1455165830490-MEP-660 - MI - Final - 3

MAINTENANCE INSTRUCTION
MANUAL
MICROPROCESSOR BASED
LOCOMOTIVE CONTROL SYSTEM
MEP 660
FOR DIESEL ELECTRIC LOCOMOTIVES
As Per
RDSO Specification No. MP.0.24.00.26 Rev.0.04
May, 2007
P- 4 / 5 B, I.D.A NACHARAM
HYDERABAD 500 076
Ph. No. 040- 2717 3990 Fax. 040 2717 4908
Email: marketing@medhaindia.com URL: www.medhaindia.com
Doc No: IM – 53 Rev. 0.0 Print: Sept’ 2008

MEP-660 – Maintananace Instructions
INDEX SHEET
1. Introduction 1
2. Circuit Description 2
3. Control Unit TYPE MEP 660 2
3.1. Control Card MEP_CC 3
3.2. Control Card MAU_CC 4
3.3. Control Card MWS_CC 5
3.4. Digital Input Card MDIP16 / MIDIP16 5
3.5. Digital Output Cards 6
3.5.1. Medha High Side drive Card MHSD16 / MIHSD16 6
3.5.2. Medha Low Side drive Card MLSD16 6
3.6. Analog Input Cards 7
3.6.1. Medha Analog Input card MAIP8_AU 7
3.6.2. Medha Analog Input Card MAIP8_WS 8
3.6.3. Medha Analog Input card MAIP8_EP 8
3.6.4. Medha Improved Analog Input card MAIP16 / MIAI 8
3.7. Medha Frequency Input Card MFIP16 8
3.8. Medha Pulse Width Modulator Card MPWM2 9
3.9. Medha Excitation and Propulsion Power Supply Card MEPPS 9
3.10. Medha Display Unit MDS 733 10
3.11. Analog Distribution Box (ADB) MDB 701 11
3.12. RPM Distribution Box (RDB) TYPE MDB 702 12
4. Current Sensors 13
4.1. Medha Current Sensor MCS 850 13
4.4. Medha Current Sensor MCS 10A 14
5. Voltage Sensors 14
5.1. Medha Voltage Sensor MVS 815 15
5.2. Medha Voltage Sensor MVS 801 15
Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008

6. Temperature Sensors 15
6.1. Medha Temperature Sensor MTS 815A 16
6.2. Medha Temperature Sensor MTS 815L 16
6.3. Medha Temperature Sensor MTS 815W 16
7. Pressure Sensors 17
7.1. Medha Pressure Sensor MPS 841 17
7.2. Medha Pressure Sensor MPS 842 17
7.3. Medha Pressure Sensor MPS-844 17
7.6. Altitude Sensor MPS 843 17
8. Speed Sensors 18
8.1. Tr. Motor Speed Sensor T815 18
8.2. Engine Speed Sensor T817 19
9. Resistor Unit Type - MRP 703 20
10. Ancillary Units 22
10.1. CGR/PGR Resistor unit MRP706 22
10.2. Memory Freeze cum VCD Disable UNIT MMF 705 23
10.3. XD23-XC13 Assembly unit 24
10.4. Motor Cut Out Switch Box MSP 707 25
10.5. Speed Sensor Interface Unit MSI 761 26
10.6. FCP Panel 27
10.7. HLD Relay Module MRA 710 28
10.8. VCD Magnet valve 29

List of Annexure
1. Interconnection diagram of all MEP components Annexure – 1

2. Interconnection diagram of all cards in MEP Annexure – 2
3. List of digital input cards - channel wise Annexure – 3
4. Manual digital input check procedure through Disp. Unit Annexure – 4
5. List of digital output cards - channel wise. Annexure – 5
6. Manual digital output check procedure through Disp. Unit Annexure – 6
7. List of analog inputs Annexure -- 7
8. Crimping tool & connector pin details Annexure – 8

1. INTRODUCTION
The Diesel Electric Locomotives of Indian Railways, driven by DC traction motors, employ
AC/DC Power Transmission System. The MEP-660 Medha Excitation and Propulsion
system is a Microprocessor Based Locomotive Control System. The system provides a
superior control mechanism, protection to traction equipment, fault diagnostics, and
adaptability to different engine types. The Microprocessor based Locomotive Control
System Type MEP-660 control the entire locomotive. There are four-sub control systems
like
• Engine and loco propulsion

• Auxiliary generator / Battery charging
• Excitation.
• Wheel Slip control
There are no mechanical sequential interlocks between inputs and output devices of the
engine cranking and loco propulsion system. As per the operational requests by the
driver, the MEP-660 directly energies the required output devices. The sequential / safety
interlocking and the required timings are provided through software which is loaded in the
micro controller.
The Microprocessor based Locomotive Control System MEP 660 continuously monitors
the train line signals (MU signals) and controls the excitation of the Alternator based on
the operating requests of the Driver. It monitors various analog and digital feedback
signals from the traction equipment and controls the excitation in such a way as to
maintain constant Horse Power of the Diesel Engine.
The MEP 660 system controls the excitation of the Auxiliary Generator so as to maintain
constant output voltage for Battery Charging as well as control circuits in spite of variation
in the engine speed from Idle to the 8th notch.
Being a Microprocessor based system; the MEP 660 has Fault Diagnostic capabilities.
The System continuously monitors various operational parameters and checks for
abnormalities in the functioning of various traction equipments. In case a fault is identified,
an appropriate action by way of isolating a sub system or limiting the power, etc is taken
to prevent further damage to the equipment and other connected equipments. The fault is
also displayed on a Display Unit along with the restrictions imposed because of fault, for
the information of the Driver. The fault code along with Real Time and Date stamp is
logged in the Error Log Memory.
The MEP 660 Control System displays various operating parameters on the Display Unit
continuously from the selected predefined groups for the benefit of the driver and
maintenance staff.
All the functions described above are implemented in the Microprocessor based
Locomotive Control System MEP 660, which is designed with number of sub assemblies
for ease of maintenance and reducing the amount of cabling required. The
Microprocessor based Locomotive Control System MEP 660 consists of the following sub
assemblies.
Control Unit Type MEP 660

Display Unit Type MDS 733
Analog Distribution Units Type MDB 701
RPM Distribution Unit Type MDB 702
Current Sensors Type MCS xxx
Voltage Sensors Type MVS 8xx
Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 1

Temperature Sensors Type MTS 815x

Pressure Sensors Type MPS 8xx
Altitude Sensors Type MPS 843
Speed Sensors Type T815/T817
Resister Unit Type MRP 703
XD23-XC13 assembly unit Type MDA 751
Memory Freeze cum / VCD Disable Type MMF 705
CGR/PGR Resistor unit Type MRP 706
Engine Speed Sensor Interface unit Type MSI 761
HLD Relay Module Type MRA 710
Field Control Panel (FCP) Type SFCP- 25
VCD Magnet Valve Type 3332-10-4G
The Interconnection Diagram of all the above sub assemblies of MEP-660 is given in
Annexure – 1. All these sub assemblies are interconnected through plug in type MS
Connectors for ease of installation and maintenance. These sub assemblies are
described below. Please refer the electrical schematics of Microprocessor based control
system MEP-660, document No. ED100 or ED1001, for the details of individual
connecting cables and their pin Numbers.
2. CIRCUIT DESCRIPTION
Please refer ‘Hand Manual’ on Microprocessor Based Loco Control system MEP-660,
document No. IM 39 for detailed circuit explanation.
3. CONTROL UNIT TYPE MEP 660

Description:
This is main control equipment of the Microprocessor system. The control unit consists
18+1(spare) plug in module type cards in dust proof enclosures. These modules are
provided with proper identification number both on the module and as well on the control
unit of each slot. The unit is engineered for quick replacement of any plug in card. These
plug in cards are functionally separated in to modules of the main system. The backplane
of the control unit is designed in such a way that insertion of a module can be done only
at its earmarked position. The complete unit has a Transparent cover with a lock. The
lock provides protection against unauthorized opening. With transparent cover, the
indication LED’s provided on some of the individual modules can be seen from outside.
These LED’s can give information about the status of various signal inputs as well as
proper functioning of the concerned modules. Please refer ‘System Manual’ of
Microprocessor based loco control system MEP-660, document No. IM 08, for
Dimensional Drawing and mounting details of the control Unit.
All the external connections to this control unit are done through MS circular connectors.
These connectors are earmarked and similar identification markings are provided on the
cables, which are connected, to these connectors. These connectors are also polarized to
avoid wrong insertion of connectors in service.
The block diagram of interconnections of all these modules through the back plane is
given in Annexure – 2
Maintenance: There are no user serviceable components available in the control unit
base. The connectors are wired to the back plane PCB directly. No preventive
maintenance is required to the base up to M48 schedule as there are no passive
components in the base unit. Only external blowing and cleaning of dust is required from
M4 schedule onwards.

Running maintenance on loco:
All the MS connectors on the control unit are polarized. Insert the male/female connectors
of the cable in a proper direction and into the right female/male connector on the control
unit while reconnecting.
Ensure tightness of external connectors once in M4 schedule. Press the connector of the
cable and then tighten the connector. Repeat the process till the connector is completely
tight.
S.No. Schedule Nature of attention

1. Pre- Ensure all connectors are fixed and are tight.
Commissio. The following are the Cable connectors connected to MEP-660
control unit.
A,B,C,D,E,F,G,H,I,J,K,L,M,N,O,P,Q,R,S,T,U,V,W,X,Y,Z,AA,AB,AC
,AD,AE,AF,AG,AH,AI,AJ,AK,AL,AM,AN,AP,AQ,AR,AS,AT,AU,AV,
AW,AX,AY,AZ,BA,BE,BF,BG,BH,BI,BJ,BK,BL,BM,BN,BO,BP,BU.
2. T1, T2 -
3. M2 -
4. M4, M8 Check the tightness of the MS connectors.
5. M12
6. M24
7. M48 Unload the base from locomotive:
Clean the external dust with a dry cloth.
Use medium size vacuum cleaner to suck the dust accumulated
on the back plane of the base.
Do not use compressed air to blow out the dust
Any dust entry into female sockets can cause bad contact of
the connector.
Check for any physical damages to the connectors on the control
unit.
Replace the damaged connectors of same type numbers.
Please refer ‘Electrical Schematics’ for Microprocessor based Loco
control system MEP-660, document No. ED 1000 / ED1001 for
connector details.
8. M96 Same as M48
3.1. Control Card MEP_CC

The MEP_CC card is the main control card having a micro controller along with its
programmed software, various peripheral circuits and interface circuits. All the digital,
analog and frequency inputs are connected to this card after processing to the required
level through their respective cards.
This card is built in a rugged enclosure with a cover to protect it from dust and EMI noise.
There are no user serviceable components available in the card.
Warning:
Handle the card very carefully and do not store near magnetic fields. Static
electricity of human body / heavy magnetic fields may destroy the components in
side the module. Do not drop down the card.
Maintenance:
There are no adjustable components on this card. The card does not require any
preventive maintenance schedule and calibration, unless otherwise mishandled.
Maintenance on locomotive: Ensure proper fitment of card and tightness of card holding
screws on the base when ever the card is replaced or once in M12 (12 months) schedule.


1. Pre- Check the tightness of the card fixing screws on the control unit.
Commissio.
2. T1, T2 -
3. M2 -
4. M4, M8 Check the tightness of the card fixing screws on the control unit.
5. M12 Remove the card from the base and clean the external dust with
dry cloth.
Gently slide in the card into the ear marked slot and press gently
into the socket. And tighten the card fixing screws.
Do not drop down the card into the base unit.
Check the tightness of the card fixing screws on the control unit.
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48
3.2. Control Card MAU_CC

The MAU_CC card is the second control card having a micro controller along with its
programmed software, various peripheral circuits and interface circuits. This card controls
the Auxiliary Generator field current to regulate the terminal voltage at 72±1V (set limit).
Warning:
Handle the card very carefully and do not store near magnetic fields. Static electric
city of human body / heavy magnetic fields may destroy the components in side
the module. Do not drop down the card.
Maintenance:

Commissio.
2. T1, T2 -
3. M2 -
4. M4, M8 Check the tightness of the card fixing screws on the control unit
dry cloth.
into the socket. And tighten the card fixing screw.
Check the tightness of the card fixing screw on the control unit
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48

3.3. Control card MWS_CC

The MWS_CC card is the third control having a micro controller along with its
programmed software, various peripheral circuits and interface circuits. This card detects
the wheel slip and communicates to the MEP_CC card to control the power during wheel
slip.
Warning:
Handle the card very carefully and do not store near magnetic fields. Static electric
city of human body / heavy magnetic fields may destroy the components in side
the module. Do not drop down the card.
Maintenance:

1. Pre- Check the tightness of the card fixing screws on the control unit
Commissio.
2. T1, T2 -
3. M2 -
4. M4, M8 Check the tightness of the card fixing screws on the control unit
dry cloth.
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48
3.4. Digital Input Cards (MDIP16 / MIDIP16)

These digital input cards consist the hardware required for converting the high voltage
signals of nominal 72V DC from the locomotive circuits to isolated low voltage signals of
5V DC required for the microprocessor of the system. Each card can process 16 input
channels. The Green color LED’s provided on this card indicates presence of 72 VDC
voltage on that particular channel. The Yellow LED’s indicate the signal being sent to
Micro controller after isolation and signal conditioning. Thus at any stage, both the LED’s
of a particular channel either OFF or ON indicate the correct functioning of card.
There are 5 such digital input cards accommodated from slot 9 to slot 13. These cards
MDIP16 / MIDIP16 can be swapped in between them. The list of channel wise digital
inputs that are connected to these cards is given as Annexure-3
Maintenance:


Commissio.
2. T1, T2 -
3. M2
4. M4, M8 Conduct manual digital input test on loco as per the procedure.
Kindly refer the ‘Manual Test for Inputs’ explained in ‘System
Manual’ document No. IM 08.
dry cloth.
Conduct manual digital input test on loco as per the procedure.
Kindly refer the ‘Manual Test for Inputs’ explained in ‘System
Manual’ document No. IM 08.
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48
Testing and Trouble shooting: The functionality of these cards can be tested on the
locomotive through Display Module even with engine not running. Kindly refer the ‘Manual
Test for Inputs’ explained in ‘System Manual’ document No. IM 08 and ‘Trouble Shooting
Manual’ document No. IM51 for Microprocessor Based Loco control system MEP-660.
The test procedure of individual digital input is given as Annexure-4 These cards can be
tested on the locomotive to their functionality from M24 schedule on wards.
3.5. Digital Output Cards (MLSD16 & MHSD16 / MIHSD16)

The digital output card converts 5V digital signals generated by the micro controller
system (MEP_CC card) to 72VDC power signals required for driving relays, contactors,
solenoids, indication lamps etc in the locomotive circuit. These cards provide electrical
isolation, between locomotive circuits and micro controller circuits. Each card can process
16 out put signals. There are 2 types of Digital Output cards.
3.5.1. Medha High Side drive Card MHSD16 / MIHSD16

The High Side Drive Card (MHSD16 / MIHSD16) drives an output device (Solenoid / LED)
when switched ON through the MEP system, by providing positive supply to the device.
The negative supply is directly connected to the device.
3.5.2. Medha Low Side drive Card MLSD16
The Low Side Drive Output Card (MLSD16) drives an output device (Contactor, Relay)
when switched ON through the MEP system, by connecting the device to negative supply.
The positive supply is directly connected to the device.
In both the cards, each output channels are individually reverse polarity, surge and short
circuit protected.
A list of digital outputs connected to each card, is given in Annexure–5.

Maintenance:
There are no adjustable / user serviceable components on this card. The card does not
require any preventive maintenance schedule and calibration unless otherwise
mishandled.

Commissio.
2. T1, T2 -
3. M2 -
dry cloth.
Conduct manual digital output test on loco as per the procedure.
Kindly refer the ‘Manual Test for outputs explained in
‘System Manual’ document No. IM 08.
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48
Testing and Trouble shooting: The functionality of these cards can be tested on the
locomotive through Display Module even with engine not running. Kindly refer the ‘Manual
Test for outputs’ and ‘Auto Test for Relays’ explained in ‘System Manual’ document No.
IM 08 and Trouble shooting Manual document No. IM51 for Microprocessor Based loco
control system MEP-660. The test procedure of individual digital outputs is given as
Annexure-6. These cards can be tested on loco to their functionality from M24 schedule
onwards.
3.6. Analog Input Cards

The MEP-660 system continuously monitors various parameters like voltages, currents,
pressures, and temperatures of various equipments in the locomotive through different
sensors. These sensors generate a low current signal, which is proportional to the real
value. These low current signals are connected to these analog cards via analog
distribution boxes (ADB)
The analog input card process these low current signals into proportionate low voltage
signals suitable to micro controller and communicates to the concerned micro controller
cards. These Cards provides electrical isolation, between locomotive circuits and micro
controller circuits. Each card can process 8 analog inputs.
There are 4 cards used for processing the total Analog Signals that are monitored by the
MEP-660 system. The individual card is factory calibrated for accepting the relevant
output from the relevant sensor. A list of Analog inputs connected to each card is given in
Annexure – 7.
3.6.1. Medha Analog Input card MAIP8_AU

This card MAIP8_AU card is connected between MAUCC card and ADB1 Parameters
pertaining to Auxiliary generator and Battery charging is mainly connected to this card.

3.6.2. Medha Analog Input Card MAIP8_WS

This card MAIP8_WS card is connected between MWS_CC card and ADB2 Individual
traction motor current signals are mainly connected to this card.
3.6.3. Medha Analog Input card MAIP8_EP

This card MAIP8_EP card is connected between MEP_CC card and ADB3 All the
excitation related parameters are mainly connected to this card.
3.6.4. Medha Improved Analog Input card MAIP16 / MIAI

This Card MAIP16 / MIAI (Modified analog input card) is connected between MAU_CC
control card and ADB4. This card process the signals received from BPP, BCP, FOP,
BAP, and LOP sensors. It also provides low current output signals proportional to LOP,
FOP and BAP pressure signals measured by the MEP 660 system
Maintenance:
All these cards are factory calibrated and does not require any intermediate calibration in
shed. These cards do not require any preventive maintenance schedule unless otherwise
mishandled.

Commissio.
2. T1, T2 -
3. M2 -
dry cloth. Get the card calibrated at factory if necessary.
If any of the displayed parameters is deviated from the standard
value, get the cards calibrated at the factory
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48
3.7. Medha Frequency Input Card (MFIP16)

This card consists of the hardware required for converting the signals generated by speed
sensors of Traction motors and diesel engine to isolated low voltage signals required for
the micro controller control system. This card provides electrical isolation, between sensor
circuits and micro controller circuits. All the inputs are surge protected. This card can
process 16 input signals.
Maintenance:
There are no user serviceable components in this card, and does not require any
preventive maintenance schedule and calibration unless otherwise mishandled.


Commissio.
2. T1, T2 -
3. M2 -
dry cloth.
Check the tightness of the card fixing screw on the control unit.
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48
3.8. Medha Pulse Width Modulator Card (MPWM2)

The PWM card converts the low voltage pulse width modulated signals generated by the
micro controller system to a high power 72V output for controlling the exciter field current
and auxiliary generator field current. This card has two independent channels. An IGBT
based PWM driving circuit with built in protection circuits is used for both PWM controls.
Maintenance:
There are no user serviceable components in this card, and does not require any

Commissio.
2. T1, T2 -
3. M2 -
dry cloth.
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48
3.9. Medha Excitation and Propulsion - Power Supply Card (MEPPS)

This module supplies various regulated power supplies of ±9V, ±12V and ±15V required
for the operation of all the cards in the control unit. These regulated power supplies are
generated from nominal 72V DC These are basically switch mode power supplies, which
can accept wide variation of input voltage. It provides electrical isolation between input
supply from locomotive and various regulated power supply outputs. The input supply is
reverse polarity protected, and surge protected. LED’s provided on this unit indicate
availability of a particular supply voltage.

Maintenance:
There are no user serviceable components in this card. and does not require any

Commissio.
2. T1, T2 -
3. M2 -
dry cloth.
Check the tightness of the card fixing screws on the control unit
6. M24 Same as M12
7. M48 Same as M24
8. M96 Same as M48
3.10. Medha Display Unit - MDS 733

This sub assembly consists of a 40 character X 4 line alphanumeric vacuum fluorescent
display (VFD). It also consists of a keyboard for data entry by the operator, and an
acknowledge switch to silence the built in Buzzer (Hooter) and Alarm Gong (ALG) during
fault massage display. It has an RS485 Serial communication interface for communication
with Control Unit. It has its own Power Supply module working on 72V DC for generating
regulated power supplies required for display circuits.
Please refer ‘System Manual’ of Microprocessor based loco control system MEP-660,
document No. IM 08 for the Dimensional Drawing and mounting details of the control Unit.
Maintenance:
There are no user serviceable components in this module. and does not require any
Maintenance on locomotive: Ensure tightness of power supply connector and

communication cable connector available at the back side of the display unit once in M4
schedule.

1. Pre- Check the tightness of the MS connectors available at the
Commissio. backside of the display unit.
2. T1, T2 -
3. M2 -
4. M4, M8 Check the tightness of the MS connectors available at the
backside of the display unit.
5. M12 Same as M4, M8 +
Test the Display unit as per the procedure mentioned in Testing
and Trouble shooting.
6. M24 Same as M12
7. M48 Same as M24 +
If necessary replace the following items by sending to factory.
• Membrane key board,


• Acknowledge button,
• Hooter and Glass.
Replace the following items by sending to factory.
• Membrane key board,
• Acknowledge button,
• Hooter and Glass.
Testing and Troubleshooting: ---
Connect 72 Volts DC power supply to the display unit in the test LAB with suitable
female connector and cable. The display should initially indicate:
‘Excitation And Propulsion Control

Power ON Self-Check’
After few seconds, the display show:
‘Communication Fail’
Press Menu key. The display shows main menu options:
1. Faults
2. Display Mode
3. Test Mode
4. Exit
Ensure that no other characters are displayed during the above sequence of check. If any
other characters are displayed, the display unit has to be serviced.
3.11. Analog Distribution Box (ADB) - MDB 701

The Analog Distribution Box provides regulated DC power to various sensors that are
connected to the ADB. It also collects output signals from these sensors and transmits
them to the main control unit. Each analog distribution unit can serve eight sensors and
provide one analog out put for driving load ammeter. The unit consists of regulated power
supplies required for the sensors. These regulated power supplies work on 72V DC.
The unit consists of eight plug-in type MS connectors (circular connectors) for connecting
eight individual sensors through independent cables and one connector for connecting
one analog output. It also has one MS connector for transmitting all the signals collected
from the sensors to the main control unit.
There are 4 ADBs per loco. All are identical and can be interchanged. Please refer
‘System Manual’ of Microprocessor based loco control system MEP-660, document No.
IM 08 for the Dimensional Drawing and mounting details of the control Unit.
Maintenance:
There are no user serviceable components in this module and does not require any

Maintenance on locomotive: Ensure tightness of all connector once in M4 schedule.

1. Pre- Check the tightness of the MS connectors available at the front
Commissio. side of the ADB.
2. T1, T2 -
3. M2 -
4. M4, M8 Check for any physical damages to the pins and threading on
each and every connector of the ADB.
If necessary replace the connector of it type No.
Please refer ‘Electrical Schematics’ for Microprocessor based
Loco control system MEP-660, document No. ED1000 / ED1001
for connector details.
Check the tightness of the MS connectors available at the front
side of the ADB.
5. M12 Same as M4, M8 +
Test the ADB as per the procedure given in ‘Testing and Trouble
shooting.’
Connect all the connectors in the loco and check the tightness of
the MS connectors.
6. M24 Same as M12
Replace the interconnecting cable between ADB and sensor
on condition basis.
Replace interconnecting cable between ADB and sensor.
Loco control system MEP-660, document No. ED1000 / ED 1001
for cable details.
Connect 72 Volts DC power supply to the display unit in the test LAB with suitable female
connector. Measure Voltage between pins A & B and C & B With B as common point the
voltage should be +24V between A&B and –24V between C&B. Check these voltages in
all the 1 to 8 connectors. If the voltages are deviated from +24V and –24V then the ADB
has to be sent for servicing.
3.12. RPM Distribution Box (RDB) - MDB 702

The RPM Distribution Box (RDB) supplies power to all the speed sensors connected to
the RDB. It also collects speed signals from these sensors and transmits these signals to
the main control unit. It has eight plug-in type MS Connectors for connecting to individual
speed sensors through independent cables.
Maintenance:
Maintenance on locomotive: Ensure tightness of all connector once in M4 schedule.

1. Pre- Check the tightness of the MS connectors available at the front
Commissio. side of the RDB.


2. T1, T2 -
3. M2 -
4. M4, M8 Check for any physical damages to the pins and threading on
each and every connector of the RDB.
If necessary replace the connector of it type No.
Loco control system MEP-660, document No. ED1000 / ED1001
for connector details.
Check the tightness of the MS connectors available at the front
side of the RDB.
5. M12 Same as M4, M8 +
Test the RDB as per the procedure given in ‘Testing and Trouble
shooting.’
Connect all the connectors in the loco and check the tightness of
the MS connectors.
6. M24 Same as M12
Replace the interconnecting cable between RDB and sensor
on condition basis.
Replace interconnecting cable between RDB and sensor.
for cable details.
Connect 72 Volts DC power supply to the display unit in the test LAB with suitable female
connector. Measure Voltage between pins and C & B With B as common point the
voltage should be +12V between C&B Check these voltages in all the connectors. If the
voltages are deviated from +12V then the RDB has to be sent for servicing.
4. Current Sensors
The current sensors are non-contact type and works on Hall effect principle. These
sensors measure DC current flowing through the conductor, which is passing through
them in a non-contact way. The current carrying cable generates a magnetic field around
the sensor, which is proportional to the magnitude of the current flowing through the
conductor. By measuring the magnetic flux generated by the cable, the sensor can
accurately measure the actual DC current flowing in the cable.
The sensor and its electronic circuits are contained in a dust and water proof enclosure. It
has an MS connector for connecting it with Analog Distribution Unit.
There are various range of current sensors used in the MEP-660 control system
4.1. Medha Current Sensor MCS 850

The MCS 850 current sensor is used to measure the Traction alternator current. It can
measure from 0 to 5000Amps.

The MCS 820 current sensors are used to measure the individual Traction motor
armature current. It can measure from 0 to 2000Amps.

Please refer ‘System Manual’ of Microprocessor based loco control system MEP660,

The MCS 803 current sensors are used to measure the Auxiliary Generator Armature
current, battery charging current and Exciter Armature current. It can measure from 0 to
300Amps.
4.4. Medha Current Sensor MCS 10A

The MCS 10A current sensors are used to measure the Auxiliary Generator Field current,
Exciter field current, Control circuit leakage current and Power circuit leakage current. It
can measure from 0 to 10Amps.
Maintenance:
There are no user serviceable components in this module and does not require any
Maintenance on locomotive: Ensure tightness of connector once in M4 schedule.

1. Pre- Check the tightness of the MS connectors available at the sensor
Commissio. end.
2. T1, T2 -
3. M2 Clean the dust accumulated on the sensor body and heat sink.
4. M4, M8 M2 +
Check the tightness of the MS connectors.
Ensure proper anchoring of the cable with out any hanging.
5. M12 Same as M4, M8
6. M24 Remove the sensor from the locomotive and check for any
physical damages to the pins or threading on connector.
If necessary, send the sensor for calibration at factory.
for cable details.
Replace the interconnecting cable between sensor and ADB
on condition basis.
Replace interconnecting cable between sensor and ADB.
for cable details.
5. Voltage Sensors
The voltage sensors also work on Hall effect principle. The sensor can measure DC
voltage accurately consuming very low current (as low as few mA). The sensor and its
electronic circuits are contained in a dust proof and water proof enclosure. It is equipped
with a plug in type of MS Connector for electrical connection with Analog Distribution Unit.

5.1. Medha Voltage Sensor - MVS 815

The MVS 815 voltage sensor is used to measure Traction Alternator Voltage. It can
measure from 0 to 1500Volts.
document No. IM 08, for the Dimensional Drawing and mounting details of the control
Unit.
5.2. Medha Voltage Sensor - MVS 801

The MVS 801 voltage sensor is used to measure Battery voltage, Aux. Gen. Voltage,
BKCP Voltage, LCP voltage. It can measure from 0 to 100Volts.
Maintenance:

Commissio. end.
2. T1, T2 -
4. M4, M8 M2 +
5. M12 Same as M4, M8
for cable details.
on condition basis.
for cable details.
6. Temperature Sensors
This is a semi conductor temperature sensor built in a rugged outer enclosure, which
measures the temperature of the outer enclosure body. Different shapes of outer
enclosures are used depending upon the application such as water temperature, lube oil
temperature, air temperature etc. The sensor is equipped with a plug in type of MS
connector for electrical connection with Analog Distribution Unit. It can measure the
temperature from -50°C to + 150°C. Different mounting arrangements are provided
depending upon the application.

6.1. Medha Temperature Sensor MTS 815A

The model MTS 815A is used to measure the ambient air temperature mounted at the
backside of the CP. Please refer ‘System Manual’ of Microprocessor based loco control
system MEP-660, document No. IM 08 for the Dimensional Drawing and mounting details
of the control Unit.
6.2. Medha Temperature Sensor MTS 815L

The model MTS 815L is used to measure the Lube oil temperature mounted on the lube
oil pipeline in the expresser room. Please refer ‘System Manual’ of Microprocessor based
loco control system MEP-660, document No. IM 08, for the Dimensional Drawing and
mounting details of the control Unit.
6.3. Medha Temperature Sensor MTS815W

The model MTS 815W is used to measure the cooling temperature mounted on the water
manifold pipeline near temperature gauge in the expresser room. Please refer ‘System
Manual’ of Microprocessor based loco control system MEP-660, document No. IM 08 for
the Dimensional Drawing and mounting details of the control Unit.
Maintenance:

Commissio. end.
2. T1, T2 -
4. M4, M8 M2 +
5. M12 Same as M4, M8.
for cable details.
on condition basis.
for cable details.
7. Pressure Sensors:
These are basically piezo-electric type sensors generating 4 to 20 mA out put. The body
is made up of stainless steel construction and has a threaded mounting arrangement.
The sensor is provided with a plug in type MS connector for electrical connection with
Analog Distribution Unit.

7.1. Medha Pressure Sensor MPS - 841

The pressure sensor of type No. MPS 841 is used to measure MR pressure in the
locomotive to provide cut in and cut out limits for the electro pneumatic governor (EPG). It
can measure from 0 to 21Kg/cm². Please refer ‘System Manual’ of Microprocessor based
loco control system MEP-660, document No. IM 08 for mounting details and dimensional
details of the Pressure sensor.

The pressure sensor of type No. MPS 842 is used to measure Brake Pipe Pressure
(BPP) and Brake Cylinder Pressure (BCP) in the locomotive. It can measure from 0 to
14Kg/cm² Please refer ‘System Manual’ of Microprocessor based loco control system
MEP-660, document No. IM 08 for mounting details and dimensional details of the
Pressure sensor.

The pressure sensor of type No. MPS 844 is used to measure Lube Oil Pressure (LOP) in
the locomotive. It can measure from 0 to 10Kg/cm². Please refer ‘System Manual’ of
Microprocessor based loco control system MEP-660, document No. IM 08 for mounting
details and dimensional details of the Pressure sensor.
7.4. Medha Pressure Sensor MPS- 845

The pressure sensor of type No. MPS 845 is used to measure Booster Air Pressure
(BAP) in the locomotive. It can measure from 0 to 3.5Kg/cm². Please refer ‘System
Manual’ of Microprocessor based loco control system MEP-660, document No. IM 08 for
mounting details and dimensional details of the Pressure sensor.
7.5. Medha Pressure Sensor MPS- 846

The pressure sensor of type No. MPS 846 is used to measure Fuel Oil Pressure (FOP) in
the locomotive. It can measure from 0 to 7kg/ cm². Please refer ‘System Manual’ of
Microprocessor based loco control system MEP-660, document No. IM 08 for mounting
details and dimensional details of the Pressure sensor.
7.6. Altitude Sensor MPS - 843

The Altitude sensor of type No. MPS 843 is used to dynamically measure altitude of the
site where the locomotive is working. It can measure from 0 to 3000 meters from sea
level. Please refer ‘System Manual’ of Microprocessor based loco control system MEP-
660, document No. IM 08 for mounting details and dimensional details of the Pressure
sensor.
Maintenance:

Commissio. end.
2. T1, T2 -
4. M4, M8 M2 +


for cable details.
on condition basis.
for cable details.
8. Speed Sensors
The speed sensors are used to measure Tr. Motor speed and engine speeds. These
sensors are Hall effect magnetic type sensors. These sensors are mounted over a
rotating gear. The sensor generates one electric pulse for every teeth of the wheel and
hence the signal frequency is proportional to the RPM of the gear over which the sensor
is mounted.
8.1. Tr. Motor Speed Sensor - T815

T815 is a Hall effect magnetic sensors are used to measure the individual traction motor
armature speed and from which the wheel RPM is calculated. The sensor is mounted on
the Traction Motor end shield to measure the RPM of Traction Motor shaft with the help of
a toothed wheel (like any gear wheel). The toothed wheel has been on to the armature
shaft at the end of the CE bearing. The sensor is built in an rugged enclosure with a
cable. The cable is coupled to the sensor cable coming from ADB available in the CP.
The frequency output is 60 Hz if the Tr. Motor Armature rotates at 60RPM.
Maintenance:
There are no user serviceable components in the sensor module and does not require
any preventive maintenance schedule unless otherwise mishandled.
Cleaning:
Blow out the dust accumulated on the sensor element and cable.
Remove the Tr. Motor speed sensor from the Tr. Motor.
Clean the sensor element and cable with a light cleaning solution to remove
oil and dirt.
Clean the connectors and pins with a light cleaning solvent.
Inspection:
Check for any physical damages on the sensor tip.

Check for any physical damages to the cable coming out of the sensor.
Check the connector for proper locking with female socket. If the connector is
slack replace both Male and female connectors of the sensor cable.

Please refer Annexure – 8 for type of connector and crimping tool required for
replacement.
Maintenance on locomotive:

1. Pre- Check the tightness of the Bayonet connector available at the
Commissio. sensor top.
2. T1, T2 -
3. M2 Check the tightness of the MS connectors. Ensure proper
anchoring of the cable with out any hanging.
Check the tightness of intermediate cable connectors at the
anchoring bracket for the Traction motor speed sensor cables.
4. M4, M8 Same as M2 +
Ensure tightness of Traction Motor speed sensor mounting
screws on the Tr. Motor commutator end bearing end cup.
5 M12 Check the tightness of the MS connectors. Ensure proper
Check the tightness of intermediate cable connectors at the
anchoring bracket for the Traction motor speed sensor cables.
Ensure the sensor cable in intact with out any damage.
Replace cable if damaged.
Ensure tightness of Traction Motor speed sensor mounting
screws on the Tr. Motor commutator end bearing end cup.
6. M24 Same as M12
7. M48 While the Tr. Motor is taken for over haul, remove the sensor
element from the Tr. Motor.
Send the sensor for calibration at factory.
Assemble the sensor on the overhauled traction motor.
Replace the interconnecting cables from the sensors and RDB
on condition basis.
Replace the interconnecting cables from the sensors and
RDB.
for cable details.
8.2. Engine Speed Sensor - T817

The Engine speed sensor T817 is also a hall effect magnetic sensor used for measuring
the engine RPM. The sensor is mounting on the cam gear cover to measure the engine
RPM. It generates one pulse for each teeth of the cam gear. As the cam gear is directly
driven by the engine crankshaft, the pulses per second or frequency generated by the
sensor is proportional to the engine RPM.
Maintenance:
There are no user serviceable components in the sensor module and does not require
any preventive maintenance schedule and calibration unless otherwise mishandled.
Cleaning:
Blow out the dust accumulated on the sensor element.

Remove the Engine speed sensor from cam gear cover while the cover is on
the engine block itself, as per the MAINTANANCE INSTRUCTIONS FOR
ENGINE SPEED SENSOR T-817, document No. IM 47.

Do not remove the cover from the engine block with Engine speed
sensor available on the cover. Slippage of the cover over the gear can
damage the sensor.
Remove the cam gear cover for inspection and secure in a safe place.
Provide proper protecting cover for the sensor fixing nut on the cam gear
cover to avoid damage to threads.
Clean and remove iron particles accumulated on the sensor tip.
Clean the sensor element with a light cleaning solution to remove oil and dirt
accumulated on the sensor.
Clean the connectors and pins with a cleaning light solvent. Provide
protecting cap to safe guard the pins in the connector.
Inspection:
Check for any physical damages on the sensor and its accessories.
Testing: --
After cam gear cover is fitted on the engine block, mount the engine speed sensor as
per the MAINTANANCE INSTRUCTIONS FOR ENGINE SPEED SENSOR T-817,
document No. IM 47.

1. Pre- Check the tightness of the MS connector available at the
Commissio. sensor end.
2. T1, T2 -
3. M2 Check for any oil leakage from the sensor weld nut and the
sensor is in tact on the cam gear cover.
4. M4, M8 Check the tightness of the MS connectors. Ensure proper
Check for any oil leakage from the sensor weld nut and the
sensor is in tact on the cam gear cover.
5 M12 Same as M4, M8.
6. M24 Remove and re-assemble the engine speed sensor as per the
above maintenance schedule.
Calibrate the sensor at factory.
Re-assemble the engine speed sensor as per the above
maintenance schedule.
Replace the interconnecting cable between sensor and RDB
on condition basis.
Replace the interconnecting cables from the sensors and
RDB.
for cable details.
9. Resistor Unit - MRP 703

This Unit consists of various filter resistors used for protection of micro controller from
surges and electrical noise on train lines (MU wires) and other connections from switches
and feedback contacts from relays etc. The unit has got 3 MS connectors for electrical
connection. Please refer ‘System Manual’ of Microprocessor based loco control system
MEP-660, document No. IM 08, for the Dimensional Drawing and mounting details of the
resistor unit.

Maintenance:
Cleaning:
Blow out the dust accumulated on the resistor elements with a dry
compressed air.
Clean the elements and the body with a dry cloth.
Clean the connectors and pins with a cleaning solvent after blowing.
Inspection:
Check for any physical damages to the resistor elements.

Check for any disconnected wires at the resistor element and connectors.
Replace the damaged resistor elements. The resistor element is 1.0K Ohms
/ 25watts.
Testing:
Check the value of each resistor element between connector pins as given
below. The value of resistor element should be 1.0 K Ohms ±10%.
S.No. Load 1 Load 2 Load 3

Pin Pin Pin Pin Pin Pin
1. U A U A U A
2. B B B
3. C C C
4. D D D
5. E E E
6. F F F
7. G G G
8. H H H
9. V J V J V J
10. K K K
11. L L L
12. M M M
13. N N N
14. P P P
15. R R R
16. S S S
If any resistance is open circuited, replace the resistor element.

1. Pre- Check the tightness of the MS connectors.
Commissio.
2. T1, T2 -
3. M2 Check for any damaged / over heated resistor elements.
4. M4, M8 Check for any damaged / over heated resistor elements
6. M24 Unload and service it as per the above maintenance schedule.
7. M48 Same as M24


Replace the interconnecting cable from the resistor unit and
TB.
for cable details.
10. ANCILARY UNITS:

10.1. CGR / PGR Resistor unit – MRP 706
CGR and PGR are two separate resistor panels mounted on a single bracket. The
resistors are used to limit the ground leakage current when ever any control circuit or
power circuit are grounded in service. Please refer ‘System Manual’ of Microprocessor
based loco control system MEP-660, document No. IM 08, for the Dimensional Drawing
and mounting details of the CGR / PGR resistor units.
CGR Panel: This is a single resistor element panel. The value of the resistor element is
50 ohms / 300watts.
PGR Panel: The PGR panel has got two resistor elements of 50 Ohms / 300Watts. The
effective resistance between the terminals should read as 100 Ohms / 300Watts / ±10%.
Maintenance:
Cleaning:
compressed air.
Inspection:
Check for any physical damages to the resistor elements like cracked /
broken insulators / tubes.
Check for any disconnected / over heated wires/shoes at the resistor
element connections.
Replace the damaged resistor elements. The resistor element is 50 Ohms /
300 watts.
Testing:
Check the value of each resistor element between terminals. The resistance
should be with in ± 10%. of the specified value in the following table.
Panel name Resistance value.

CGR 50 Ohms / 300Watts
PGR 100 Ohms / 300 Watts
If any resistance is open circuited, replace the resistor element.

1. Pre- Blow out the dust accumulated on the resistor panel.
Commissio. Check the tightness of the connections at the panel.
Check for any over heated / burnt wires at the terminal
connections.


2. T1, T2 -
3. M2 Check for any damaged / over heated resistor elements.
4. M4, M8 Same as M2
6. M24 Unload the panel from loco and service it as per the above
maintenance procedure.
7. M48 Same as M24
8. M96 Same as M48
10.2. Memory Freeze cum VCD Disable Unit - MMF 705

This is a simple module consisting two toggle switches and one LED. One of the toggle
switch is used to freeze the memory from recording the events. The LED will glow if this
switch is kept in ON position after breaking the glass. The second toggle switch is used to
disable the VCD. Normally these switches are sealed with different glass. Please refer
‘System Manual’ of Microprocessor based loco control system MEP-660, document No.
IM 08, for the Dimensional Drawing and mounting details of the Memory freeze unit.
In regular schedule it is essential to ensure that the sealing glass is in tact and not
broken.
Maintenance:
Cleaning:
Blow out the dust accumulated on the module with a dry compressed air.
Clean the module with a dry cloth.
Inspection:
Dismantle the unit.

Inspect for any dis-connected wires. From the PCB and the connector.
Inspect for any damaged threads / pins on the connector.
Test the module as per the given testing procedure.
Assemble the unit.
Testing:
Alerter Disable switch:
Connect a multi-meter in the very low resistance range between pin Number
A&B.
Switch ON the ALTS DSBL SW.
The meter should indicate 0 resistance. Otherwise replace the switch.
Memory Freeze switch:
Connect a multi-meter in the very low resistance range between pin Number
A&C.
Switch ON the MMF SW.
The meter should indicate 0 resistance. Otherwise replace the switch.
MMF LED
Connect 72Volts DC variable source between pin numbers E&D.

The LED should glow. If not replace the LED circuit.


1. Pre- Clean the module with dry cloth.
Commissio. Ensure sealing glass is in tact. If glass is broken replace the MMF
box after providing the glass.
2. T1, T2 -
3. M2 Check the connector tightness of MMF cum VCD disable module.
4. M4, M8 Same as M2.
6. M24 Remove the MMF box from the loco and service it as per the
above maintenance procedure.
7. M48 Same as M24
8. M96 Same as M48
10.3. XD23-XC13 Assembly unit

These are basically a protection components connected in the exciter field circuit to
quench the inductive surges generated in the exciter field during switching operation of
the PWM.
Maintenance:
Cleaning:
Inspection:
Base: Inspect the base for any cracks / broken pieces. The base should not
have any cracks.
Heat sink: Check the heat sink for any flash over / burning marks. The heat
sink should be clean and there should not be any flash over / burning marks.
Terminals and leads: Inspect the terminals and the leads for loose
connections. There should not be any burning / over heated symptoms.
Tightness of the connections: The terminal stud should be tight on the base.
The Diode connections should be tight on the terminal studs.
Shorting links: Shorting link plates should be available between diode
connecting terminals and loco connection studs.
Check the capacitor connections are intact and the capacitor is in good
condition.
Testing:
Diode:
Measure forward resistance with a multi-meter. The forward resistance
should be between infinity (13.7MΩ)
Measure the reverse resistance with a multi-meter. The reverse resistance
should be between low (10.3KΩ)
If the Resistance values are deviated, replace the diode of same capacity.
Capacitor
Measure the capacitor value with an LCR meter.

The value of the capacitor is 1µ fd.


1. Pre- Clean the dust accumulated on the module with a dry cloth
Commissio. Check for any over heated / flash over marks on the terminals.
If any overheating symptoms are found attend and check for
any loose connections.
2. T1, T2 -
3. M2 Check for any over heated / flash over marks on the terminals.
Check the tightness of connecting terminals on Panel.
6. M24 Remove the unit from loco and service it as per the above
While reconnecting ensure the connections are given correctly
as per drawing.
for cable details.
7. M48 Same as M24
8. M96 Same as M48
10.4. Motor Cut Out Switch Box - MSP 707

This module is a traction motor isolation box used to isolate any defective traction motor
in service. Six toggle switches are provided on the box with an ear marking of MCOS1 to
MCOS6. Operating this switch on the locomotive will isolate the concerned traction motor.
Maintenance:
Cleaning:
Inspection:
Base: Inspect the box for any physical damages.

Toggle switches: Check the physical condition of the switches. There should
not be any broken / damaged switches.
Terminals and leads: Inspect the switch terminals and the leads for loose
connections. All the connections should be tight. If the connections are
soldered inspect for any dry solder. There should not be any burning / over
heated symptoms.
Connector connections: The wires coming from the switches should have
good soldering at the connector. Inspect for the interconnecting leads.
Replace any damaged leads.
Connector: Check for any damaged pins or damaged threads on the
connector.
Testing:
Measure contact resistance of each toggle switch between the pins of the
connector as below. There should not be any resistance.

Between pins of the connector Resistance between pins

A
B
C
G
D
E
F

Commissio. Ensure the switches are in normal position.
Check the tightness of MS connector.
2. T1, T2 -
3. M2 Ensure the switches are in normal position.
Check the tightness of MS connector.
While reconnecting ensure the connections are given correctly
as per drawing.
for cable details.
7. M48 Same as M24
8. M96 Same as M48
10.5. Speed Sensor Interface Unit - MSI 761

This module is an interface unit to split the engine speed signal into two isolated speed
signals. One set of speed signals derived from ESS1 / ESS2 are connected to MEP-660.
The second set of speed signals are connected to MCBG. In this unit one toggle switch is
provided to select MEG601 or Other governor mode. The switch should be always on
‘MEG601’ side if Medha make MCBG is connected other wise the switch should be kept
in ‘Others’ position.
Maintenance:
Cleaning:
Inspection:
Base: Inspect the box for any physical damages.

Toggle switch: Check the physical condition of the switch. There should not
be any broken / damaged switch.
Terminals and leads: Inspect the switch terminals and the wiring for any dry
solder / disconnected wires. All the connections should be tight. There should
not be any burning / over heated symptoms.

Connectors: Check for any damaged pins or damaged threads on the

connectors. Check the soldering condition of the wires for any dry solder /
broken strands of the wire. If any damages are found, re-solder the wires.

1. Pre- Clean the dust accumulated on the module with a dry cloth.
Commissio. Check the tightness of connectors.
2. T1, T2 -
3. M2 Check the tightness of connectors.
While reconnecting ensure the connections are given
correctly as per drawing.
for cable details.
7. M48 Same as M24
8. M96 Same as M48
10.6. FCP Panel – Type SFCP - 25

Field Control Panel (FCP) is a resistor panel. These resistors are used in the Exciter field
circuit to drop the voltage from 72V to the required level. This panel consists of four
adjustable resistors.
Maintenance:
Cleaning:
compressed air.
Clean the terminals from dust.
Inspection:
Check for any physical damages to the resistor elements. Replace the
damaged resistor elements if any with same value.
Check for any over heated lugs at the resistor elements. If found replace the
lugs.
Check for any disconnected wires at the resistor element and connectors.
Check the tightness of adjustable clamps on the resistor element.
Testing:
Check the values of each resistor between the terminals specified in brackets. The
values of each resistor are as under. If the resistance values are deviated, adjust the
values with in the range. If any resistance is open circuited, replace the resistor
element.
EFR1 ---69.5 to 70.5 ohms (B-C) EFR2 ---1.38 to 1.42 ohms (C-D)
EFR3 ---14.5 to 14.7 ohms (E-F) EFR4 ---2.65 to 2.75 ohms (D-E)


1. Pre- Check for any damaged / over heated resistor elements. Check for
Commissio. any over heated lugs on the terminals or at resistor elements. If so
replace the FCP.
2. T1, T2 -
3. M2 Check for any damaged / over heated resistor elements
Ensure proper anchoring of the connecting wires with out any
loose hanging.
6. M24 Unload and service it as per the above maintenance schedule.
7. M48 Same as M24.
Replace the interconnecting wires between the resistor
element and TB.
Harness the wires properly.
10.7. HLD Relay Module - MRA 710

This is a simple relay module incorporated in the head light circuit. With introduction of
DC-DC converter instead of HLPR for headlight, the output voltage signal is 24 volts. Any
digital input signals are recognized as high when the voltage is more than 30V. So simple
relay logic has been used to convert this 24VDC signal into 72VDC signal. The status of
the headlight is sensed through this relay box and is communicated to MEP-660 and
recorded in the event recorder.
Maintenance:
Cleaning:
Inspection:
Dismantle the unit.

Inspect for any disconnected wires.
Check the tightness of connecting wires on TB
Assemble the unit.
Testing:
Connect 72 Volts DC power supply to the HLD relay module across 50A &
52HL terminals.
Check the voltage across HLB - 52HL and HLD-52HL. The voltage should
be zero. If voltage is available at HLB and HLD terminals, replace the 24V
relays on the PCB.
Apply 24 volts between HLBR and 52HL.
Measure the voltage between HLB and 52H terminals. The Voltage should
be same as applied across 50A and 52HL.
If voltage is zero or less than the 72V, replace the 24V relay on the PCB.
Remove 24 volts and connect between HLDR and 52HL.
Measure the voltage across HLD and 52HL. The voltage should be same as
applied across 50A and 52HL.

If voltage is zero or less than the 72V, replace the 24V relay on the PCB.
Disconnect all the supply wires.

Commissio.
2. T1, T2 -
3. M2 Check the tightness of connecting terminals.
6. M24 Remove the HLD Relay module from the loco and service it as
per the above testing procedure.
7. M48 Same as M24
8. M96 Same as M48
10.8. VCD Magnet Valve – Type: 3332-10-4G

VCD magnet valve is direct operated electro Pneumatic valve used to apply penalty
brakes whenever any safety devices like VCD / AEB / Fire Alert are operated in the
locomotive. It is normally closed valve and the valve open when ever 72V is applied to
coil. When this valve is energized the valve vents out the pilot air connected to inlet
causing automatic brake application. The Valve model No. 3332-10-4g and is
manufactured by M/s. Rotex.
Maintenance:
Cleaning:
Inspection:
Dismantle the unit and check the condition of valve as per the maintenance
procedure given by M/s. Rotex.
Replace the rubber components if required as specified by the principle
manufacturer.
Testing:
Check the operating coil resistance. The resistance should be with in the
specified limits of the maintenance data as per the principle supplier.
Connect the air supply with a pressure 5Kg/cm² to port no.1 and ensure there
is no leakage of air from port 2 of the valve.
Apply variable DC voltage slowly from 0 to 72Volts to the operating coil of the
Magnet Valve.
Slowly rise the voltage until the valve is fully opened. The valve should open
fully between 25 to 48VDC.
Slowly decrease the voltage until the valve is fully closed. The valve should
close between 9 to 21 V.
Remove all the electrical and pneumatic connections to the valve.


1. Pre- Clean the dust accumulated on the valve with a dry cloth.
Commissio.
2. T1, T2 -
3. M2 The cut out cock provided in front of VCD magnet valve should
always be in open position.
6. M24 Remove the VCD Magnet valve from the loco and service it as
per the above testing procedure.
7. M48 Same as M24
8. M96 Same as M48.

Annexure 1

Annexure - 2
Inter connections of Cards in MEP-660 Control unit
DIGITAL
OUTPUT
CARDS
MLSD16 MPWM2
1
MLSD16
2 ANALOG INPUT
CARDS
MHSD16
1 MIAI
MAUCC
SPARE MAIP8_AU
MEPCC MAIP8_EP
MDIP16
1 MAIP8_WS
MDIP16 MWSCC
2 MFIP16
MDIP16 FREQUENCY
3 INPUT CARD
MDIP16
4
MDIP16 MEPPS
5
DIGITAL
INPUT Communication Low Voltages for
Ports all other cards
CARDS

Annexure 3
List of Digital Input cards - channel wise
Digital DIP Card

Signal Name Signal Description
Input No. No./Channel
TL8 REVERSER in forward (SH) DI00 1/0
TL0 REVESER in reverse (LH) DI01 1/1
TL15 MCH 2,4,6,8 (AV) DI02 1/2
TL12 MCH 5,6,7,8 (BV) DI03 1/3
TL7 MCH 3,4,5,6,7,8 (CV) DI04 1/4
TL3 MCH 5,6 (DV) DI05 1/5
TL16 Throttle DI06 1/6
TL6 Motoring DI07 1/7
TL13 MFPB Contactor on FPC DI08 1/8
TL17 Brake Setup DI09 1/9
TL23 Braking DI10 1/10
TL2 ALG- Alarm Gong DI11 1/11
TL10 Wheel Slip Buzzer DI12 1/12
TL64 Sanding DI13 1/13
TL25 EP Compressor ON/OFF DI14 1/14
REV-OFF / 16D Both Rev in OFF / MCB 1&2 OFF DI15 1/15
CK1FB CK1 FB contact DI16 2/0
P1FB P1 FB contact DI19 2/3
S1FB S1 FB contact DI25 2/9
BKT-B FB BKT in B FB contact DI28 2/12
BKT-M FB BKT in Mot FB contact DI29 2/13

Digital DIP Card

REV-F FB REV in Forward FB contact DI30 2/14
REV-R FB REV in Reverse FB contact DI31 2/15
GF FB1 GF FB contact DI32 3/0
RFC FB (72) RFC Supply contact DI33 3/1
EXPR FB EXPR FB contact DI34 3/2
AGPR FB AGPR FB contact DI35 3/3
LWS FB LWS I/P DI36 3/4
OPS FB (1B) OPS in Governor DI37 3/5
ALARM FB (37) Alarm FB DI38 3/6
STOP Engine Stop FB DI39 3/7
START (43E) Engine Start FB DI40 3/8
ECS FB ECS in Run Switch DI41 3/9
MCOS1 TM 1 Cut Out DI42 3/10
FP FB (71) FP Contactor DI48 4/0
GF FB2 GF Contactor FB DI49 4/1
PCS FB PCS FB DI50 4/2
AG FB (49B) AG FB DI51 4/3
PSH DB3 Power Supply Health DB3 DI52 4/4
Rect. Hot Rectifier Diode Hot (presently by passed) DI56 4/8
RBBFB Rectifier Blower Fail (presently by passed) DI57 4/9
FSFB Field Shunting Contactor FB DI58 4/10

VCDR FB VCD Relay FB DI59 4/11
AFLR FB Flasher Relay FB DI60 4/12
AFL P1 AFL Pressure Switch P1 FB DI61 4/13
AFL P2 AFL Pressure Switch P2 FB DI62 4/14

Digital DIP Card

AFL RST AFL Reset PB DI63 4/15
VCD RST VCD Reset PB DI64 5/0
Auto Emergency Brake Enable / Disable
AEB Disable DI65 5/1
switch
HORN Horn PB FB DI66 5/2
W171 W171 AFL Enable FB DI67 5/3
PCS1 PCS1 FB DI68 5/4
DEB ENG FB * Dust Exhauster Breaker Engine Feed back DI69 * 5/5
DEB CB-FB ** Dust Exhauster Breaker Car body Feed back DI70 ** 5/6
CEBFB Crankcase Exhauster Breaker Feed back DI71 5/7
ALTR DSBL FB VCD disable switch DI71 5/8
MMF FB
Applicable to locos with Memory Freeze switch DI73 5/9
event recorder
FL FB
Applicable to locos with Flasher feed back DI74 5/10
event recorder
HLD FB
Applicable to locos with Headlight Dim Feed back DI75 5/11
event recorder
HLB FB
Applicable to locos with Headlight Bright feed back DI76 5/12
event recorder
SLBC FB
Applicable to Locos Self load box contactor Feed back DI77 5/13
with Self Load Box
feature only.
TE_LIMIT_SW
Applicable for Tractive effort limitation feature. DI78 5/14
TE_limit featured
locos only
AEB RESET AEB Reset Feed back DI79 5/15
* D169 is changed to MU penalty brake feedback signal.

** D170 is changed to Fire Alarm feed back signal.

Annexure – 4
MANUAL DIGITAL INPUTS CHECK PROCEDURE THROUGH DISPLAY UNIT
1 Ensure that all Digital Input Connectors are connected to Control Unit of MEP 660 System.
2 Switch ON MPCB available on the control panel. After displaying initial power ON check
message, the display shows Default screen parameters.
3 The digital input status LED’s on the digital input cards in Slots 9, 10,11,12 and 13 will glow
as per the annexure-4A
4 Switch ON MCB1 and MCB2 on both control stands.
5 Ensure control air pressure is more than 4.8Kg/Sq.cm.
6 Ensure that BP is more than 4.2Kgs/Sq.cm or PCS is in pick up condition or DMR is in ON
position.
7 Press “MENU” key on display unit keyboard. The display shows main menu options. Select
“Test Mode” from available options. The display prompts for a password. After entering a valid
password (5 Digit), a sub menu options under ‘Test Mode’ are displayed. Select the option
“Manual Tests for Inputs”.
8 The display prompts for the conditions to be fulfilled before conducting manual test. Ensure
that the required conditions are fulfilled and then press ‘Enter’ button to proceed for manual
testing.
9 Press down “arrow” key to proceed with the testing of all inputs one after the other.
10 The Display shows the name of the input and its status. If the status is “ON”, it corresponds to
72V and if the status is OFF, it corresponds to 0 V for that particular digital input.
11 If the status of digital input is shown as ON, the corresponding green and yellow LEDs on the
card should also glow.
12 Change the status of the input from ON to OFF and vice versa by operating corresponding
handles, switches, interlocks etc., and verify that the digital input signal status is correctly
recognized by the system as indicated by the corresponding LED on the Digital input cards
“MDIP16” and displayed status of the digital input on the display unit. Glowing GREEN LED
on the Card means input is detected as “ON” and GREEN LED OFF means input is detected
as “OFF”. Also verify that the Green and Yellow LED’s on the same “MDIP16” card are
showing the same status. If this condition is not satisfied, the card could be faulty.
13 Repeat 9 to 12 till all the Digital Inputs as listed below are checked.
14 Ensure that status shown by the display and the status shown by the LED’s are matching
correctly.
Corresp.
Digital LED
S. Signal
Signal Description Input Location Test Condition Observation
No. Name
No. Slot LED
No. No.
1 TL8 Reverser Handle in DI00 9 0 Move RH to Forward DI status toggles
forward (Short Hood) Switch ON both GF with GF switch
direction switches ON/OFF.
Move Master Handle to
st
1 notch.
2 TL0 Reverser Handle in DI01 9 1 Move RH to Reverse DI status toggles
forward (Short Hood) Switch ON both GF with GF switch
direction switches ON/OFF.
1st notch.

Corresp.
Digital LED
S. Signal
No. Name
No. Slot LED
No. No.
3 TL15 MHW 2,4,6,8 (AV) DI02 9 2 Move Master Handle to DI status ON in
2,4,6,8 Notch positions. prescribed notch
positions.
DI status OFF in
other notch
positions.
4 TL12 MHW 5,6,7,8 (BV) DI03 9 3 Move Master Handle to DI status ON in
5,6,7,8 Notch positions. prescribed notch
positions.
DI status OFF in
other notch
positions.
5 TL7 MHW 3,4,5,6,7,8 (CV) DI04 9 4 Move Master Handle to DI status ON in
3,4,5,6,7,8 Notch positions. prescribed notch
positions.
DI status OFF in
other notch
positions.
6 TL3 MHW 5,6 (DV) DI05 9 5 Move Master Handle to 5,6 DI status ON in
Notch positions. prescribed notch
positions.
DI status OFF in
other notch
positions.
7 TL16 Throttle (Engine Speed) DI06 9 6 Move throttle to IDLE. DI status toggles
Control Ensure MCB1 & MCB2 are with switching
in ON position. ON/OFF of
MCB1 or MCB2.
8 TL6 Motoring Control DI07 9 7 Switch ON both GF DI status toggles
switches with GF switch
Move Master Handle to ON/OFF.
1st notch.
9 TL13 FPC Contactor DI08 9 8 Ensure MFPB1and MFPB2 DI status toggles
are switched ON. with switching
ON/OFF of
MFPB1 or
MFPB2.
10 TL17 Dy. Brake Setup DI09 9 9 Move RH to either DI status toggles
Forward or Reverse. with Master
Move Master Handle to Handle position
“OFF” position. OFF to Idle
position.
11 TL23 Dy. Brake Control DI10 9 10 Move RH to either DI status toggles
Forward or Reverse. with Master
Move Master Handle to Handle position
“B” position. OFF to “B”
positions.

Corresp.
Digital LED
S. Signal
No. Name
No. Slot LED
No. No.
12 TL2 Alarm signal DI11 9 11 Operate SR relay manually. DI status ON if
SR relay
operated
manually.
13 TL10 Wheel Slip Buzzer DI12 9 12 Operate SANDR relay DI status ON if
manually. SANDR relay
operated
manually
14 TL64 Sanding signal DI13 9 13 Press SAND push button DI status ON if
SAND push
button is
pressed.
15 TL25 EP Compressor DI14 9 14 Version 1.0 locos DI status toggles
ON/OFF Switch on LPS10 with EPG switch
switch (EPG switch) operation.
Version 2.0 and above DI status ON if
Switch on LPS10 CMR relay
switch (EPG switch) operated
Operate CMR relay manually.
manually.
16 REV-OFF Both RH in neutral DI15 9 15 Version 1.0 Locos DI status toggles
Both RH in neutral position. with RH
operation.
16D MCB1 & MCB2 OFF Version 2.0 and above DI status toggles
Switch ON both MCB1 & with MCB1
MCB2 breakers. operation.
17 CK1FB CK1 FB signal DI16 10 0 Manually open and close DI status toggles
18 CK2FB CK2 FB signal DI17 10 1 the Feed Back contact. with feed back
contact
19 CK3FB CK3 FB signal DI18 10 2
close/open.
20 P1FB P1 FB signal DI19 10 3 Manually operate power DI status toggles
contactor by operating with feed back
magnet valve. Feedback contact
contact should open or operation
close.
close.
close.

Corresp.
Digital LED
S. Signal
No. Name
No. Slot LED
No. No.
close.
close.
close.
26 S1FB S1 FB signal DI25 10 9 Manually operate power DI status toggles
close.
close.
close.
29 BKT-B BKT in B FB signal DI28 10 12 Manually operate BKT to DI status ON if
FB braking side. BKT B feedback
Manually open or close the interlock closes.
BKT B Feed back interlock.
30 BKT-M BKT in Mot FB signal DI29 10 13 Manually operate BKT to DI status ON if
FB motoring side. BKT M feed
Manually open or close the back interlock
BKT M feedback interlock. closes.
31 REV-F REV in Forward FB DI30 10 14 Manually operate Reverser DI status ON if
FB signal by pressing magnet valve to REV F feedback
forward position. interlock closes.
Manually open or close the
REV F feedback interlock.
32 REV-R REV in Reverse FB DI31 10 15 Manually operate Reverser DI status ON if
FB signal by pressing magnet valve to REV R feedback
reverse position. interlock closes.
Manually open or close the
REV R feedback interlock.

Corresp.
Digital LED
S. Signal
No. Name
No. Slot LED
No. No.
33 GF FB1 GF FB signal DI32 11 0 Close and Open the DI status toggles
auxiliary contact of GF with GF auxiliary
Contactor. contact
operation
34 RFC FB RFC Supply DI33 11 1 Switch ON FPB DI status toggles
(72) Breaker with RFCB
Switch ON RFCB breaker
Breaker operation
35 EXPR FB EXPR FB signal DI34 11 2 Operate EXPR relay DI status toggles
manually. with EXPR
operation.
36 AGPR FB AGPR FB signal DI35 11 3 Operate AGPR relay DI status toggles
manually. with AGPR
operation.
37 LWS FB LWS FB signal DI36 11 4 Verify by opening and DI status toggles
closing the LWS cutout cock with LWS
and ensure LWS is operation
operating.
38 OPS FB OPS signal from WW DI37 11 5 Pull out Low lube oil button DI status toggles
(1B) Governor in WW Governor. And reset with LLOB
the button. button operation.
39 ALARM Alarm PB DI38 11 6 Press ALARM push button DI status toggles
FB (37) with ALARM
push button
operation.
40 STOP Engine Stop PB DI39 11 7 Press Engine Stop push DI status toggles
button with Engine Stop
Push button
operation.
41 START Engine Start PB DI40 11 8 Pack CK1, CK2 and CK3 DI status toggles
(43E) main contacts with with Engine Start
insulation sheet. push button
Press Engine Start push operation.
button
42 ECS ECS status DI41 11 9 Move ECS to RUN position DI status toggles
RUN FB and back to IDLE with ECS
operation.
43 MCOS1 TM 1 Cut Out DI42 11 10 Operate the switch OFF and DI status toggles
ON with MCOS1
operation.
ON with MCOS2
operation.
ON with MCOS3
operation.

Corresp.
Digital LED
S. Signal
No. Name
No. Slot LED
No. No.
ON with MCOS4
operation.
ON with MCOS5
operation.
ON with MCOS6
operation.
49 FPC FB FP Contactor DI48 12 0 Switch ON FPB and switch DI status toggles
(71) OFF with FPB
breaker
operation.
50 GF FB2 GF Contactor Feed DI49 12 1 Close and Open the DI status toggles
Back auxiliary contact of GF with GF auxiliary
Contactor. contact
operation
51 PCS FB PCS Feed Back DI50 12 2 Apply emergency DI status toggles
through A9 and drop the with the BP
BP pressure below 2.8 pressure
Kg/cm″. operation.
Release A9 to normal
position.
PCS closes at
4.2Kg/cm″.
52 AGFB FB AGFB feedback DI51 12 3 Switch ON AGFB Breaker DI status toggles
(49B) with AGFB
breaker
operation.
53 PSH3 Power Supply Health DI52 12 4 Disconnect and connect DI status toggles
DB3 the PSH3 wire on the TB. with PSH3 wire
Reconnect the PSH3 disconnection
wire to the same TB. and connection.
Ensure tightness of the
wire.
wire to the same TB. and connection
wire
DB1 the PSH1wire on the TB. with PSH1 wire
wire

Corresp.
Digital LED
S. Signal
No. Name
No. Slot LED
No. No.
wire
57 Rect. Hot Rectifier Diode Hot DI56 12 8 Disconnect and connect the DI status toggles
DLK1 wire on the TB. with DLK1 wire
connection /
disconnection.
58 Rect. Rectifier Blower Breaker DI57 12 9 Switch ON and OFF circuit DI status toggles
Blower status breaker RBB. with RBB
Fail Breaker
operation.
59 FS FB Field Shunting Contactor DI58 12 10 Short the auxiliary contact DI status toggles
Feed Back wires of any field shunting with FS feed
contactor. back operation.
60 VCDR FB VCD Relay Feed Back. DI59 12 11 Operate VCDR relay DI status toggles
Note: In Ver.1 the name manually. with VCDR relay
is ALRTRB relay. operation.
61 AFLR FB Auto Flasher Relay FB DI60 12 12 Operate AFLR relay DI status toggles
manually. with AFLR relay
operation.
62 AFL P1 Auto Flasher Pressure DI61 12 13 Move A9 handle to full DI status toggles
switch P1FB service zone and release. with P1 pressure
switch operation.
63 AFL P2 Auto Flasher Pressure DI62 12 14 Move A9 handle to full DI status toggles
switch P2FB service zone and release. with P2 pressure
switch operation.
64 AFL RST Auto Flasher Reset DI63 12 15 Press AFL Reset push DI status toggles
Push Button button. with AFL reset
button operation.
65 VCD VCD reset Push Button DI64 13 0 Press VCD reset push DI status toggles
RST button with VCD reset
button operation.
66 AEB IP AEB Enable/Disable DI65 13 1 Operate the AEB input key DI status toggles
status. if AEB is provided. with AEB input
key operation.
67 HORN Horn Push Button FB DI66 13 2 Press any HORN push DI status toggles
button with HORN push
button operation.
68 W171 Wire 171 Auto Flasher DI67 13 3 Move RH to either Forward DI status toggles
enable FB or Reverse direction. with RH direction
operation.

Corresp.
Digital LED
S. Signal
No. Name
No. Slot LED
No. No.
69 PCS1 FB PCS 1 FB (for dual DI68 13 4 Open the PCS DI status toggles
brake Loco only) connecting wire 162 with PCS switch
(ID: AX) at TB. operation.
Reconnect the wire
back to same TB.
wire.
70 VCD/AEB Penalty Brake MU signal DI69 13 5 Short the wire TL20 DI status toggles
MU FB with 51. with energisation
Remove the short link. of wire TL20
(MU).
71 FAS FB Fire Alarm System Feed DI70 13 6 Short the wire TL11 DI status toggles
Back with 51. with energisation
Remove the short link. of wire TL11
(MU).
72 CEB FB CEB Breaker feed back DI71 13 7 Switch ON / OFF CEB DI status toggles
Breaker. with CEB
Breaker
operation.
73 VCD Dsbl VCD Disable Switch DI72 13 8 Operate Alerter disable DI status toggles
SW switch. with Alerter
disable switch
operation.
74 MMF FB Memory freeze switch DI73 13 9 Operate Memory freeze DI status toggles
for event recorder switch. with Memory
freeze switch
operation.
75 FL FB Flasher Light feed back DI74 13 10 Operate flasher light switch DI status toggles
for event recorder with Flasher light
switch operation.
76 HLD Head light Dim for event DI75 13 11 Switch ON HLPB DI status toggles
recorder Breaker with Head light
Kept head light switch switch position.
in Dim position.
77 HLB Head light Bright for DI76 13 12 Switch ON HLPB DI status toggles
event recorder Breaker with Head light
Kept head light switch switch position..
in Bright position.
78 SLBC FB Self load box Contactor DI77 13 13 Close the auxiliary contact DI status toggles
feed back for locos fitted of self-load box contactors if with SLBC
with Self Load Box available. auxiliary contact
feature only operation.
79 TELS FB TE limit switch FB DI78 13 14 Operate the TE limit switch DI status toggles
with TE limit
switch operation.
80 AEB AEB Reset input DI79 13 15 Operate the AEB reset DI status toggles
Reset switch if provided with AEB reset
button operation.

Annexure – 4A (1/2)
Digital input status shown with all breakers ON and master handles in IDLE, BKT in motoring and
Reverser in Forward and air brake system working normal. – PCS and PCS1 Status depend on Air
brake. Rect. Blo Fail & Rect. Hot status depends on type of rectifier.
Card level input status LEDS Card level input status LEDS Card level input status LEDS
7 15 REV-OFF 7 P22FB 15 REVRFB 7 15

TL6 STOP MCOS6
6 6 14
TL16 14 TL25 6 P2FB 14 REVFFB ALARM
FB
MCOS5
5 13 5 P31FB 13 BKTMFB
5 OPS FB 13 MCOS4
TL3 TL64
4 12 4 P21FB 12 BKTBFB 4 LWSFB 12 MCOS3
TL7 TL10
3 3 11
TL12 11 TL2 3 P1FB 11 S31FB AGPR
FB
MCOS2
2 2 10 2 EXPR FB 10
TL15 10 TL23 CK3FB S21FB MCOS1
1 9 1 CK2FB 9 S1FB 1 RFCB 9 ECSRUN

TL0 TL17
B
0 0 8 0 8
TL8 8 TL13 CK1FB P32FB GFFB START
Loco input status Loco input status Loco input status

LEDS REV-OFF LEDS REVRFB 7 LEDS
7
TL6 15 7 P22F 15 STOP 15 MCOS6
6 6 ALARM 14
TL16 14 TL25 6 P2FB 14 REVFFB
FB
MCOS5
5 5 OPS FB 13
TL3 13 TL64 5 P31F 13 BKTMFB MCOS4
4 4 LWSFB 12
TL7 12 TL10 4 P21F 12 BKTBFB MCOS3
3 B 3 11
P1FB 11
3 AGPR
TL12 11 TL2 S31F FB
MCOS2
2 2 EXPR FB 10
TL15 10 TL23 2 CK3F 10 S21F MCOS1
1 9 1 9
9 1 RFCB ECSRUN
TL0 TL17 CK2F S1FB
0 B 8 0 8
8 0 GFFB START
TL8 TL13 CK1F P32F
B
Slot-9 Slot-10 Slot-11

Annexure – 4A (2/2)
Card level input status LEDS Card level input status LEDS
7 15 AFLRST
7 CEB FB 15
PSH4 SPAR
6 6 E
14 DEB-Car. 14
PSH1 AFL FB
SPAR
5 13 P2 5 DEB-Eng. 13
SLBC FB
PSH2 AFL FB
4 PSH3 12 AFLRFB
4 12 HL
PCS1
Brit
3 11 ALRTRB 3 11 HL Dim
AGFB FB W171
2 10 2 10 FL FB
PCSF FSFB HOR
1 9 Rect. 1 N 9
IBPS MMF FB
GFFB Blo. Fail
0 8 Rect. 0 ALRT 8 Altr.Dsbl

FPFB HOT SW
R
Loco input status Loco input status
7 LEDS 7 LEDS
PSH4 15 AFLRST CEB-FB 15 SPAR
6 PSH1 14 6 DEB-Car. 14 E
AFL P2 SPAR
FB
5 PSH2 13 5 DEB- 13 E
AFL P1 SLBC FB
Eng. FB
4 PSH3 12 AFLRFB 4 12
PCS1 HL
3 11 ALRTRB 3 11 HL Dim
AGFB FB
W171
2 10 2 10
PCSF FSFB HOR FL FB
1 9 1 9
GFFB Rect. IBPS MMF FB
0 8 Blo.
Rect. 0 ALRTR 8 Altr.Dsbl
FPFB HOT RST SW
Slot-12 Slot-13

Annexure 5
List of Digital Output cards - channel wise
Digital
DOP Card
Signal Name Signal Description Output
No./Channel
No.
Low Side Drive
P1 CL P1 Coil DO00 1/0
S1 CL S1 Coil DO06 1/6
BKT-M CL BKT - Mot Coil DO09 1/9
BKT-B CL BKT-Brake Coil DO10 1/10
REV-F CL REV Forward Coil DO11 1/11
REV-R CL REV Reverse Coil DO12 1/12
GF CL 1 GF Contact Coil 1 DO13 1/13
CKC CL CKC Coil DO14 1/14
EXPR CL EXPR Coil DO15 1/15
R1 CL R1 Coil DO16 2/0
R2 CL R2 Coil DO17 2/1
GF CL 2 GF Contact Coil 2 DO18 2/2
AGPR CL AGPR Coil DO19 2/3
SANDR CL Sanding Relay Coil DO20 2/4
BKIV CL BKIV Coil DO21 2/5
SR CL Signal Relay Coil DO22 2/6
DMR CL DMR Relay Coil DO23 2/7
FSR CL Field Shunting Relay Coil DO24 2/8
VCDR CL VCD Relay Coil DO25 2/9
AFLR CL Flasher Relay Coil DO26 2/10
CMR CL CMR Relay Coil DO27 2/11
SLBR CL
Self Load Box Relay Coil DO28 2/12
Applicable to Locos

Digital
DOP Card
Signal Name Signal Description Output
No./Channel
No.
with Self Load Box
feature only.
PLPC CL
Applicable for locos Pre lubrication Pump Contactor DO29 2/13
fitted with pre-
lubrication feature
SPARE DO30 2/14
SPARE DO31 2/15
High Side Drive
AV CL (15A) AV Coil DO32 3/0
BV CL (12A) BV Coil DO33 3/1
CV CL (7C) CV Coil DO34 3/2
DV CL (3A) DV Coil DO35 3/3
HOT_ENG_LED
Hot Engine LED DO36 3/4
(16L)
CK_TIP_W 73) CK Tip Weld LED DO37 3/5
GND_LED (35) Ground Indication LED DO38 3/6
OVR_LD_LED (RL-
Over Load Indication LED DO39 3/7
2)
AFL LED Flasher LED DO40 3/8
VCD LED VCD LED DO41 3/9
MMF LED Memory Freeze indication LED DO42 3/10
Pre/post LED Pre and post lubrication LED DO43 3/11
SPARE DO44 3/12
SPARE DO45 3/13
SPARE DO46 3/14
SPARE DO47 3/15

Annexure – 6
MANUAL DIGITAL OUTPUTS CHECK PROCEDURE THROUGH DISPLAY UNIT
1 Ensure that all Digital Output Connectors are connected to Control Unit of MEP 660 System.
2 Ensure control air pressure is more than 4.8Kg/Sq.cm.
3 Ensure that BP is more than 4.2Kgs/Sq.cm or PCS is in pick up condition or DMR is in ON
position.
4 Press “MENU” key on display unit keyboard. Main Menu options are displayed on the screen.
Select “Test Mode” from available options. The display prompts for a password. After entering
the valid password (5 digits), sub-menu options under ‘Test Mode’ are displayed. Select
“Manual Tests for Outputs”. The display prompts for the conditions to be fulfilled before
conducting the manual output tests.
5 After fulfilling the required conditions, Press “ENTER” key to proceed for testing.
6 Press down “arrow” key to proceed with testing of all outputs one after the other starting from
the output channel 1.
7 The Display shows the name of the output and its status.
8 Change the status of output from ON to OFF and vice versa by pressing 1 for ON and 0 for
OFF and verify that it is correctly recognized by the system as seen by the corresponding
Feed Back LED on the “MDIP16” card and also Feedback status shown on display. Also
ensure output device is toggled ON/OFF correctly as per the (1/0) key pressed.
9 Repeat 6 to 8 till all the Digital Outputs as listed in the “Digital Outputs list” are checked and
found to be working as desired and also recognized correctly by the system and shown
correctly on the Display Unit.
Corresponding
Signal Digital LED on Digital
Signal
S.No. Descriptio Output input card Test condition Observation
Name
n No. Slot LED
No. No.
Digital Input DI19
Press 1 to switch ON &
1 P1 CL P1 Coil DO00 10 3 should glow when
press 0 to switch OFF.
Output is made ON
Digital Input DI20
Output is made ON
Digital Input DI21
Output is made ON
Digital Input DI22
Output is made ON
Digital Input DI23
Output is made ON
Digital Input DI24
Output is made ON
Digital Input DI25
7 S1 CL S1 Coil DO06 10 9 should glow when
Output is made ON

Corresponding
Signal
Name
n No. Slot LED
No. No.
Digital Input DI26
Output is made ON
Digital Input DI27
Output is made ON
Set BKT to Braking side
Move RH to For/Rev
Switch ON both GF
BKT - Mot switches BKT should through
10 BKT-M CL DO09 10 13
Coil Move Master Handle to to Motoring position.
1st notch.
Set BKT to Motoring
side
Move RH to For/Rev
BKT- Switch ON both GF
BKT should through
11 BKT-B CL Brake DO10 10 12 switches
to Braking position.
Coil Move Master Handle to
1st notch.
Set REV to reverse
position.
Move RH to FOR side in
CS1
Reverser should
REV For Switch ON both GF
12 REV-F CL DO11 10 14 through to forward
Coil switches
position.
1st notch.
Set REV to Forward
position.
Move RH to REV side
on CS1
Reverser should
REV Rev Switch ON both GF
13 REV-R CL DO12 10 15 through to reverse
Coil switches
position
1st notch.
11 0 Digital Inputs DI32 &
GF
Press 1 to switch ON & DI 49 should glow
14 GF CL 1 Contactor DO13
12 1 press 0 to switch OFF. when Output is made
Coil 1
ON
15 CKC CL CKC Coil DO14 Cannot be tested. No feedback

Corresponding
Signal
Name
n No. Slot LED
No. No.
Digital Input DI34
EXPR Press 1 to switch ON &
16 EXPR CL DO15 11 2 should glow when
Coil press 0 to switch OFF.
Output is made ON
Ensure MFPB1 and
MFPB2 are in ON
position. Digital Input DI33
17 R1 CL R1 Coil DO16 11 1 Switch ON FPB should glow when
Breaker Output is made ON
Ensure MFPB1 and
MFPB2 are in ON
position. Digital Input DI33
18 R2 CL R2 Coil DO17 11 1 Switch ON FPB should glow when
Breaker Output is made ON
11 0 Digital Inputs DI32 &
GF
Press 1 to switch ON & DI49 should glow
19 GF CL2 Contactor DO18
12 1 press 0 to switch OFF. when Output is made
Coil 2
ON
Digital Input DI35
AGPR Press 1 to switch ON &
20 AGPR CL DO19 11 3 should glow when
Coil press 0 to switch OFF.
Output is made ON
Both Digital Inputs
Sanding
Press 1 to switch ON & DI12 and DI13 should
21 SANDR CL Relay DO20 9 13
press 0 to switch OFF. glow when Output is
Coil
made ON
Ensure BKIV valve is
energised when
Output is made ON.
Press 1 to switch ON & Display shows ‘No
22 BKIV CL BKIV Coil DO21 -- --
press 0 to switch OFF. Feed back’.
Ensure magnetization
of the valve through
an iron plate.
Signal DI11 LED & Alarm
23 SR CL Relay DO22 9 11 should ON when
Coil output is made ON

Corresponding
Digital LED on Digital
Signal Signal
S.No. Output input card Test condition Observation
Name Description
No. Slot LED
No. No.
DMR Should pick up
when output is made
DMR Press 1 to switch ON &
24 DMR CL DO23 -- -- ON.
Relay Coil press 0 to switch OFF.
Display shows ‘No
Feed Back’
FSR relay and FS
contactors should
Field pick up when out put
25 FSR CL Shunting DO24 12 10 is made ON. Digital
Relay Coil input DI 58 should
glow when out put is
made ON
Digital Input DI59
VCD Press 1 to switch ON &
26 VCDR CL DO25 12 11 should glow when
Output is made ON
Digital Input DI60
Flasher Press 1 to switch ON &
27 AFLR CL DO26 12 12 should glow when
Output is made ON
Digital Input DI14
should be ON when
output is made OFF
Ensure LPS10 is switched and should be OFF
CMR
28 CMR CL DO27 9 14 ON. when output is made
Relay Coil
Press 1 to switch ON & ON.
press 0 to switch OFF. Display shows ‘No
Feed back’ when the
output is made ON
SLBR relay and
SLBC contactors
should pick up when
output is made ON.
SLBR Press 1 to switch ON & Digital Input DI 77
29 SLBR CL DO28 13 13
relay coil press 0 to switch OFF. should glow when
output is made ON.
Applicable for locos
fitted with self load
box features only.
PLPC should pickup
when output is made
PLPC
Press 1 to switch ON & ON. Applicable for
30 PLPC CL contactor DO29
press 0 to switch OFF. locos fitted with Pre
coil
lubrication feature
only
31 Spare DO30
32 Spare DO31

Corresponding
Signal
Name
n No. Slot LED
No. No.
Check voltage
between 15A and 4
AV CL Press 1 to switch ON & wires.
33 AV Coil DO32
(15A) press 0 to switch OFF. It should be more
than 65VDC when
Output is made ON.
Check voltage
between 12A and 4
BV CL Press 1 to switch ON & wires.
34 BV Coil DO33
(12A) press 0 to switch OFF. It should be more
than 65VDC when
Output is made ON.
Check voltage
between 7C and 4
Press 1 to switch ON & wires.
35 CV CL (7C) CV Coil DO34
press 0 to switch OFF. It should be more
than 65VDC when
Output is made ON.
Check voltage
between 3A and 4
Press 1 to switch ON & wires.
36 DV CL (3A) DV Coil DO35
press 0 to switch OFF. It should be more
than 65VDC when
Output is made ON.
Hot Engine LED
Hot
HOT_ENG Press 1 to switch ON & Indication should
37 Engine DO36
_LED (16L) press 0 to switch OFF. glow when Output is
LED
made ON
CK Tip Weld LED
CK_TIP_W CK Tip Press 1 to switch ON & indication should
38 DO37
(73) Weld LED press 0 to switch OFF. glow when Output is
made ON
Ground LED
Ground
GND_LED( Press 1 to switch ON & Indication should
39 Indication DO38
35) press 0 to switch OFF. glow when Output is
LED
made ON
Over Over Load LED
OVR_LD_L Load Press 1 to switch ON & indication should
40 DO39
ED (RL-2) Indication press 0 to switch OFF. glow when Output is
LED made ON
Auto Flasher LED
Flasher Press 1 to switch ON & indication should
41 AFL LED DO40
LED press 0 to switch OFF. glow when Output is
made ON

Corresponding
Signal
Name
n No. Slot LED
No. No.
VCD LED indication
VCD Press 1 to switch ON &
42 VCD LED DO41 should glow when
LED press 0 to switch OFF.
Output is made ON
Memory freeze LED
indication should
Memory glow when output is
43 MMF LED freeze DO42 made ON.
LED Applicable only to
locos fitted with event
recorder.
Pre / Post Lubrication
LED indication should
Pre/Post glow when output is
44 PPL LED Lubricatio DO 43 made ON. Applicable
n LED for locos fitted with
pre lubrication feature
only.
45 Spare DO 44
46 Spare DO 45
47 Spare DO 46
48 Spare DO 47

Annexure 7
LIST OF ANALOG INPUTS IN MEP660
Signal Sensor
Signal Description Measuring Range
Name Type
TAV MVS 815 Rectifier Output Voltage 1500 V
LCPV MVS 801 Governor Load Control Rheostat Output 100 V
BKCPV MVS 801 Master Controller Braking Potentiometer 100 V
BATV MVS 801 Battery Voltage 100 V
AGAV MVS 801 Auxiliary Generator Armature Voltage 100 V
TAAI MCS 850 Rectifier Output Current 5000 A
TM1AI MCS 820 TM1 Armature Current +/- 2000 A
EXAI MCS 803 Exciter Armature Current +/- 300 A
AGAI MCS 803 Auxiliary Generator Armature Current +/- 300 A
BATI MCS 803 Battery Charging/ Discharging Current +/- 300 A
AGFI MCS 10A Auxiliary Generator Field Current +/- 10 A
EXFI MCS 10A Exciter Field Current +/- 10 A
BANGI MCS 10A Battery Earth Fault Current +/- 10 A
TANGI MCS 10A Power Ground Fault Current +/- 10 A
MRPR MPS 841 MR Pressure 0 to 20 kg/cm2
BPP MPS 842 Brake Pipe Pressure 0 to 14Kg/ cm2
2
BCP MPS 842 Brake Cylinder Pressure 0 to 14Kg/ cm
APR MPS 843 Altitude Sensor 0 to 3000 Mtrs
LOP MPS844 Lube oil pressure 0 to 14 Kg./ cm2
BAP MPS845 Booster air pressure 0 to 3.5 Kg./ cm2
2
FOP MPS846 Fuel Oil pressure 0 to 7 Kg./ cm
EWT MTS 815 Engine Water Temperature -50 to +150 deg C
EOT MTS 815 Lube Oil Temperature -50 to +150 deg C
AAT MTS 815 Ambient Air Temperature -50 to +150 deg C

Annexure – 8
CRIMPING TOOL & CONNECTOR PIN DETAILS
Crimping tool model No : M22520 / 1-01
Make of the tool : Astro Tool Corporation,

21625 S.W. T-V Hwy. Beaverton,
Oregon 97006 USA.
Web Site: .
Approximate price : Rs. 20,000/-.
Crimp type pin details are given below:
S. No. Connector Model Pin Part No. Where used. Cost

1 MS 3108F 16-9S, C30 AEC # 12SKT C30 EWT / EOT cable Rs. 510/-
2 MG 00F 18-10S GP AEC # 12SKT C30 TM speed sensor Rs. 540/-
C30 cable
3 MS 3108F-12SP-10S AEC # 16SSC C30 ESS cable Rs. 342/-
GP C30

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MAINTENANCE INSTRUCTION

Doc No: IM – 53 Rev. 0.0 Print: Sept’ 2008

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008

1. Interconnection diagram of all MEP components Annexure – 1

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008

• Engine and loco propulsion

Control Unit Type MEP 660

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 1

Temperature Sensors Type MTS 815x

3. CONTROL UNIT TYPE MEP 660

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 2

Running maintenance on loco:

S.No. Schedule Nature of attention

3.1. Control Card MEP_CC

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 3

S.No. Schedule Nature of attention

3.2. Control Card MAU_CC

S.No. Schedule Nature of attention

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 4

3.3. Control card MWS_CC

S.No. Schedule Nature of attention

3.4. Digital Input Cards (MDIP16 / MIDIP16)

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 5

S.No. Schedule Nature of attention

3.5. Digital Output Cards (MLSD16 & MHSD16 / MIHSD16)

3.5.1. Medha High Side drive Card MHSD16 / MIHSD16

A list of digital outputs connected to each card, is given in Annexure–5.

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 6

S.No. Schedule Nature of attention

3.6. Analog Input Cards

3.6.1. Medha Analog Input card MAIP8_AU

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 7

3.6.2. Medha Analog Input Card MAIP8_WS

3.6.3. Medha Analog Input card MAIP8_EP

3.6.4. Medha Improved Analog Input card MAIP16 / MIAI

S.No. Schedule Nature of attention

3.7. Medha Frequency Input Card (MFIP16)

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 8

S.No. Schedule Nature of attention

3.8. Medha Pulse Width Modulator Card (MPWM2)

S.No. Schedule Nature of attention

3.9. Medha Excitation and Propulsion - Power Supply Card (MEPPS)

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 9

S.No. Schedule Nature of attention

3.10. Medha Display Unit - MDS 733

Maintenance on locomotive: Ensure tightness of power supply connector and

S.No. Schedule Nature of attention

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 10

S.No. Schedule Nature of attention

Testing and Troubleshooting: ---

‘Excitation And Propulsion Control

After few seconds, the display show:

Press Menu key. The display shows main menu options:

3.11. Analog Distribution Box (ADB) - MDB 701

Doc No. :IM 53 Rev. 0.0 Print: Sept’ 2008 11

Maintenance on locomotive: Ensure tightness of all connector once in M4 schedule.

S.No. Schedule Nature of attention