LOCO TESTING SEQUENCE

S.N. TEST NAME PREPARTI TESTING TIME PAGE

ON TIME No.
01 BATTERY CONNECTION & MACHINE 10MIN 20MIN. 2
ROOM LIGHTING

02 FIR (FIRST INSPECTION REPORT) --- 20 MIN. 3

03 BL KEY OPERATION --- 20MIN. 4
04 PT CONTINUITY TEST 10 MIN 20MIN 5
05 INSULATION RESISTANCE TEST 10 MIN 10MIN 6
(MEGGER TEST)
06 CURRENT SENSOR TRIPPING TEST 15 MIN 15MIN 7
07 MAIN TRANSFORMER POLARITY TEST 8
20MIN
08 MAIN TRANSFORMER TURN RATIO 25MIN 9-10
TEST
09 AUXILIARY TRANSFORMER TURN 10 MIN 10 MIN 11
RATIO TEST
10 SOFTWARE PREPARATION & LOADING 45MIN 90MIN LOADING 12-15
11 HEX ADDRESS SETTING 15 MIN 16-18
12 TRACK TEST 1 HOUR 1.5 HOUR 19-21
13 MVR (MINIMUM VOLTAGE RELAY) 15 MIN 15 MIN 22
TEST
14 MCR (MAXIMUM CURRENT RELAY) 15 MIN 15 MIN 23
TEST
15 BDV TESTING 30MIN 10MIN 24
16 AUXILIARY MACHINE CONTACTOR ------------- 25
SEQUENCE TEST 30 MIN
17 BUR REDUNDANCY TEST ------------ 26

INDEX
 1) Battery Connection & Machine Room Lighting

Purpose of Test Check battery polarity and output

voltage, connection of jumper,
Equipment Tools Required Multi Meter
Man Power Required 2
Duration of Time 15 Min.

Test Procedure

1. Open the cover of each battery box.

2. Check the output voltage of each battery bank with the help of Multi Meter. The output
voltage of each battery bank should be in between 47 v to 55 v. So, total supplied voltage
of battery banks should be in between 94 volt to 110 volt.

3. To check polarity connect +ve probe of multi meter to positive connector of battery box
and -ve probe of Multi Meter to negative connector of battery box. Multi Meter should
shows +ve output voltage.

4. If +ve terminal of Multi Meter connected to the +ve terminal of any battery bank and -ve
terminal of Multi Meter connected to the body of the loco and if volt meter shows current
flow then loco should be said that loco is negatively grounded. If -ve terminal of Multi
Meter connected to the -ve terminal of battery bank and +ve terminal Multi Meter
connected to the body of the loco and Multi Meter shows current flow then loco should
be said that it is positively grounded. It should be noted that loco should neither be +ve
grounded nor be –ve grounded for the safety of man and machine.

5. After the getting proper output voltage, Polarity of battery bank and checking the loco
grounding, connect the both battery banks with help of jumpers and switch on the MCB
112 of battery bank for power supply from battery bank to SB2 PANEL inside loco.

6. Now connect roof couplers for mushroom type switch present near gate of both end
machine room for machine room lighting purpose.

7. Further make control circuit operative by switching ON MCB 112.1 present in SB-2
PANEL.

8. Jumper cable from 112.1 (battery MCB) to 310.4 (Machine room lighting MCB) so light
remains ON irrespective of BL key operation.
9. Next all other MCBs for machine room lighting, driver cab lighting, both cab front
lighting, central electronics etc present in SB/1 and SB/2 Panel are made operative for
various purposes.

2) FIR (First Inspection Report)

Objective of Test To check visually/physically that all loco

items are available, their condition and make.
Equipment Tools Required ----
Man Power Required 2
Duration of Time 30 Min.

Test Procedure

FIR is the physical/visual verification of loco items, which are installed/assembled by

previous assembly shops, that whether the items are assembled or not & whether the items are
in good condition or in damage condition.
1. Visual checking of Under frame items.
2. Leakage of oil and coolant if any.
3. Visual checking of CAB1 and CAB2 items, Machine Room item, connection of
couplers.
4. Note down the make of equipments like Cab items- A,B,C,D,F Panel, Machine Room
items- SB , SR, HB, FB Panel, Transformer.
 3) BL KEY OPERATION

Purpose of Test Check operation if various contactors

in C &D MODE
Equipment Tools Required BL Key
Man Power Required 2
Duration of Time 20Min.

Test Procedure

AIM:- To check the working of different contactors present in SB1 & SB2 in C
Mode, D Mode & Self Mode of BL Key.
PROCEDURE:-Insert the BL Key in Cab 1 & 2 and check the working of
contactors present in SB1 & SB2 as per following table-

BL Key 211 126 126 7/1 or 218 126.6

SB2 SB1 SB-1/2 SB-1 SB-2
126.7/2
D Mode ON ON ON ON ON
C Mode ON ON ON OFF OFF
Self Mode ON ON ON OFF OFF

NAME OF CONTACTORS:-

Sl.
Contactor No. Name
No.
1 211 Relay Temp. CE
2 126 Contactor Control Ckt. ON
3 126.7 Contactor P/Supply Cab
4 218 Contactor CE
5 126.6 Safety Relay CE
6 126.5 Relay CE OFF

CE-CONTROL ELECTRONICS
 4) PT CONTINUITY TEST

Purpose of Test To check Continuity of wiring from

PT output terminal to Load Resister
terminal. And from load resister
terminal to f panel in both cab

Equipment Tools Required Multi Meter

Man Power Required 2
Duration of Time 20min

Test Procedure

PROCEDURE:-
1) Check wire polarity of wire no. 1511 & 1512 coming from output of PT at Load Resister
Box mounted on roof of machine room. Wire No.1511 should be grounded and 1512 will
be corresponding phase supply.
2) Resistance between wire no. 1511 & 1512 should be < 10 Ohm (Not in test procedure,
Acc. to RDSO spec) when load resistance connected across 1511 & 1512 is removed.
3) Load Resistance connected across output of PT i.e. wire no. 1511 & 1512 is 3.9 K Ohms.
(not verified)
4) 1511 & 1512 cable become 1501 & 1502 at PT Junction box. From PT junction box it
goes to SB-1. From SB -1, it goes to 5 locations. (MVR(in SB-1), SR-1, SR-2, CAB-1,
CAB-2)
5) Similarly Check the continuity of wire no. 1501 & 1502 in F panel at coupler no.
332XK86B in CAB2 and 332XK86A in CAB1
 5) INSULATION RESISTANCE TEST(MEGGER TEST)

Purpose of Test CHECK IR value of PT secondary

winding load side
Equipment Tools Required MEGGER
Man Power Required 2
Duration of Time 15min

Test Procedure

AIM:-It is done to test insulation resistance of PT output secondary wire (load side) in
SB 1 Panel with the help of megger.

PROCEDURE:-
1. Terminals of hand driven megger is connected to output of PT wire no. 1501(-ve) &
1502(+ve).

2. Megger set at 500 volt is then hand driven and corresponding value of resistance will
be noted.
 6) CURRENT SENSOR TRIPPING TEST
Purpose of Test To check working of different current
sensors namely Primary Current Sensor,
Harmonic Current Sensor & Auxiliary
Current Sensor without actual high voltage
charging of loco.

Equipment Tools Required DC Supply, Multi Meter, Clamp Meter

Man Power Required 2
Duration of Time 30min

Test Procedure

Procedure-
1. 11 volt DC supply is given to different sensors whose test is to be conducted through
Loop Box.
2. DC supply current is then varied to check the working/tripping of respective current
sensor which is under test.
3. Loco is put under simulation mode i.e. system understands both raising of Pantograph
and closing of VCB contact without happening in actual.
4. i) AA Sub D port present above SR1 panel is for main transformer primary winding
current sensor.
ii) AC Sub D port present above SR1 panel is for Auxiliary Current Sensor.
iii) AE Sub D port present above SR 1 panel is for Harmonic Current Sensor.
Similar ports are also present above SR 2 panel.
5. Loco is put under D Mode, ZPT and BLDJ command is then given. Simultaneously DC
supply from DC source via Loop Box is given to AA Sub D Port at a particular SR.
6. Physically 2 Primary and 2 Harmonic current sensor are present in FB. While Aux
current sensor is present in HB-2
7. DC current supply is then gradually increased after a certain normal value. The high flow
of current will be sensed by primary current sensor which will open the VCB contact and
display the current value on DDU Interface.
8. Same procedure is adopted for auxiliary current sensor and harmonic current sensor
working through respective port AC and AE present on both SR-1 & SR-2 panel.
9. The prescribed value for different current sensors for which the system is tripped are as
follow-

SR1 SR 2
Sensor Ampere Sensor Ampere
AA 320 AA 323
AC 410 AC 405
AE 440 AE 413

7) MAIN TRANSFORMER POLARITY TEST

Purpose of Test To check polarity of secondary output

voltage of main transformer without
actual high voltage charging of loco.
Equipment Tools Required Multi Meter, oscilloscope
Man Power Required 2
Duration of Time 20min

Test Procedure

Aim:- To check polarity of secondary output voltage of main transformer without actual high
voltage charging of loco.
Procedure:-
1. Low voltage AC supply (140 Volt) through Variac is given to Power Supply Incoming of
VCB at roof.
2. This will charge the primary winding of the main transformer and the return current will pass
through carbon brushes mounted on respective axle to the ground.
3. For checking polarity of different secondary output voltage of main transformer oscilloscope
is used.
4. Phase and neutral supply is given as input supply to one probe of oscilloscope and another
probe of oscilloscope used as output is attached to different secondary winding connections
provided in SR 1,SR 2, BUR 1, BUR 2 & 3 and Harmonic Winding in FB Panel.
5. To check polarity of output voltage with reference to input voltage at SR 1 phase supply is
given to 2U1 &2U4 and neutral to 2V1 & 2V4 respectively in step wise manner.
6. Similarly for SR 2 phase supply is given to 2U2 &2U3 and neutral to 2V2 & 2V3
respectively in step wise manner.
7. If the output voltage polarity is same as input voltage polarity then the input voltage sin
wave and output voltage sin wave will be displayed in same phase in the oscilloscope.
8. Similarly polarity of output voltages of BUR 1, BUR 2 & BUR 3 is tested by connecting
phase supply of probe of oscilloscope to 1103 and neutral to 1117 both input and output sin
wave will be displayed in the same phase of the oscilloscope. If the output voltage polarity
conforms to input voltage polarity.
9. Similarly polarity of output voltages of Harmonic Filter Winding present in FB Panel is
tested by connecting phase supply of probe of oscilloscope to 4 no. cable and neutral to 12
no. cable.Both input and output sin wave will be displayed in the same phase on the
oscilloscope if the output voltage polarity conforms to input voltage polarity.
 NOTE:- If connections in the SR 1, SR 2, BUR 1, BUR 2, BUR 3 & Harmonic Filter
Winding reversed then sin wave will also be out of phase with respect to input sin
wave.

8) MAIN TRANSFORMER TURN RATIO TEST

Purpose of Test To check output voltage of Main

Transformer secondary windings so as
to ensure the proper turn ratio of main
transformer.
Equip Multi Meter, variac, supply wire
ment Tools Required
Man Power Required 2
Duration of Time 20min

Test Procedure

1.The same setup is used in this test as earlier done in Polarity Test(Input supply through Variac
will be same 140 Volt).

2. Additionally a Multi Meter is connected with output probe of Oscilloscope by which different
secondary output voltages of Main Transformer is measured along with Polarity Wave form being
displayed on the Oscilloscope.

The following reading of output voltage is measured on Multi Meter to ensure the proper
turn ratio of main transformer is furnished below-

SL. Component Input Measured Standard Remarks

No. Voltage Output Output
Voltage(RMS) Voltage
1 SR 1 & SR 2 140 7.1 7.1 OK
2 BUR 1, BUR 2&3 140 5.6 5.6 OK
3 Harmonic Filter 140 6.5 6.5 OK
Winding

NOTE:-Turn Ratio is calculated by following methods-

Actual Operating Input Voltage(OHE Voltage)=25 KV
Standard Output Voltage of SR 1 & 2=1269 V
For any Transformer,
Output Voltage of secondary winding(V2) = No. of coil turns in secondary winding(N2) = K (Constant)
Input Voltage of Primary Winding(V1) No. of coil turns in primary winding(N1)
1269 =0.05076 (Constant)
25000
So, If input voltage is 140 V then
V2 = 0.05076
140
V2 = 0.05076 X140
V2=7.1
Therefore, if we give 140 input voltage in primary winding we will get 7.1 volt output
voltage from secondary winding. Which is measured by conducting this test.

NOTE:- Standard Output voltage of BUR1, BUR 2 & BUR 3 is 1000 V and Harmonic Filter
Winding is 1154 V. Output voltage of these will be measured by same method. For which
corresponding input voltage is same 140 V.
 9) AUXILIARY TRANSFORMER TURN RATIO TEST

Purpose of Test To check Turn Ratio of Auxiliary

Transformer
Equipment Tools Required Variac, Multi Meter
Man Power Required 2
Duration of Time 15 Min.

Procedure:-
1. Auxiliary Transformer is present behind HB1 panel with input supply at 1000v and it
Gives rated output voltage at 415/110 Volt used for cab heater and fans.
2.Under low voltage test the output of auxiliary transformer is checked by giving low voltage
input supply.
3. Apply 100 V to input of the auxiliary transformer at cable no 1203-1117 and output is
measured at

Description of wire Prescribed Output Voltage Measured Output

no.
Cable No. 1218-1200 41.5 VRMS
Cable 1218-6500 11.0 VRMS
 10) SOFTWARE PREPARATION & LOADING

Purpose of Test Load company software (Alstom) in

propulsion system
Equipment Tools Required Ethernet cable , laptop with software
to be installed
Man Power Required SSE, with 2 staff
Duration of Time 1hrs for preparation and 1.5 hrs for
loading

Test Procedure

All Sub-Ds of SR 1 & SR 2 as well as VCU 1 & VCU 2 are applied in respective Sub-D port
for the further process of Software loading in components like SR1, SR2, BUR1, BUR2,
BUR3, VCU 1, VCU2, DDU1, DDU2.
Following voltage supply in corresponding pin of different component are checked as per
following chart-
 SOFTWARE LOADING IN ALSTOM(BT) LOCO

BT Software Loading
CCON- Traction Converter Software loading
1. Double click on file IRPRP _set_CCON_1.0.4.7
2. For Traction Converter-1
3. DCU2L_SPIF1>>>Right Click>>>Connection Check
4. Top 2 files >>>Right Click>>>Download Single
5. DCU2L_SPIF1>>>Right Click>>>Configure CPU>>>Format file system>>>press YES
6. DCU2L_SPIF1>>>Right Click>>>Download Selected
Same Procedure for DCU2_M-1, DCU2_M-2, DCU2_M-3, DCU2L_SPIF2, DCU2_M-4, DCU2_M-5,
DCU2_M-6, TCNGW
CCUO TCNGW VCU Software loading
1. Double click on file IRPRPSET_TCMS_1.6.8.25
2. VCU1 >>>Right Click>>>Connection Check
3. VCU1 >>>Right Click>>>Configure CPU>>> Erase All (BL Key should not be off)
4. Top 2 files>>>Right Click>>>Download Single
5. VCU1 >>>Right Click>>>Configure CPU>>>Format File System>>>press YES
6. Select from bottom 4rd file for WAP7
7. Select from bottom 8rd file for WAG9H
8. VCU1 >>>Right Click>>>Download Selected
Same Procedure for VCU2

HMI 4G- DDU Software loading

On Display Screen-

1. DDU Password- 8529

2. IP Mode- Select Fixed IP
3. IP Address- 10.0.0.200 for Cab-1 and 10.0.0.201 for Cab-2
4. Subnet Mask- 255.255.240.0
5. Gateway- 10.0.0.1
6. Device Coding- 1 for Cab-1 & 2 for Cab-2
7. Reboot
8. Reboot Now
9. Again Enter DDU Password-8529

Software Loading through Laptop-

1. Double click on file HMI NEW SW DL2 IR PRPSET

2. HMI Cab-1>>>Right Click>>>Connection Check
3. Fsovl_rootfsext>>>Right Click>>>Download Single
4. Open Google Chrome
5. Enter 10.0.0.200 for Cab-1 & 10.0.0.201 for Cab-2
6. User Name- admin
7. Password- eiWEB press Login
8. Select Software->>> Select Software Update>>> Choose file
9. HMI 4G>>>new_SW_4G_2_6_9_0_21_oct_2019.tar>>>open>>>Update eiCAB

Time Setting in DDU

1. Select DCU term

2. Time_set space 23(year)space 09(month)space 30(date)space 19(Hrs)space 05(min)space 20(second)
3. Enter
 4. Password-css
5. Enter

HEX Address Setting only in SR-2

MIO-1 Card and MIO-2 Card

1. BL Key OFF position in S2 nob move between B & D

2. BL Key ON position in S3 nob move EMD to Set
3. Wait for 10 Second
4. In S3 nob move Set to CON
5. Wait for 30 Second
6. In S3 nob move CON to EMD
7. BL Key OFF- ON

Software loading in following devices

(1) line converter and motor via CCON folder

Traction converter 1 Traction converter 2

DCU2L_SPIF1 DCU2_M1 DCU2L_SPIF2 DCU2_M4
DCU2_M2 DCU2_M5
DCU2_M3 DCU2_M6

(2) CCUO_TCNGW_1391
(For VCU sft. loading)

VCU1 VCU2
TCNGetway
(3) HMI4G -DDU Software loading
(it is in VCU folder but Steps
will same as motor
Cab 1 Cab 2
M1,M2,M3,M4,M5,M6)

(4) CAB Software loading (software updating via Google chrome tab)

Cab 1 Cab 2
 (5) HEX ADDRESS setting (in SR2)
(6) DATE AND TIME SETTING.
Note :-At end get the confirmation for proper SOFTWARE loading, HEX setting and
DATE & TIME setting in DDU.
 11) HEX ADDRESS SETTING

Purpose of Test Set hex address at SR PANEL

Equipment Tools Required Screw driver
Man Power Required 1
Duration of Time 15min

Test Procedure
In SR2 2 nos MIODX fitted, MIODX 1, MIODX 2 (Only SR 2 needs for HEX ADDRESS setting)

Individually setting to be done for each MIODX .

S3, S2, are only used for Hex address setting

Position of nob.

Steps for HEX setting

( Follow steps for miodx1 & miodx2 individually )

1. Place the screw Driver on nob of S3 and move the arrow from EMD to SET

2. Move S2 arrow and set in between B & D

3. Now come to S3 arrow, move the arrow from SET to CON

4. And wait for 30 sec

5. Move S3 arrow from CON to EMD

6. BL key OFF –ON

7. Again repeat step 1 ,3 ,4 , 5 & 6.

(No need to touch S2 during repeat steps)

 12) TRACK TEST

Purpose of Test Perform various test with certain

condition during loco movement and
also check working and direction of
rotation of traction motors and
different blowers.
Equipment Tools Required --------
Man Power Required 2
Duration of Time 2hrs

Test Procedure

AIM:- This test is done with certain condition during loco movement.

PROCEDURE:-
After air brake test ok, following step done during track test

1 -Ensure A9 and SA9 brake application and release operation physically.

2 -Put reverser in any direction for DCL charging with both SR (NODE 590), DCL voltage will develop
about 1850 Volt

3- For traction move throttle handle towards TE slightly for checking Node 596 on DDU and release air
brake (SA9) observe TM direction and speed as per reverser operation with both bogies.

I- Ensure all TM rotation (On DDU) should be in same direction as per reverser operation.

II-Ensure all TM temperature (On DDU) are ok.

III- Ensure all TE of TM are accordance to its reference TE (On DDU).

4 - Check loco movement in both direction from both cabs.

5. Check regenerative brake in both direction from both cabs.

6. BPCS operation (situated at A panel, Loco constant speed operation) at loco speed 5 kmph or more
than this. Then push BPCS sw. what speed is showing on DDU (more than 5kmph). Do not operate
throttle handle in this condition.

7. Check VCD operation as following:

I -All pressure charge BC at zero condition. And BC#1&2 release icon should be green at DDU.

II -Move loco more than 1.5 kmph speed for 60 sec. Without operating throttle, SA9 and PVEF
 a. First warning indication (LSVW at A panel) for 8 sec will glow.
b. After that audible (buzzer) signal with warning lamp noticed for another 8 sec and
penalty brake applied if not acknowledge by Vigilance foot switch. Vigilance brake
applied message at DDU and auto flasher will operate.
c. Put throttle in neutral or zero position.
d. After 120 sec vigilance brake application reset sw. (BPVR) on A panel.
e. Acknowledge can be done by foot switch Vigilance if throttle movement more than 3%
or applied A9 brake.
f. If acknowledge done within 60 sec. (after LSVW blinking) vigilance timing will increase
next 60 sec.

8. Check ACP operation -move loco at yard speed and slowly open emergency cock, BP start leaking (up
to 3.5 kg per sq.cm) and air flow indication in Air flow gauge at B panel indicated sufficient flow. Alarm
chain pulling message will come at DDU with audible signal buzzer and auto flasher will also operate.

9- Inching mode- (Applicable for WAG9 only)

I -Put ZTEL sw. at A panel in ON condition.

II -Open MENU at DDU of inching mode and set speed at 1.5 kmph.

III -Also put reverser handle in any direction.

IV -Loco speed restricted to preset value i.e. 1.5 kmph.

V- Do not operate throttle handle during inching mode test.

10 -Configuration mode (configuration rotary switch situated in SB1 panel)

I- First operate rotary switch in configuration mode in SB1 panel.

II -BL key operate in D mode, charge the loco.

III -Move the loco and ensure for message at DDU as shunting mode with loco speed not more
than 15 kmph ir-respective of throttle position.

11- Failure mode (rotary switch situated in SB 1 panel)

I Put loco in OFF condition (not active) and remove 150.B sub D connector of angle transmitter
(Master controller)

II Loco operate in D mode and charge the loco. Put reverser in any direction with operate throttle
towards TE up to max, found angle transmitter failed message at DDU.

III De-energies the loco and operate failure mode rotary switch at SB1. Charge the loco and move
to any direction, TE will increase stepwise i.e. 1/3, 2/3 and so on.

12 Bogie cut out operation (Rotary switch situated at SB 1)

I. Operate rotary switch for bogie 1 cutout position at SB1.

 II. BL key operate in D mode and ensure bogie 1 cutout message and also icon highlighted
in DDU
III. Charge the loco and ensure DCL should charge with SR2 (traction converter) only.
IV. Move the loco and ensure TE generate of TM4,5,6 (SR2) on DDU only.
V. Same process follows for Bogie 2 cutout. DCL charged by SR1 only and TE will
generate for TM1,2,3.

13. VCD cut out sw. operation (Rotary sw. on SB1)- If VCD fail and restrict loco movement then operate
VCD rotary sw. in off position

14 -Individual TM operation for BT propulsion

I. Cut any SR with cutout rotary switch in SB1 and another SR, 2 no TM temperature
sensor sub-D remove at SR end.
II. Now 1 TM is in operation in forward or reverse direction and check another TM like that.

For MEDHA/BHEL propulsion

I. Loco put in D mode and cut out the 5 no TM by processor at DDU menu
II. Charge the loco and single TM operation in both directions.
III. Again, same process for another rest TM operation.

15. Emergency switch operation at A panel

i. Charge the loco and move loco at yard speed.

ii. Operate emergency switch at A panel and ensure panto and VCB will be OFF with
emergency stop shut down on the loco showing message at DDU.
iii. BP will drop and BC (Brakes)are applied.

16. Deadman operation

i. Vigilance foot switch press continuously during loco running operation up to 60sec.
ii. Ensure VCD will come and brake applied.

17. Throttle stall test

1. For gripping of brake shoe initially put TE up to 50KN gradually with full air brake,
if loco start to move then put throttle in zero position. Again, increase TE 70KN, then
repeat this step up to 125KN.

2.Ensure loco will not move up to 125KN (TE) with full mechanical brake applied
condition.

18. Wheel diameter setting- Setting done at DDU and speedometer (Cab 2) at 1092 mm for new wheel.

19. Max speed limit setting- done in speed recorder unit in cab2

i. WAG9-100kmph WAP7-140kmph
 13) MVR (MINIMUM VOLTAGE RELAY) TEST

Purpose of Test check the operation of minimum voltage

relay present in SB1 Panel
Equipment Tools Required Variac ,multimeter
Man Power Required 2
Duration of Time 30min

Test Procedure
PROCEDURE:-
1) Activate loco in cooling mode i.e. C Mode.
2) select simulation mode through DDU so that system understands itself being connected to OHE
supply whenever its given command to do so.
2) Check power supply of 48 V DC to minimum Voltage Relay.
3) Disconnect wire no 1511 & 1512 from Load Resistor of PT present in Load Resistor Box.
4) Disconnect wire no 1501 (Phase) & 1502(Neutral) from Load Resistor of PT present in Load
Resistor Box and connect Phase and Neutral of Variac Cable to corresponding wire no.1501 &
1502 respectively.
5)supply 200V through variac in this case MVR picks up and contactor 218 does not close and
Central electronics will not work
5) Then ZPT and BLDJ command is given through A PANEL in driver cab so that system
understand that Panto is raised and VCB is closed.
6)supply 200V through variac to wire no 1501&1502 c
7) When gradually voltage is dropped gradually through Variac below 140 voltage then MVR
operates, Panto down and VCB goes off after 2 second time delay.

NOTE:- 1) MVR Test is done in “C” Mode.

2) Monitoring of under voltage (OHE) under “D” Mode is done from SR1 & SR2.
 14) MCR (MAXIMUM CURRENT RELAY) TEST

Purpose of Test check the operation of maximum current

relay present in SB1 Panel
Equipment Tools Required Variac,multimeter, clamp meter
Man Power Required 2
Duration of Time 30min

Test Procedure
AIM:-This test is done to check the operation of maximum current relay present in SB1 Panel.
PROCEDURE:-
1) For safe operation of electric locomotive the maximum current should not raise above 360
ampere.
2) Disconnect wire 1521&1522 of primary current transformer and connect it to variac
3) Now loco is put under simulation mode and ZPT BLDJ COMMAND is given from driver
cab.
4) Now gradually increase current supply through variac and measure same with help of
clamp meter.
5) Since CT of ratio 1/100 is used in the locomotive so that the current when reaches to value
of 3.6A given through external supply will now operate the MCR which in turn will open
the contact of VCB and system will isolate itself.

NOTE: 1) This test is done under both C and D MODE.

2) THE LOCO IS PUT UNDER SIMULATION MODE ( SYSTEM FALSELY
UNDERSTAND ITSELF CONNECTED TO OHE) AS THIS TEST IS DONE
UNDER LV CONDITION I.E. WITHOUT ACTUAL CHARGING OF LOCO.
 15) BDV TESTING

Purpose of Test To check Breakdown voltage of main

transformer oil
Equipment Tools Required BDV MACHINE, glass Jar
Man Power Required 1
Duration of Time 45min

Test Procedure
AIM:-Breakdown voltage of main transformer oil is checked in this test before sending loco
HV charging. Transformer oil are designed to operate effectively at very high
temperature. So, it is necessary to check their insulating property and dielectric
strength.
PROCEDURE:-1) Collect 300-400 ml oil sample of main transformer from bottom valve of
the transformer in a glass vessel.
2) Before pouring oil in oil pot of BDV machine it should properly cleaned and
flushed thoroughly with transformer oil to be tested.
3) Pour the oil sample in oil pot of BDV Testing Machine.
4) Keep the oil pot in open air for 30 min. so that air bubble if any get out.
Follow the steps as under for BDV testing.
a) Switch on the power supply of BDV machine.
b) On display of machine ENTER the password as 11111.
c) Press Enter button against break down voltage test menu.
d) Press Enter button against standard test menu.
e) Press Enter button against test time 5 min.
f) Press Start button for BDV test.
After 1 min. BDV reading will be shown on display and further after
interval of 30 sec each two more reading will appear on display.
At last final BDV average reading will be shown on display.
NOTE:-
1) Before pouring transformer oil in oil pot of BDV machine both electrode
gap should be checked for 2.5mm with the help of GO/NOGO Gauge.
2) New transformer oil BDV value should not be less than 60 KV.
 16) AUXILIARY MACHINE CONTACTOR SEQUENCE TEST

Purpose of Test The sequence of operation of BUR

Contactors for different condition is
checked.
Equipment Tools Required ----
Man Power Required 2
Duration of Time 20 Min.

Test Procedure
Procedure:- Following BUR condition

1) All BUR OK

2) BUR 1 OUT

3) BUR 2 OUT & BUR 3 OUT

Has to be verified by putting the loco in driving mode and isolating the BURs one by one by giving the
command on DDU. Contactor status of BUR 1, 2 & 3 is furnished below-
 17) BUR REDUNDANCY TEST

Purpose of Test Performance of BURs when one BUR goes

out.
Equipment Tools Required ----
Man Power Required 2
Duration of Time 20 Min.
Procedure:-When any BUR goes out then rest of the two BURs should take
the load of all auxiliaries as shown in table-

Condition of Load on BUR 1 Load on BUR 2 Load on BUR 3

BURs
All BURs OK Oil Cooling Unit 1 TM Blower 1& 2, Compressor 1& 2,
&2 TFP Oil Pump Battery Charger,
1&2, SR Coolant TM Scavenger
Pump 1&2 Blower 1& 2
BUR 1 out ----- Oil Cooling Unit Compressor 1& 2,
1& 2, TM Blower TFP Oil Pump
1 & 2, TM 1&2, SR Coolant
Scavenger Blower Pump 1&2 and
1& 2 Battery Charger
BUR 2 out Oil Cooling Unit 1 ------ Compressor 1& 2,
&2, TM Blower TFP Oil Pump
1& 2,TM 1&2, SR Coolant
Scavenger Blower Pump 1&2 and
1& 2 Battery Charger
BUR 3 out Oil Cooling Unit 1 Compressor 1& 2, ---------
&2, TM Blower TFP Oil Pump
1& 2,TM 1&2, SR Coolant
Scavenger Blower Pump 1&2 and
1& 2 Battery Charger
 FIRST HV CHARGING PREPARATION AND ROOF INSPECTION

After completion of LV Testing loco is made ready for its first HV CHARGING
i.e. before being placed under OHE for first time.

1. Loco roof is being inspected physically for well being of all components
mounted on roof.

2. The loco earth switch mounted on roof must en-gage and dis-engage properly
when operated from handle present inside locomotive.

3. The electrical grounding of VCB,CT,PT, through wire on roof must be properly

Fitted .

4. NO any foreign material ,leftover like plastic tie, rope ,hardboard etc should be
present on roof.

5.LOCO must also be inspected properly from inside during its first charging
preparation.

6.ALL high voltage cabinets of SR AND BURs must be closed properly, earth
Grounding wire wherever present must be properly connected to floor and secured.

7. Any leftover boxes or covers opened during LV testing must be closed properly.

8.BDV(break down voltage ) as well as DGA(Dissolved gas analysis done by

CMT LAB) must be carried out before 1st HV charging.

9.Transformer as well as SR oil coolant level should be upto mark as indicated

outside.

10.Earth return brush mounted in respective axles serving as a path of return

current for primary winding of main transformer should be checked by opening
box for their intactness.

11.ERB to rail resistance is .3ohm max and rail to wheel is 0 ohm.

 HVAC (AIR CONDITIONER ) TESTING.

1) CAB HVAC 2.0 TR is provided in both cabs for air conditioning purpose.
2) only one cab AC operates at a time.
3) Contactor 52.5/1 present in HB2 Panel must pickup for HVAC to operate which
operates only when All BURs are healthy and ok.
4) Internal supply cab AC layout is as follows.

1000V 3PHASE AC CONTACTOR 52.5/1 CIRCUIT BREAKER

SUPPLY FROM BUR-2 FOR CAB AC 64.1 IN
PRESENT IN HB-2 HB/2
MUST PICK UP

CHANGE OVER SWITCH ( 3 POLE DOUBLE AC CONTACTOR 52.7

THROW) FOR CAB SELECTION
IN HB/2
1.COUPLER XK67AC CAB1 FOR CAB1 AC

2.COUPLER XK67AC CAB2 FOR CAB2 AC

Respective AC CONTROL PANEL IN CAB/1 AND

CAB/2

4) AC operation and its effective cooling is checked in respective cabs.

5) mode of operation of ac unit is selected with help of selector switch present

On indication panel i.e. OFF AUTO MANUAL

6) In case of low pressure /high pressure trip AC UNIT system will show fault with
LED indication on switching/indication panel and compressor will be shut off.

7)for low pressure trip fault the refrigent problem maybe suspected and in case of

HP TRIP FAULT condenser failure may be suspected.

8)sometimes it is noticed that direction of rotation of blower motor is opposite to

that designed. To overcome this phase sequence of supply to blower motor is
reversed.

FIRST HIGH VOLTAGE CHARGING OF LOCO

1)During this act loco is placed under OHE for first time, certain necessary
conditions are checked and tested so that loco may proceed for further activity.

2)Loco is first charged in C Mode( no load transformer charging).

3) All safety operations like pantograph operation, VCB operation,BL key,

Emergency push button are checked for there proper working from both

Driver cab.

4)Both cab ventilation, crew fan working is also checked.

5) Now loco is charged under D Mode .

6) Again all safety operation mentioned above are checked from both cabs.

7)Transformer oil pump and coolant pressure are checked.

8)both MRB(MACHINE ROOM BLOWER) and their scavenge motor operations

are checked.

9)both TMB(TRACTION MOTOR BLOWER) and their respective scavenge

motor operation and direction of rotation is checked.

10)Working of both main compressors and direction of rotation is checked.

11) both OCB (Oil cooling blower ) direction of rotation is checked .

12)contactor sequence and BUR redundancy is checked.

13) working of all earth fault relays like auxiliary winding, harmonic filter , control
circuit earth fault are checked.

Pantograph test and calibration

1) During this test functional working of pantograph is done as well as it is
calibrated to work at different heights with certain load conditions.

2) this test is done in non OHE condition to ensure proper working of pantograph
during first charging condition and so on.

3) For conventional type pantograph normal rise and fall of pantograph should be
between 6 to 10 seconds.

3.1) Max height is 2 Mt and min height is 0.5 Mt. Sarvo motor output pressure is
4.5 Kg/cm2.

4) For high reach pantograph normal rise and fall of pantograph should be
between 6 to 15 seconds

5) Conventional type pantograph is calibrated at different heights with a static load

of 7kg attached at middle of carbon or current collector strip so as to simulate the
pantograph under dynamic condition with tension force of OHE over it.

In conventional type, there is throttle for pressure control. Output of throttle is 4.5
Kg/cm2 in Sarvo motor. In high reach, panto is raised by pneumatic pressure,
while in conventional panto, it is raised by spring tension. In shop, spring tension is
adjusted so that balancing on 7 Kg weight.

HEIGHT WEIGHT OF STATIC LOAD

1. 2.0 M 7KG
2. 1.75M 7KG
3. 1.50M 7KG
4. 1.0M 7KG
5. 0.5M 7KG

NOTE:- 1)The pantograph should be stable at these heights with static load
being attached to it. The pantograph should NOT move up OR down in these
conditions.

2) In case of conventional pantograph if it moves UP calibration process then

Tension should be increased in both supporting springs of pantograph so as to

hold it back and vice-versa.
HIGH REACH PANTOGRAPH
1) Maximum reach of high reach pantograph is 3600mm and working range lies
between 150mm-3450mm.

Same calibration and testing process is used for high reach pantograph. The only
difference is that since this pantograph is pneumatically controlled a device known
as Pneumatic control unit (PCU) present inside loco is used for this purpose.
Input pressure in PCU is from MR (8-10 Kg/cm2) and output is fixed 5 Kg/cm2.
There is a Over Rise Device (ORD) which lower Panto if Panto goes above
3600mm. Once ORD operated, it can only be reset from roof only. & Kg weight is
used in testing for force balancing

Hotel load Operation:

On Pin 7 of IV coupler, 110 volt is given from UIC pin. Then ON the BLHO key.
On Hotel load display, it will show Output 750 Volt.

PTDC: If electrical brake fail i.e. A-9, SA-9. Then PTDC help in charging BP

BP& FP: Through BP or FP pipe, Directly loco MR to all Coaches air flow.

PVEF: Loco brake gets release but coaches brake remains. In this case BC=0,
BP=3.5. It is useful on gradient when loco is moving but rest coaches have brake
applied. Think like scooty on slope, front brake is released but rear brake is
applied.

SR1-2 coolant level (combined 250 Lt), Top up coolant nearly 5-10 Lt (needed
because filled coolant flows in pipes so level decreased)

FDU: Fire detection unit. Here smoke is sucked and dust on optical sensor glass
tell either smoke or Fire. There are small holes throughout pipe. For testing fire on
page put near pipe holes.
Brake Application:

SA-9 (Direct brake): Only Loco brake

Two mode: 1- Run, 2- Release

Brake: BP= 5 BC=3.5

RELEASE: BP= 5 BC=0

A-9 (Auto brake): Loco + Coaches

Knorr:- 5 Mode (Release, Run, Minimum, Full Speed, Emergency)

Favely:- 6 Mode (Knorr+ Neutral{deactivate A-9, handle wont move})

Release: BP=5.5 BC= 0

Run: BP=5 BC= 0

Min: BP=4.6 BC= .4-.5

FS: BP=3.4 BC= 2.5

Emergency: BP=0 BC= 2.5

TM Boot: Small particles/chips may be present initially in TMB duct which can go
to TM stator winding via TMB operation. Hence TM boot is applied after Blower
application.

Pressure build up time:

Aux compressor: 1 min 30 second (0-8 kg/cm2)

MCP-1: 6 min 30 second (0-10 kg/cm2)

MCP-2 6 min 30 second (0-10 kg/cm2)

MCP-1 & MCP-2 3 minute 15 second (0-10 kg/cm2)

MCP 1&2 Safety valve working (11.5+-.35)

MR Safety valve working (10.7+-.3)

Compressor run automatically to maintain MR 8-10 Kg/cm2. BLCP key in A panel

helps in checking safety valve. By BLCP, pressure will keep on increasing beyond
10 Kg/cm2 and we can check safety valve functioning

There are 5 Pressure switch

1- Low MR (5.6-6.4) At low MR, traction not allowed

2- MR (8-10) Compressor 1&2
3- MR (8-10) Compressor 1&2
4- BC-1 (.65+-.15)
5- BC-2 (.65+-.15)

MREQ: Main reservoir Equalizer pipe for safety work. If train parting, MR will
not go below 5 so that brake can be applied.

Below MR= 5 FP wont charge & Horn wont work, FP will start charging only
when MR goes above 5.