Medha MEP 660. Troubleshooting Manual (2008)

1.0

INTRODUCTION

The Microprocessor Based Locomotive Control system MEP 660 continuously monitors

operating levels of various parameters like currents, voltages, temperatures, pressures,

RPMs etc. and status of all Auxiliary and main contacts of Contactors. The MEP 660

identifies any abnormal working conditions of any equipment that can indicate a fault in

that equipment. Various faults that are identified are given in the Fault Manual document

No. IM 10 issued by M/S Medha Servo Drives. On identification of any such fault, an

appropriate control action is taken instantly to avoid damage to traction equipments. A

fault message, along with any restriction applied due to the fault, is displayed on the

display unit for guiding the driver. The fault is recorded in the error log along with date

and time stamp. Eight data packs of various locomotive parameters are recorded from 5

seconds prior to the occurrence of fault to three seconds after the occurrence of fault @

one data pack every second. These data packs help the maintenance staff later for

analysis of how the fault has developed and also helps analyse complicated faults.

The classification of these faults and their reset procedure are given in Annexure - 1 for

easy reference

This trouble-shooting manual provides information like restrictions imposed by the fault,

probable causes that can cause the fault and the remedial actions to isolate the fault. The

isolation procedures are written for each and every fault message Identified and listed in

the above Fault Message Manual. No troubleshooting guide is required for the fault

recovery messages that are listed in the Fault Message Manual.

There are 19 cards / modules in the MEP 660 control unit. These modules are plug in

type and inserted in the corresponding slots. Through out this manual the slots are

assumed as 1 to 19, from left to right. The card type No. is labeled both on the card and

MEP-660 control unit to avoid wrong insertion of card. A list of cards and their location of

slots are given as Annexure-2

In this manual an attempt is made to explain step by step procedure to isolate the fault

both in locomotive and as well as MEP 660 components. The trouble-shooting manual has

been discussed anticipating that the user has got basic concept on the locomotive,

through knowledge on MEP 660 components and their functionality. It is recommended

that the user should read the system manual document No. 08 and schematics of MEP

660 document No. ED1000 before this document is used.

In the step by step procedure of fault isolation, the user has been asked to perform

Manual testing of inputs and outputs through display unit wherever necessary to find the

status of digital inputs/outputs and proper functioning of out put devices. The procedure

for Manual testing of inputs and outputs are described in the System Manual document

No. IM 08.

Similar way there are three Digital out cards available from slot 14 to 16. The list of

output devices that are connected to each card is given as Annexure - 3 for easy

reference.

There are 5 digital input cards in the MEP 660 control unit from slot 9 to slot 13. A set of

16 inputs are connected to each card through ear marked cables having unique ID nos.

(like ID:xx). The digital input cards MDIP16 are provided with Green and Yellow LEDs on

the front fascia of the card to know the status of the digital inputs. There are 16 green

LEDs on the bottom portion and 16 Yellow LEDs on the top portion of the front fascia. A

number side to the LED identifies these LEDs. The logic between these Green and Yellow

LEDs is that both LEDs of same number should toggle their status either ON or OFF

simultaneously. The matrix of these LEDs is given as Annexure-4 for reference

indicating which LED represents to what digital input. These LEDs are addressed by their

Numbers printed on the front fascia by side of the LED and corresponding slot on the

base in which the card is available.

The various digital inputs and digital outputs with their connections between locomotive

and the control unit having their corresponding cable IDs and pin numbers are given as

Annexure-5. This data is extracted from the Electrical schemnatics for MEP 660 system.

Doc. No. ED-1000.

The menu system and the display parameters are extensively referred in this manual to

identify the fault. Various menu and submenu options available and the displayed

parametes in each group are given as Annexure-6 for easy reference to navigate

through Display menu.

Precautions to be followed while troubleshooting:

Where ever locomotive has been asked to move or open first notch with GF

ON, extreme care should be taken that brakes are applied physically on the

wheels and brake system is working normal as per Rail Road instructions.

Wherever user has been asked to replace the card or cable, Switch off all

breakers, replace the card/cable and switch ON the breakers and then continue

the test. Removal of card or cable with supply can damage the respective card /

module.

Use proper tools like spanners / nut drivers etc to remove / replace defective

components. Do not try with un-sized tools.

While reconnecting wires / cables ensure proper cable tags are available and

they are connected correctly to the correct terminals. If cable tags are missing,

disconnect cables / wires checkup continuity, re-tag the wires and connect.

Wrong connection of any wire / cable can lead into further complicated trouble.

1.0

HIGH PRIORITY FAULTS

PARAMETER

DESCRIPTION

FAULT CODE

1001

FAULT MESSAGE

Low Water Level.

RESTRICTIONS

Engine Shutdown

ALARM BELL

Continuous ON

RESET LEVEL

LOW, MANUAL.

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when fault is cleared and 20 seconds itime is lapsed.

RECOVERY

PROBABLE

LWS operated due to low water level.

CAUSES

Faulty micro switch, bellow, float. Etc. in the LWS unit.

Any open ciduit in LWS wiring from LWS to MEP660.

FAULT

Check Water level. If water is less add water. Reset the fault.

ISOLATION

If water is full, Check operation of the LWS by operating the LWS

cock.

The number 4 green and yellow LEDs on MDIP-16 card in slot 11

indicate the status of LWS feed back signal.

Both LEDs glow with LWS normal position (full water) and both

LEDs are OFF with LWS operated (low water)

If both LEDS are not ON with LWS normal position (full water),

a) Check Voltage at wire No. TO1 on backside TB. Observe for

any disconnected wires. If so reconnect.

b) If voltage at wire No. TO1 is zero

1) Check voltage at wire No. 51 at backside TB. Observe for

any disconnected wires at the terminal. If so reconnect.

2) If voltage is >65V.

i. Either LWS wiring or LWS faulty

Check wiring continuity of wire 51 from backside

TB to LWS.

Check wiring continuity of wire No. TO1 from LWS

to backside TB.

Check for any disconnected wires at LWS.

If wire continuity is good, LWS micro switch is

defective. Replace and check.

c) If the Voltage at back side TB on wire No. TO1 is > 65V

1) Check the wiring continuity of wire No. TO1 from

backside TB to MEP-660 by removing the coupler (DI32-

DI47) - (Pin. E). If no continuity replace the cable.

B. If only Green LED is glowing, and yellow LED is not glowing, it

indicates that the LWS feed back input is available upto digital

input card and the DI card in slot 11 is defective. Replace the

card.

PARAMETER

DESCRIPTION

FAULT CODE

1002

FAULT MESSAGE

Engine Over Speed.

RESTRICTIONS

Engine Shutdown

ALARM BELL

30 Seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when engine is not running and Master Handle is kept in

RECOVERY

IDLE position for 10 secconds.

PROBABLE

1. Faulty wiring from tacho generator to MEP-660

CAUSES

2. Faulty Tacho generator

3. Faulty governor / sticky racks

FAULT

1. Reset the fault. Ensure that there are no sticky racks or fuel

ISOLATION

injection pumps. If OSTA is tripped, reset it. Crank the engine.

2. Check the notch wise engine RPM.

A. If the RPM is not correct

a) Check up with the governor and set the notch wise engine

RPMs with in limits.

B. If the displayed RPM is correct

a) Check up with tacho generator wiring from tacho generator

terminal board to backside TB to MEP-660 for any open

circuit or loose connections.

b) Check up tacho generator frequency (engine RPM) with

conventional RPM meter as used in conventional WDM3A

locomotives.

c) If notch wise readings are not stable and hevy fluctaution is

noticed, check for tacho generator and replace.

PARAMETER

DESCRIPTION

FAULT CODE

1003

FAULT MESSAGE

Exciter Drive Short Circuit Fault.

RESTRICTIONS

Motoring and Dynamic Brake Prohibited

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

No auto recovery.

RECOVERY

PROBABLE

1. There may be a wiring fault with FCP (EFR1 to EFR4)

CAUSES

2. PWM output card is defectie.

3. The current sensor is giving faulty output.

FAULT

1. Check foe any disconnected wires and shorting to other terminals at

ISOLATION

FCP terminal board. If any found, check and reconnect the wires.

2. Connect DC ammeter 0-10Amps to wire terminals 61F (+) and 61FF

(-) at EXPR interlocks.

3. Pack the EXPR interlock 61F and 61FF with insulating sheet.

4. Switch on breakers. From the display menu, Select Display mode to

Excitation Display to view exciter field current EXFI.

A. If current in the meter is equal to the displayed current of EXFI,

then the current sensor is good. PWM output card is defective.

Replace the card.

B. If current in the meter is less than the displayed current of EXFI,

then the current sensor is faulty. Replace the current sensor.

However this will have an accompanied message or

‘Exciter

field current sensor EXFI Faulty’ (Fault code 1176).

PARAMETER

DESCRIPTION

FAULT CODE

1004

FAULT MESSAGE

LLOB trip. Reset Plunger.

RESTRICTIONS

Cranking Prohibited

ALARM BELL

Continuous ON

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when the fault is cleared and 20 seconds of time is lapsed.

RECOVERY

PROBABLE

1. Low Lube Oil Button might have tripped in the Woodward governor.

CAUSES

2. The feedback input wire OPSFB is getting wrong supply.

FAULT

1. Check the Low Lube Oil Button position on the Woodward governor.

ISOLATION

2. If tripped (projecting outside),

A. Press the button inside to reset.

B. Reset the Fault manually and crank the engine.

3. If LLOB is not in tripped position

A. Pull the knob outside and reset once again.

B. Check the OPS (LLOB) feed back signal level with Number 5

Green and Yellow LEDs on Digital Input card MDIP-16 in 11^th

slot.

With LLOB in normal position, both LEDs are OFF.

With LLOB in tripped position, both LEDs are ON.

C. If both LEDs are ON with LLOB in normal position

a) Check voltage at wire No. 1B at the back side TB.

b) If voltage is > 65V

c) Disconnect the wires 1B and identify which wire is getting

supply.

d) If the wire is from governor amphonal plug, then the micro

switch in the Governor is shorted. Replace the micro switch.

e) If the wire is from loco side, there may be a wrong feed back

from indication panel side. Check up and isolate the supply.

Note: Most probably this fault is accompanied with a Fault message

‘LLOB Trip. Reset Plunger’ (Fault code 1005). Driver might have reset

the fault on the display with out reseting the LLOB on the Governor.

PARAMETER

DESCRIPTION

FAULT CODE

1005

FAULT MESSAGE

LLOB Trip. Reset Plunger.

RESTRICTIONS

Cranking Prohibited

ALARM BELL

Continuous ON

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when the fault is cleared and 20 seconds of time is lapsed.

RECOVERY

PROBABLE

1. Low Lube Oil Button might have tripped in the Woodward governor.

CAUSES

2. The feedback input wire OPSFB is getting wrong supply.

FAULT

1. Check the Low Lube Oil Button position on the Woodward governor.

ISOLATION

2. If tripped (Knob projecting outside),

A. Press the button inside to reset.

B. Reset the Fault manually and crank he engine.

3. If LLOB is not in tripped position

A. Pull the knob outside and reset once again.

B. Check the OPS (LLOB) feed back signal level with Number 5

Green and Yellow LEDs on Digital Input card MDIP 16 in 11^th

slot.

With LLOB in normal position, both LEDs are OFF.

With LLOB in tripped position, both LEDs are ON.

C. If both LEDs are ON with LLOB in normal position

a) Check voltage at wire No. 1B at the back side TB.

b) If voltage is > 65V

c) Disconnect the wires 1B and identify which wire is getting

supply.

d) If the wire is from governor amphonal plug, then the micro

switch in the Governor is shorted. Replace the micro switch.

e) If the wire is from loco side, there may be a wrong feed back

from indication panel side. Check up and isolate the supply.

Note: Most probably this fault is logged due to LLOB tripping while

notching up or notching down or sudden easing of throttle

after working in higher notches.

Imp. : If the fault is repeatedly logging and engine shutting

down, the shutting down pressures of lube oil and the

timings need to be recalibrated on the governor.

PARAMETER

DESCRIPTION

FAULT CODE

1007

FAULT MESSAGE

Power Circuit Ground Fault.

RESTRICTIONS

Motoring and Dynamic Brake Prohibited.

Engine speed restricted to Idle.

ALARM BELL

Continuous ON

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when the traction alternator neutral to ground leakage

RECOVERY

current value is reduced below the set limit and Master Handle is

brought to IDLE.

PROBABLE

1. The fault may be transient or permanent.

CAUSES

2. The Fault is automatically recovered after 15 seconds once the

throttle is brought to IDLE.

3. Driver can work further with out any trouble.

4. If the fault is recoring for more than 3 times in one hour, it

indicates fault is persisting and needs attention.

5. The fault is logged due to

A. Moisture in Traction Motors.

B. Flash over in Traction Motors

C. Cracked insulators on traction Traction Alternators / Traction

Motors / Power Rectifier / Dynamic brake grids / BKT / REV /

power contactors.

D. Any external metal parts touching to power terminals.

E. Any power circuit cables are rubbing to body and insulation is

damaged.

FAULT

If the fault is recurring:

ISOLATION

1. Set the display mode to ‘Mixed’ through Display Menu setup.

2. Apply Loco motive brakes and ensure locomotive brakes are

physically applied.

3. Set the locomotive operation to motoring mode and notch to 1.

4. Observe the traction alternator leakage current (TANGI) on the

display.

5. If the leakage cauurent ismore than set (0.4 Amps) value, then

there is a real ground.

A. Inspect traction alternator power circuit cables for any rubbing

to loco body. If so isolate the cables.

B. Inspect traction motor cables for any rubbing to locobody. If so

isolate the cables.

C. Check for any cracked insualators in the equipements as

mentioned above.

D. Check for any flash over / burnt marks in the power rectifier and

connected cables.

PARAMETER

DESCRIPTION

FAULT CODE

1008

FAULT MESSAGE

Control Circuit Ground Fault.

RESTRICTIONS

Cranking prohibited.

ALARM BELL

Continuous ON

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the control circuit negative to ground leakage current

RECOVERY

value is reduced below the set limit and 15 seconds lapsed with Master

Handle in IDLE. Automatic Fault reset is permitted for 3 times in an

hour and after that manually reset is required.

PROBABLE

1. Any control circuit wiring is grounded.

CAUSES

2. Any equipements like dust blower motors, sander coils, lighting

circuit etc. connected in control circuits are having low / zero

insulation resistance value.

FAULT

1. Identify the control circuit having low/zero Insulation Resistance

ISOLATION

(IR) value.

2. Isoalte the low insulation either replacing the equipement or by

insulating the grounded wires.

Note: This fault is logged during cranking only.

PARAMETER

DESCRIPTION

FAULT CODE

1009

FAULT MESSAGE

Locked Axle on Wheel Number 1

RESTRICTIONS

Motoring and Dynamic Brake Prohibited.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

No auto recovery.

RECOVERY

PROBABLE

1. There may be a physical locked axle.

CAUSES

2. Traction Motor speed sensor is faulty.

3. The speed signal gear assembly worked out from the Traction Motor

Armature shaft.

FAULT

1. If there is physically locked axle, act according to Rail Road rules

ISOLATION

and regulations.

2. If the axle is not locked physically,

A. Reset the fault manually. Set the display mode to ‘Wheel Slip

Display Mode’ under Display Menu. Open the notch to 1 in

motoring and slowly release the brakes.

B. Observe the individual Traction Motor speeds and currents on

the display.

C. If the currents of all Traction Motor are with in limits, and speed

of Traction Motor No.1 is zero / less, MEP-660 is not getting

proper speed signal from Traction Motor No.1.

D. Stop the locomotive and

a) Check for any cable disconnection in the No.1 Traction Motor

Armature speed sensor circuit. Replace / reconnect the cable.

b) Check for any dislocation of the speed sensor on the end

shield of Traction Motor 1. Reconnect the sensor properly.

c) Remove the end shield of Traction motor No.1 and check for

dislocation of sensor gear on the shaft. If so replace the Tr.

Motor / refit the sensor gear properly.

PARAMETER

DESCRIPTION

FAULT CODE

1010

FAULT MESSAGE

Locked Axle on Wheel Number 2

RESTRICTIONS

Motoring and Dynamic Brake Prohibited.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

No auto recovery.

RECOVERY

PROBABLE

1. There may be a physical locked axle.

CAUSES

2. Traction Motor speed sensor is faulty.

3. The speed signal gear assembly worked out from the Traction Motor

Armature shaft.

FAULT

1. If there is physically locked axle, act according to Rail Road rules

ISOLATION

and regulations.

2. If the axle is not locked physically,

A. Reset the fault manually. Set the display mode to ‘Wheel Slip

Display Mode’ under Display Menu. Open the notch to 1 in

motoring and slowly release the brakes.

B. Observe the individual Traction Motor speeds and currents on

the display.

C. If the currents of all Traction Motor are with in limits, and speed

of Traction Motor No.2 is zero / less, MEP-660 is not getting

proper speed signal from Traction Motor No.2.

D. Stop the locomotive and

a) Check for any cable disconnection in the No.2 Traction Motor

Armature speed sensor circuit. Replace / reconnect the cable.

b) Check for any dislocation of the speed sensor on the end

shield of Traction Motor 2. Reconnect the sensor properly.

c) Remove the end shield of Traction motor No.2 and check for

dislocation of sensor gear on the shaft. If so replace the Tr.

Motor / refit the sensor gear properly.

PARAMETER

DESCRIPTION

FAULT CODE

1011

FAULT MESSAGE

Locked Axle on Wheel Number 3

RESTRICTIONS

Motoring and Dynamic Brake Prohibited.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

No auto recovery.

RECOVERY

PROBABLE

1. There may be a physical locked axle.

CAUSES

2. Traction Motor speed sensor is faulty.

3. The speed signal gear assembly worked out from the Traction Motor

Armature shaft.

FAULT

1. If there is physically locked axle, act according to Rail Road rules

ISOLATION

and regulations.

2. If the axle is not locked physically,

A. Reset the fault manually. Set the display mode to ‘Wheel Slip

Display Mode’ under Display Menu. Open the notch to 1 in

motoring and slowly release the brakes.

B. Observe the individual Traction Motor speeds and currents on

the display.

C. If the currents of all Traction Motor are with in limits, and speed

of Traction Motor No.3 is zero / less, MEP-660 is not getting

proper speed signal from Traction Motor No.3

D. Stop the locomotive and

a) Check for any cable disconnection in the No.3 Traction Motor

Armature speed sensor circuit. Replace / reconnect the cable.

b) Check for any dislocation of the speed sensor on the end

shield of Traction Motor 3. Reconnect the sensor properly.

c) Remove the end shield of Traction motor No.3 and check for

dislocation of sensor gear on the shaft. If so replace the Tr.

Motor / refit the sensor gear properly.

PARAMETER

DESCRIPTION

FAULT CODE

1012

FAULT MESSAGE

Locked Axle on Wheel Number 4

RESTRICTIONS

Motoring and Dynamic Brake Prohibited.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

No auto recovery.

RECOVERY

PROBABLE

1. There may be a physical locked axle.

CAUSES

2. Traction Motor speed sensor is faulty.

3. The speed signal gear assembly worked out from the Traction

Motor Armature shaft.

FAULT

1. If there is physically locked axle, act according to Rail Road rules

ISOLATION

and regulations.

2. If the axle is not locked physically,

A. Reset the fault manually. Set the display mode to ‘Wheel Slip

Display Mode’ under Display Menu. Open the notch to 1 in

motoring and slowly release the brakes.

B. Observe the individual Traction Motor speeds and currents on

the display.

C. If the currents of all Traction Motor are with in limits, and speed

of Traction Motor No.4 is zero / less, MEP-660 is not getting

proper speed signal from Traction Motor No.4.

D. Stop the locomotive and

a) Check for any cable disconnection in the No.4 Traction Motor

Armature speed sensor circuit. Replace / reconnect the cable.

b) Check for any dislocation of the speed sensor on the end

shield of Traction Motor 4. Reconnect the sensor properly.

c) Remove the end shield of Traction motor No.4 and check for

dislocation of sensor gear on the shaft. If so replace the Tr.

Motor / refit the sensor gear properly.

PARAMETER

DESCRIPTION

FAULT CODE

1013

FAULT MESSAGE

Locked Axle on Wheel Number 5

RESTRICTIONS

Motoring and Dynamic Brake Prohibited.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

No auto recovery.

RECOVERY

PROBABLE

1. There may be a physical locked axle.

CAUSES

2. Traction Motor speed sensor is faulty.

3. The speed signal gear assembly worked out from the Traction Motor

Armature shaft.

FAULT

1. If there is physically locked axle, act according to Rail Road rules

ISOLATION

and regulations.

2. If the axle is not locked physically,

A. Reset the fault manually. Set the display mode to ‘Wheel Slip

Display Mode’ under Display Menu. Open the notch to 1 in

motoring and slowly release the brakes.

B. Observe the individual Traction Motor speeds and currents on

the display.

C. If the currents of all Traction Motor are with in limits, and speed

of Traction Motor No.5 is zero / less, MEP-660 is not getting

proper speed signal from Traction Motor No.5.

D. Stop the locomotive and

a) Check for any cable disconnection in the No.5 Traction Motor

Armature speed sensor circuit. Replace / reconnect the cable.

b) Check for any dislocation of the speed sensor on the end

shield of Traction Motor 5. Reconnect the sensor properly.

c) Remove the end shield of Traction motor No.5 and check for

dislocation of sensor gear on the shaft. If so replace the Tr.

Motor / refit the sensor gear properly.

PARAMETER

DESCRIPTION

FAULT CODE

1014

FAULT MESSAGE

Locked Axle on Wheel Number 6

RESTRICTIONS

Motoring and Dynamic Brake Prohibited.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

No auto recovery.

RECOVERY

PROBABLE

1. There may be a physical locked axle.

CAUSES

2. Traction Motor speed sensor is faulty.

3. The speed signal gear assembly worked out from the Traction Motor

Armature shaft.

FAULT

1. If there is physically locked axle, act according to Rail Road rules

ISOLATION

and regulations.

2. If the axle is not locked physically,

A. Reset the fault manually. Set the display mode to ‘Wheel Slip

Display Mode’ under Display Menu. Open the notch to 1 in

motoring and slowly release the brakes.

B. Observe the individual Traction Motor speeds and currents on

the display.

C. If the currents of all Traction Motor are with in limits, and speed

of Traction Motor No.6 is zero / less, MEP-660 is not getting

proper speed signal from Traction Motor No.6.

D. Stop the locomotive and

a) Check for any cable disconnection in the No.6 Traction Motor

Armature speed sensor circuit. Replace / reconnect the cable.

b) Check for any dislocation of the speed sensor on the end

shield of Traction Motor 6. Reconnect the sensor properly.

c) Remove the end shield of Traction motor No.6 and check for

dislocation of sensor gear on the shaft. If so replace the Tr.

Motor / refit the sensor gear properly.

PARAMETER

DESCRIPTION

FAULT CODE

1016

FAULT MESSAGE

Alternator Field Circuit Open FAULT

RESTRICTIONS

Nil

ALARM BELL

30 Seconds.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when Traction Alternator Field circuit is closed.

RECOVERY

PROBABLE

Internal fault with Exciter.

CAUSES

Disconnected cable at Exciter terminals.

Disconnected cables at the Terminal board.

Poor contact of GF contactor main tips / the main tips may not be

closing due to mechanical obstruction in the contactor assembly.

Bad contact between Traction Alternator brushes and slip rings.

Tr. Alternator field showing high resistance / Open circuited.

FAULT

Set the Display mode to ‘Excitation’ through Display menu.

ISOLATION

Apply locomotive brakes. Keep Reverser Hnadle in neutral position.

Switch ON both the GF switches and open notch to 1.

Observe Exciter Field current (EXFI) and Exciter PWM output

(EXPWM). Exciter Field current should be around 2.4 Amps and

Exciter PWM output should be around 4000.

Measure Exciter output Voltage on Exciter terminals LA and LAA.

A. If the Exciter output Voltage is less than 10 Volts then

a) Exciter is defective. Replace the Exciter.

B. If Exciter Voltage is more than the minimum value, then check

the Voltage on terminals 61L and 44 at the backside TB.

C. If the voltage is zero, then

a) The cables 61L or / and cable 44 are having high resistance

or open circuited. Identify and repalce the cable.

D. If the Voltage is equal to Exciter Voltage, then check the voltage

on terminals 44 at backside TB and 61L at GF contactor.

E. If the voltage is zero, then

a) The cable 61L from backside TB to GF contactor is having

high resistance or open circuited. Check and replace the

cable.

F. If the Voltage is equal to the Exciter Voltage, then check the

voltage on the terminals 44 at backside TB and 61K at GF

contactor. (Ensure that the GF contactor is in picked up

condition and AFR connectons are removed.)

G. With GF contactor closed and the Voltage is zero, then

a) GF contactor main tips are not closing properly. Remove the

archute and exmine for any mechanical obstruction / foreign

materials inside the contactor. Remove and clean the

contactors. If the contactor itself is defective, replace the

contactors.

H. If the Voltage is equal to Exciter Voltage, then check the Voltage

on terminals 61K and 44 at backside TB.

I. If the Voltage is zero, then

a) The cable 61K from GF contactor to backside TB is having

high resistance or open circuited. Check and replace the

cable.

J. If the Voltage is equal to the Exciter Voltage, then check the

Voltage on the Traction Alternator brush arms.

Extreme care should be taken while measuring the Voltage at

the Traction Alternator slip rings. It is highly recommended to

shut down the engine and connect measuring leads at the brush

arms. After connecting the leads to meter, set up the

locomotive as per the Sl. No. 1 to 3.

K. If the Voltage is zero, then

a) The cables AF1 and AF2 connecting Traction Alternator brush

arms and back side TB are having high resistance / open

circuit. Check and replace the cables.

L. If the Voltage is equal to Exciter Voltage, then

a) The problem is inside the Traction Alternator. Check the

following and fix up the problem

1) Check up the brush arms and brushes for any open

circuit / burnt sysmptoms.

2) Check up for any discoloration of slip rings that can

cause bad contact between brushes and slip rings.

3) Check up any burnt / fused slip ring connections.

4) Check for any open circuit in the Traction Alternator Field

circuit.

5. If every thing is nrmal, measure the Traction Alternator Field

current with a clip on DC ammeter clipped to any one of the

Traction Alternator Field cables.

6. If the meter indicates current and the value of EXAI on the display

is less / zero, then

A. The communication cable between the current sensor EXAI and

MEP-660 is bad. Check the continuity of the cable and if

necessary replace the cable.

B. If the cable is good, then the sensor is bad. Replace the sensor.

7. Return the throttle to IDLE.

PARAMETER

DESCRIPTION

FAULT CODE

1017

FAULT MESSAGE

Exciter Field Circuit Open / Short Fault.

RESTRICTIONS

Nil

ALARM BELL

30 Seconds.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when Exciter Filed Current found normal.

RECOVERY

PROBABLE

Defective wiring (Open circuited at Ex. Gen. TB or back side TB.)

CAUSES

Defective Current Sensor.

Bad interlocks of EXPR. (61F-61FF, 61G-61GA)

Defective Ex. Gen. (Field is internally open circuited.)

Defective MPWM2 card.

FAULT

Set the display mode to ‘Excitation’ under ‘Display Mode’ menu.

ISOLATION

Move the master handle to Notch 1, by applying brakes.

If EPWM is more than 0 and EXFI is zero,

Check voltage between wire 61F (at EXPR 2 interlock) and

locomotive 4-wire.

A. If Voltage is zero, check 71-wire loop coming to FCP. If it is

open, identify and replace.

B. If the voltage is 72V, check 4-wire loop coming to FCP from the

locomotive 4-wire.

C. If voltage is still 0, replace the FCP.

D. If voltage is greater than 30V.

Check voltage between wire 61FF (at EXPR 2 interlock) and

locomotive 4-wire.

A. If the voltage between wire 61FF at FCP and locomotive 4-wire

is 0, check the EXPR 2 interlock.

B. If the voltage between wire 61FF at FCP and locomotive 4-wire

is greater than 30V, check the current sensor proper polarity.

Identify and replace the sensor.

Check voltage between wir LSS (E) at Exciter field winding and

locomotive 4-wire.

A. If Voltage is 0, check the Exciter field winding resistance with a

multimeter. If it is open circuited replace the Exciter Gen.

B. If Voltage is greater than 30V, check the EXPR 3 interlock

condition.

If still EXFI is showing zero, MPWM2 card might be defective.

Replace the card check.

PARAMETER

DESCRIPTION

FAULT CODE

1018

FAULT MESSAGE

GF Stuck Open. Run Auto/Manual Test

Can’t Power up: Electrical Control Problem

RESTRICTIONS

Nil

ALARM BELL

30 Seconds.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when GF contactorfound closed.

RECOVERY

PROBABLE

Defective GF contactor.

CAUSES

Wiring fault from MEP-660 to GF contactor coil.

Positive supply to GF contactor operating coil is missing.

FAULT

Set the Display to ‘Manual Tests for Ouputs’ mode through Test

ISOLATION

Mode Menu and satisfy the initial conditions required to run manual

test as prompted on the display unit.

Press 13 + ‘Enter Key’+1 to energise GF contactor.

If GF contactor energises, then

A. Check up for proper closing of main contact tips and Auxilary

contacts.

B. The status of GF Aux. Contact 1 can be checked through 0

number Green and Yellow LEDs on digital input card MDIP-16 in

slot 11.

C. The status of GF Aux. Contact 2 can be checked through 1

numbered Green and Yellow LEDs on Digital Input card MDIP-16

in slot No. 12.

D. All the 4 LEDs should glow.

Press ‘0’ key to deenegise the GF contactor.

A. All the 4 LEDs in both the digital input cards should be OFF.

B. If LEDs are not as per the sequence and remains always OFF,

then

a) Check voltage on wire No. 51 at the GF contactor auxiliary

contacts 1 and 2 with respect to wire No. 4

b) If the voltage is zero, then

1) Wiring loop of wire No. 51 is open circuited. Identify the

open circuit and ensure supply at the terminal 51 on Aux.

Contact of GF contactor is available.

c) If Voltage is greater than 65V, then

1) Check voltage at the wire terminals FCD and FCE on

Auxiliary contacts of GF contactor.

2) If Voltage is zero, then the Aux. Contacts of GF

contactors are bad. Check, clean and adjust the auxiliary

contacts. If necessary replace them.

3) If voltage is greater than 65V, then wiring between GF

contactor and MEP-660 is open circuited. Identy and

replace the cable.

C. If the GF contactor is not energizing as per the test sequence,

then

a) Connect Voltmeter across the operating coil of the GF

contactor and switch ON GF contactor by pressing 1 key.

b) If the Voltage is more than 65V, then

1) The GF contactor-operating coil is open circuited

internally or there may be a physical obstruction in the

contactor operation. Check and replace the GF contactor

if necessary.

c) If the voltage is zero, then

d) Check the voltage on coil terminal wire No. 13 and 4.

1) If Voltage is zero, then wire loop 13 connected to GF

operating coil is open circuited. Identify and replace.

2) If the voltage is more than 65V, then negative feed is not

coming to GF contactor oerating coil.

3) This may be due to cable fault or digtal ouput card

defective.

4) Check the cable continuity from MEP-660 to GF contactor

coil. If necessary replace the cable.

5) If continuity is available, replace the digital ouput card.

And check the operations of GF contactor.

PARAMETER

DESCRIPTION

FAULT CODE

1019

FAULT MESSAGE

CEB Breaker OFF.

RESTRICTIONS

No restrictions, only indication.

ALARM BELL

Continuous ON

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when CEB breaker is switched ON.

RECOVERY

PROBABLE

1. Crank Case Exahauster Motor is not getting supply due to CCEB

CAUSES

tripped or switched OFF.

2. Crankcase Exhauster Breaker Feed Back (CEB FB) status is low as

sensed by MEP-660.

FAULT

1. If Breaker is in tripped/OFF position, reset/switch ON the breaker.

ISOLATION

2. The high level status of the Crankcase Exhauster Breaker Feed Back

is indicated by 7 Numbered Green and Yellow LEDs on digital input

card MDIP-16 in slot No. 13.

3. With CEB in ON position, CCEM fail indication LEDs on both control

desks should be OFF. Both 7 numbered Green and Yellow LEDs on

the Digital Input card in slot 13 should be ON.

A. If the indications LEDs on both the control desks are ON, then

the breaker is defective and the CCEM is not working. Replace

the breaker.

B. If 7 numbered Green LED is OFF on digital input card in slot 13,

then wiring from CEB breaker to MEP-660 open circuited. Check

and replace wiring.

C. If 7-numberED Green LED is ON and 7-numbered Yellow LED is

OFF, the digital input card in slot 13 is defective. Replace and

check.

PARAMETER

DESCRIPTION

FAULT CODE

1020

FAULT MESSAGE

Rectifier Diodes HOT.

RESTRICTIONS

Engine RPM and Power Limited to 4th Notch.

ALARM BELL

30 Sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when thermostate switch in the power rectifier closes.

RECOVERY

PROBABLE

1. The thermostate switch in the power rectifier unit is showing open

CAUSES

circuit due to blower might have failed resulting in high temperature

or the thermostate contact itself is open circuited permanently.

Note: Probably this fault message will be logged in locomotives

equipped with self-cooled rectifiers and having thermal protection for

the diodes.

FAULT

The thermostate switch is a normally closed interlock. 8 numbered

ISOLATION

Green and Yellow LEDs on the digital input card MDIP-16 in slot 12

indicate the status of this interlock ‘RECT HOT’. Both Green and Yellow

LEDs should be ON in normal working condition of the loco. Reset the

message and check the status of both the LEDs

If both Green and Yellow LEDs are not ON, then

The power rectifier blower might have failed and the diodes

might have heated up. Check up proper working of rectifier

blower. If necessary replace the blower.

If blower had failed, please ensure that no diodes/fuses

are burnt out inside rectifier unit before releasing the

locomotive.

If the rectifier is cool and blower is working normal, then check

voltage at the rectifier terminal board on wire terminal No.

DLK1.

a) If the voltage is zero, check voltage on wire terminal 51.

1) If the voltage is zero, then 51-wire loop from CP/TB to

rectifier TB is open circuited. Check and replace.

2) If the voltage is > 65V, the thermostae switch is

defective or internal wiring is burnt. Check up with

rectifier and attend.

If the voltage is > 65V, check voltage at terminal DLK1 on

backside TB.

a) If the voltage is zero, then the wire loop DLK1 from backside

TB to Rectifier TB is open circuited. Check and replace.

If the voltage is > 65V and

a) The 8 numbered Green LED on the Digital Input card in slot

12 is not ON, then the wire loop from backside TB to MEP-

660 is open circuited. Check and replace.

b) Green LED is ON and 8 numbered Yellow LED on the digital

input card in slot 12 is OFF, then the digital card is defective.

Check and replace.

PARAMETER

DESCRIPTION

FAULT CODE

1021

FAULT MESSAGE

Rectifier Blower Failed or RBB Breaker OFF.

RESTRICTIONS

Engine RPM and Power Limited to 4th Notch.

ALARM BELL

30 Sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when Rectifier blower Breaker is switched ON.

RECOVERY

PROBABLE

1. The Rectifier Blower Breaker is in switched OFF / tripped position.

CAUSES

Note: Probably this fault message will be logged in locomotives

equipped with self-cooled rectifiers and having thermal protection for

the diodes.

FAULT

1. If the Rectifier Blower Breaker is in switched OFF / Tripped position,

ISOLATION

switch ON / reset the breaker. 9 numbered Green and Yellow LEDs

on the digital input card in slot 12 indicate the status of the Rctifier

Blower Breaker. With RBB in ON position, Both LEDs should be ON.

2. If the Green LED is not ON, then

A. Check supply at wire terminals 50AA and 4 on the backside TB.

B. If the voltage is zero, then the breaker is defective or wire 55A

between RRB to backside TB is open circuited. Check up and

replace.

C. If voltage is > 65V, then rectifier blower should work. If rectifier

blower is not working, check up the voltage at same wire

terminals on rectifier TB.

a) If voltage is zero, then the wire 55A or 4 wire between

backside TB and Rectifier TB is open circuited. Check and

replace.

b) If Voltage is > 65 V, then check up with blower / Rectifier

wiring.

D. If the 9 numbered Green LED is OFF, then the wire No. RBBFB

from backside TB and MEP-660 is open circuited. Check up and

replace the wires.

E. If the Green LED and 9 numbered Yellow LED on Digital input

card in slot 12 is OFF, then digital input card is defective. Check

and replace.

PARAMETER

DESCRIPTION

FAULT CODE

1022

FAULT MESSAGE

Wrong Command: TL6 & TL17/TL23 High.

Can’t Change Mode

RESTRICTIONS

Motoring and Dynamic Brake Prohibited

ALARM BELL

30 Sec.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when master handle is brought to IDLE.

RECOVERY

PROBABLE

Most probably this fault is an intermittent fault logged. The fault might

CAUSES

have recovered by the time it is tried to find out the reason. However if

the fault is continuously logging, it may be due to

1. Non-working control stand might not be in IDLE position.

2. Wrong interlocking of any one of the master controllers.

3. Locomotive is being controlled from two locomotives

simultaneously.

4. Wrong feed back of train line wires through MU cables.

5. Any wiring fault causing simultaneous energisation TL6 along with

TL17 or TL23 while operating Master Handle.

FAULT

If the fault is cleared check the operation of the master controller

ISOLATION

interlocks as follows:

1. Shut down the engine. Set the display mode to “Manual Test for

Inputs” under test menu. When prompted for input number Enter

07 + Enter Key to view the status of the Train Line wire TL6 on the

display.

2. Set the control stand to motoring mode. Operate the Master Handle

between IDLE to 1^st notch two to three times. Observe the status of

the TL6 on the display. The staus of TL6 should toggle as per the

master handle position. Bring back the master handle to IDLE.

3. Press

‘down arrow’ key + 09 + ‘Enter’ key to check the status of

the train line wire TL17.

4. Set the Master Handle to Dynamic Brake set up position. Operate

the Master Handle between IDLE to OFF positions two to three

times. Observe the status of Train Line wire TL17 while moving the

Master Handle and ensure it is as per Master Handle position.

5. Press ‘down arrow’ key +10 + ‘Enter’ key to check the status of the

train line wire TL23.

6. Move the Master Handle between OFF position to Dynamic brake

position for two to three times and observe the status of TL23 wire.

It should follow the Master Handle movement.

7. Repeat the steps from 2 to 7 on the other control stand. This

ensures proper operation of the Master Handle interlocks.

If the fault is not cleared and continuously logging:

1. Remove the MU jumper cables to isolate wrong feed through MU

jumper cables.

2. If the fault is not rectified, keep both Master Handles in IDLE

position.

3. Check voltage on Train Line Wires TL6, TL17 and TL23 at the

backside TB.

4. If voltage is available on any of the above wires, Disconnect the

bunch wires and identify which lead is getting wrong supply and

rectify.

5. If no voltages are found on the above wires,

A. Operate Master Handle to Motoring position (Notch 1) on control

stand 1. Check voltages on TL17 and TL23.

a) If voltage is >35V on any of the two wires, then repeat the

step 4.

B. Operate the Master Handle to OFF position (Dynamic Brake set

up). Check Voltage on TL6.

a) If Voltage is >35V on TL6, then repeat step 4.

C. Operate the Master Handle to Dy. Brake position. Check Voltage

on TL6.

a) If voltage is > 35V on TL6, then repeat step 4.

D. Move the Master Handle to IDLE position.

E. Rpeat checks from A to D on control stand 2.

PARAMETER

DESCRIPTION

FAULT CODE

1023

FAULT MESSAGE

BKT Stuck in Braking. Run Auto/Manual Test.

Can’t Motor: Electrical Control Problem

RESTRICTIONS

Motoring Prohibited

ALARM BELL

30 Sec.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when BKT stuck is cleared

RECOVERY

PROBABLE

Control Air pressure is less or zero.

CAUSES

Foreign particles fallen in Paul assembly.

BKT motoring side magnet valve is defective.

Air leaking from the Air cylinder gasket.

Air hose connection to magnet valve given up.

FAULT

Check control air pressure in the nose compartment. It should be

ISOLATION

5kg/Cm.².

A. If it is less adjust the pressure.

B. If it is zero, check and attend air brake system.

Operate BKT manually with ‘L’ rod.

A. If BKT is not operating manually, then

a) Inspect Paul assembly for any foreign particles inside the

Rack and pinion teeth. Check and attend.

b) Inspect other operatig mechanism for any disorders or

broken iolite bushes etc. Replace wherever necessary.

c) Check for any main contacts welding. Inspect and replace if

necessary.

If BKT is operating manually, and control air pressure is 5 Kg/Cm²

operate the BKT through magnetvalves by pressing manual levers /

armature plates on both Motoring and Braking side magnetvalves.

A. If BKT is not operating, then

a) Check which magnet valve is defective and replace.

b) Check for any air leakages through air engine gaskets and

replace the gaskets.

c) Check for any damged piston buckets and replace.

If BKT is operating through magnetvalves, set up the display mode

to “Manual Tests for outputs” under Test Mode menu by pressing

the following keys.

‘Menu’ + 3 + (Pass code) + 3 + ‘Enter’ + 09 + ‘Enter’ + 1 to

operate magnet valve of BKT motoring side.

If the BKT is not operated to motoring side, then

A. Check the voltage at the operating coil of BKT motoring side

magnet valve.

B. If the Voltage is > 65V, then the operating coil is open circuited

internally. Replace amgnet valve.

C. If the Voltage is zero, check the voltage between wire terminal 6

on the BKT motoring magnet valve and 4 wire.

D. If the voltage is zero, 6 wire loop coming to BKT motoring side

magnet valve is open circuited. Check and replace.

E. If voltage is > 65V, then positive supply is available but

negative supply through MEP-660 is missing.

PARAMETER

DESCRIPTION

FAULT CODE

1024

FAULT MESSAGE

BKT-M Aux Contact ckt. Open. Run Auto/Manual Test.

Can’t Motor: Electrical Control Problem.

RESTRICTIONS

Motoring Prohibited

ALARM BELL

30 Sec.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when BKT-M Aux. Contact circuit closes.

RECOVERY

PROBABLE

1. Wiring faulty causing low status level of BKT-M feed back.

CAUSES

2. BKT Interlock

FAULT

13 & 14 numbered Green LEDs on the digital input card MDIP-16 in slot

ISOLATION

10 indicate the status of BKT position in the following pattern.

BKT position

Green LED - 13

Green LED - 14

BKT in Motoring Position

OFF

BKT in Dynamic Brake Position

OFF

Check BKT Aux. Contactacts for any dislocation of contacts /

disconnected wires. In any found rectify or replace the Aux.

Contacts if necessary. Ensure proper closing of Aux. Contacts both

in motoring and dynamic brake position. Reset the message.

Ensure control air pressure is 5 Kg/Cm². Set the display mode to

“Manual Tests for outputs” under Test Mode menu by pressing the

following keys in the same sequence.

‘Menu’ + 3 + (Pass code) + 3

+ ‘Enter’ + 09 + ‘Enter’ + 1 to operate magnet valve of BKT

motoring side.

BKT is operated to motoring side. Ensure the aux. Contacts are

operated and closing properly. Check the status of Green LEDs on

the Digital Input card in slot 10.

If Green LED-13 is not ON, then

A. Check the supply between wire terminal 51 at the common

terminal of the Auxiliary contacts of BKT and wire 4.

a) If the voltage is zero, then wire 51-loop open circuited.

Check and replace.

b) If voltage is > 65 V, then check the voltage between Aux.

Contact BKTM and 4.

c) If voltage is zero, then the Aux. Contact is bad. Check and

clean. If necessary replace.

d) If the Voltage is > 65V, then check the voltage between wire

terminals BKTM and 4 at the backside TB.

e) If voltage is zero, then the wire BKTB between Aux. Contact

and backside TB is open circuited. Check and replace.

f) If the voltage is more than 65V, then the wire BKTMFB

bwteeen backside TB and MEP-660 open circuited. Check

and replace.

Press the keys listed with in brakets on the display unit in the same

sequence (0 + ‘Menu’ +’Menu’ + 5). The display returns to normal

mode. Reset the fault and release the loco.

PARAMETER

DESCRIPTION

FAULT CODE

1025

FAULT MESSAGE

Alternator Output Voltage High FAULT

RESTRICTIONS

Motoring and Dynamic Brake Prohibited

ALARM BELL

30 Sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when Traction Alternator Voltage is reduced below 100V and

RECOVERY

Master Handle is brought to IDLE. Auto recovery is permitted for 3

times in one hour. There after Manual reset is required.

PROBABLE

Momentarily the Traction Alternator Voltage might have shooted up

CAUSES

Some wiring short circuit has occurred in FCP and Exciter field

circuit.

FAULT

Connect a DC voltameter 0 to 1000V range between GA11 and GA2.

ISOLATION

Crank the engine and ensure loco brakes are applied.

Press the following keys on the display unit in the same sequence to

set the display mode to “Load Box Test” under Test mode menu.

‘Menu’ + 3 + (pass code) + 1 + 1 +’Enter’.

Move the master Hnadle to notch 1 with both GF switches are ON.

Observe the Traction Alternator Voltage displayed on the display

unit under TA Volts.

Compare this reading with the voltage reading on the external

voltmeter.

If the Voltage on the display is abnormally higher than the

voltmeter reading, then

A. The voltage sensor is faulty. Check up the cable connections on

the Tr. Alternator Voltage sensor TAV. If necessary replace.

If both the voltages are same and are abnormally high as compared

to 1^st notch no load voltage, then move the Master Handle to IDLE.

A. Check wiring connections at FCP1 (EFR1, 2, 3 and 4). Check for

any disconnected / short-circuited / over heated wire terminals

at the FCP1. Check and rectify.

B. Check wiring connections at wire terminals 61G and 61GA on

the backside TB for any disconnected / short-circuited / over

heated terminals. Check and rectify.

If both the voltages are equal and with in limits, then the fault is a

transient.

PARAMETER

DESCRIPTION

FAULT CODE

1026

FAULT MESSAGE

Alternator Output Current High FAULT in DB

RESTRICTIONS

Motoring and Dynamic Brake Prohibited

ALARM BELL

30 Sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when Traction Alternator current is reduced below 100A and

RECOVERY

Master Handle is brought to IDLE. Auto fault recovery is permitted for 3

times in one hour. There after Manual reset is required.

PROBABLE

1. Defective FCP

CAUSES

2. Any foreign materials in between REV or BKT contacts cuasing high

current to flow

3. Defective current sensor

FAULT

1. Check for any disconnected / over heated wires at the FCP. Identify

ISOLATION

and reconnect the wires.

2. Check BKT and REV contacts. Remove any foreign materials if

avialble.

3. Apply loco brakes and ensure that the brakes are physically applied.

Take all precausions required to move a locomotive.

4. Set up the locomotive to motoring and move the master handle to

notch 1.

5. If the current indicated on the display is with in limits of 1^st notch

current, then the fault is transient.

6. If the current indicated on the display is abnormally high with out

any jerk, then the current sensor is faulty. Check and replace the

Traction alternator current sensor.

7. If the current idicated is abnormally high with heavy jerk, PWM

output card is defect.

8. Replace the card and check once again.

PARAMETER

DESCRIPTION

FAULT CODE

1027

FAULT MESSAGE

Alternator Field Over Current fault.

RESTRICTIONS

Motoring and Dynamic Brake Prohibited

ALARM BELL

30 Sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Alternator field current is reduced below 20A

RECOVERY

and Master Handle is brought to IDLE. Auto fault recovery is permitted

for 3 times in one hour. There after Manual reset is required.

PROBABLE

1. Defective FCP

CAUSES

2. Defective Exciter

3. Exciter field drive circuit defect

FAULT

1. Check for any disconnected / over heated wires at the FCP. Identify

ISOLATION

and reconnect the wires.

2. Check for any short circuit between armature and field circuit due

to either internally or externally like terminals touching to

inspection cover. If found rectify and remove short circuit.

3. Apply loco brakes and ensure that the brakes are physically

applied. Take all precausions required to move a locomotive.

4. Set the display mode to excitation mode.

5. Set up the locomotive to motoring and move the master handle to

notch 1.

6. Observe the exciter field current and exciter armature current on

the display unit. If both the values are with in the limits, then the

fault is transient.

PARAMETER

DESCRIPTION

FAULT CODE

1028

FAULT MESSAGE

Exciter Field Over Current Fault.

RESTRICTIONS

Motoring and Dynamic Brake Prohibited

ALARM BELL

30 Sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Autometic when exciter field current is reduced below 0.5A and Master

RECOVERY

Handle is brought to IDLE. Auto fault recovery is permitted for 3 times

in one hour. There after Manual reset is required.

PROBABLE

1. Defective / Wrong connection at FCP

CAUSES

2. Defective Exciter (Field internally shorted)

3. Any one-diode short circuit in the rectifier making the system to

pump more current in the exciter field.

4. One of the alternator phase is not generating any voltage.

5. Defective EXFI current sensor

6. Defective MAIP8_EP card.

FAULT

1. Check for any disconnected / over heated wires at the FCP. Identify

ISOLATION

and reconnect the wires correctly.

2. Check for any short circuit between exciter terminals either

internally or externally like terminals touching to inspection cover.

If found rectify and remove short circuit.

3. Check backside Terminal board for any disconnected exciter field

wires and touching to nearby positive wires. Identify and isolate

them.

4. Check and ensure that there are no short-circuited diodes in the

rectifier.

5. Measure the Exciter field current with an ammeter and compare

with the displayed EXFI value.

6. If the displayed EXFI value is greater than the actual current:

A. EXFI current sensor might be defective.

B. MAIP8_EP card might be defective.

PARAMETER

DESCRIPTION

FAULT CODE

1029

FAULT MESSAGE

Cranking Contactor CK Stuck Closed.

RESTRICTIONS

Motoring Prohibited. Dynamic Brake Prohibited.

ALARM BELL

Continuous

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be

generated again.

FAULT RECOVERY

Automatic on releasing of stuck condition as sensed through

Auxiliary contacts of CK1/CK2/CK3.

PROBABLE

CK1/CK2/CK3 contactor main tips are welded.

CAUSES

Defective wiring.

(Wiring from these auxiliary interlocks

disconnected)

Defective MDIP16 card.

FAULT ISOLATION

Check the status of CK1/CK2/CK3 feed back LEDs on the

MDIP_16 card in slot 10 and green LEDs numbered 0,1,2.

Which ever the LED is not glowing, corresponding cranking

contactor is welded or interlock is bad.

LED 0 for CK1, LED 1 for CK2 and LED 2 for CK3. on MDIP16

card in slot 10.

Check for any weld condition of the contactors. Release the

main tips with a wooden stick.

If there is no welding of contactors, check and clean the

concerned N/C interlocks of that particular contactor.

If interlock is good, check the voltage between CK#FB and

locomotive 4 wire.

If the Voltage is more than 65V,

A. Check the slackness of the connector of cable ID: AU at

control unit. If slack press the connector towards the control

unit and tighten the connector.

B. If connector is tight and still the green LED is not glowing

a) MDIP16 card might be defective.

PARAMETER

DESCRIPTION

FAULT CODE

1030

FAULT MESSAGE

SLBR / SLBC Contactor Stuck Closed.

RESTRICTIONS

Motoring Prohibited Dynamic Brake Prohibited

ALARM BELL

30 Seconds

RESET LEVEL

Low, Manual

FAULT RECOVERY

Autometic. When stuck condition is released as sensed through

auxiliary contacts of SLBC1, SLBC2, SLBC3 and SLBC4.

Manual fault clearing through keyboard on the display unit. (If the

fault condition is present when cleared manually, the fault will be

generated again.

PROBABLE

1. Defective SLBR relay. (Permanently ON)

CAUSES

2. Defective MLSD16 card (slot 15)

3. Welded SLBC1/SLBC2/SLBC3/SLBC4

4. Defective wiring. (SLBC FB wire is getting +ve supply)

5. Defective MDIP16 card (Slot 13)

FAULT ISOLATION

1. Check the status of SLBR relay.

2. If SLBR is in pick up condition:

A. Check the supply voltage at SLBR coil. If voltage is more than

65V, then MLSD16 card in slot 15 is defective. Replace the

card.

B. If the voltage is zero, then the relay is defective. Replace the

relay.

3. If SLBR is in drop out conditio, check status of SLBC contactors.

4. If any SLBC contactor is in pick up position, check the supply at

the magnet valve coil.

A. If the voltage is more than 65V, the SLBR relay is defective or

SLBC wire is getting supply.

B. Replace the SLBR relay or identify the wrong supply to SLBC

contactor.

5. If no SLBC contactors are in pick up condition, check for the

welded interlocks of SLBC auxiliary contacts. If found replace the

Aux. Contacts.

6. If no aux. Contacts of SLBC is welded, check the supply between

SLBC FB wire and wire 4 of locomotive.

A. If voltage is more than 65V, then SLBC FB wire is getting wrong

supply. Identify wrong wiring and rectify.

B. If the voltage is zero, then MDIP16 card in slot No. 13 is

defective. Replace the card.

PARAMETER

DESCRIPTION

FAULT CODE

1031

FAULT MESSAGE

Wheel Number 1 Continuously Sliding

RESTRICTIONS

No restrictions. Warning only.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic on arresting of wheel slide as sensed through TM speed

RECOVERY

sensor.

PROBABLE

1. Brake binding on No.1 wheel resulting in low speed.

CAUSES

2. Defective Speed sensor on TM 1

FAULT

1. If any brake binding is found, clear it as early as possible.

ISOLATION

2. Check for tightness of the speed sensor coupler of TM No.1 and

ensure coupler is tight.

3. Speed sensor gear in the TM No.1 is slack or freely rotating in the

end cup. If found replace the TM.

PARAMETER

DESCRIPTION

FAULT CODE

1032

FAULT MESSAGE

Wheel Number 2 Continuously Sliding

RESTRICTIONS

No restrictions. Warning only.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic on arresting of wheel slide as sensed through TM speed

RECOVERY

sensor.

PROBABLE

1. Brake binding on No.2 wheel resulting in low speed.

CAUSES

2. Defective Speed sensor on TM 2

FAULT

1. If any brake binding is found, clear it as early as possible.

ISOLATION

2. Check for tightness of the speed sensor coupler of TM No.2 and

ensure coupler is tight.

3. Speed sensor gear in the TM No.2 is slack or freely rotating in the

end cup. If found replace the TM.

PARAMETER

DESCRIPTION

FAULT CODE

1033

FAULT MESSAGE

Wheel Number 3 Continuously Sliding

RESTRICTIONS

No restrictions. Warning only.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic on arresting of wheel slide as sensed through TM speed

RECOVERY

sensor.

PROBABLE

1. Brake binding on No.3 wheel resulting in low speed.

CAUSES

2. Defective Speed sensor on TM 3

FAULT

1. If any brake binding is found, clear it as early as possible.

ISOLATION

2. Check for tightness of the speed sensor coupler of TM No.3 and

ensure coupler is tight.

3. Speed sensor gear in the TM No.3 is slack or freely rotating in the

end cup. If found replace the TM.

PARAMETER

DESCRIPTION

FAULT CODE

1034

FAULT MESSAGE

Wheel Number 4 Continuously Sliding

RESTRICTIONS

No restrictions. Warning only.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic on arresting of wheel slide as sensed through TM speed

RECOVERY

sensor.

PROBABLE

1. Brake binding on No.4 wheel resulting in low speed.

CAUSES

2. Defective Speed sensor on TM 4

FAULT

1. If any brake binding is found, clear it as early as possible.

ISOLATION

2. Check for tightness of the speed sensor coupler of TM No.4 and

ensure coupler is tight.

3. Speed sensor gear in the TM No.4 is slack or freely rotating in the

end cup. If found replace the TM.

PARAMETER

DESCRIPTION

FAULT CODE

1035

FAULT MESSAGE

Wheel Number 5 Continuously Sliding

RESTRICTIONS

No restrictions. Warning only.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic on arresting of wheel slide as sensed through TM speed

RECOVERY

sensor.

PROBABLE

1. Brake binding on No.5 wheel resulting in low speed.

CAUSES

2. Defective Speed sensor on TM 5

FAULT

1. If any brake binding is found, clear it as early as possible.

ISOLATION

2. Check for tightness of the speed sensor coupler of TM No.5 and

ensure coupler is tight.

3. Speed sensor gear in the TM No.5 is slack or freely rotating in the

end cup. If found replace the TM.

PARAMETER

DESCRIPTION

FAULT CODE

1036

FAULT MESSAGE

Wheel Number 6 Continuously Sliding

RESTRICTIONS

No restrictions. Warning only.

ALARM BELL

As long as Loco moves and for 30 Seconds minimum.

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic on arresting of wheel slide as sensed through TM speed

RECOVERY

sensor.

PROBABLE

1. Brake binding on No.6 wheel resulting in low speed.

CAUSES

2. Defective Speed sensor on TM 6.

FAULT

1. If any brake binding is found, clear it as early as possible.

ISOLATION

2. Check for tightness of the speed sensor coupler of TM No.6 and

ensure coupler is tight.

3. Speed sensor gear in the TM No.6 is slack or freely rotating in the

end cup. If found replace the TM.

PARAMETER

DESCRIPTION

FAULT CODE

1037

FAULT MESSAGE

Traction Motor 1 High Current While Motoring.

RESTRICTIONS

Tr. Motor No.1 is cutout and Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Tr. Motor / car body cables grounded / short-circuited.

CAUSES

2. No.1 wheel might be locked physically or brakes are jammed.

3. Foreign materials fallen in between BKT/REV contacts.

FAULT

1. Set the locomotive operation to motoring. Take necessary

ISOLATION

precautions to move the locomotive.

2. Set the display mode to wheel slip.

3. Open 1^st notch and observe the traction motor currents. If all the

traction motor currents are equal, there could be momentary short

circuit in the traction motor / car body cables while on run.

A. Check up the traction motor cables for any damage of insulation

or pressed cables.

4. If the current in traction motor No.1 is showing high,

A. Check for free movement of axle 1 with out any brake binding.

If necessary attend and make the wheel movement free.

B. Observe for any foreign materials in between BKT and REV

contacts. If found, remove them and attend to BKT/REV

contacts.

5. If the wheel is rotating freely and BKT / REV contacts are free from

foreign materials and still traction motor current is showing high as

compared to other motors, the TM1AI sensor might be defective.

Replace the sensor and check up.

PARAMETER

DESCRIPTION

FAULT CODE

1038

FAULT MESSAGE

Traction Motor 2 High Current While Motoring.

RESTRICTIONS

Tr. Motor No.2 is cutout and Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Tr. Motor / car body cables grounded / short-circuited.

CAUSES

2. No.2 wheel might be locked physically or brakes are jammed.

3. Foreign materials fallen in between BKT/REV contacts.

FAULT

1. Set the locomotive operation to motoring. Take necessary

ISOLATION

precautions to move the locomotive.

2. Set the display mode to wheel slip.

3. Open 1^st notch and observe the traction motor currents. If all the

traction motor currents are equal, there could be momentary short

circuit in the traction motor / car body cables while on run.

A. Check up the traction motor cables for any damage of insulation

or pressed cables.

4. If the current in traction motor No.2 is showing high,

A. Check for free movement of axle 2 with out any brake binding.

If necessary attend and make the wheel movement free.

B. Observe for any foreign materials in between BKT and REV

contacts. If found, remove them and attend to BKT/REV

contacts.

5. If the wheel is rotating freely and BKT / REV contacts are free from

foreign materials and still traction motor current is showing high as

compared to other motors, the TM2AI sensor might be defective.

Replace the sensor and check up.

PARAMETER

DESCRIPTION

FAULT CODE

1039

FAULT MESSAGE

Traction Motor 3 High Current While Motoring.

RESTRICTIONS

Tr. Motor No.3 is cutout and Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Tr. Motor / car body cables grounded / short-circuited.

CAUSES

2. No.1 wheel might be locked physically or brakes are jammed.

3. Foreign materials fallen in between BKT/REV contacts.

FAULT

1. Set the locomotive operation to motoring. Take necessary

ISOLATION

precautions to move the locomotive.

2. Set the display mode to wheel slip.

3. Open 1^st notch and observe the traction motor currents. If all the

traction motor currents are equal, there could be momentary short

circuit in the traction motor / car body cables while on run.

A. Check up the traction motor cables for any damage of insulation

or pressed cables.

4. If the current in traction motor No.3 is showing high,

A. Check for free movement of axle 3 with out any brake binding.

If necessary attend and make the wheel movement free.

B. Observe for any foreign materials in between BKT and REV

contacts. If found, remove them and attend to BKT/REV

contacts.

5. If the wheel is rotating freely and BKT / REV contacts are free from

foreign materials and still traction motor current is showing high as

compared to other motors, the TM3AI sensor might be defective.

Replace the sensor and check up.

PARAMETER

DESCRIPTION

FAULT CODE

1040

FAULT MESSAGE

Traction Motor 4 High Current While Motoring.

RESTRICTIONS

Tr. Motor No.4 is cutout and Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Tr. Motor / car body cables grounded / short-circuited.

CAUSES

2. No.4 wheel might be locked physically or brakes are jammed.

3. Foreign materials fallen in between BKT/REV contacts.

FAULT

1. Set the locomotive operation to motoring. Take necessary

ISOLATION

precautions to move the locomotive.

2. Set the display mode to wheel slip.

3. Open 1^st notch and observe the traction motor currents. If all the

traction motor currents are equal, there could be momentary short

circuit in the traction motor / car body cables while on run.

A. Check up the traction motor cables for any damage of insulation

or pressed cables.

4. If the current in traction motor No.4 is showing high,

A. Check for free movement of axle 4 with out any brake binding.

If necessary attend and make the wheel movement free.

B. Observe for any foreign materials in between BKT and REV

contacts. If found, remove them and attend to BKT/REV

contacts.

5. If the wheel is rotating freely and BKT / REV contacts are free from

foreign materials and still traction motor current is showing high as

compared to other motors, the TM4AI sensor might be defective.

Replace the sensor and check up.

PARAMETER

DESCRIPTION

FAULT CODE

1041

FAULT MESSAGE

Traction Motor 5 High Current While Motoring.

RESTRICTIONS

Tr. Motor No.5 is cutout and Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Tr. Motor / car body cables grounded / short-circuited.

CAUSES

2. No.5 wheel might be locked physically or brakes are jammed.

3. Foreign materials fallen in between BKT/REV contacts.

FAULT

1. Set the locomotive operation to motoring. Take necessary

ISOLATION

precautions to move the locomotive.

2. Set the display mode to wheel slip.

3. Open 1^st notch and observe the traction motor currents. If all the

traction motor currents are equal, there could be momentary short

circuit in the traction motor / car body cables while on run.

A. Check up the traction motor cables for any damage of insulation

or pressed cables.

4. If the current in traction motor No.5 is showing high,

A. Check for free movement of axle 5 with out any brake binding.

If necessary attend and make the wheel movement free.

B. Observe for any foreign materials in between BKT and REV

contacts. If found, remove them and attend to BKT/REV

contacts.

5. If the wheel is rotating freely and BKT / REV contacts are free from

foreign materials and still traction motor current is showing high as

compared to other motors, the TM5AI sensor might be defective.

Replace the sensor and check up.

PARAMETER

DESCRIPTION

FAULT CODE

1042

FAULT MESSAGE

Traction Motor 6 High Current While Motoring.

RESTRICTIONS

Tr. Motor No.6 is cutout and Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Tr. Motor / car body cables grounded / short-circuited.

CAUSES

2. No.6 wheel might be locked physically or brakes are jammed.

3. Foreign materials fallen in between BKT/REV contacts.

FAULT

1. Set the locomotive operation to motoring. Take necessary

ISOLATION

precautions to move the locomotive.

2. Set the display mode to wheel slip.

3. Open 1^st notch and observe the traction motor currents. If all the

traction motor currents are equal, there could be momentary short

circuit in the traction motor / car body cables while on run.

A. Check up the traction motor cables for any damage of insulation

or pressed cables.

4. If the current in traction motor No.6 is showing high,

A. Check for free movement of axle 6 with out any brake binding.

If necessary attend and make the wheel movement free.

B. Observe for any foreign materials in between BKT and REV

contacts. If found, remove them and attend to BKT/REV

contacts.

5. If the wheel is rotating freely and BKT / REV contacts are free from

foreign materials and still traction motor current is showing high as

compared to other motors, the TM6AI sensor might be defective.

Replace the sensor and check up.

PARAMETER

DESCRIPTION

FAULT CODE

1043

FAULT MESSAGE

Traction Motor 1 High Current While in Dynamic Brake.

RESTRICTIONS

Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Short circuited / burnt grids between R1 and R4 (TM1 and TM4

CAUSES

Armatures)

2. Wrong connection of Dynamic brake grids.

3. SLBC4 power contactor tips got welded. (In case of self load box

feature equipped locos)

4. Welded / burnt contacts of BKT.

FAULT

1. Check for any wrong connections at the Dynamic brake grids and

ISOLATION

as well at BKT. Identify and reconnect the cables correctly.

2. Check for welded tips of SLBC4 power contactor. If welded separate

them and clean the tips.

3. Check the BKT contacts thoroughly for any burnt / welded contacts

or foreign material on the contacts. If necessary attend / replace

BKT.

4. Check for any short circuit between R1 and R4 cables from BKT to

Grids.

5. Remove the Grids which are connected between R1 and R4 cables

and check for any burnt / short circuited grid panels. If found

replace the damaged grids.

PARAMETER

DESCRIPTION

FAULT CODE

1044

FAULT MESSAGE

Traction Motor 2 High Current While in Dynamic Brake.

RESTRICTIONS

Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Short circuited / burnt grids between R21 and R24 (TM2 and TM5

CAUSES

Armatures)

2. Wrong connection of Dynamic brake grids.

3. Welded / burnt contacts of BKT.

FAULT

1. Check for any wrong connections at the Dynamic brake grids and

ISOLATION

as well at BKT. Identify and reconnect the cables correctly.

2. Check the BKT contacts thoroughly for any burnt / welded contacts

or foreign material on the contacts. If necessary attend / replace

BKT.

3. Check for any short circuit between R21 and R24 cables from BKT

to Grids.

4. Remove the Grids which are connected between R21 and R24

cables and check for any burnt / short circuited grid panels. If found

replace the damaged grids.

PARAMETER

DESCRIPTION

FAULT CODE

1045

FAULT MESSAGE

Traction Motor 3 High Current While in Dynamic Brake.

RESTRICTIONS

Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Short circuited / burnt grids between R11 and R14 (TM3 and TM6

CAUSES

Armatures)

2. Wrong connection of Dynamic brake grids.

3. Welded / burnt contacts of BKT.

FAULT

1. Check for any wrong connections at the Dynamic brake grids and

ISOLATION

as well at BKT. Identify and reconnect the cables correctly.

2. Check the BKT contacts thoroughly for any burnt / welded contacts

or foreign material on the contacts. If necessary attend / replace

BKT.

3. Check for any short circuit between R11 and R14 cables from BKT

to Grids.

4. Remove the Grids which are connected between R11 and R14

cables and check for any burnt / short circuited grid panels. If found

replace the damaged grids.

PARAMETER

DESCRIPTION

FAULT CODE

1046

FAULT MESSAGE

Traction Motor 4 High Current While in Dynamic Brake.

RESTRICTIONS

Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Short circuited / burnt grids between R1 and R4 (TM1 and TM4

CAUSES

Armatures)

2. Wrong connection of Dynamic brake grids.

3. SLBC4 power contactor tips got welded. (In case of self load box

feature equipped locos)

4. Welded / burnt contacts of BKT.

FAULT

1. Check for any wrong connections at the Dynamic brake grids and

ISOLATION

as well at BKT. Identify and reconnect the cables correctly.

2. Check for welded tips of SLBC4 power contactor. If welded separate

them and clean the tips.

3. Check the BKT contacts thoroughly for any burnt / welded contacts

or foreign material on the contacts. If necessary attend / replace

BKT.

4. Check for any short circuit between R1 and R4 cables from BKT to

Grids.

5. Remove the Grids which are connected between R1 and R4 cables

and check for any burnt / short circuited grid panels. If found

replace the damaged grids.

PARAMETER

DESCRIPTION

FAULT CODE

1047

FAULT MESSAGE

Traction Motor 5 High Current While in Dynamic Brake.

RESTRICTIONS

Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Short circuited / burnt grids between R21 and R24 (TM2 and TM5

CAUSES

Armatures)

2. Wrong connection of Dynamic brake grids.

3. Welded / burnt contacts of BKT.

FAULT

1. Check for any wrong connections at the Dynamic brake grids and

ISOLATION

as well at BKT. Identify and reconnect the cables correctly.

2. Check the BKT contacts thoroughly for any burnt / welded contacts

or foreign material on the contacts. If necessary attend / replace

BKT.

3. Check for any short circuit between R21 and R24 cables from BKT

to Grids.

4. Remove the Grids which are connected between R21 and R24

cables and check for any burnt / short circuited grid panels. If found

replace the damaged grids.

PARAMETER

DESCRIPTION

FAULT CODE

1048

FAULT MESSAGE

Traction Motor 6 High Current While in Dynamic Brake.

RESTRICTIONS

Dynamic brake is Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. Short circuited / burnt grids between R11 and R14 (TM3 and TM6

CAUSES

Armatures)

2. Wrong connection of Dynamic brake grids.

3. Welded / burnt contacts of BKT.

FAULT

1. Check for any wrong connections at the Dynamic brake grids and

ISOLATION

as well at BKT. Identify and reconnect the cables correctly.

2. Check the BKT contacts thoroughly for any burnt / welded contacts

or foreign material on the contacts. If necessary attend / replace

BKT.

3. Check for any short circuit between R11 and R14 cables from BKT

to Grids.

4. Remove the Grids which are connected between R11 and R14

cables and check for any burnt / short circuited grid panels. If found

replace the damaged grids.

PARAMETER

DESCRIPTION

FAULT CODE

1049

FAULT MESSAGE

High Current in Cutout Traction Motor 1. Can’t Load: Power Circuit

Problem

RESTRICTIONS

Motoring and Dynamic brake are Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. P2 power contactor stuck closed and there is no feed back signal

CAUSES

from P2 power contactor.

2. S1 power contactor stuck closed and there is no feed back signal

from S1 power contactor.

3. Wrongly connected power cables.

4. Defective digital output card.

FAULT

1. Check for welded contact tips of P2 and S1 power contactors. If

ISOLATION

welded tips are found:

A. Separate the tips and clean them.

B. Operate the power contactor manually and verify the status of

corresponding LEDs on the respective digital input card.

2. If no welded tips are found and the contactors are in good

condition, check up thoroughly the power cable connections for any

wrong connection.

3. Switch on all the breakers. If power contactors P2 or S1 are directly

picking up, then the digital output card MLSD16 in slot No. 14 is

defective. Replace the card.

PARAMETER

DESCRIPTION

FAULT CODE

1050

FAULT MESSAGE

High Current in Cutout Traction Motor 2. Can’t Load: Power Circuit

Problem

RESTRICTIONS

Motoring and Dynamic brake are Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. P32 power contactor stuck closed and there is no feed back signal

CAUSES

from P32 power contactor.

2. S31 power contactor tuck closed and there is no feed back signal

from S31 power contactor.

3. Wrongly connected power cables.

4. Defective digital output card.

FAULT

1. Check for welded contact tips of P32 and S31 power contactors. If

ISOLATION

welded tips are found:

A. Separate the tips and clean them.

B. Operate the power contactor manually and verify the status of

corresponding LEDs on the respective digital input card.

2. If no welded tips are found and the contactors are in good

condition, check up thoroughly the power cable connections for any

wrong connection.

3. Switch on all the breakers. If power contactors P32 or S31 are

directly picking up, then the digital output card is defective. Replace

the card.

PARAMETER

DESCRIPTION

FAULT CODE

1051

FAULT MESSAGE

High Current in Cutout Traction Motor 3. Can’t Load: Power Circuit

Problem

RESTRICTIONS

Motoring and Dynamic brake are Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. P22 power contactor stuck closed and there is no feed back signal

CAUSES

from P22 power contactor.

2. S21 power contactor tuck closed and there is no feed back signal

from S21 power contactor.

3. Wrongly connected power cables.

4. Defective digital output card.

FAULT

1. Check for welded contact tips of P22 and S21 power contactors. If

ISOLATION

welded tips are found:

A. Separate the tips and clean them.

B. Operate the power contactor manually and verify the status of

corresponding LEDs on the respective digital input card.

2. If no welded tips are found and the contactors are in good

condition, check up thoroughly the power cable connections for any

wrong connection.

3. Switch on all the breakers. If power contactors P22 or S21 are

directly picking up, then the digital output card is defective. Replace

the card.

PARAMETER

DESCRIPTION

FAULT CODE

1052

FAULT MESSAGE

High Current in Cutout Traction Motor 4. Can’t Load: Power Circuit

Problem

RESTRICTIONS

Motoring and Dynamic brake are Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. P1 power contactor stuck closed and there is no feed back signal

CAUSES

from P1 power contactor.

2. S1 power contactor tuck closed and there is no feed back signal

from S1 power contactor.

3. Wrongly connected power cables.

4. Defective digital output card.

FAULT

1. Check for welded contact tips of P1 and S1 power contactors. If

ISOLATION

welded tips are found:

A. Separate the tips and clean them.

B. Operate the power contactor manually and verify the status of

corresponding LEDs on the respective digital input card.

2. If no welded tips are found and the contactors are in good

condition, check up thoroughly the power cable connections for any

wrong connection.

3. Switch on all the breakers. If power contactors P1 or S1 are directly

picking up, then the digital output card is defective. Replace the

card.

PARAMETER

DESCRIPTION

FAULT CODE

1053

FAULT MESSAGE

High Current in Cutout Traction Motor 5. Can’t Load: Power Circuit

Problem

RESTRICTIONS

Motoring and Dynamic brake are Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. P31 power contactor stuck closed and there is no feed back signal

CAUSES

from P31 power contactor.

2. S31 power contactor tuck closed and there is no feed back signal

from S31 power contactor.

3. Wrongly connected power cables.

4. Defective digital output card.

FAULT

1. Check for welded contact tips of P31 and S31 power contactors. If

ISOLATION

welded tips are found:

A. Separate the tips and clean them.

B. Operate the power contactor manually and verify the status of

corresponding LEDs on the respective digital input card.

2. If no welded tips are found and the contactors are in good

condition, check up thoroughly the power cable connections for any

wrong connection.

3. Switch on all the breakers. If power contactors P31 or S31 are

directly picking up, then the digital output card is defective. Replace

the card.

PARAMETER

DESCRIPTION

FAULT CODE

1054

FAULT MESSAGE

High Current in Cutout Traction Motor 6. Can’t Load: Power Circuit

Problem

RESTRICTIONS

Motoring and Dynamic brake are Prohibited.

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Traction Motor current is reduced and Master

RECOVERY

Controller Handle is brought to Idle. Automatic Fault Reset is permitted

for maximum 3 times in an hour, after which manual clearing is

required.

PROBABLE

1. P21 power contactor stuck closed and there is no feed back signal

CAUSES

from P21 power contactor.

2. S21 power contactor tuck closed and there is no feed back signal

from S21 power contactor.

3. Wrongly connected power cables.

4. Defective digital output card.

FAULT

1. Check for welded contact tips of P21 and S21 power contactors. If

ISOLATION

welded tips are found:

A. Separate the tips and clean them.

B. Operate the power contactor manually and verify the status of

corresponding LEDs on the respective digital input card.

2. If no welded tips are found and the contactors are in good

condition, check up thoroughly the power cable connections for any

wrong connection.

3. Switch on all the breakers. If power contactors P21 or S21 are

directly picking up, then the digital output card is defective. Replace

the card.

PARAMETER

DESCRIPTION

FAULT CODE

1055

FAULT MESSAGE

Traction Motor 1 Ckt. Open.

RESTRICTIONS

Traction Motor 1 Cutout and Dynamic Brake Prohibited

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Master Controller Handle is brought to Idle. Automatic

RECOVERY

Fault Reset is permitted for maximum 3 times in an hour, after which

manual clearing is required.

PROBABLE

1. Defective power contactor P2. Power contactor picking up but main

CAUSES

contact tips are not closing.

2. Foreign materials (Insulation) in REV contacts.

3. Foreign materials (Insulation) in BKT contacts.

4. Tr. Motor cables burnt or disconnected

5. Tr. Motor open circuited internally.

FAULT

1. Ease the throttle and Switch OFF GF switch. Remove the archute of

ISOLATION

P2 power contactor.

2. Operate the power contactor either through display unit by

selecting the manual test for outputs or by manually operating

power contactor. Check and ensure the main tips are closing

correctly and there is no obstruction in between.

3. Manually operate BKT to braking side and REV to non-working side.

Check up thoroughly any foreign materials are fallen in between

contacts of BKT and REV like insulating tape etc. (Especially BKT 9^th

contact. REV No.1 contact.)

4. Check up under truck cable joints of Tr. Motor 1 for any burnt /

disconnected cables. If found replace / attend the cables. Remake

the joints.

5. Disconnect the TM cables and check for continuity of field and

armature. If any open circuit is found, replace the motor.

PARAMETER

DESCRIPTION

FAULT CODE

1056

FAULT MESSAGE

Traction Motor 2 Ckt. Open.

RESTRICTIONS

Traction Motor 2 Cutout and Dynamic Brake Prohibited

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Master Controller Handle is brought to Idle. Automatic

RECOVERY

Fault Reset is permitted for maximum 3 times in an hour, after which

manual clearing is required.

PROBABLE

1. Defective power contactor P32. Power contactor picking up but main

CAUSES

contact tips are not closing.

2. Foreign materials (Insulation) in REV contacts.

3. Foreign materials (Insulation) in BKT contacts.

4. Tr. Motor cables burnt or disconnected

5. Tr. Motor open circuited internally.

FAULT

1. Ease the throttle and Switch OFF GF switch. Remove the archute of

ISOLATION

P32 power contactor.

2. Operate the power contactor either through display unit by

selecting the manual test for outputs or by manually operating

power contactor. Check and ensure the main tips are closing

correctly and there is no obstruction in between.

3. Manually operate BKT to braking side and REV to non-working side.

Check up thoroughly any foreign materials are fallen in between

contacts of BKT and REV like insulating tape etc. (Especially BKT 7^th

contact. REV No.2 contact.)

4. Check up under truck cable joints of Tr. Motor 2 for any burnt /

disconnected cables. If found replace / attend the cables. Remake

the joints.

5. Disconnect the TM cables and check for continuity of field and

armature. If any open circuit is found, replace the motor.

PARAMETER

DESCRIPTION

FAULT CODE

1057

FAULT MESSAGE

Traction Motor 3 Ckt. Open.

RESTRICTIONS

Traction Motor 3 Cutout and Dynamic Brake Prohibited

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Master Controller Handle is brought to Idle. Automatic

RECOVERY

Fault Reset is permitted for maximum 3 times in an hour, after which

manual clearing is required.

PROBABLE

1. Defective power contactor P22. Power contactor picking up but main

CAUSES

contact tips are not closing.

2. Foreign materials (Insulation) in REV contacts.

3. Foreign materials (Insulation) in BKT contacts.

4. Tr. Motor cables burnt or disconnected

5. Tr. Motor open circuited internally.

FAULT

1. Ease the throttle and Switch OFF GF switch. Remove the archute of

ISOLATION

P22 power contactor.

2. Operate the power contactor either through display unit by

selecting the manual test for outputs or by manually operating

power contactor. Check and ensure the main tips are closing

correctly and there is no obstruction in between.

3. Manually operate BKT to braking side and REV to non-working side.

Check up thoroughly any foreign materials are fallen in between

contacts of BKT and REV like insulating tape etc. (Especially BKT 6^th

contact. REV No.3 contact.)

4. Check up under truck cable joints of Tr. Motor 3 for any burnt /

disconnected cables. If found replace / attend the cables. Remake

the joints.

5. Disconnect the TM cables and check for continuity of field and

armature. If any open circuit is found, replace the motor.

PARAMETER

DESCRIPTION

FAULT CODE

1058

FAULT MESSAGE

Traction Motor 4 Ckt. Open.

RESTRICTIONS

Traction Motor 4 Cutout and Dynamic Brake Prohibited

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Master Controller Handle is brought to Idle. Automatic

RECOVERY

Fault Reset is permitted for maximum 3 times in an hour, after which

manual clearing is required.

PROBABLE

1. Defective power contactor P1. Power contactor picking up but main

CAUSES

contact tips are not closing.

2. Foreign materials (Insulation) in REV contacts.

3. Foreign materials (Insulation) in BKT contacts.

4. Tr. Motor cables burnt or disconnected

5. Tr. Motor open circuited internally.

FAULT

1. Ease the throttle and Switch OFF GF switch. Remove the archute of

ISOLATION

P1 power contactor.

2. Operate the power contactor either through display unit by

selecting the manual test for outputs or by manually operating

power contactor. Check and ensure the main tips are closing

correctly and there is no obstruction in between.

3. Manually operate BKT to braking side and REV to non-working side.

Check up thoroughly any foreign materials are fallen in between

contacts of BKT and REV like insulating tape etc. (Especially BKT 4^th

contact. REV No.4 contact.)

4. Check up under truck cable joints of Tr. Motor 4 for any burnt /

disconnected cables. If found replace / attend the cables. Remake

the joints.

5. Disconnect the TM cables and check for continuity of field and

armature. If any open circuit is found, replace the motor.

PARAMETER

DESCRIPTION

FAULT CODE

1059

FAULT MESSAGE

Traction Motor 5 Ckt. Open.

RESTRICTIONS

Traction Motor 5 Cutout and Dynamic Brake Prohibited

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Master Controller Handle is brought to Idle. Automatic

RECOVERY

Fault Reset is permitted for maximum 3 times in an hour, after which

manual clearing is required.

PROBABLE

1. Defective power contactor P31. Power contactor picking up but main

CAUSES

contact tips are not closing.

2. Foreign materials (Insulation) in REV contacts.

3. Foreign materials (Insulation) in BKT contacts.

4. Tr. Motor cables burnt or disconnected

5. Tr. Motor open circuited internally.

FAULT

1. Ease the throttle and Switch OFF GF switch. Remove the archute of

ISOLATION

P31 power contactor.

2. Operate the power contactor either through display unit by

selecting the manual test for outputs or by manually operating

power contactor. Check and ensure the main tips are closing

correctly and there is no obstruction in between.

3. Manually operate BKT to braking side and REV to non-working side.

Check up thoroughly any foreign materials are fallen in between

contacts of BKT and REV like insulating tape etc. (Especially BKT 2^nd

contact. REV No.5 contact.)

4. Check up under truck cable joints of Tr. Motor 5 for any burnt /

disconnected cables. If found replace / attend the cables. Remake

the joints.

5. Disconnect the TM cables and check for continuity of field and

armature. If any open circuit is found, replace the motor.

PARAMETER

DESCRIPTION

FAULT CODE

1060

FAULT MESSAGE

Traction Motor 6 Ckt. Open.

RESTRICTIONS

Traction Motor 6 Cutout and Dynamic Brake Prohibited

ALARM BELL

30 Seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when Master Controller Handle is brought to Idle. Automatic

RECOVERY

Fault Reset is permitted for maximum 3 times in an hour, after which

manual clearing is required.

PROBABLE

1. Defective power contactor P21. Power contactor picking up but main

CAUSES

contact tips are not closing.

2. Foreign materials (Insulation) in REV contacts.

3. Foreign materials (Insulation) in BKT contacts.

4. Tr. Motor cables burnt or disconnected

5. Tr. Motor open circuited internally.

FAULT

1. Ease the throttle and Switch OFF GF switch. Remove the archute of

ISOLATION

P21 power contactor.

2. Operate the power contactor either through display unit by

selecting the manual test for outputs or by manually operating

power contactor. Check and ensure the main tips are closing

correctly and there is no obstruction in between.

3. Manually operate BKT to braking side and REV to non-working side.

Check up thoroughly any foreign materials are fallen in between

contacts of BKT and REV like insulating tape etc. (Especially BKT 1^st

contact. REV No.6 contact.)

4. Check up under truck cable joints of Tr. Motor 6 for any burnt /

disconnected cables. If found replace / attend the cables. Remake

the joints.

5. Disconnect the TM cables and check for continuity of field and

armature. If any open circuit is found, replace the motor.

PARAMETER

DESCRIPTION

FAULT CODE

1061

FAULT MESSAGE

Battery Voltage LOW

Warning: Loco may STALL

RESTRICTIONS

Nil

ALARM BELL

Continuously ON

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the battery voltage is more than 62V for 5 seconds.

RECOVERY

PROBABLE

This is a warning message indicating Batteries are getting discharged.

CAUSES

Normally this message is followed by

Fault message ‘Aux. Gen. output open circuited.’ Fault code 1145 or

Fault message ‘Aux. Gen Field circuit open / shorted’ Fault code 1146

FAULT

1. If none of the above faults are logged, prior to this fault message:

ISOLATION

A. Change the display mode to ‘Auxiliary’

B. Measure Voltage with a voltmeter at the BATV battery voltage

sensor (wire No. 51 and 4) and voltage at AGAV Voltage sensor

(wire No. 49 and 44D).

C. If the measured voltages are tallying with the displayed

parameters and really battery voltage is low and battery-

charging current is zero, Then RCD is open circuited. Replace

RCD.

D. If the measured battery voltage is higher than displayed voltage

the voltage sensor or its wiring is defect. Check and identify.

2. If the ‘Aux. Gen. output open circuited.’ Fault message is also

logged trouble shoot to find open circuit in the Aux. Gen. output

circuit. Refer Fault code 1145.

3. If Aux. Gen. Field Circuit open / Shorted’ message is also logged

trouble shoot to find open circuit in the Auxiliary Generator field

circuit. Refer fault log No. 1146. ‘Aux. Gen. Field Circuit Open or

Short’.

PARAMETER

DESCRIPTION

FAULT CODE

1062

FAULT MESSAGE

Battery Voltage HIGH Fault

RESTRICTIONS

Battery charging prohibited.

ALARM BELL

Continuously ON

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the battery voltage is less than the set limit by 2 Volts

RECOVERY

for 15 seconds.

PROBABLE

1. The battery charging voltage is more than the set voltage.

CAUSES

Normally this message is followed by ‘Aux.Gen. Voltage High’. Fault

code 1141.

FAULT

1. Switch off AGFB. And reset the fault.

ISOLATION

2. Change the display mode to ‘Auxiliaries’ under display menu option.

3. Measure battery voltage with a voltmeter. If the measured value is

equal to the displayed BATV value and is less than 69V, then the

fault is transient.

4. If the displayed value is more than the measured value, the voltage

sensor is bad. Replace the sensor.

5. Switch ON AGFB and observe the AGAV on the display. If AGAV is

72 Volts, then the fault is transient.

6. If AGAV is more than 72Volts, trouble shoot for Aux. Gen.Voltage

High. Refer fault code No. 1141. ‘Aux. Gen. Output Voltage High

FAULT’

PARAMETER

DESCRIPTION

FAULT CODE

1063

FAULT MESSAGE

Aux. Gen. Field drive short circuit fault.

RESTRICTIONS

Battery charging prohibited. Warning: Battery life limited. Loco may

stall.

ALARM BELL

30 sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

No auto recovery.

RECOVERY

PROBABLE

1. Defective MPWM2 card.

CAUSES

2. Defective wiring.

3. Defective AGFI current sensor

FAULT

1. Switch OFF all breakers. Connect DC ammeter 0-10Amps to wire

ISOLATION

terminals AGC (+) and AGF (-) at AGPR interlocks.

2. Switch ON MB1, MB2, MFPB1, MFPB2, FPB and MPCB breakers.

3. Change the display mode to ‘Auxiliary’ under ‘Display’ option

available in main menu.

4. Check the Auxiliary Field current AGFI.

5. If current in the meter is equal to the displayed current of AGFI,

A. PWM output card is defective. Replace the card.

B. There may be a short externally from AGC to locomotive 4 wire.

6. If current in the meter is zero and AGFI indicating some value then

the current sensor is faulty. Replace the current sensor.

7. If both the currents are zero,

A. There could be an external short between Auxiliary Generator

field LSS and locomotive 4 wire. Identify and remove the short

circuit.

B. There could be an internal short between LSS and LAA in side

the machine.

PARAMETER

DESCRIPTION

FAULT CODE

1064

FAULT MESSAGE

Low Lube Oil Pressure

RESTRICTIONS

Engine Shutdown.

ALARM BELL

30 sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when engine is shutdown. Automatic Fault Reset is

RECOVERY

permitted for maximum 5 times in an hour, after which manual

clearing is required.

PROBABLE

This message will only be logged when ‘Low LOP shut down enabled’

CAUSES

flag is enabled. By default this flag is disabled as Governor is taking

care of low lube oil pressure.

This message will be logged if engine is shut down due to low lube oil

pressure as sensed by LOP pressure sensor available in MEP-system.

1. Lube Oil Pressure is really dipped below the set limit.

2. Pressure sensor might be defective.

3. MIAI card might be defective.

FAULT

1. Check the real conditions at which the engine is shut down. If realy

ISOLATION

there is a dip in LOP, identify the root cause for LOP dipping.

2. Check the difference of pressures between LOP guage / diplay

reading on Governor. If there is a difference between the MCBG

display / LOP gauge:

A. Connect a calibrated gauge at the pressure inlet of LOP sensor

by providing a ‘T’ joint. Crank the engine. Compare the

readings.

B. If there is a difference between display and the calibrated

gauge:

a. Replace the sensor and verify the readings.

b. If still difference of reading is available, change the MIAI

card and check the readings.

C. If the difference is permisable, check the pipelines and clean the

pipes.

PARAMETER

DESCRIPTION

FAULT CODE

1068

FAULT MESSAGE

REV Stuck in Reverse. Run Auto/Manual Test

RESTRICTIONS

Forward Motoring and Forward Dynamic Brake Prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the RVFFB and RVRFB feed back signals become

RECOVERY

normal.

PROBABLE

Control air pressure is < 2Kg./Sq.Cm.

CAUSES

The REV is physically got stuck due to mechanical obstruction.

Defective wiring of REV feed back signals RVFFB and RVRFB

Defective digital input card.

REV forward direction magnet valve defective.

REV forward direction magnet valve is not getting electrical supply.

Defective digital output card.

FAULT

Check and adjust the control air pressure to 5 Kg./Sq.Cm.

ISOLATION

Manually operate the Reverser by pressing the forward and reverse

magnet valves alternatively to ensure free operation of the

contacts.

A. Ensure that change over contacts and auxiliary contacts are

changing their position freely.

B. If the operation of the REV is sluggish / not operating, attend /

replace the reverser.

C. Check the status of the corresponding feed back LEDs (14 & 15)

on the digital input card in slot 10. Both Green and Yellow LEDs

should toggle their status with respect to REV operation.

D. If the status is not syncronysing to REV operation:

a) Adjust the feedback auxiliary contacts to get correct logic.

b) If both Green LEDs (14 & 15) are not glowing, check the

incoming supply at the common terminal of the Aux. Contacts.

(wire No. 51) with respect to locomotive 4 wire.

c) If the supply is zero, check the continuity of 51wire loop. If

necessary change the wiring.

d) If supply is more than 65V, check the supply at out going

terminals (wire nos. RVFFB and RVRFB).

e) If supply is more than 65V on the corresponding terminal with

respective REV position

1) Check the slackness of the connector of cable ID: AU. If

slack tighten the connector.

2) Check the wire continuity of wires from REV feed back

auxiliary contacts to MEP-660. (Cable ID: AU, Pins - R &

S). If necessary replace the cable.

f) If only Green LEDs (14 & 15) are toggling their status and

corresponding Yellow LEDs are not toggling, then Digital input

card in slot 10 is defective. Replace the card.

Manually set the REV in Reverse direction.

Set the display mode to ‘Manual Test for outputs’ under Test Mode

menu.

Enter 11 and press ‘Enter’ key to test reverser forward.

Press 1 to energise the REV forward side magnet valve.

7. The REV should operate to forward direction. The Green LED 14 on

the digital input card MDIP16 in slot 10 should glow.

8. If REV is not operating to forward direction, Check supply at the

REV forward side magnet valve coil.

9. If supply is more than 65 volts, then magnet valve is defective.

Replace the magnet valve.

10. If supply is zero, check the supply at the magnet valve coil terminal

(wire no. 8) with respect to locomotive 4 wire.

11. If the voltage is zero, check continuity of 8-wire loop coming to

magnet valve.

12. If voltage is more than 65V, Check the voltage between locomotive

wire 13 and wire RVFCL at the magnet valve coil

13. If the voltage is zero,

A. Check the slackness of the connector of the cable ID: AY at

MEP-660. If slack tighten the connector.

B. Check the continuity of wire RVFCL from the magnet valve coil

to the connector of cable ID: AY Pin No.M. If necessary replace

the cable.

C. The digital output card might be defective. Change the card and

check up once again.

14. Press 0 to de-energise the magnet valve and press menu key to

exit.

PARAMETER

DESCRIPTION

FAULT CODE

1069

FAULT MESSAGE

REV-F Aux. Contact ckt. Open. Run Auto/manual Test.

RESTRICTIONS

Forward Motoring and Forward Dynamic Brake Prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the REV-F Auxiliary contact circuit is closed.

RECOVERY

PROBABLE

1. Bad contact of REV-F auxiliary contact.

CAUSES

2. Disconnected wires at auxiliary contacts / open circuited wiring.

3. Defective digital input card.

FAULT

1. Ensure Reverser is in forward direction. If not operate manually.

ISOLATION

2. Check the status of the Green LED 14 on the digital input card in

slot 10.

3. If the Green LED is not glowing:

A. Auxiliary contact is bad. Clean/adjust the contact and check.

B. Check supply voltage at incoming terminal (wire No. 51) with

respect to locomotive 4 wire.

C. If supply is zero, check the continuity of 51-wire loop.

A. If the supply voltage is more than 65V, check supply between

wire no. RVFFB and locomotive 4 wire.

D. If the supply voltage is more than 65V,

a) Check the slackness of the connector of the cable ID: AU at

MEP660. If slack tighten the connector.

b) Check the continuity of the wire REFFB, from the reverser

aux. Contact to connector of cable ID: AU, Pin - R. If

necessary replace the cable.

4. If green LED 14 is glowing but the corresponding yellow LED is not

glowing, then the digital input card is defective. Replace the card

and check up.

PARAMETER

DESCRIPTION

FAULT CODE

1070

FAULT MESSAGE

REV Stuck in Forward. Run Auto/Manual Test

RESTRICTIONS

Reverse Motoring and Reverse Dynamic Brake Prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the RVFFB and RVRFB feed back signals become

RECOVERY

normal.

PROBABLE

Control air pressure is < 2Kg./Sq.Cm.

CAUSES

The REV is physically got stuck due to mechanical obstruction.

Defective wiring of REV feed back signals RVFFB and RVRFB

Defective digital input card.

REV reverse direction magnet valve defective.

REV reverse direction magnet valve is not getting electrical supply.

Defective digital output card.

FAULT

Check and adjust the control air pressure to 5 Kg./Sq.Cm.

ISOLATION

Manually operate the Reverser by pressing the forward and reverse

magnet valves alternatively to ensure free operation of the

contacts.

A. Ensure that change over contacts and auxiliary contacts are

changing their position freely.

B. If the operation of the REV is sluggish / not operating, attend /

replace the reverser.

C. Check the status of the corresponding feed back LEDs (14 & 15)

on the digital input card in slot 10. Both Green and Yellow LEDs

should toggle their status with respect to REV operation.

If the status is not syncronysing to REV operation:

A. Adjust the feedback auxiliary contacts to get correct logic.

If both Green LEDs (14 & 15) are not glowing, check the voltage

between wire 51 at the Aux. Contact of reverser and locomotive 4

wire.

A. If the supply is zero, check the continuity of 51wire loop. If

necessary change the wiring.

If supply is more than 65V, check the supply at out going terminals

(wire nos. RVFFB and RVRFB by changing the REV position).

A. If supply is more than 65V on the corresponding terminal with

respective REV position, check the wire continuity of wires from

REV feed back auxiliary contacts to MEP-660. (Cable ID:AU, Pins

- R & S). If necessary replace the cable.

B. If only Green LEDs (14 & 15) are toggling their status and

corresponding Yellow LEDs are not toggling, then Digital input

card in slot 10 is defective. Replace the card.

Manually set the REV in Forward direction.

Set the display mode to ‘Manual Test for outputs’ under Test Mode

menu.

To test REV reverse side operation, enter 12 and press ‘Enter’ key.

Press 1 to energise the REV reverse side magnet valve.

10. The REV should operate to reverse direction.

11. If REV is not operating to reverse direction, check supply at the

REV reverse side magnet valve coil.

A. If supply is more than 60 volts, then magnet valve is defective.

Replace the magnet valve.

12. If supply is zero, check the supply at the magnet valve coil terminal

(wire no. 0) with respect to locomotive 4 wire.

A. If the voltage is zero, check continuity of 0 wire loop connected

to magnet valve.

13. If voltage is more than 65V, check the voltage between locomotive

wire No. 13 (TB) and wire RVRCL at magnet valve coil.

A. If the voltage is zero,

a) Check the slackness of the connector of the cable ID: AY. If

slack tighten the connector.

b) Check the wire continuity of RVRCL from the magnet valve to

connector of cable ID: AY pin - N. If necessary replace the

cable.

c) The digital output card might be defective. Change the card

and check up once again.

14. Press 0 to de-energise the magnet valve and press menu key to

exit.

PARAMETER

DESCRIPTION

FAULT CODE

1071

FAULT MESSAGE

REV-R Aux. Contact ckt. Open. Run Auto/manual Test.

RESTRICTIONS

Reverse Motoring and Reverse Dynamic Brake Prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the REV-R Auxiliary contact circuit is closed.

RECOVERY

PROBABLE

1. Bad contact of REV-R auxiliary contact.

CAUSES

2. Disconnected wires at auxiliary contacts / open circuited wiring.

3. Defective digital input card.

FAULT

1. Ensure Reverser is in reverse direction. If not operate manually.

ISOLATION

2. Check the status of the Green LED 15 on the digital input card in

slot 10.

3. If the Green LED is not glowing:

A. Auxiliary contact is bad. Clean/adjust the contact and check.

B. Check supply voltage at incoming terminal (wire No. 51) with

respect to locomotive 4 wire.

C. If supply is zero, check the continuity of 51-wire loop.

B. If the supply voltage is more than 65V, check supply between

wire no. RVRFB and locomotive 4 wire.

D. If the supply voltage is more than 65V,

a) Check the slackness of the connector of the cable ID: AU at

MEP660. If slack tighten the connector.

b) Check the continuity of the wire RVRFB, from the reverser

aux. Contact to connector of cable ID: AU, Pin - S. If

necessary replace the cable.

4. If green LED 15 is glowing but the corresponding yellow LED is not

glowing, then the digital input card is defective. Replace the card

and check up.

PARAMETER

DESCRIPTION

FAULT CODE

1072

FAULT MESSAGE

Wrong Command: TL23 High & TL17 Low. Can’t Brake

RESTRICTIONS

Dynamic Brake Prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the TL23 and TL17 are found both High.

RECOVERY

PROBABLE

1. This fault generally logs while the locomotive is set to dynamic

CAUSES

brake mode or while changing from dynamic brake to motoring.

2. Wrong wiring.

3. Jumper cable defective while working MU consist.

FAULT

1. Most probably this fault is a transient fault and recovers

ISOLATION

automatically when dynamic brake is applied in correct sequence.

2. Set the locomotive to dynamic brake mode. If the fault is not

logging, then the fault is transient.

3. If the fault is logging frequently, check the following.

4. Proper sequence of master controller interlocks which are

energizing wire No. 23 and wire no. 17.

5. Wire No. 17 should get energized in OFF position.

6. Wire No. 23 should get energized in Big. D position.

7. Check up whether wire No. 23 is getting any wrong feed due to

wrong connections or defective MU cable.

PARAMETER

DESCRIPTION

FAULT CODE

1073

FAULT MESSAGE

Fire Alarm ON. Check Loco and MU Locos for fire and extinguish fire.

RESTRICTIONS

Engine Shutdown.

ALARM BELL

30 sec.

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when engine is shut down and fire alert signal is OFF.

RECOVERY

PROBABLE

1. MEP detected fire alert signal from Fire Alert System and shut down

CAUSES

the engine.

2. MDIP16 card in slot No. 13 might be defective.

3. Defective wiring.

4. Deective MU cable.

FAULT

This message can log when any fire accident occurred either in leading

ISOLATION

loco or trailing loco.

Ensure that there is no fire accident in any loco before trouble shooting

the fault.

1. Check the status of green LED 6 on MDIP 16 card in slot No. 13. If

LED is glowing:

A. Check the voltage between wire TL 11 and 4. If voltage is more

than 65V.

a. Then the fire alerter system is ON. Check the Fire alerter

system and reset. If already system is reset then wire TL 11

is getting a wrong supply. Identify and rectify the problem.

B. If voltage is zero, Fire alerter system is not activated and

message is logged then the MDIP16 card in slot 13 might be

defective.

C. Replace the MDIP16 card and verify.

Note: Malfunction / wrong detection of fire by the fire alerter system

can cause logging of the above fault.

PARAMETER

DESCRIPTION

FAULT CODE

1074

FAULT MESSAGE

Field Shunting Relay FSR or FS Contactor FS2X Stuck Closed.

RESTRICTIONS

Motoring always with field shunting. Motoring in parallel prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the stuck closed relay/contactor is detected as open.

RECOVERY

PROBABLE

1. Welded FS contactors.

CAUSES

2. Defective FSR Relay

3. Defective wiring.

4. Defective output card.

FAULT

1. Check the status of Green LED 10 and yellow LED 10 on the digital

ISOLATION

input card in slot 12.

2. If both the LEDs are glowing, check the status of FSR relay.

A. If FSR is energized,

a) Check the condition of FSR relay for any dislocated springs. If

necessary change the relay.

b) The digital output card in slot 15 might be defective. Replace

the card.

3. If FSR is in de-energised position, check FS contactors for any

welded contact tips. If found welded contactors, separate the tips

and clean them. The LEDs should be OFF.

4. If still LEDs are glowing, FSFB wire is getting wrongly supply due to

wrong wiring / shorted wiring. Identify and rectify.

5. If both the LEDs are not glowing but the fault is logged, check

operation of FS contactors for proper operation. Delayed dropout of

any FS contactor can log this fault and later on it is recovered.

Note: This Error message will be generated only if either “Series Field Shunting” or

“Parallel Field Shunting” ENABLED flags are set (√).

PARAMETER

DESCRIPTION

FAULT CODE

1075

FAULT MESSAGE

Field Shunting Relay FSR circuit open.

RESTRICTIONS

Motoring with field shunting and Motoring in parallel prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the master handle is brought to IDLE. Automatic reset

RECOVERY

is permitted for 3 times after which manual reset is required.

PROBABLE

Defective FSR relay.

CAUSES

Defective digital output card

Defective wiring of FS contactor feed back.

Defective digital input card.

FAULT

Set the display mode to ‘Manual Test for outputs’ under Test Mode

ISOLATION

menu.

Enter 24 and press ‘Enter’ key to test the FSR operation.

Press ‘1’ key to switch on FSR relay.

FSR relay should pickup and along with that FS contactors also

should pick up.

If FSR relay not picking up check Voltage across FSR relay coil with

a voltmeter.

A. If voltage is more than 65V, then the Relay is defective. Replace

the relay.

If voltage is zero, check voltage at FSR coil terminal (Wire No. 13)

with respect to locomotive 4 wire with a voltmeter.

A. If voltage is zero, check the continuity of 13-wire loop

connected to FSR relay. Check and replaced the open circuited

wires.

If Voltage is more than 65V, check the voltage between Locomotive

13 wire and wire FSRCL at FSR relay coil terminal.

A. If the voltage is zero:

a) Check slackness of connector of cable ID: AZ at MEP660

control unit. If slack tighten the connector.

b) Check continuity of FSRCL wire from FSR coil terminal to MEP-

660 (Cable ID: AZ, Pin-J). If necessary replace the cable.

c) If continuity is available, the digital output card 2 in slot No.

15 is defective. Replace the card and recheck.

If FSR relay is picking up and FS contactors are not picking up:

A. Bad interlock of FSR relay. Replace the FSR relay.

B. There is no 13-wire supply at FSR relay interlocks. Check up

continuity of 13-wire loop. Replace any open circuited wires.

If FS contactors are picking up:

10. Check the status of Green LED 10 on the Digital input card in slot

No. 12. The LED should glow.

11. If the Green LED 10 is not glowing, check voltage at incoming wire

51 at FS contactor auxiliary contacts with respective to locomotive 4

wire.

A. If the voltage is zero, check continuity of 51-wire loop. Replace

any open circuited wires/ wrong connections.

12. If voltage is more than 65V, Check the voltage at FS contactor

auxiliary contact (wire No. FSFB) with respective locomotive 4 wire.

PARAMETER

DESCRIPTION

FAULT CODE

1076

FAULT MESSAGE

Loose Contact in S1 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM1 and TM4 are cut out in 2S-3P mode only. Dynamic brake

prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1077

FAULT MESSAGE

Loose Contact in S21 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM3 and TM6 are cut out in 2S-3P mode only. Dynamic brake

prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1078

FAULT MESSAGE

Loose Contact in S31 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM2 and TM5 are cut out in 2S-3P mode only. Dynamic brake

prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1079

FAULT MESSAGE

Loose Contact in P1 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM4 is cut out in 6P mode only. Dynamic brake prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1080

FAULT MESSAGE

Loose Contact in P21 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM6 is cut out in 6P mode only. Dynamic brake prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1081

FAULT MESSAGE

Loose Contact in P31 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM5 is cut out in 6P mode only. Dynamic brake prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1082

FAULT MESSAGE

Loose Contact in P2 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM1 is cut out in 6P mode only. Dynamic brake prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1083

FAULT MESSAGE

Loose Contact in P22 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM3 is cut out in 6P mode only. Dynamic brake prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1084

FAULT MESSAGE

Loose Contact in P32 circuit. Run Auto/Manual Test

Power Limited: Power Circuit Problem

RESTRICTIONS

TM2 is cut out in 6P mode only. Dynamic brake prohibited.

ALARM BELL

30 seconds

RESET LEVEL

Medium, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

RECOVERY

PROBABLE

1. Fluttering of power contactor due to improper air supply.

CAUSES

2. Power contactor itself defective.

3. Loose connections in the wiring.

FAULT

1. Ensure control air pressure is 5kg. /Sq.Cm. Adjust if necessary.

ISOLATION

2. Check for air leakages in the pneumatic pipeline connected to

power contactor. If necessary replace the pneumatic pipe.

3. Manually operate the power contactor by pressing the armature

plate.

4. Check for air leakages from the magnet valve and power contactor

cylinder. There should not be any leakages.

5. The contactor should pick up with out any sluggish operation. If

found sluggish, replace power contactor.

6. Check power contactor main tips for any slackness. Ensure there is

no loose contact.

7. Check for magnet valve coil connection. The coil connections should

be tight and no loose crimped wires.

8. Ensure connector tightness at MEP-660. (Cable ID: AY).

PARAMETER

DESCRIPTION

FAULT CODE

1085

FAULT MESSAGE

P1 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in series prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when the P1 Auxiliary contact detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

P1 power contactor main contact tips welded.

P1 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 MLSD16 in slot No. 14.

Defective Digital input card 2 MDIP16 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 3 on digital input card in slot 10. If

both Green and yellow LEDs 3 are glowing.

A. Check status of P1 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of P1 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 3 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. P1FB wire is getting wrong supply. Check

continuity of wiring.

PARAMETER

DESCRIPTION

FAULT CODE

1086

FAULT MESSAGE

P21 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in series prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when P21 auxiliary contact is detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

P21 power contactor main contact tips welded.

P21 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 MLSD16 in slot No. 14.

Defective Digital input card 2 MDIP16 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 4 on digital input card in slot 10. If

both Green and yellow LEDs 4 are glowing.

A. Check status of P21 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of P21 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 4 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. P21FB wire is getting wrong supply. Check

continuity of wiring.

PARAMETER

DESCRIPTION

FAULT CODE

1087

FAULT MESSAGE

P31 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in series prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when P31 auxiliary contact is detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

P31 power contactor main contact tips welded.

P31 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 MLSD16in slot No. 14.

Defective Digital input card 2 MDIP16 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 5 on digital input card in slot 10. If

both Green and yellow LEDs 5 are glowing.

A. Check status of P31 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of P31 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 5 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. P31FB wire is getting wrong supply. Check

continuity of wiring.

PARAMETER

DESCRIPTION

FAULT CODE

1088

FAULT MESSAGE

P2 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in series prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when P2 auxiliary contact is detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

P2 power contactor main contact tips welded.

P2 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 MLSD16 in slot No. 14.

Defective Digital input card 2 MDIP16 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 6 on digital input card in slot 10. If

both Green and yellow LEDs 6 are glowing.

A. Check status of P2 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of P2 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 6 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. P2FB wire is getting wrong supply. Check

continuity of wiring.

PARAMETER

DESCRIPTION

FAULT CODE

1089

FAULT MESSAGE

P22 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in series prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when P22 auxiliary contact is detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

P22 power contactor main contact tips welded.

P22 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 MLSD16 in slot No. 14.

Defective Digital input card 2 DIP16 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 7 on digital input card in slot 10. If

both Green and yellow LEDs 7 are glowing.

A. Check status of P22 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of P22 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 7 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. P22FB wire is getting wrong supply. Check

continuity of wiring.

PARAMETER

DESCRIPTION

FAULT CODE

1090

FAULT MESSAGE

P32 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in series prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when P32 auxiliary contact is detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

P32 power contactor main contact tips welded.

P32 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 in slot No. 14.

Defective Digital input card 2 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 8 on digital input card in slot 10. If

both Green and yellow LEDs 8 are glowing.

A. Check status of P32 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of P32 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 8 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. P32FB wire is getting wrong supply. Check

continuity of wiring.

PARAMETER

DESCRIPTION

FAULT CODE

1091

FAULT MESSAGE

S1 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in parallel prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when S1 auxiliary contact is detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

S1 power contactor main contact tips welded.

S1 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 MLSD16 in slot No. 14.

Defective Digital input card 2 MDIP16 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 9 on digital input card in slot 10. If

both Green and yellow LEDs 9 are glowing.

A. Check status of S1 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of S1 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 6 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. S1FB wire is getting wrong supply. Check

continuity of wiring.

PARAMETER

DESCRIPTION

FAULT CODE

1092

FAULT MESSAGE

S21 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in parallel prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when S21 auxiliary contact is detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

S21 power contactor main contact tips welded.

S21 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 MLSD16 in slot No. 14.

Defective Digital input card 2 MDIP16 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 10 on digital input card in slot 10. If

both Green and yellow LEDs 10 are glowing.

A. Check status of S21 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of S21 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 10 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. S21FB wire is getting wrong supply. Check

continuity of wiring.

PARAMETER

DESCRIPTION

FAULT CODE

1093

FAULT MESSAGE

S31 stuck closed. Run Auto/manual test.

RESTRICTIONS

Motoring in parallel prohibited

ALARM BELL

30 seconds

RESET LEVEL

Low, Manual

After manual reset if the fault still present, the fault will be generated

again.

FAULT

Automatic when S31 auxiliary contact is detected as open.

RECOVERY

PROBABLE

Low control air pressure can cause delayed operation of power

CAUSES

contactor and cause this fault.

S31 power contactor main contact tips welded.

S31 power contactor auxiliary contact tips welded.

Defective wiring.

Defective Digital output card 1 MLSD16 in slot No. 14.

Defective Digital input card 2 MDIP16 in slot No. 10.

FAULT

Most probably this fault is logged due to delayed operation of the

ISOLATION

power contactor. Fault may not exist while testing. If so

A. Ensure proper over travel of the auxiliary contacts.

B. Ensure control air pressure is 5 Kg./Sq.Cm.

Check the status of Green LED 11 on digital input card in slot 10. If

both Green and yellow LEDs 11 are glowing.

A. Check status of S31 power contactor. If found in energized

position, check the status of magnet valve.

B. If magnet valve is not energized, then the power contactor tips

are welded. Separate them.

C. If magnet valve is energized, then the digital output card 1 in

slot 14 is defective. Replace the card and check

Check for welding of S31 power contactor auxiliary contact tips. If

welded change the auxiliary contacts.

If auxiliary contacts are not welded,

A. Check the status of Green LED 11 on digital input card 2 in slot

10.

B. If green LED is glowing with power contactor de-energised, then

defective wiring. S31FB wire is getting wrong supply. Check

continuity of wiring.

Medha MEP 660. Troubleshooting Manual (2008) - page 1