Loss of Tractive Effort

         Indication:

         On moving MPT from OFF to shunt or half power or
         full power, traction ammeter not deviating and train is
         not moving.

         Action:
         1.     Ensure MR pressure is above 6 kg/cm2.
         2.     Ensure BIVS is properly turned ‘ON’ and BP
                pressure is 5 kg/ cm2.
         3.     Check MCB for MPT (15A) in Driver’s desk
                (3rd MCB).
                a.   If it is tripped, reset and resume traction.
                b.   If not able to reset/ trips again, place MCS–I
                     in 1 & 2 out and MCS-II in 3 & 4 out and try
                     to reset.
                c.   If unsuccessful, remove ‘B’ jumper next to the
                     leading motor coach and place it in its dummy
                     socket. If still unsuccessful, try to clear section
                     from rear motor coach.
                d.   If not able to reset/ trips again, place HOBA in
                     fault position in all motor coaches and reset.
         4.     Check BL for proper unlocking and ensure control
                switch is in ‘ON’.
         5.     Operate reverser from forward to reverse a few
                times.

Trouble Shooting Directory for 25 kV AC EMU/MEMU           December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                       38


         6.     Check DMH for acted condition.
                a. If it is in acted condition, reset by bringing the
                   MPT to ‘OFF’ position.
                b. Press MPT and resume traction.
         7.     Ensure PB pressure in parking brake gauge is 5
                kg/cm2 and check parking brake application LED
                is extinguished (MSTWL lamp also will glow).
                a. Ensure wheel no. 1, 4, 5 & 8 brakes are
                   released.
                b. Put parking brake governor bypass switch (near
                   GS panel) in ‘bypass’ position.
                c. Inform TLC and record in the logbook.
         8.     Check the interlock in MPT, DMH for any poor
                contact and clean them.
         9.     If unsuccessful, clear the block section from other
                MC. Work as per GR & SR rules and contact TLC.

3.6.2 Partial Loss of Tractive Effort
         Indication 1:
         On moving MPT from ‘OFF’ to ‘Shunt’, MSTWL
         glows. Unit fault lamp also glows in defective motor
         coach and unit is moving.
         Action:
         1. Open ‘Control’ switch, close over load reset switch,
            close control switch and resume traction.
         2. If again OL 1 & 2 or OL 3 & 4 acts, place the
            concerned MCS on any one motor cutout position in
            defective coach.

Trouble Shooting Directory for 25 kV AC EMU/MEMU         December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                     39


         3. If unsuccessful, keep the same MCS on the other
            position and try. Resume traction duly informing
            TLC and record in the logbook.
         4. If unsuccessful, work with good units.
         Indication 2:
         On moving MPT from ‘OFF’ to ‘Shunt’, MSTWL lamp
         glows along with rectifier fuse blown blue lamp. Unit
         fault lamp also glows in defective motor coach and unit
         is moving.
         Action:
         1. Check CBAR in relay panel. If it is in tripped
            condition, try to reset.
         2. If unable to reset, keep MCS-I in 1& 2 out position
            or MCS-II in 3 & 4 out position and resume
            traction.
         3. If one motor is already isolated, isolate the other
            motor in the same pair.
         4. Inform the same to the TLC and record in the
            logbook.
         Indication 3:
         On moving MPT from ‘OFF’ to ‘Shunt’ MSTWL glows
         along with unit fault light indication and unit is moving.
         Action:
         1. Check RFAR in relay panel.
              a. If it is in tripped condition, check the 10A MCB
                 & 32A fuse panel (1st row) for rectifier fan.
              b. If RF is working, and RFAR in trip condition,
                 wedge RFAR in SET condition and work
                 onwards.
Trouble Shooting Directory for 25 kV AC EMU/MEMU       December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                       40


              c. If RF is not working do not wedge RFAR and
                 work with good MC.
              d. Inform TLC and record in the logbook.
         2. Check TTR in relay panel.
              a. If TTR is in tripped condition, check
                    i.    OP- 15A MCB & 32A fuse.
                    ii.   KF1 & KF2– 5A MCB (for each) & 16A
                          fuse (common for both)
                   If any abnormality noticed, reset the MCB or
                   replace the fuse duly opening of HVCB.
              b. If all is normal, work with other MCs.
              c. Inform TLC.
              d. After transformer temperature comes below
                 75°C, TTR comes to set position and allows
                 traction.
         Indication 4:
         On moving MPT from ‘OFF’ to ‘Shunt’, MSTWL
         glows without unit fault light indication and unit is
         moving.
         Action:
         1. Check MR pressure in the pressure guage.
             a. If it is less, trouble shoot for pressure not
                building up.
             b. If pressure is above 6 kg/cm2, put the equipment
                governor bypass switch GS1 in ‘ON’ position,
                duly informing TLC and record in the logbook.
         2. Check BP pressure in the dual pressure guage.



Trouble Shooting Directory for 25 kV AC EMU/MEMU         December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                   41


         3. If it is 5 kg/cm2, put control governor bypass switch
            GS2 in ‘ON’ position, duly informing TLC and
            record in the logbook.
         4. Check the parking brake guage. If it shows 5
            kg/cm2, put PB governor bypass switch GS5 in
            ‘ON’ position and try.
         5. Operate the reverser to forward and reverse for a
            few times.
         Indication 5:
         On moving MPT from ‘OFF’ to ‘Shunt’, MSTWL
         glows and extinguishes, traction ammeter not deviating
         and SR not energized but unit is moving.
         Action:
         1. Check NVR in relay panel.
         2. If it is not energized, check MCB for NVR in Relay
            panel. If tripped, reset. If MCBs are normal, pack
            NVR and resume traction.
         3. Change both MCS position one by one and try.
         4. If NVR is in energized condition, check SR for
            energisation. If SR is not energized, clean the NC
            interlock of SR.
         5. Do not pack SR. Work with good unit.
         6. Inform TLC and record in the logbook.




Trouble Shooting Directory for 25 kV AC EMU/MEMU     December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                                                           42




                              BATTERY
                              CHARGER




                                                                                       A
                                                             BCFR                               D10
                              GD

                                                                                       D10
                                                            BIS             30-0-30A
                      63A




                                                                                A
                                                                 B3    B5                        63A

                                             B3                                        B2

                                                                                                 D102
                                                     80 A   B4             B1   80 A
                                                                 BATTERY
     TO ALL 110 VDC
     CONTROL EQUIP


                       41 -




                                                                                                   35A
                                                                                D104 32A
                                 0- 150V




                                                                      N1
                                                   14 B
                             V
                              1423


                                             TLC




                                                                           E1
                                                   14
                                                                                SWITCH
                                                                                OVER
                                                                                CHANGE
                                                                                CONTROL




                                                                           N2

                                                                           E2
                                           2.5A 14 A
                                                                                           14
                      14 +




                                             BATTERY CIRCUIT

Trouble Shooting Directory for 25 kV AC EMU/MEMU                                            December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                  43


3.6.3 All MCs Not Responding Beyond ‘Shunt’
         Cause: T2 not energising.
         Action:
         1. Check warning switch, it should be on ‘OFF’
            position.
         2. Operate the warning switch one or two times and
            put the switch in ‘OFF’ position.
         3. Still unsuccessful, clear section from rear MC and
            contact TLC.

3.7      BATTERY VOLTMETER INDICATES ‘ZERO’ OR
         LESS THAN 85V
         Action:
         1. Ensure BIS is in ‘ON’ position.
         2. Switch ‘ON’ emergency cab light and check BA
            voltmeter MCB 18th in Driver’s desk.
         3. If unsuccessful, keep CCOS in E1 or E2 position of
            defective MC and work onwards duly informing
            TLC and record in the log book.
         4. Check the battery fuses (63A) in positive and
            negative side, control fuse (32A) in fuse panel 3rd
            row and MCB (35A) in 4th row.
         5. If any fuse is blown, replace with a spare fuse of
            same rating. If MCB is tripped, reset the same.
         6. If fuse melts and MCB tripped again, put HOBA in
            fault position in all MCs, replace fuse and reset
            MCB.



Trouble Shooting Directory for 25 kV AC EMU/MEMU    December 2009
PANTO & ABB


                                                                                        15A                15A                                      2.5A
                                                                                  D11
                                                                                                                                                  1420

                                                                                                                                                          AUX. GOV.
                                                                                                                                                                      CAMTECH/2005/E/TSD/AC EMU/1.1




                                                                                          CC2                                      GS4
                                                                                                           BL KEY

                                                                                  D12                                                              CI5.3 Kg/cm. sq.
                                                                                                                                           1421
                                                                                                                                                  CO6.3 Kg/cm. sq.




Trouble Shooting Directory for 25 kV AC EMU/MEMU
                                                                                        AUX.               OPEN                    HVCB
                                                                                        COMPRESSOR         HVCB                    CLOSE
                                                                                                                                                   ABR/ 2
                                                                                  GD1
                                                                                                           9
                                                                                                                                  10              1422


                                                                                                     ABR             ARR          ABR              CC2
                                                                                  16A
                                                                                                     SET                          TRIP             COIL




                                                   AUXILIARY COMPRESSOR CIRCUIT
                                                                                  -41




December 2009
                                                                                                                                                                      44
CAMTECH/2005/E/TSD/AC EMU/1.1                                     45


3.8      AUXILIARY COMPRESSOR NOT WORKING
         Action:
         1. Check BA voltage is above 85 volts.
         2. Check ABR in relay panel.
              a. If it is not latch, check Panto/ ABB/ VCB MCB
                 is in ‘ON’ position.
              b. If it is in ‘ON’ position, latch ABR manually.
         3. Check CC2 contactor in contactor panel.
              a. If it is not closed, check 2.5A MCB in fuse
                 panel. Place auxiliary compressor governor
                 bypass switch GS4 (in GS panel) in ‘ON’
                 position.
              b. If unsuccessful, wedge the contactor and record
                 in the logbook.
              c. If contactor is closed, check 15A MCB and 16A
                 fuse in fuse panel. Reset the MCB if tripped and
                 replace the fuse if fused.
              d. If MCPA still not working, tap the MCPA gently
                 to overcome the poor bedding of carbon brush in
                 the commutator.
              e. After creating sufficient pressure, put back the
                 bypass switch to ‘OFF’ position or remove the
                 wedge.
         4. If still the auxiliary compressor is not working,
            energise the rear unit and start the main compressor.
            After building up the MR pressure, energise this
            unit.



Trouble Shooting Directory for 25 kV AC EMU/MEMU       December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                                46



          + 14


              15 A PANTO/ ABB

           1406


              BL KEY
                                     1407

               PANTO           PANTO               HVCB         HVCB
               RAISE           LOWER               OPEN         CLOSE

   1408                                                     9
          MPT
          N/C                               10
          7                                        ABB/ 5              LTR/ 1
             ABB                   ABR/ 1



                           8                  10A           901
          701


    PT              PT              ABR               ABR             ARR
   UP                               TRIP              SET
                    DN




       -41


              PANTOGRAPH CONTROL CIRCUIT


Trouble Shooting Directory for 25 kV AC EMU/MEMU                  December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                     47


3.9      AUXILIARY COMPRESSOR WORKING BUT
         PRESSURE NOT BUILDING UP
         Action:
         1. Check drain cocks of Panto reservoir, control
            reservoir, air separator for ABB/ VCB reservoir,
            ABB/ VCB reservoir, CDC and safety valve for any
            air leakage in HT room.
         2. Close CR, MR cock, ABB/ VCB cock, Panto cock
            and try.
         3. If successful, open Panto cock and ABB/VCB cock.
            Raise Panto and close ABB/VCB. Start MCP and
            build up MR pressure. Open MR and CR cock and
            resume traction.
         4. If still the auxiliary pressure is not building up,
            energise the rear unit and start the main compressor.
            After building up the MR pressure, energise this
            unit.

3.10     ALL PANTOGRAPHS NOT RAISING
         Action:
         1. Ensure BA voltage is above 85 volts.
         2. Check air pressure. If it is below 6 kg/cm2, start
            auxiliary compressor.
         3. Check Panto/ABB/VCB MCB in Driver’s desk.
         4. If it is tripped, reset. If it trips again, put HOBA in
            ‘FAULT’ position in all motor coaches and try. If
            unsuccessful, contact TLC.
         5. Ensure ABB/ VCB open red lamp is glowing.
         6. If it is not glowing, open ABB/ VCB.

Trouble Shooting Directory for 25 kV AC EMU/MEMU       December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                     48


         7. Ensure MPT is in ‘OFF’ position. Clean the MPT
            ‘interlock’ (10th interlock from top).
         8. If still not raising, operate ESMON relay and try.
         9. Check Panto COC and EAS in HT room of leading
            MC.
         10. If Panto COC is closed or EAS is operated,
             normalize the same.
         11. If still not raising, enter in HT room with precaution
             and operate Panto up coil manually duly informing
             TLC and record in the log book.




Trouble Shooting Directory for 25 kV AC EMU/MEMU       December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                                                                        49

                   + 14



                          5A                                                          2.5A

                                                                                 1445
             1404
                                                                       BY 127
                                                                                 1446

                          BL KEY                                                      CR
                                          1405
                                                                                 1447

                                                                                                  MCP GOVERNOR
        MCP                               MCP              GS 3                                   CI 6.0, Kg/cm sq
       START                              TRIP                                                    CO 7.0 Kg/cm sq

                                                                                             13

                                                                                                    TO NEXT
                     12                           42
                                                                                      2.5A          MOTOR
                                                                                                    COACH
            CR                                                            1301
            SET                           CR                                      CC1
                                          TRIP                                    COIL
            COIL
                                          COIL

                   - 41

                                          MCP CONTROL CIRCUIT

                                                                                                           D1
                                           D1                      D2                 D3

                                                          160 A                                               25 A
                      A 22                                               CC1

                                                                       CONTACTOR




                                                                                                          D 17
                                                 ASR
 25 KV AC




                            141 V AC




                                                                                                              LTR/1
                                                                                             D4
                                                                                MCP
                                                       110 V DC




                                   A 26                           GD



                                          MCP AUXILIARY CIRCUIT
Trouble Shooting Directory for 25 kV AC EMU/MEMU                                                    December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                      50


3.11     MAIN COMPRESSORS NOT WORKING
         Action:
         1. Work with the help of main compressor of other
            MCs.
         2. Check CR latched in relay panel. If not latched,
            latch it manually.
         3. Check CC1 contactor in contactor panel.
         4. If it is not closed, check 2.5A MCB in fuse panel. If
            it is tripped, reset the MCB. If it trips again, put
            HOBA in FAULT position in all motor coaches.
         5. Check synchronizing MCB 2.5A in 4th row. If it is
            tripped reset it. If it trips again, put HOBA in
            FAULT position in all motor coaches and reset.
         6. If unsuccessful, place main compressor governor
            bypass switch (GS3) in ‘ON’ position.
         7. Even after bypassing GS3, if CC1 is not closed,
            wedge the contactor (If all the main compressors are
            not working) or work with other compressors.
         8. If CC1 is closed but compressor is not working.
            Check 160A fuse in RELAY panel 3rd row 4th fuse.
            If it is fused, replace that fuse with same rating after
            taking safety precautions.
         9. If compressor is defective, trip synchronizing MCB
            (2.5A) in 4th row of RELAY panel.
         10. Work onwards duly informing TLC and record in
             the logbook.




Trouble Shooting Directory for 25 kV AC EMU/MEMU        December 2009
CAMTECH/2005/E/TSD/AC EMU/1.1                                   51


3.12 MAIN COMPRESSOR WORKING BUT
     PRESSURE NOT BUILDING UP
         Action:
         1. Check drain cocks, pipe lines and safety valves in
            the formation for any air leakage.
         2. If there is any leakage, arrest it. If BIVS is turned
            ‘ON’, bring it to ‘OFF’ position. After building up
            7 kg/cm2 MR pressure, turn ‘ON’ BIVS.

3.13     BP PRESSURE NOT CHARGING
         Action:
         1. Ensure MR pressure is above 6.0 kg/cm2.
         2. Turn ‘ON’ BIVS properly. Operate BIVS few times
            until a cut sound is heard, close EP switch and
            ensure EP supply lamp is glowing.
         3. Ensure Guard emergency brake valve handle in all
            MCs are in ‘OFF’ position and BCH in release
            position.
         4. Ensure BP CDC drain COC in all coaches are in
            closed condition.
         5. Ensure front BP end COC in leading MC and
            trailing MC are in closed condition.
         6. Ensure MPT is in ‘OFF’ condition in all MCs.
         7. Check for any leakage in the BP line.
         8. BP guage may be defective, check in the Guard side
            BP guage.




Trouble Shooting Directory for 25 kV AC EMU/MEMU     December 2009
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