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Page 1 of 77 Issued on 12.09.2016 Report RDSO/2016/EL/IR/0175, Rev.`0’
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lR;eso t;rs
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
Technical Report on
Maintenance & Reliability issues of
Micro-Processor based Control &fault
Diagnostic System (MPCS) for
25 kV AC Tap-Changer
Electric Locomotives.
Report No.: RDSO/2016/EL/IR/0175, Rev.`0’
Issue Date: 12.09.2016
Approved by
O. P. Kesari
EDSE(Co-Ord) Signature
Issued by
Electrical Directorate
Research, Designs and Standards Organization
Manak Nagar, Lucknow-226011
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Status of Revision
S.N. Date of Revision Page no. Revision Reason for
revision
1. - all 0 First Issue
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Contents
S.N. Subject Description Page nos.
1. Chapter - I Introduction 4
2. Chapter - II In-house developments 5 - 6
3. Chapter - III Development through industry-
MPCS version-0
7 - 12
4. Chapter - IV MPCS version-1 13 - 30
5. Chapter - V MPCS version-2 31 - 64
6. Chapter - VI MPCS version-3 65 - 74
7. Chapter-VII MPCS Repair & AMC 75
8. Chapter -VIII List of SMI/MS/TC related with
MPCS
76 - 77
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Chapter I
1. Introduction :
1.1. Existing AC tap-changer type electric locomotives working on Indian Railways had
relay based protection and control scheme. It consists of large amount of cabling,
relays and associated interlocks/contacts. Reliability of all these interlocks, relays and
interconnections was low and maintenance intensive.
1.2. RDSO had started development of Microprocessor based system in late eighties and
taken a decision to eliminate majority of all these relays and interlocks. Moreover, for
troubleshooting of any fault in a locomotive, crew had to waste substantial time and
so blocking the section. At the end, maintenance personnel had to depend upon the
sequence of events, as recorded in loco logbook, which makes fault analysis
inadequate. Hence, microprocessor based control and fault diagnostic system was
developed to solve following issues:
Frequent and specialized maintenance requirement for relays
Frequent calibration need for time delay relays due to drift
Complex control cabling
Poor reliability due to wear & tear of large quantity of moving parts like
contactors.
Manual record keeping of DJ tripping and others occurrences
Limitation of manual recording of fault logs.
1.3. The control scheme of tap-changer type AC electric locomotives had been modified
using microprocessor. This had helped in reducing cabling, as well as maintenance of
intensive relays which were not only maintenance prone and unreliable.
1.4. The modified scheme had helped operating crew in diagnosis and reducing pressure
on maintenance staff as well. It was financially viable too.
1.5. Presently, Tap changer electric locomotives working on Indian Railways were
provided with control based on electromechanical and Electro-pneumatic relays/
contactors. Microprocessor-based Control System (MPCS) version-2 and 3 was
provided in conventional electric locomotives (approximately 2000 locomotives) as
per specification no. ELRS/SPEC/MPC-FDS/0001 Rev. ‘2’ & Rev. ‘3’ by procuring
MPCS from M/s Medha/Hyderabad, M/s Stesalit/Kolkata, M/s ICECPL/Haridwar,
M/s SIL/Kolkata, and M/s Laxven/Hyderabad.
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Chapter II
2. In-house developments:
2.1. At the end of the eighties, in 1989 this project was started in RDSO with a concept to
replace existing relay logic into soft logic with the help of 8 bit microprocessor (8085
microprocessor trainer kit). RDSO developed and demonstrated a software program
on above mentioned trainer kit with the help of controlling relays and indicating
LEDs on in-house lab model successfully.
2.1.1. RDSO had again developed actual loco logic on 8-bit microprocessor (8085
microprocessor trainer kit) up to DJ closing including Q118, Q45, Q44 and MTDJ
branches in software logic and tested it successfully on WAM4 training simulator at
Electric Loco Training School, Kanpur in 1991-92.
2.1.2. During visit of Member (Electrical) to RDSO in September, 1991, a demonstration on
working of a microprocessor based Control System for Electric Locomotives,
designed and developed by RDSO was made and a prototype unit was fitted on
WAM4 loco no. 20414 at ELS/BSL/CR which had worked satisfactorily. The
development of engineering model was done by IRIEEN/Nasik as a project.
2.1.3. The proposal for in-house development of microprocessor based locomotive control
and fault diagnostic system was sanctioned by DG/RDSO on 16.11.1992 and an
amount of Rs.8.3 lakhs was allocated for the procurement of four numbers of
microprocessor based system for electric locomotive.
2.1.4. Railway Board vide D.O. no. 91/Elect(TRS)/441/1 dated 27.01.1993 had advised
RDSO to prepare detailed specification for adoption of MPCS system based on the
performance of loco no. 20414.
2.1.5. Railway Board vide D.O. no. 91/Elect(TRS)/441/1 dated 30.03.1993 had decided that
microprocessor control system for WAG5 locomotives should be developed by RDSO
and CLW.
2.1.6. Meanwhile, another prototype unit (based on 8085 8-bit microprocessor) had been
developed by M/s WML free of cost. A hardware MPCS system was installed along
with software developed by RDSO up to DJ closing (MTDJ branch) on WAM4 20437
loco at Electric Loco Shed, Mugalsarai, but the system could not be commissioned
successfully on the loco for field trials due to hardware issues of M/s WML system.
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2.1.7. RDSO had issued specification no. E-16/22 in May 1993 for microprocessor based
control system of 25 KV AC electric locomotives. Order for procurement of four nos.
microprocessor based control system was placed on M/s ADC, Roorkee, as per
RDSO specification no. E-16/22 (May 1993). One unit was installed on WAM4 class
loco number 20437 at ELS/MGS. The system had worked satisfactorily for about 4
years. It had since been taken out, as maintaining a single unit was difficult. Other
three units were fitted on WAG7 locomotives by CLW.
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Chapter III
3. Development through industry-
3.1. MPCS version-0:
3.2. RDSO had issued specification No. E-16/22 in May 1993. CLW had placed
developmental order on M/s ADC; Roorkee for 25 Number of the microprocessor
based control & fault diagnostic system as per CLW’s specification No. D&D/202
dated 27.4.94
3.3. Total 29 units of MPCS version-0 were procured (25 by CLW & 4 by RDSO), out of
which 27 units were provided in locomotives, one was kept as spare at
ELW/Kachrapara and one was used in Electric Training center (ETC), Kanpur for
training of the drivers.
3.4. ELS/CNB had 16 locomotives and ELS/GMO had 11 locomotives of MPCS version
0.
3.5. Salient feature of MPCS version-0
a. 8 bit (Z-80) microprocessor used.
b. 48 binary inputs
c. 48 binary outputs were used with OEN* relays to drive loco contactors and 110 V
dc relays.
(Note: *O/E/N India Limited (OEN), A Relay manufacturer company)
d. Two display unit having 2 line 20 characters LCD display with 24 operating keys
in each cabs for displaying messages and use two big size (2 inch) seven segment
LED display for Notch indicators.
e. One 110 V to 5V & 24 V, 5Amps current rating power supply used for the
system.
f. Surge, RF/EMI protection and opto-isolation were used for the system.
g. The following 20 relays were eliminated with this system:
(i) Time Delay Relays (5 Nos.)
Q118, Q44, QTD105, QTD106, Q120
(ii) Sequencing Relays (10 Nos.)
Q45, Q100, Q46, Q48, Q49, Q50, Q51, Q52, QRS, QWC
(iii) Signaling Relays (5 Nos)
QV60, QV62, QV63, QV64, QVSOL
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h. Reduction of Interlocks :
Only 4 out of 36 auxiliary contacts of Master Controller and 2 contacts each of
CTFs & Reversers were used in MPCS.
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3.6. Summary of Failures of MPCS Version-0 for electric locomotives.
Year 1997-98 1998-99 1999-2000 2000-01 2001-02 2002-03 2003-04 2004-05
Defective Items
Power supply card 1 5 3 3 4 5
Input card 1 9 5 3 2 1 1
Display unit 2 19 18 6 2 3 3
Output card 9 9 11 11 12 4 1
CPU card 2 1 7 4 1 1
Controller card 9 5 1
Mother Board 2 2
Complete unit 2
CFN loose connection 1 2 7 2 2 3 2
Misc. faults 1 6 1
Population 11 11 27 27 27 17 13 7
Total Failures 4 15 67 50 24 25 17 15
FRPCPY 36.36 136.36 248.14 185.18 88.88 147.05 130.76 214.28
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36.36
136.36
248.14
185.18
88.88
147.05 130.76
214.28
0
50
100
150
200
250
300
1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05
Year wise FRPCPY For MPCS Ver-0 of M/s ADC Make
FRPCPY
21
22
53
57
16
15
4
2
19
8
0 10 20 30 40 50 60
Power supply card
Input card
Display unit
Output card
CPU card
Controller card
Mother Board
Complete unit
CFN loose connection
Misc. faults
Item wise failurs For MPCS Ver-0 of M/s ADC Make
Failurs
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3.7. Failure analysis of MPCS version ‘0’ :
3.7.1. Largest number of failures was on account of failure of output cards due to which
locomotive fails on line.
3.7.2. Second largest number of failure was of display units, which doesn’t fail locomotive on
line, but leads to un-scheduled withdrawal from traffic.
3.7.3. Other major contributors towards failure of the system were input cards, power supply
cards, loose connection, CPU Card, controller card and mother boards.
3.7.4. Such high level of failures on account of the MPCS version-0 itself was not at all
acceptable, which disrupts traffic in the section or leads to un-scheduled withdrawal
from traffic.
3.8. Major problems experienced in this system can be broadly categorized into Technical
and Commercial issues.
3.8.1. Technical Problems :
a. Except for initial teething problems, the system had given satisfactory performance.
The problems experienced mainly were related to engineering design and the
service support from the supplier.
b. This design had input/output connector on the individual cards and card was
dedicated for inputs and outputs, this concept requires large number of spare cards.
c. Maintenance was not easy for cards due to connector fitted on the card.
d. No analog parameter had been processed.
3.8.2. Commercial Problems:
It was basically due to the Vendor, whose capacity to provide after sales support and
upgrade the existing system based on fault analysis was not at all adequate. Lack of
alternate source was another reason, so that, no substantial action could be taken to
improve the reliability of the MPCS Version-0 system.
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Photograph of MPCS version-0 (M/s ADC make)
Front View with Door Closed Back view Front View with Door open
Main Unit MPCS Version-0
16 channel input card Display unit
Using terminal strip (RDSO) 2 line 20 character LCD display With 24 keys
Card & Display Unit MPCS Version-0
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Chapter IV
4. MPCS version-1
4.1. Based on the performance reports, feedback and lack of service support from the M/s
ADC for MPCS version-0, it was felt necessary to increase the vendor base, before large
scale implementation of MPCS.
4.2. Based on the feedback received, following points were considered for preparing revised
specification:
The interface between the system and locomotive had been standardized.
All interfacing cables, connectors with their pin configurations were frozen.
The display unit was modified. It was very similar in appearance to the unit used
on three-phase locomotive. Provision for Audio-visual alarm and conspicuous
fault acknowledgement button was made.
An expert system was developed to guide the crew, in case of fault.
Dedicated slots for inputs and outputs were used in place of dedicated cards.
4.3. 5 more relays was eliminated in MPCS version-1 and total 25 relays were eliminated as
given below-
(a) Time Delay Relays (6 Nos.)
Q118, Q119, Q44, QTD105, QTD106, Q120
(b) Sequencing Relays (11 Nos.)
Q45, Q100, Q46, Q48, Q49, Q50, Q51, Q52, QRS, QWC, QCVAR
(c) Protection Relays (2 Nos)
Q30, Q20
(d) Signaling Relays (6 Nos)
QV60, Q61, QV62, QV63, QV64, QVLSO
4.4. RDSO had revised old specification no. E16/22for electric locomotives with
standardization and improvements, and again issued a new specification No.
ELRS/Spec/MPC-FDS/0001 Rev ‘0’ in Dec. 1998.
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4.5. The following major changes had been made in revised specification.
S.N. Old spec. no. E16/22 (1993) Revised spec. No.
ELRS/SPEC/MPC-FDS/0001
Rev-0
MPCS ver-0 MPCS ver-1
1. Two CPU card of (8 bit)
microprocessor used, operated with
manual changeover
Two CPU card of (8 bit or more)
microprocessor used with
software operation of 100%
redundancy provision to avoid
single fault that may lead to loco
failure.
2. 48 binary inputs (24V &5V) DC 64 binary inputs 110V DC and
analog inputs
3. 48 Binary Outputs (24V) DC relay
based
48 Binary Outputs 110V DC
transistor based
4. One display is used in each cab for
displaying all inputs and outputs
with 24 operating keys
2 lines 40 characters LCD
alphanumeric display used for
display messages.
5. Notch indicator used two 1” seven
segment LED display on each
display unit.
Notch indicator used two 1”
seven segment LED display on
each display unit.
6. Male/female lock type connectors
was used.
Circular threaded connectors had
been used
7. Details of test was not define Follows IEC-571-1 Rules for
electronic equipment on rail
vehicle.
8. Warranty not defined 1 year warranty defined
9. Memory not defined 100 faults memory with ring
buffer defined
10. Analog parameters not defined. Analog parameters included
11. -- Future provision for interfacing
of other MP based system like
ESMON and SIV.
12. -- System shall have real time clock
(RTC) for recording faults with
date and time.
13. ---- Stored fault data can be down
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loaded through handheld
terminal and print with MS-
DOS/Windows operating system.
14. -- The system has power-up and
periodic self-diagnostics
4.6. CLW had placed developmental orders on 4 firms for 60 loco sets as per the new
specification number ELRS/Spec/MPC-FDS/0001 Rev ‘0’ Dec. 1998. RDSO had
approved the designs and carried out type testing on the prototypes offered by three
firms. Details are given below;
S.N. Firm Quantity
ordered
Remarks
1. M/s Advance Digital Controls/
Roorkee
30 nos.
Order completed after
prototype 2. M/s Medha Servo Drives/
Hyderabad
10 nos.
3. M/s Stesalit Limited/Kolkata 10 nos.
4. M/s TATA consultancy limited/
SBC
10 nos. prototype and order
not completed
4.7. COMPARATIVE CHART OF MICROPROCESSOR BASED CONTROL AND
FAULT DIAGNOSTIC SYSTEM FOR ALL VENDOR
S.N. Parameters ADC Medha Stesalit
1. Ordered
quantities
30 no. for WAP4 5 no. WAG7 + 5no.
WAP4 =10
5 no. WAG7 +
5no. WAP4 = 10
2. PO order no.
& date
31/98/2709/8099
2 date 6.3.2000
31/98/2709/80995
date 6.3.2000
31/98/2709/80990
date 6.3.2000
3. Cost of the
system
₹ 2,30,000/- ₹ 1,84,000/- ₹ 1,65,000/-
4. Design
document
submitted for
hard ware
portion on
2.8.2000 11.7.2000 17.7.2000
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S.N. Parameters ADC Medha Stesalit
5. Design
approval given
for the same
13.10.2000 27.9.2000 25.9.2000
6. Prototype
cleared on
10.04.2002 1.2.2002 22.7.2002
7. Loco
commissioned
at ELS/CNB
on
20.07.2002 29.05.2002 11.01.2003
8. Performance Satisfactory Satisfactory Satisfactory
9. CPU Card
Microprocesso
r used
Hitachi 3048 MP
32 bit
RTC Y2K
Compliance,
Watch dog timer
used with
indication
Intel 196 m-controller
16 bit Watch dog
timer used with
indication
Intel 80C196KC
16 bit micro
controller with
front panel LED
indications for
status. Two
separate processor
cards used with 2-
out-of-2
architecture to
ensure fail-safe
operation. In case
of failure of one
subsystem, the
system works with
the other healthy
unit.
10. Input card Total =80 inputs
16 inputs/card, 5
cards
Facia had LED
indication
Opto isolation,
Surge protection
Total =80 inputs
16 inputs/card , 5
cards
Facia had LED
indication
Opto isolation, Surge
protection, reverse
polarity
Total = 96 inputs
with dual
redundancy
32 inputs/card, 3
cards under each
processor. Total 6
cards.
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S.N. Parameters ADC Medha Stesalit
11. Output card Total =48 outputs
16 outputs/card ,
3 cards
Facia had LED
indication
Opto isolation,
over load and
short circuit
protection
Total =48 outputs
16 outputs/card, 3
cards
Opto isolation, over
load and short circuit
protection
Total =48 outputs
with built-in
testability and
feedback
8 outputs/card,
Total 6 cards
Opto isolation,
over load and
short circuit
protection
12. Interfacing
card
For display unit
RS232
Downloading
RS232
For display unit
RS485;
Downloading RS232
For display unit -
RS485;PC
Interface- RS232
13. Analog input
card
8 channel
12 bit resolution
8 channel 8 channel with
opto-isolation
10 bit resolution
14. Display unit 4 lineX40Ch
backlit type
Communication
– RS232
4 lineX40Ch backlit
type LCD Display
with Communication
for Control Unit on –
RS485
4 lineX40Ch with
backlit LCD.
Communication –
RS485. Display &
Keyboard design
same as
recommended by
RDSO/CLW
Screen
Structure
Starting
sequential
operation for the
driver
MENU driven with 4
keys Isolation, LT
mode and BPAR
status on line 1 of
LCD
Eliminated relay
status for better
Trouble shooting.
MENU driven
with 4 keys
Isolation, LT
mode and BPAR
status on line 1 of
LCD
Eliminated relay
status for better
trouble shooting.
7-singment
Display
RED color, size
1”
RED color, size 1” RED color, size 1”
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S.N. Parameters ADC Medha Stesalit
Color Dark green
(Reason given by
the firm because
of dirty hand of
the driver this
color was more
suitable.)
Specified gray Specified gray
Size of the unit 345 mm X 143
mm X 53 mm
310 mm X 230 mm X
61 mm
310 mm X 230
mm X 100 mm
Keys Membrane type
(MENU,
,,ACK and
ENTER keys)
Membrane type (
MENU, ,,ACK
and ENTER keys)
Membrane
type,(MENU,
,,ACK and
ENTER keys)
Audio
annunciation with
acknowledgement
against any alarm.
Memory for
the faults
in display
100 faults
380 faults Logs last 128
events, which can
be displayed on
the panel or
downloaded to the
PC through serial
link.
Look wise Good
Some difference
with given Keys
position.
Best Better
Note: Functioning of
Control Unit was not
dependent on
healthiness of Display
Unit
15. Cabling/
Harness
Provided as per
spec. with level
and tags
Provided as per spec.
with label and tags
Provided as per
specification with
labels and tags
16. Back-plane
Soldering
64 pin EURO
connector
Soldering
64 pin EURO
connector
Soldered with
64/96 pin EURO
connector
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S.N. Parameters ADC Medha Stesalit
17. Connectors
Round threaded
as per
specification with
polarization.
Round threaded as
per specification with
polarization.
Round threaded as
per specification
with polarization.
18. Fabrication of
the cabinets
Good Very good Good.
19. Front door &
locking system
Left side hinged
with gasket and
lock, detachable.
Left side hinged with
gasket and lock,
detachable.
Left side hinged
with gasket and
lock, detachable.
20. PCB qualities
Double sided
with PTH and
semi SMD were
used
Double sided with
PTH
Double sided with
PTH.
21. Housing of the
PCB
Plastic tracker
was used
Easy to insert and
opening of PCB
Powder Coated
enclosure for PCBs
totally sealed with
handles
Easy to insert and
opening of PCB
Plastic tracker was
used
Easy to insert and
opening of PCB
22. PCB card
orientation
Vertical Horizontal & packed Vertical
23. Soldering Wave and hand
soldering both
Wave and hand
soldering both
Wave and hand
soldering both
24. Component
placing
Satisfactory Good Good
25. Tracking of
the PCB
Jumper was used Extra wire used for
tracking somewhere
to correct layout
mistakes
Good Layout
26. Size of the
main unit
770 mm X 383
mm X 296 mm
760 mm X 380 mm X
305 mm
744 mm X 380
mm X 300 mm
27. Size of the SC
unit
200 mm X 150
mm X 100 mm
200 mm X 150 mm X
100 mm
200 mm X 150
mm X 75 mm
28. Size for
mounting studs
As per
specification OK
As per specification
OK
As per
specification. OK
29. Redundancy Only CPU card Only CPU card CPU, Input and
Analog cards
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S.N. Parameters ADC Medha Stesalit
30. Analog signal
measurements
Resistive
technique used
Use frequency
conversion technique
with live zero
With this it was
possible to detect
Interconnecting Cable
short and open
circuiting
Resistive
attenuator pad
with optical
isolation to bring
the signals to
scale.
31. Downloading
Data
In specified
format
In specified format on
Laptop/PC
As per specified
format
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S.N. Parameters ADC Medha Stesalit
32. Extra feature Status of CPU
MEM and working
of analog channels
was shown in the
self-test mode
Provision to add 2
Input and 2 Output
cards in the system
for future
expansion
All Input, Output
and CPU cards
were
interchangeable
within their
respective
designated slots
Insertion of a card
at a wrong place
was not possible
CPU card
functioning was
toggled at every
normal DJ opening
to ensure that both
cards were
functionally
working
Galvanic (Opto
/Transformer)
isolation for all
analog inputs
Separate DC/DC
Converter for
Display Unit
Power Supply
This system had
hardware
redundancy of 2
out of 2 to
ensure higher
degree of
safety, which
was necessary
for such type of
application.
One fault LED
was provided on
the display
panel.
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4.8. Performance of MPCS version-1
Make 2002-03 2003-04 2004-05 2005-06 2006-07
P F %F P F %F P F %F P F %F P F %F
ADC 1 2 200 4 4 100 37 71 191 44 34 77 44 10 23
Medha 1 3 300 1 1 100 10 16 160 10 4 40 10 0 0
Stesalit 1 2 200 1 4 400 1 2 200 9 13 144 9 6 67
Total 3 7 233 6 9 150 48 89 185 63 51 81 63 16 25
(Note: P = Population, F = Failures and %F = FRPCPY)
0
50
100
150
200
250
300
350
400
450
2002-03 2003-04 2004-05 2005-06 2006-07
FRP
CP
Y
Years
FRPCPY of MPCS version-1
ADC
Medha
Stesalit
Total
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4.9. Failure Analysis of M/s ADC make MPCS version-1 (from 2002-07)
Items Failures
Power supply card 3
MPCS 9
CPU card 2
Input card 1
Output card 8
Controller card 6
Mother board 0
Display unit 72
SCU 2
Connectors 4
Software 2
Misc 2
Analog card 10
Total Failures 121
Population 44
3
9
2
1
8
6
0
72
2
4
2
2
10
0 20 40 60 80
Power supply card
MPCS
CPU card
Input card
Output card
Controller card
Mother board
Display unit
SCU
Connectors
Software
Misc
Analog card
Item wise failures of M/s ADC make MPCS version-1
Failur…
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4.10. Failure Analysis of M/s Medha make MPCS version-1 (from 2002-07)
Items Failures
Power supply card 0
MPCS 2
CPU card 0
Input card - 0
Output card 9
Controller card 0
Mother board 0
Display unit 1
SCU 6
Connectors 1
Software 0
Misc 5
Analog card 0
Total Failures 24
Population 10
0
2
0
0
9
0
0
1
6
1
0
5
0 2 4 6 8 10
Power supply card
MPCS
CPU card
Input card
Output card
Controller card
Mother board
Display unit
SCU
Connectors
Software
Misc
Analog card
Item wise failures of M/s Medha make MPCS version-1
Failures
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4.11. Failure Analysis of M/s Stesalit make MPCS version-1 (from 2002-07)
1
1
1
2
4
0
0
8
6
3
1
0 2 4 6 8 10
Power supply card
MPCS
CPU card
Input card
Output card
Controller card
Mother board
Display unit
SCU
Connectors
Software
Misc
Analog card
Item wise failures of M/s Stesalit make MPCS version-1
Failures
Items Failures
Power supply card 1
MPCS 1
CPU card 1
Input card 2
Output card 4
Controller card 0
Mother board 0
Display unit 8
SCU 6
Connectors 3
Software 1
Misc 0
Analog card 0
Total Failures 27
Population 9
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4.12. Problems Related With Maintainability:
4.12.1. M/s ADC make MPCS version-1:
(I) Fault detection and replacement of card was no problem, however M/s ADC did not
hand over the key of the unit in warranty period as a result of which loco had to
wait for their representative even though it could be attended by shed staff.
(II) Spare cards were not kept in shed.
(III) Component on the cards were manually soldered instead of wave soldering.
(IV) Input output cards were dedicated which had increased the inventory, i.e. for each input and output cards, shed had to maintain the spares.
4.12.2. M/s Medha make MPCS version -1:
(I) Detection and replacement of card was no problem.
(II) Only 1 output card had been kept in shed as spare.
(III) Input cards were common i.e. it can be replaced for any input card. Similar was the
case for output card i.e. lesser inventory.
(IV) No LED indication on output card. Identification of defective output cards can be
done with the help of digital output status in the diagnostic display, which was
cumbersome. The problem gets worsened in case of communication failure to
display unit. However LED indication was available for Input Cards.
4.12.3. M/s Stesalit make MPCS version-1:
(I) Detection and replacement of card was no problem.
(II) Input cards were common i.e. it can be replaced for any input card. Similar was the
case for output cards i.e. lesser inventory.
(III) For any fault in the output cards, the complete unit will shut down which makes
troubleshooting to find defective output difficult. The only way was to replace each
card one by one and only then faulty card was identified.
(IV) There was no LED indication both for Input as well as output cards.
(V) Identification of defective input cards can be done with the help of digital input
status in the diagnostic display, which was cumbersome. The problem gets
worsened in case of communication failure to display unit.
(VI) One set of cards had been kept in shed as spare.
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4.13. Repair Of Defective Cards
(I) Repairing was not possible in any of the units supplied by Original Equipment
Manufacturer (OEM) due to non-availability of details to the circuit & components.
(II) Only repair contracts with the OEM were possible.
4.14. Software Related Problems and Issues
4.14.1. M/s ADC make MPCS version-1:
(I) Software, both for downloading new version of software to the loco as well as
downloading of faults from loco had not been given.
(II) There was no background data for faults stored.
4.14.2. M/s Medha make MPCS version-1:
(I) Slight time delay in command execution.
(II) Software for downloading new version of software to the loco had not been given.
(III) There was no background data for faults stored.
4.14.3. M/s Stesalit make MPCS version-1:
(I) Slight time delay in executing the commands as they had used the system of double
check in input.
(II) For any fault in outputs, the systems got shutdown. This should be limited to only
particular major areas i.e. SMGR (up), C118 & VCB circuits.
(III) Software for downloading new version of software to the loco had not been given.
(IV) There was no background data for faults stored.
4.15. Other problems of MPCS version-1:
(I) M/s ADC had not given the system keys &manual for trouble shooting of MPCS
Version–1.
(II) M/s ADC had not given any training on the revised system.
(III) None of the OEMs had supplied hand held terminal data extraction units.
(IV) Sometimes display units remain blank when ‘BA’ put ON. After putting BA ‘OFF’
& then ‘ON’ it displays.
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4.16. Photograph of MPCS version-1 of M/s Medha Make
Covered cards Enclosed I/O cards
Horizontally mounted cards Connector fitted on left side Main unit
Display unit Signal Condition Unit (SCU)
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4.17. Photograph of MPCS version-1 of M/s Stesalit make
Main unit with doors closed Main unit with doors open
I/O card Display unit
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4.18. Photograph of MPCS version-1 of M/s ADC make
Main unit with doors closed
I/O card Display unit
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Chapter V
5. MPCS Version-2
5.1. Based on the performance reports and feedback of MPCS version-1, RDSO had revised
specification no. ELRS/Spec/MPC-FDS/0001 Rev ‘0’ of Dec. 1998 with standardization
and improvements, and issued specification No. ELRS/Spec/MPC-FDS/0001 Rev ‘2’ in
Aug 2005.
5.2. The following points were incorporated in MPCS Version II specification.
S.
no.
Clause no. changes from old spec. Added in new spec.
1 1.4.6 Quote the cost of repair for cards
2 1.4.10 Warranty:
(a) 1year to 2 years
(b) Penalty for late responding at the
time of failures.
3 1.6 Modification
4 1.7 Field trials
5 1.9 ToT (As a special condition)
6 1.10 (a) Infrastructural requirements
(b) Region wise service centers
7 1.5.7 / 1.11 IEC 571 to IEC60571
WAG7 CKT to all type
(a) IEC61000
(b) WAM4,WAG5 & WAP4 locos
(c) Spec. ELRS/SPEC/SI/0015
8 2.1 Design should have built-in testability to
ensure the reliability and safety.
9 3.1.1 / 2.1.1 8 bit MP to 16 bit MP or
above
Working of both processors defined
properly
10 2.1.2, 2.1.3 64 inputs to 96 inputs Details of input / output cards were given
with spare and redundant cards
11 2.1.4 Signal conditioning unit details were
given
12 2.1.5 (iii) Status memory capacity was increased to
512 faults
13 2.1.6 Included more analog signal for
measurement.
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S.
no.
Clause no. changes from old spec. Added in new spec.
14 2.1.7 Fix the mounting details and specify in
the spec.
15 2.1.8 3.1.8 Power supply details were given with
redundancy.
16 2.1.9 3.1.9
2.1.9.1
Display unit:
2 line 40 Ch to 4 line 40
Ch
Detailed screen structure was given
17 2.1.10.1 Coupler: Circular
threaded to bayonet
circular.
18 2.1.11 3.1.11 Algorithm: only WAG7 Added with WAM4, WAG5 &WAP4
19 2.1.12 More relays were eliminated like QD’s
and QF’s
20 2.2.13 USB device for downloading the data
from the system
21 2.3.4.2 & 3 Priority of faults was specified
22 2.4 & 2.4.3 Safety feature:
A switch was provided for tripping the
DJ and lowering the pantograph when
system fails with the MTDJ output.
23 3.8 Electromagnetic and RFI pollution
24 4.1.1 Details of number of items were defined
with 5 years backup support, cost of
spare parts, repairs of cards and annual
maintenance contract.
25 Chapter 5 Inspection
26 Chapter 6 Details of tests were given with
parameters and process as per IEC
60571.
27 Annexure SB connection list, Burn in test,
Input/output list, Fault messages list,
Screen structure, Mounting Details,
display unit Details
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5.3. 4 more relays was eliminated in MPCS version-2 and total 29 relays were eliminated as
given below-
(a) Time Delay Relays (6 Nos.)
Q118, Q119, Q44, QTD105, QTD106, Q120
(b) Sequencing Relays (11 Nos.)
Q45, Q100, Q46, Q48, Q49, Q50, Q51, Q52, QRS, QWC, QCVAR
(c) Protection Relays (6Nos)
Q30, Q20, QD1, QD2, QF1, QF2
(d) Signaling Relays (6 Nos)
QV60, Q61, QV62, QV63, QV64, QVLSO
5.4. Approved Vendor status of MPCS V2
The following vendors were approved for MPCS version-2
Firms Status
1. M/s Medha Part-1
2. M/S ICEPL Part-2
3. M/s SIL Part-2
4. M/s Laxvan Part -2
5. M/s Stesalit Temporary delisted from Part-2
category for MPCS V2 vide letter
no. EL4.2.15/STE Dated
07.04.2015
5.5. Performance of MPCS version-2
Make 2007-08 2008-09 2009-10
P F %F P F %F P F %F
ICECPL 11 22 200.0 11 14 127.3 4 4 100
Medha 4 11 275.0 66 6 9.1 270 8 2.9
Stesalit 5 4 80.0 58 41 70.7 156 146 93.6
SIL 1 5 500.0
Total 20 37 185.0 135 61 45.2 431 163 37.8
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Make 2010-11 2011-12 2012-13
P F %F P F %F P F %F
ICECPL 6 10 166.6 4 1 25.0 25 11 44.0
Medha 428 30 7.0 550 34 6.2 622 37 5.9
Stesalit 207 99 47.8 400 254 63.5 621 152 24.4
SIL 6 9 150.0 13 6 46.2 25 7 28.0
Total 647 148 22.8 967 295 30.5 1293 207 16.0
Make 2013-14 2014-15 2015-16
P F %F P F %F P F %F
ICECPL 62 74 119.3 85 119 140.0 92 122 132.6
Medha 898 107 11.9 1017 128 12.58 1105 149 13.48
Stesalit 690 372 53.9 711 433 60.90 693 391 56.42
SIL 49 15 30.6 52 18 34.62 75 28 37.33
Laxven 5 4 80 5 14 280.0 4 9 225.0
Transtel 2 0 0 2 0 0 1 2 200.0
Total 1706 572 33.5 1872 712 38.03 1970 701 35.58
(Note: P = Population, F = Failures and %F = FRPCPY)
5.6. Warranty Failure Status of MPCS ver-2 for last 2 years
2014-15
2015-16
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5.7. Shed wise FRPCPY of MPCS ver-2 for last 3 years
(Note: P = Population, F = Failures and %F = FRPCPY)
2013-14 2014-15 2015-16
Railway Shed P F F%/Y P F F%/Y P F F%/Y
SCR LGD 10 1 10.00 10 2 20.00 7 5 71.43
SER BNDM 78 34 43.59 77 33 42.86 80 46 57.50
SCR BZA 168 89 52.98 174 91 52.30 182 115 63.19
NCR CNB 61 26 42.62 67 49 73.13 69 43 62.32
SCR KZJ 66 15 22.73 82 64 78.05 92 43 46.74
SER BKSC 49 23 46.94 67 20 29.85 70 30 42.86
ECoR ANGL 96 27 28.13 105 41 39.05 110 58 52.73
NR LDH 142 56 39.44 142 53 37.32 146 63 43.15
WCR TKD 32 21 65.63 32 28 87.50 32 14 43.75
SECR BIA 95 13 13.68 95 35 36.84 95 37 38.95
WCR NKJ 68 93 136.76 74 38 51.35 74 29 39.19
ECR MGS 68 23 33.82 85 29 34.12 87 30 34.48
SR ED 48 6 12.50 49 22 44.90 50 13 26.00
ER ASN 74 21 28.38 81 36 44.44 86 20 23.26
SR RPM 57 12 21.05 44 18 40.91 28 6 21.43
2013-14 2014-15 2015-16
Railway Shed P F F%/Y P F F%/Y P F F%/Y
SR AJJ 46 6 13.04 53 23 43.40 76 20 26.32
WR BRC 36 3 8.33 38 5 13.16 47 13 27.66
NR SRE 12 2 16.67
NR GZB 26 7 26.92 30 3 10.00 32 10 31.25
NCR JHS 79 11 13.92 102 24 23.53 103 23 22.33
CR BSL 70 13 18.57 84 17 20.24 90 13 14.44
WR BL 81 19 23.46 92 27 29.35 103 22 21.36
CR KYN 8 4 50.00 14 2 14.29 16 5 31.25
ECR GMO 25 16 64.00 25 6 24.00 20 4 20.00
ER HWH 16 1 6.25 22 1 4.55 21 3 14.29
SER TATA 61 18 29.51 56 18 32.14 53 5 9.43
WCR ET 93 7 7.53 99 13 13.13 114 14 12.28
ECoR VSKP 27 2 7.41 38 7 18.42 36 9 25.00
SER SRC 35 5 14.29 35 7 20.00 39 6 15.38
GRAND Total 1706 572 33.53 1872 712 38.03 1970 701 35.58
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5.8. Modifications:
RDSO had issued following modifications for MPCS version-2 based on the feedback
and suggestions of Zonal Railways. Details of common modifications for all firms are
given below;
Stages Reference Sl.
No. Brief Description of Modifications Works carried out
M-1
RDSO's
letter no.
EL/4.2.15 dt.
12.08.10
1 C145 logic to be changed. It shouldn't
open when QF / QE acted
1. Software of CPU card to be
modified
2. Software of Display Unit to
be modified
Status: completed
2
I-62 can be used for locos having
conventional QD relays i.e. if ISCU
was not fitted, system should work
with conventional QD also
3 Message should be generated for all
TLTE cases i.e. RGAF input high, P2
input was low
4
C145 logic to be made as
conventional logic and additionally
L1_6 FB to be added. QVRF
interlock to be eliminated
5 SIV_ON command (BLSI) logic to be
modified as per conventional logic
6 For "SIV not picking up" message,
time to be increased to 30 sec.
7 IP coil logic to be modified as per
conventional locomotive logic
8 It should be possible to see the
logged faults through the display in
DJ closed condition
9 "Auto regression via QD can be
announced with specific TM, through
which TM QD was acting
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Stages Reference Sl.
No. Brief Description of Modifications Works carried out
10
While pressing BLRDJ, Q30 should
be bypassed through Q45 interlock in
Q44 branch as per conventional
circuit
M-2
RDSO's letter
no. EL/4.2.15
dt. 30.09.10
11 2 sec on time delay of QSVM
Software of CPU card to be
modified
Status: completed
M-3
RDSO's letter
no. EL/4.2.15
dt.15.12.10
12 6th notch tripping due to BLVMT off
message display
1. Software of CPU card to be
modified
2. Software of Display Unit to
be modified
13 Display message for protective relays
ie. DJ tripped via QLM, check other
safety relays also"
14 Message "Line contactor stuck up, do
not use DBR"
15 Provision of QF interlock in Q50
circuit instead of Q51
16 Data downloading front end software
should be made compatible with
Windows Vista & Windows 7 also
Lab-view based front end
(downloaded data viewer)
software to be installed in the
PC or Laptop.
17 Change in the logic of auto regression
which was bypassed by shifting of
HMCS (I60)
This modification was not
possible by modifying software
logic alone, hence the same had
been superseded later by RDSO
modification sheet no.
RDSO/2011/EL/MS/0404 Rev
0, Dated:28.12.11
Status: completed
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Stages Reference Sl.
No. Brief Description of Modifications Works carried out
MS
404
RDSO's letter
no. EL/4.2.15
dt. 28.12.11
19
Modification in Electric locomotive
control circuit fitted with MPCS for
individual isolation of hard/soft QDs
during operation of HMCS program
switch.
1. Software of CPU card to be
modified
2. Wiring of control cables of
the loco to be done as per
modified arrangement shown in
modification sheet.
5.9. Firms wise failures analysis and reliability action plans for MPCS Version ‘2’
5.9.1. Performance Analysis of M/s Medha MPCS Version ‘2’
a. Year wise performance of MPCS version-2 of M/s Medha is given below;
(Note: P = Population, F = Failures and %F = FRPCPY)
Year P F %F
2007-08 4 11 275.0
2008-09 66 6 9.1
2009-10 270 8 2.9
2010-11 428 30 7.0
2011-12 550 34 6.2
2012-13 622 37 5.9
2013-14 898 107 11.9
2014-15 1017 128 12.58
2015-16 1105 149 13.48
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b. Details of Item wise failures of MPCS V2 of M/s Medha make are as under:
c. Modification Status
Stages Sl.
No. Brief Description of Modifications Work carried out /status
M1 to
M3 1 to 17 As specified in para 5.8 Completed
M4
High state level for inputs (say 60 V DC) completed
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d. Current modification status
Sn. Item description Target date Current Status
1. Rectify correct message
for DJ tripping when SI
voltage fail.
10.03.2015 completed
2. QD modification 31.03.2015 Pending in 16 locomotives
at GZB Due to HMCS
switch not available
3. Viewing message in DJ
closed
31.03.2015 completed
5.9.2. Performance Analysis of M/s Stesalit MPCS Version ‘2’
a. Year wise performance of MPCS version-2 of M/s Stesalit make is given below;
(Note: P = Population, F = Failures and %F = FRPCPY)
Year P F %F
2007-08 5 4 80.0
2008-09 58 41 70.7
2009-10 156 146 93.6
2010-11 207 99 47.8
2011-12 400 254 63.5
2012-13 621 152 24.4
2013-14 690 372 53.9
2014-15 711 433 60.90
2015-16 693 391 56.42
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b. Details of Item wise failures of M/s Stesalit MPCS V2 are given below:
Faulty ItemNos per
loco
In
service2013-14 2014-15 2015-16
SoftwareCalibration 3 9 4
Software 9 6 5
External 15 7 3
Maintenance 18
Modification 3 6
workmanship
Misc 4
Transient 13 10 10
Found normal 8 9 6
Grand Total 372 433 391
Population 690 711 693
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c. Modifications completed by M/s Stesalit
Firm had taken the following actions for improving reliability of the MPCS system:
(i) Filter card: After analysis, it was found that choke was getting defective due to high
surges of output Power supply.
Action taken: Design of filter choke was improved.
(ii) CPU Card: After analysis, it was found that IC no 74HC574 was failing due to problem
in pull up resistor.
Action taken: The higher value of pull up resistor was used with IC no. 74HC574 in
circuit modification.
(iii) Software: After analysis, it was observed that fault downloading in pen drive was not
proper.
Action taken: necessary modification incorporated in all the locos Software.
(iv) Input Card: After analysis, it was observed that failures of this card had occurred due to
EMI interference in input sensing side.
Action taken:
(i) LC filter introduced in each input channel.
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(ii) SMD Surface Mounted Devices (SMD) component used instead of Dual in package
(DIP) components.
(v) Output Card: After analysis, it was observed that MOSFET & Zener Diodes were
failing.
Action taken: Rating of MOSFET had been changed from 200 V to250V. Zener diode
wattage had been changed from .5W to 2W. A new design Single In
Package (SIP) hybrid module has been used.
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(vi) TM current sensing unit (ISCU): After the analysis it was observed that ISCU was
failing due to generated noise by the loco side & pickup of low level voltage sensing
current input.
Action taken: A new card was design by the firm using hall effect based sensing IC in place
of sensing current through milli volt drop across shunts.
(vii) Backplane cabling: After analysis, it was found that short/flashes in backplane happened
due to rubbing of cables with wall of backplane
Action taken: all the cables inside were properly insulated with additional silicon sleeve
and proper creepage distance from body was ensured.
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d. Modifications not completed by M/s Stesalit
Stages Reference Sl.
No. Brief Description of Modifications Work carried out/status
M1 to
M3 1 to 17 As specified in para 5.8
Completed
M-5*
RDSO's letter
no. EL/4.2.15
dt. 31.12.10
18 Resolution of analog voltage sensor
by TM CSU was to be finalized
1. Replacement of TM
current sensing units by
modified one
2. Replacement of Analog
Input card by modified one
3. Software of CPU card to
be modified for improved
resolution.
4. Software of Display Unit
to be modified for improved
resolution.
Status : Merged with M7
M-6*
RDSO's letter
no. EL/4.2.15
dt.21.02.12
19
Q44 logic to be made as conventional
logic. ASMGR ''ON Notch I/C"
(Input-24) to be utilised in place of
"Between Notch I/C" (Input-16)
1. Software of CPU card to be
modified
2. Software of Display Unit to
be modified
M-7*
RDSO's
letter no.
EL/4.2.15 dt.
04.06.12
20
Old TM CSU and Analog Cards were
being replaced with upgraded TM
CSU (Ver 6x) and Analog Cards for
reliability
1. Replacement of TM CSUs by
upgraded one (Ver 6x)
2. Replacement of Analog cards
by upgraded one
3. Software of CPU card to be
modified for improved
resolution.
4. Software of Display Unit to
be modified for improved
resolution.
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Stages Reference Sl.
No. Brief Description of Modifications Work carried out/status
M-8* 21
In the Output cards- modification in
MOSFET protection Circuit by
adding one resistance with the
freewheeling diode for better
response and energy dissipation
Replacement of Output cards by
modified cards which were
provided with resistance with
freewheeling diode
Modification in CPU cards by
providing sleeve on USB connector
Replacement of CPU cards by
modified cards provided with
sleeve on USB connector
In the Display units, replacing the
fuses with slow blow fuses.
Replacement of Display Units
by modified Displays provided
with slow blow fuses.
M-9*
RDSO's
letter no.
EL/4.2.15 dt.
15-06-2013
22
Implementation of Software Release
no. 2.0 in WAG7 locomotives fitted
with MPCS Ver-2 of Stesalit makes
for several Software and operational
problems identified by RDSO
Replace the CPU and Display
Software with new released
software
(* M5, M6, M7, M8 & M9 modifications had not completed by M/s Stesalit, these modifications
were included in Integrated Modification which was also not carried out by M/s Stesalit)
e. Integrated Modification:
(i) Integrated modification covering hardware modification for output card, CPU card,
Multifunction card, Display unit, SCU, ISCU, & Analog card and Software
modification issues was issued vide letter no. EL/4.2.15/STE dated 31.07.2014.
(ii) Target for completion of 100 locomotives was given 15.10.2014. However M/s
Stesalit had not carried the Integrated modification.
(iii) M/s Stesalit had been temporarily delisted from Part-II source vide letter no.
EL/4.2.15/STE dated 07.04.2015.
(iv) Salient features of Integrated Modification are given below:
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A. Hardware modifications for integrated modification:
S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
1. OUTPUT CARD
1.1 Sometimes Flickering
of Outputs causing
malfunction / failure
of Locomotives
An RC circuit with 1.5KΩ/0.125W/0805
resistance and (0.47µF/50V) &
(47pF/50V) capacitances were brought in
the path of “AHEALTH#” and
“BHEALTH#” signal line coming from
backplane. R1 & R3 resistance would be
changed with 47K(0.25W) resistance.
New RC filter was
introduced to
reduce flickering
The problem of
output flickering
was expected to be
reduced by this
modification
1.2 Damage of MOSFET
/ SIP module of
Output cards leading
to failure of output
channels
The old SIP card was completely
replaced with the modified one. The
modified SIP card had been designed to
ensure that it had enough latching and
holding current for the proper operation
of SCR (for short circuit protection) and
high watt resistors were used therein for
those were always in conducting mode.
Moreover there will be less heat
dissipation across the new SIP card. Old
SIP cards to be replaced by modified SIP
cards.
M9 HW Short circuit
protection / Over
current
protection of
Output channels
had been
modified
Failure of Output
cards due to damage
of MOSFET / SIP
had been reduced
considerably by
using the new SIP
modules. The result
was tested by the
performance of 45
locos (M9 hardware
and software
modified) which
were running last 9-
12 months.
1.3 Damage of MOSFET
of Output cards
Transorb 1.5KE200A should be present
in all the 16 channels across the M8 All these
components were
This modification
had improved the
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
leading to failure of
output channels
MOSFET.2. Put the snubber circuit (Res
10E 2W connected in series with poly
cap 0.1uF 250V) across (between Source
& Drain) each MOSFET.3. One 56V
Transorb in series with a FR304 / FR306
Diode to be put across each output and
SGND.
used to improve
protection of
MOSFET
performance of
output cards
1.4 Components burnt-
out due to electrical
contact (closely
assembled
components /
modules) causing
failure of output
channels
Put 1.5mm glass epoxy sheet in between
3 pairs of SIP cards assembled very
closely. Also put the same thing in
between pairs of MOSFETs (assembled
with heat sinks) placed very closely (back
to back) to take precautionary measure
(not required in ver 46) against any
burning-out problem caused by
undesirable contact among closely
assembled components.
M8 Precautionary
measures were
taken by
mechanical
assembly to
avoid any
burning out,
caused by
electrical contact
This mechanical
modification
reduced the failure
of output cards
caused by burnt-out
of components due
to close assembly
2. CPU CARD
2.1 Wrong Analog values
read by CPU card
which might be one
of the causes of
malfunctioning of
Q20, Q30, QCVAR,
QD etc.
The R3 resistor (2.2KΩ/0.5W), which
was connected between VREF pin of U1
and 12V power, to be replaced with
(1KΩ/0.5W) one.
2. The R1 resistor (8.2KΩ/0.25W), R2
resistor (10KΩ/0.25W) and POT1 (5KΩ)
to be removed from circuit.
New This
modification will
arrest the Change
in analog
reference voltage
which leads to
re-adjustment of
POTs in Analog
Expected better
performance of
MPCS against the
failures due to
wrong analog values
leading to POT re-
calibration
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
cards to make the
voltages read by
CPU close to
actual ones.
2.2 Communication fail
between CPU &
Display due to which
NR would not
function properly.
1. A Bi-directional TVS (6.8V) between
positive & negative lines( IC pin 6 & 7)
in MAX485 would be inserted.
2. Connect resistance 560Ω/0.25W
between pin 6 of U33 (Max 485) and
VCC in suitable place as required.
3. Connect resistance 560Ω/0.25W
between pin 7 of U33 (Max 485) and
GND in suitable place as required.
New Protection circuit
of MAX-485
(One of the ICs
driving
communication
between CPU
and Display) had
been modified.
Damage of MAX-
485 IC was expected
to be reduced by this
modification
2.3 Problem of
Date/Time corruption
which would lead to
corruption of
background data due
to lack of proper time
stamp
Failure of existing RTC IC was the root
cause of this problem. Previous RTC IC
was to be replaced by the Industrial
Grade one (part no. DS12CR887+5)
New The new part no.
IC was having
Extended
temperature
range and larger
lifetime of
embedded
battery.
Advantage of better
performance of RTC
IC will be obtained
2.4 Failure of CPU cards
due to damage of
components caused
by electrical contact
of USB device with
One sleeve had been provided on USB
Slot as a protector. M8 The sleeve will
provide
Protection
against any
undesirable
Failure of CPU due
to undesirable
electrical contact
had been reduced
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
CPU facia contact of USB
device with the
CPU facia
3. MULTI FUNCTION CARD
3.1 Communication fail
between CPU &
Display due to
which NR would
not function
properly.
1. One Bi-directional TVS (6.8V) to be
used across the differential outputs of
MAX485.
2. A Bi-directional TVS (6.8V) to be
placed across the differential inputs of U1
(6N137).
3. A Pull up resistor 10KΩ /0.1W at Pin.7
of Opto-isolator 6N137 to be inserted.
New These will
provide
protection
against damage
of 6N137 IC
(One of the ICs
driving
communication
between CPU
and Display) due
to noise / surge
in supply line
Failure of MFC
cards was expected
to be reduced by this
modification
4. DISPLAY UNIT
4.1 Failure of LCD
module (garbage
display, not resetting
properly, getting
partially blank etc)
due to which no text
could be shown in
loco cabs.
1. It was to be ensured that the body of
LCD module was totally isolated from
the Display Box.
2. A 47µF/35V Capacitor along with a
0.01µF/50V Capacitor across the supply
in LCD module would be inserted.
New Failure of LCD
module due to
improper
assembly / fitting
as well as effect
of spurious noise
had been taken
care of.
Better performance
of LCD was
expected by this
modification
4.2 Problem of less The pull up resistor (10KΩ /0.25W) of New Modification was Advantage of better
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
brightness / contrast
of LCD leading to
problem of visibility
on the display screen.
“V_BRGT” pin (Pin.2 of display
connector) was replaced with 4.7KΩ
/0.25W.
done to improve
brightness /
contrast of LCD
visibility without
any contrast
adjustment in the
locomotives will be
obtained
4.3 Communication fail
between CPU &
Display due to which
NR would not
function properly.
1. Two nos. of TVS(6.8V) from the
differential output pins (pin6 and pin 7)
of MAX-485 to earth had been removed
and one TVS across the same pins had
been put.
2. Two nos. of TVS(6.8V) from two
differential input pins (pin 2 and pin 3) of
6N137 to earth had been removed and
one TVS across the same pins had been
put.
3. A Pull up resistor 10KΩ /0.1W at Pin.7
of Opto-isolator 6N137 to be inserted.
New This will provide
better protection
of IC MAX485
and IC 6N137.
Failure of Display
units due to failure
of those two ICs
were expected to be
reduced
5. SIGCON BOX
5.1 Failures in
locomotives arising
out of Q20, Q30,
QCVAR problems
occur due to failure
of SIGCON module.
The root cause was
found as insulation
1. Insulated pillar post(12 mm & 40 mm)
will be used for placing of two cards
inside the box to improve isolation.
2. A rubber gasket was placed between
the Box and the Cover.
3. Halogen free e-beam cables (Radiant
New Mechanical
isolation as well
as quality of
insulation of
cables had been
improved.
Better performance
of SIGCON modules
with better assembly
and improved
quality of cables will
reduce the failure of
locomotives.
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
breakdown of cables
and improper
isolation between box
and PCBs of
SIGCON module.
Make) of 1 sq mm and 0.5 sq mm were to
be used for inside box wiring.
6. TM BOX
6.1 Inappropriate
operation of QD in
running locomotives
The hardware was modified in TM ver
61 cards, where resolution of each TM
channel had been increased by reducing
the effect of noise, as the processed
output was sent as currents instead of
voltages.
M7 TM channel
signals sensed by
MPCS were
made more
accurate / closer
to actual values
Activation of QD in
running locomotives
had been improved
much by M7
modification of TM
modules and Analog
cards
7. ANALOG CARD
7.1 Inappropriate
operation of QD in
running locomotives
For processing of TM channel signals
from TM modules, one RC circuit had
been incorporated for each channel to
filter out spurious noise.
M7 TM channel
signals sensed by
MPCS were
made more
accurate / closer
to actual values
Activation of QD in
running locomotives
had been improved
much by M7
modification of TM
modules and Analog
cards
B. Software modifications for integrated modification:
Failures Problem
reported
Relevance Modification
No.
Present Status Remarks
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
1. Double Notch
Progression /
Regression instead of
single notch as MP+ /
MP- was operated
To arrest failures related to this issue of
double Notch Progression / Regression
New Problem
addressed and
firmware
modified
2. The necessity of long
pressing of BLRDJ
under HT condition
in case of ARNO
fitted locos
This modification was required to fix this
problem.
New Problem
addressed and
firmware
modified
3. Auto-regression via
Q20 to be made
independent of
HPAR
It was the rectification needed as per
existing loco logic
New Problem
addressed and
firmware
modified
4. IP valve (OUT22) de-
energizing
It was the rectification needed as per
existing loco logic
New Firmware
modified
5. TM current direction
to be shown as
negative during
breaking
As per requirement of some sheds New Firmware
modified in the
Display end
6. Proper handling of
fault messages of DJ
trip via QSIT for 'SIV
Internal Fault' / 'SIV
External Fault'
Differentiation of these two fault
messages was required for proper
troubleshooting of loco
New Firmware
modified
Cables of -I64 and I-
67 were to be made
available at BD
panel for connecting
with our MPCS
7. Change in Q44 Logic RDSO's letter no. EL/4.2.15 dt. 21.02.12 M6 Problem This modification
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
as suggested by
RDSO
addressed and
firmware
modified
was still in progress
8. Soft relay parameter
viewing from Display
by the user
To check the soft relay pick-up and drop
values just by scrolling display screen
M9 Firmware
modified
9. Soft Calibration of
Analog Inputs to
avoid POT setting in
Analog card
Ease of analog channel calibration from
display end without ant POT adjustment
of Analog card
M9 Problem
addressed and
firmware
modified
10. Self withdrawl of
Faulty CPU card out
of two CPU cards.
To increase system availability by CPU
redundancy
M9 Problem
addressed and
firmware
modified
11. Modification of
LSCHBA Logic
To arrest failures caused by fluctuation of
LSCHBA input by spurious noise
M9 Firmware
modified
12. USB Download
Filename
To make the filename user-friendly M9 Firmware
modified
13. Processing of Short-
circuit outputs
To avoid the requirement of making
HBA OFF and ON upon the detection of
short-circuit by any of the output
channel(s). Now it was taken care
automatically by the firmware.
M9 Firmware
modified
14. Modification of Fault
messages
As suggested by RDSO M9 Firmware
modified
15. Storing of all Fault As suggested by RDSO M9 Firmware
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
messages modified
16. Display of Digital
Output status as 'ON'
, 'OFF', 'SRT'
To display the output status more
prominently to detect if any channel was
under short-circuit condition
M9 Firmware
modified
17. Display of Loco No.
on the default screen
Incorporated as an user-friendly feature M9 Firmware
modified
18. Increase in speed of
data downloading
This was one of the requirement of sheds
as well as improved feature of MPCS
M9 Problem
addressed and
firmware
modified
19. Individual isolation
of hard / soft QDs
during operation of
HMCS programme
switches as per
RDSO's letter no.
EL/4.2.15 dt.
28.12.11
Modification was done as per RDSO
modification sheet no.
RDSO/2011/EL/MS/0404 Rev 0,
Dated:28.12.11.
M9 Firmware
modified
Wiring of control
cables at Loco end
had to be modified
by the shed staffs.
20. Time and Data
Mismatch of
downloaded data
from CPU-A and
CPU-B
It should be rectified as this type of
mismatch was undesirable and already
reported by some sheds
Resolution was
yet to be done
21. Short circuit output
channel no. to be
saved in flash
As per the requirement highlighted by
few Loco Sheds that during scrolling of
fault history in the display screen, the
Firmware to be
modified
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S.
N
Failures/Problem
reported
Proposed Modification needed to
reduce the failure
Previous
ongoing/
New
Modification
Relevance of
proposed
modification
Advantages /
Remedies expected
by the modification
memory channel no. under short circuit condition
was not appearing in the fault message
22. Problem of Data
downloading with
ARM processor
based CPU cards
It was to be rectified as smooth
downloading of data from CPU was very
much required
Work was going
on to resolve the
problem
23. Sometimes QD was
not acting at 160A
this problem had to be resolved to make
the QDs act properly in running
locomotives
Work was going
on to resolve the
issue
24. Setting of Q30, Q20
were getting
disturbed frequently
To arrest the unwanted variations of
settings of eliminated relays like Q20,
Q30 etc.
Work was going
on to resolve the
issue
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5.9.3. Performance Analysis of M/s ICECPL MPCS Version ‘2’
a. Year wise performance of MPCS version-2 of M/s ICECPL make is given below;
(Note: P = Population, F = Failures and %F = FRPCPY)
b. Details of Item wise failures of M/s ICECPL MPCS V2 are given below:
Year P F %F
2007-08 11 22 200.0
2008-09 11 14 127.3
2009-10 4 4 100
2010-11 6 10 166.6
2011-12 4 1 25.0
2012-13 25 11 44.0
2013-14 62 74 119.3
2014-15 85 119 140.0
2015-16 92 122 132.6
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c. Modifications carried out by M/s ICECPL
These modifications had been carried out by M/s ICECPL in 88 locomotives and only 3
locomotives are balance, target for completion is 30.9.2016.
Faulty ItemNos per
loco
In
service2013-14 2014-15 2015-16
Calibration 1 1 1
Software 1 1
External 2 1
Maintenance 1 1
Modification 1 2
workmanship 1 1
Misc 2
Transient 3 3 3
Found normal 2 5 8
Grand Total 74 119 122
Population 62 85 92
S.N. Need of Modification Modification Details
1 Input card channel failure problem Transient voltage suppressor rating changed
from 200 V to 300 V
2 SCU & ISCU failure observed by
communication loss
RS485 bus resetting module in SCU & ISCU unit
provided and 680uF capacitor provided across
1N4148 diode and capacitor C1 was removed.
3 Noise problem on data bus lines 100pF Capacitor in backplane for the data bus
lines.
4 Data downloading issue Modification of USB Port
5 P.T. burst problem Surge arrester before P.T. to be provided
6 Improve Input channel redundancy to
save line failures
Software change of Master and Slave controller
on CPU & display controller
7 Shed requirement (Some important
relay Q30,QD , QF1 & QF2 setting )
Software change of Master and Slave controller
on CPU & display controller
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d. Technical Verification of Modifications Railways had informed that the quality of modifications carried out by M/s ICECPL is
not satisfactory. Technical verification of modifications at ELS/CNB had been carried out
on 24.11.2015 on 28477/WAG7 jointly with M/s ICECPL. Observations had been given
in the following paragraphs.
i. Input Redundancy: it was provided with Software change of Master and Slave controller
on CPU & display controller cards.
Recommendation: M/s ICECPL was advised to submit joint report with shed after
complete testing of Input Redundancy as specified in specification.
ii. Loco parameters settings: it was provided with Software change of Master and Slave
controller on CPU & display controller cards.
Recommendation: M/s ICECPL was advised to submit joint report with shed after
complete testing of Loco parameters settings.
iii. 100pF Capacitor Modification on backplane for the data bus lines;
100pF Capacitor placed at data bus lines on backplane. These capacitors were not properly
aligned; these should be placed with proper hole at component side on PCB. Jumper was
also not allowed which was shown in fig.-1.
Fig.-1
Recommendation: M/s ICECPL was advised to place the capacitor on component side
with proper alignment and remove the jumper on bottom side and use it properly on
component side.
100pF Capacitors
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iv. Provision of Surge arrestor before PT to arrest PT burning;
After large number of failures of PT, firm had provided surge arrester before PT to reduce
failures of PT. Firm had provided surge arrester using spark plug to arrest 2 KV surge.
Fig. 2: Surge arrestor using automobile spark plug
Recommendation: M/s ICECPL was advised to discontinue provision of spark plug and
use proper required surge arrester to improve reliability.
v. Modification of USB Port:
During verification, it was found that proper cover on USB port was not provided as
shown in fig. 3. One capacitor was fitted in hanging position on the USB module and this
module was tightened with nylon tie on the CPU card as shown in fig. 4. At the bottom
side they had used additional jumpers and lot of RTV on the USB module as shown in
fig. 5. This may reduce the reliability of the product.
Fig. 3 USB Port Fig. 4 Fixing of component with tie
Fig. 5 Excess RTV
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Recommendation: M/s ICECPL was advised to use proper cover on front side of the
USB module and capacitor should be placed properly on component side and proper
fitment of USB module on CPU card is required.
vi. 3300pF bypass capacitor modification on filter PCB from DC+ to GND.
3300 pF bypass capacitor on filter card from DC+ to GND was provided as shown in fig.
6. This capacitor was fixed with jumper and RTV on the board, which is not proper way
of fitment.
Fig. 6: Capacitor Fixing
Recommendation: M/s ICECPL was advised to placed capacitor on PCB through hole
properly.
vii. 100 µF/450 V capacitor paralleling modification on filter PCB.
Previously, 3 capacitors of 100 µF/450V were used in series as shown in fig. 7. During
this modification firm made it parallel connection using jumper and track cutting as
shown in fig. 8.
Fig. 7 & 8 Capacitor Modification
Recommendation: M/s ICECPL was advised to modify layout properly and avoid jumper on
this small PCB.
3 capacitors
Of
100F 450V
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viii. It was observed that RS485 bus resetting module in SCU unit was not properly fixed. This
module was only pasted by RTV in the SCU unit. This module was to be properly fixed with nut
and studs for rolling stock.
Recommendation: M/s ICECPL was advised to properly fix bus resetting module
5.9.4. Performance Analysis of M/s SIL MPCS Version ‘2’
a. Year wise performance of MPCS version-2 of M/s SIL make is given below;
(Note: P = Population, F = Failures and %F = FRPCPY)
Year P F %F
2009-10 1 5 500.0
2010-11 6 9 150.0
2011-12 13 6 46.2
2012-13 25 7 28.0
2013-14 49 15 30.6
2014-15 52 18 34.62
2015-16 75 28 37.33
Bus Resetting module
RTV
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b. Details of Item wise failures of M/s SIL MPCS V2 are given below:
c. Reliability Action Plan Completed
To improve the reliability M/s SIL had under taken following measures:
Faulty ItemNos per
loco
In
service2013-14 2014-15 2015-16
Software 4Calibration 2 3External 1Modification 1Found normal 1 2
Grand Total 15 18 28
Population 49 52 75
Sn
.
Item description Target date Current Status
1. Cyclic Check for dry
soldering of
components on cards
31.03.2015 Completed
2. Replacement of TVS in
output card with higher
capacity in 7 systems.
- Completed in all
7 locos
3. To keep one set of
spare cards in BL shed
- Complied
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5.9.5. Performance Analysis of M/s Laxven MPCS Version ‘2’
a. Year wise performance of MPCS version-2 of M/s Laxven make is given below;
(Note: P = Population, F = Failures and %F = FRPCPY)
b. Details of Item wise failures of M/s Laxven MPCS V2 are given below:
Year P F %F
2013-14 5 4 80
2014-15 5 14 280.0
2015-16 4 9 225.0
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Chapter VI
6. MPCS Vsersion-3
6.1 M/s Medha had developed an upgraded version of MPCS in consultation with RDSO and
commissioned in WAP4 loco no. 22594 at ELS/LGD/SCR in Nov’ 2009 for field trial,
which had worked satisfactory.
6.2 MPCS specification no. ELRS/SPEC/MPC-FDS/0001 Rev 3 (Apr 2013) had been
prepared based on field problems and to improve the reliability of the system
incorporating GPS based remote monitoring and vigilance control device (VCD) along
with ESMON speed data.
6.3 The above features and improvements will further be helpful in diagnosis,
troubleshooting and analysis of faults. Also, the elimination of conventional earth fault
relays and merger of VCD are cost effective. The single display for MPCS and VCD will
be much convenient for the crew and maintenance staff hence will reduce the stress level.
6.4 Railway Board vide letter no. 2013/Elect(TRS)/441/1 dated 25.03.20113 and 28.09.2015
had instructed that all new procurement of MPCS by Railways/CLW shall be done with
RDSO’s revised specification no. ELRS/SPEC/MPC-FDS/0001 Rev. ‘3’.
6.5 Benefits of MPCS ver-3
• Improvement in reliability of locomotives
• Real-time monitoring of locomotives for sheds and TLCs.
• Provide assistance to crew.
6.6 Features of MPCS version-3 :-
• To provide TSD assistance to crew.
• To provide REmoteMonitoring&ANalysis feature for Electric Locos
(REMAN_EL).
• To provide 10.4 inch TFT color display in place of 40chX4 lines mono LCD.
• To provide notch position through digital encoder.
• To provide inbuilt VCD system.
• To provide interfacing with existing ESMON PG for loco Speed and record it for
REMAN_EL
• To provide GSM, CDMA & GPS system for REMAN_EL.
• To provide facility to enter Driver ID, Train no. Section name, Train Load etc.
Date & Time should be updated through GPS.
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• To make provision for diagnostic tool for instantaneous faults.
• Separate serial bus for MU operation.
• Provide auto selected appropriate I/O parameters for background data of fault.
• Provide three type of server login;
(i) Admin login (ii) TLC login (iii) Shed login
• Self -test feature for Digital inputs, Outputs.
• To provide generation of report, Job cards, different charts & graphs for download
fault data.
• Fault data stored in Excel file directly from web.
• To provide BP & BC pressure measurement.
6.7 Comparitive features of MPCS Ver-3 and MPCS Ver-2
S.N. Features Ver-3 Ver-2
1. Display COLOR, 10.4”,
TFT
40ChX4line
LCD
2. Remote monitoring yes no
3. Inbuilt TSD yes no
4. BP & BC pressure data yes no
5. Speed data yes no
6. Energy data yes no
7. Hall effect sensors yes no
8. Notch indicator By encoders By logic
9. Background data,
(5 s B, C, 3 s A)
Show as per
fault
Show full data
10. VCD feature yes no
11. Soft Relay bypass yes no
12. SEC & GTKM
calculation
yes no
13. Configuration data yes no
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14. Transferring/Download
fault data
USB, laptop,
web server
USB, laptop
15. Event data display yes no
16. GPS location yes no
17. Time date setting By GPS Manually
18. Graphical data for
VCD, BP, BC, Speed
yes no
19. Diagnostic tool yes no
20. Life time counters yes no
21. Trip data counters yes no
22. Couplers bayonet crimped soldered
23. Data entry through key
pad
yes no
24. Battery voltage yes no
25. Serial bus for MU yes no
26. Server utility Yes No
27. Data for inspection
schedule
yes no
28. DBR selector for logic 4 types 2 types
28. Web page Login yes no
6.8 Comparison of hardware of MPCS version-3 and MPCS version-2:
Technical details of MPCS hardware of version-3 and version-2 are given below:
S.N. Items Quantity Brief Description
Ver-2 Ver-3
1. Main control unit 1 no 1 no Having Rack for cards, backplane and
connector on top.
A Filter card 1 no 1 no To filter the power supply of 110 V
DC for MPCS power supply card
B Power supply card 2 nos. 2 nos. To prepare 12V and 5V from 110 V
Dc for MPCS system.
C CPU card 2 nos. 2 nos. Having microprocessor 16 bit or
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S.N. Items Quantity Brief Description
Ver-2 Ver-3
higher and USB port for data
downloading.
D Analog Card 1 no 1 no For processed SCU parameters for
CPU card.
E Multifunction/
Interfacing card
1 no 1 no This card accommodates various
hardware for both the CPU and
Interface card for Main unit and the
Display unit.
F Input card 8 nos. 9 nos. Input opto isolated 16 channel in each
card
G Output Card 5 nos. 5 nos. Output opto isolated 16 channel in
each card
h Remote monitoring
module
-- 1 nos This module communicates with main
unit control card through parallel or
serial interface and transmit MPCS
information to web portal.
2. Display unit 2 nos. 2 nos. For Version-2:4 x 40 character
alphanumeric displays and segment 7-
segment LED for display of notch
position
For version-3: 10.2” colour TFT
LCD display. Notch position was
shown in same display.
3. Signal conditioning
Unit (SCU)
1 no. 1 no. Used for Auxiliary and CHBA voltage
4. Intelligent Signal
conditioning Unit
(ISCU)
2 nos. 2 nos. Use for traction motor currents. Each
unit for 3 TMs currents.
5. Antenna unit -- 1 no. Antennas for GSM, CDMA & GPS
signals
6. Sensors -- 6 nos.
2 nos.
Hall effect current sensors for TM
currents
Pressure sensors for BP & BC
pressure measurement.
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6.9 Block Diagram of MPCS Version-3
6.10 Approved Vendor status of MPCS V3
The following three vendor are approved for MPCS version-3
Firms Status
1. M/s Medha Part-1
2. M/S ICECPL Part-2
3. M/s SIL Part-2
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6.11 Performance and failure analysis of MPCS V3
Population of MPCS V3 of various makes, their failures and FRPCPY is given below:
2014-15 2015-16
Firm P F F% P F F%
Medha 0 -- -- 58 2 3.40
ICECPL 5 4 80 7 27 385.71
SIL 0 -- -- 2 0 Nil
Total 5 4 80 67 29 43.28
(Note: P = Population, F = Failures and %F = FRPCPY)
6.12 Shed/Make wise Population of MPCS V3 (till Mar 2016)
Shed ICECPL Medha SIL Total
AJJ 1 1 2
Angul 1 1
BSL 1 1
BRC 1 0 1
CNB 1 0 1
JHS 1 1
ED 5 5
GZB 1 3 4
HWH 1 9 10
KZJ 1 1
LDH 1 0 1
MGS 1 14 1 16
NKJ 10 10
TKD 9 9
BKSC 0 1 1
SRC 3 3
Grand Total 7 58 2 67
6.13 Warranty Failure Status (2015-16) of MPCS Version-3
All MPCS Version-3 failures were under warranty.
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6.14 Performance Analysis of M/s ICECPL MPCS Version ‘3’
(i) Shed wise FRPCPY of MPCS Version-3 for 2015-16 is given below:
M/s ICECPL MPCS V3
Railway Shed Population Failures FRPCPY in %
NR LDH 1 6 600.0
NR GZB 1 7 700.0
SR AJJ 1 6 600.0
ER HWH 1 1 100.0
WR BRC 1 5 500.0
ECR MGS 1 0 0
NCR CNB 1 2 200.0
TOTAL 7 27 385.71
(ii) Item wise failure details are given below:
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6.15 Photographs of M/s ICECPL make MPCS version-3
Display Unit
Main Unit
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SCU Unit
ISCU Unit
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6.16 Photographs of M/s Medha make MPCS version-3
Main Unit ISCU Unit
6.17 Photographs of M/s SIL make MPCS version-3
Display Unit Main Unit
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Chapter VII
7. MPCS repair and Annual Maintenance Contract
7.1 MPCS Repair For developing alternate sources for repairing of MPCS, RDSO had made Functional
Requirement Specification (FRS) no. RDSO/2016/EL/FRS/0015, Rev. ‘0’ dated 19.5.2016
and Schedule of Technical Requirements (STR) no. RDSO/2016/EL/FRS/0084, Rev. ‘0’
dated 19.5.2016.
Expression of Interest (EOI) no. RDSO/2016/EL/EOI/1 dated 11.8.2016 had also been
published in newspapers for developing sources for repair of MPCS.
7.2 Annual Maintenance Contract (AMC) of MPCS Technical scope of work for AMC of MPCS had been issued by RDSO vide SMI no.
RDSO/2016/EL/SMI/0288, Rev. ‘0’ dated 21.6.2016.
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Chapter VIII
8. List of SMI/MS/TC related with MPCS
8.1 List of Special Maintenance Instructions (SMI) related with MPCS
SN SMI No. Date Description
1 RDSO/2016/EL/SMI/288
Rev 0
21.6.2016 Technical scope of work for AMC
of MPCS
2 RDSO/2015/EL/SMI/284
Rev 0
11.9.2015 Review of setting of Relay Q-20 to
reduce traction motor flashing cases
3 RDSO/2012/EL/SMI/276
Rev 0
27.7.2012 Maintenance instruction of dynamic
braking excitation contactor C-
145auxiliary contact for 25 kV AC
electric locomotives
8.2 List of Modification Sheets(MS) related with MPCS
SN MS No. Date Description
1 RDSO/2016/EL/MS/450
Rev 0
19.5.2016 Deactivation of Vigilance Control
Device (VCD) acknowledgement from
ALP side on Electric Locomotives
2 RDSO/2015/EL/MS/442
Rev 0
11.9.2015 GR-0 indication of trailing locomotive
through additional signaling lamp in
leading locomotive in multiple unit
operation of two locomotives
3 RDSO/2014/EL/MS/431
Rev 0
5.2.2014 Modification in loco control circuit for
working of VEAD valve in trailing
locomotive during multiple unit
operation (MU) for 25 kV AC Electric
Locomotive fitted with microprocessor
based control and fault diagnostic
system (MPSC ver-2)
4 RDSO/2014/EL/MS/430
Rev 0
20.1.2014 Modification in loco control circuit for
connections for Auto regression bypass
(HPAR) switch in 25 kV AC electric
tap changer locomotive working with
MPCS version-2
5 RDSO/2012/EL/MS/421
Rev 1
25.10.2013 Modification of loco control circuit for
LSDBR lamp to avoid wrong indication
of working of AC MVRF in MPCS
fitted Electric locomotives
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6 RDSO/2012/EL/MS/410
Rev 0
4.6.2012 Circuit modification of I-68 branch for
C145 operation feedback for 25 kV ac
electric locomotives fitted with MPCS
7 RDSO/2011/EL/MS/404
Rev 0
28.12.2011 Modification in electric locomotive
control circuit fitted with
microprocessor based control system
(MPCS) for individual isolation of
hard/soft QDs during operation of
HMCS programme switch
8 RDSO/2009/EL/MS/386
Rev 1
29.10.2012 Modification in loco control circuit for
MU operation of 25 kV AC
conventional tap changer electric
locomotives working with
microprocessor based control & fault
diagnostic system(MPCS)(Ver.’2’)
9 RDSO/2009/EL/MS/384
Rev 0
7.10.2009 Modification of loco control circuit for
circuit breaker (DJ) opening and panto
lowering by BLDJ and ZPT switch in
25 kV conventional locomotive
equipped with microprocessor based
control and fault diagnostic system
(MPCS)
8.3 List of Technical Circulars (TC) related with MPCS
SN TC No. Date Description
1 RDSO/2012/EL/TC/119
Rev 1
20.3.2013 Technical circular for MPCS with
remote monitoring and analysis
feature of 25 kv AC electric
locomotives.