hand book on dual cab (wdp4d) locomotives (medha make traction system)rdso. on wdp4d...(govt. of...

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  • (Govt. of India) (Ministry of Railways) Hand Book

    On Dual Cab (WDP4D) Locomotives (Medha Make Traction System)

    (For official use only)

    IRCAMTECH/M/GWL/16-17/Dual Cab October 2016

    MAHARAJPUR, GWALIOR 474005

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  • IRCAMTECH/M/GWL/Dual cab 2

    Hand Book On

    Dual Cab (WDP4D) Locomotives (Medha Make Traction System)

  • IRCAMTECH/M/GWL/Dual cab 3

    FOREWORD The Hand book of Dual Cab has been prepared by CAMTECH for loco running as well as Diesel shed maintenance staff. The failure of Dual cab locomotive has a great impact on the reliability of the diesel locomotives. Due to various modifications and alterations, in existing WDP4 Locomotive there is only one driver cabin has now being upgraded to Dual cab (WDP4D) Locomotive with some additional features. I hope that this Hand book will definitely enhance the knowledge of concerned staff to do faster restoration of troubles pertaining to Dual cab (WDP4D) Locomotive while working on line. October- 2016 (A.R.Tupe)) EXECUTIVE DIRECTOR CAMTECH/GWALIOR

  • IRCAMTECH/M/GWL/Dual cab 4

    PPRREEFFAACCEE Dual cab (WDP4D) Locomotive is the vital part of diesel electric locomotives. Existing WDP4 Locomotive has now been upgraded to Dual cab (WDP4D) Locomotive with additional features. Knowledge of new Dual cab (WDP4D) Locomotive is necessary to running/maintenance staff to ensure reliability and availability of locomotives in sheds as well as on line. The purpose of this book is to enhance knowledge and competence of loco pilots in dealing with the problems of Dual cab (WDP4D) Locomotive. This book will be useful to the maintenance staff and loco inspectors also for counseling running staff about Dual cab (WDP4D) Locomotive It is clarified that this Hand book does not supersede any existing procedures and practices laid down in the maintenance instructions issued by manufacturers or by RDSO/LKO.

    October-2016

    (K.P.Yadav) Director/Mech CAMTECH/ Gwalior

  • IRCAMTECH/M/GWL/Dual cab 5

    CORRECTION SLIPS The correction slips to be issued in future for this handbook

    will be numbered as follows:

    IRCAMTECH/M/GWL/16-17/Dual Cab-II/1.0/. # XX date ------------- Where XX is the serial number of the concerned correction

    slip (starting from 01 onwards).

    CORRECTION SLIPS ISSUED

    No. of Slip

    Date of issue Page No. and Item no. Modified

    Remarks

  • IRCAMTECH/M/GWL/Dual cab 6

    Contents

    S.No. Description Page No.

    1 Introduction 9

    2.0 Dual Cab Loco (WDP4D) 15

    2.1 What is Dual Cab Loco (WDP4D) 1.5

    2.2 General Technical Information of WDP4D 15 2. 3 Major Assemblies of DUAL CAB(WDP4D)

    Locomotive 16

    2.3.1 Electrical Control Cabinet #1 16

    2.3.1(A) Circuit Breaker Panel on ECC#1 in CAB-1 17

    2.3.1(B) Engine Control Panel of ECC # 1 21

    2.3.1(C) Test Panel in ECC#1 25

    2.3.2 Electrical Control Cabinet #2 25

    2.3.3 Electrical Control Cabinet #3 26

    2.3.4 Electrical Control Cabinet #4 27

    2.3.4(A) Circuit Breaker Panel on ECC#4 in CAB-2 28

    2.3.4(B) Engine Control Panel of ECC #4 29

    2. 3.5 Traction Control Cabinet TCC (MCP 463) 30

    2.3.6 Control Console 30

    2.3.7 Control and Operating Switch Panel In CAB-1&2

    33

    3 Speedometer 37

    4 Tractive Effort /Dynamic Brake Effort Meter

    37

  • IRCAMTECH/M/GWL/Dual cab 7

    5 Starting Fuse And Battery Knife Switch Box 38

    6 Preparation for Service 39

    6.1 Ground Inspection 39

    6.2 Engine Room Inspection 39

    6.3 Starting Fuse And Battery Box Inspection 40

    6.4 Circuit Breaker Panel Inspection On Dual Cab Locomotive

    40

    6.5 Control Consoles 41

    6.6 Air Brake Equipment 41

    7 Engine Starting Procedure of Dual Cab Locomotive

    42

    8 Setting Locomotive On Line 46

    9 Precautions Before Moving Locomotive 46

    10 Handling Light Locomotive 46

    11 Coupling Locomotive Together 47

    12 Double Heading Service 48

    13 Engine Stopping Procedure 48

    14 Cab Selection or Cab Changing Procedure From One Cab to Another Cab

    50

    15 TFT LCD Display 51

    16 Advantages and Salient Features of Dual Cab Locomotives

    67

    17 CREW Messages List 68

    18 Some Important Crew Messages 73

  • IRCAMTECH/M/GWL/Dual cab 8

    19 General Safety Precautions 75

    20 Dos And Do Nots 78

  • IRCAMTECH/M/GWL/Dual cab 9

    1. Introduction

    WDP4D Diesel Electric locomotive of Indian Railways are driven by 3-phase AC Traction Motors, employing AC-DC-AC power transmission system. Medha Servo Drives Pvt. Ltd. has designed and developed the AC-AC traction system type MAS 696D suitable to the above locomotives delivering up to 4500 HP. Diesel Engine drives the main generator assembly. The main generator assembly has two Alternators which are Traction Alternator (MAIN ALT.) and Companion Alternator. The main alternator converts the Diesel Engine mechanical power into 3- AC electrical power. The Alternator two winding (left bank and right bank) outputs are connected to two air cooled Rectifier Assemblies consists of high voltage, high current Silicon diodes with fuses in 3- Full Wave Rectifier circuit which are internal parts of TA-17-CA-6B of main generator assembly. The 3- AC power is converted into DC power by Rectifier Assembly. The two rectifier outputs are connected in series across the DC LINK. Rectified DC power supply is applied to DC LINK. When DCL switch gears are close, the DC voltage applied to IGBT based Traction Inverters. Each Traction Inverter has separate control module in the Traction Computer. The Traction Computer monitors Traction Motor speed, Temperature, Voltage and Current feedbacks for controlling the IGBTs to maintain required Torques according to command received from Locomotive Control Computer. Traction inverters main role is to control the 3- induction motors. Traction Inverters convert the DC power into 3- AC power of variable voltage, variable frequency using IGBT based technology. In TCC, six DC Link switch gears

  • IRCAMTECH/M/GWL/Dual cab 10 are provided to provide DC power to six Traction Inverters, which are controlled by Locomotive Control Computer (LCC) as shown in figure. Traction Control cabinet consists of six Traction Computers, six DCL switch gears, six IGBT based Inverters, DC link capacitors, Brake Chopper and Crow bar circuit. Based on the inputs received from Locomotive Computer and analog feedback from traction motors, the Traction inverter converts the DC power into 3- AC power for the Traction motors. LCC receives the operator request as digital inputs and analog signals from different sensors and sends request to the Traction computer for converting required amount of power during Motoring and Dynamic Braking modes. The term TCC refers to an Electrical device that converts DC power into 3- AC power during Monitoring and 3- AC power in to DC power during Dynamic Brake.

    Fig: Block Diagram of Locomotive Control System Traction Motors are 3- AC Induction Motors. 3- AC power from Inverters are fed to the Traction Motors which

  • IRCAMTECH/M/GWL/Dual cab 11 are mounted on the Trucks, each Traction Motor geared with a pair of wheels with the gear ratio 17:90 (MAC loco) for Goods service and 17:77 (PAC loco) for passenger service. The Traction Motors convert the electrical power into mechanical power to move locomotive.

    1.1 Auxiliary Generator:- Auxiliary Generator is driven by the Diesel Engine gear train at three times of engine speed. Its field winding current is controlled by LCC through AG PWM module. AC power from Auxiliary Generator is supplied to an external 3- Full Wave Rectifier i.e., Battery Charging assembly, the Battery Charging assembly is converted to 74V DC power for Companion Alternator field, control system operation and Locomotive Battery charging. The Auxiliary Generator also supplies 74V DC power for Fuel Pump Motor, Turbo lube oil Pump circuits, Locomotive lighting and other miscellaneous equipments.

    1.2 Companion Alternator

    Companion Alternator is directly coupled to Traction Alternator within the main generator housing. Companion Alternator is physically connected but Electrically independent of the Traction Alternator. Companion Alternator consists of 16 field poles on the same rotor back to main generator field poles. The rotating CA field poles receive low voltage current from Auxiliary G