rdso.indianrailways.gov.inrdso.indianrailways.gov.in/works/uploads/File/TR 175_12.092016 wit… · Electric Loco Training School, Kanpur in 1991-92. 2.1.2. During visit of Member

Page 1 of 77 Issued on 12.09.2016 Report RDSO/2016/EL/IR/0175, Rev.`0’

Prepared by Checked by Issued by

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



Status of Revision

S.N. Date of Revision Page no. Revision Reason for

revision

1. - all 0 First Issue



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



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.



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.



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.



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



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.



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



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



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.



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



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.



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



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




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.




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”




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




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




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




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.



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



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…



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



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



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.



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.



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)



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



4.18. Photograph of MPCS version-1 of M/s ADC make

Main unit with doors closed

I/O card Display unit



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.



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



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



Make 2010-11 2011-12 2012-13


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


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


5.6. Warranty Failure Status of MPCS ver-2 for last 2 years

2014-15

2015-16



5.7. Shed wise FRPCPY of MPCS ver-2 for last 3 years


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



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





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


modified


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





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.


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;


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



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



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;


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



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



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.



(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.



(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.



d. Modifications not completed by M/s Stesalit


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)


modified


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


modified for improved

resolution.


be modified for improved

resolution.




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:



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



S.

N

Failures/Problem

reported


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



S.

N

Failures/Problem

reported


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



S.

N

Failures/Problem

reported


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


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



S.

N

Failures/Problem

reported


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


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.



S.

N

Failures/Problem

reported


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



S.

N

Failures/Problem

reported


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



S.

N

Failures/Problem

reported


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



S.

N

Failures/Problem

reported


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



S.

N

Failures/Problem

reported


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



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;


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



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


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



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



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



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



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;


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



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


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



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;


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



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.



• 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



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



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.



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



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


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.



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:



6.15 Photographs of M/s ICECPL make MPCS version-3

Display Unit

Main Unit



SCU Unit

ISCU Unit



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



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.



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


Rev 0

11.9.2015 Review of setting of Relay Q-20 to

reduce traction motor flashing cases


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


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



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


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.

Documents

rdso.indianrailways.gov.inrdso.indianrailways.gov.in/works/uploads/File/TR 175_12.092016 wit… · Electric Loco Training School, Kanpur in 1991-92. 2.1.2. During visit of Member