MEDHA MEMU

MTC, Kurla
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ABBREVIATIONS

1.1 Abbreviation

Abbreviation Description
ACU Auxiliary converter Unit
ADC Analog to Digital Converter
ATC Auxiliary Traction Converter
AWS Automatic Warning System
BC Brake Cylinder
BCP Brake Cylinder Pressure
BCU Brake Control Unit
BD/BN Battery Direct / Battery Normal
BE Braking effort
CAN Controlled Area Network
CCC Central Control Computer (Part of CCU)
CCU Central Control Unit
DC Direct Current
DCS Key Driver control Switch Key
DE Driving End
DIP Digital Input
DOP Digital Output
DPRAM Dual Port Random Access Memory
DMC Driver Motor Coach
DSP Digital Signal Processor
DDU Driver Display Unit
EBL Emergency Brake Loop
ECN Ethernet Consist Network
ED Electro Dynamic
EEPROM Electrically erasable and programmable memory
EOL Emergency Off Loop
EP Electro Pneumatic
ETB Ethernet Train Backbone
FDP Fault Data Pack
HWTL Hard Wired Train Line
LC Line Converter
LIC Line Inverter Computer
LTC Unit Line Traction Converter Unit
MCB Miniature Circuit Breaker
MCH Master Control Handle
MCC Main Control Computer
MCU Main Control Unit
MEMU Main Line Electrical Multiple Unit
MU Multiple Unit
NVRAM Non-Volatile Random-Access Memory
PCC Passenger comfort computer
PLL Phase Locked Loop
PWM Pulse Width Modulation
RAM Random Access Memory
RDM Rescue Drive Mode
ERMS EMU Remote Monitoring System
RPM Revolution per Minute
SRAM Static Random-Access Memory
TC Trailer Coach
TE Tractive Effort
TI Traction Inverter
TIC Traction Inverter Computer
TM Traction Motor
USB Universal Serial Bus
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 SYSTEM OVERVIEW

One basic unit of 4-car unit is the building block for MEMU rake formation. Each basic unit consists of
one Driving Motor Coach (DMC) at the end and remaining 3 coaches are Trailer Coach (TC).

Two to three such basic units can be coupled together to form MEMU rakes of 8 and 12 cars.

|-----------------------------BASIC UNIT----------------|-----------------------BASIC UNIT ---------------------- |

2.1 DRIVER MOTOR COACH (DMC)

 Driving Motor Coach (DMC) is a powered vehicle with one Traction Motor driving each axle.
 High Tension (HT) Compartment (for propulsion equipment) and
 Driver cab at one end and passenger saloon area is at other side.
 Driver cab is furnished with a pre-fabricated driver desk.
 All driving operations are possible from this driver desk, and feedback from all systems in all the
coaches/ basic units is available for viewing by the loco pilot on the driver desk.
 In this regard MCU aggregates all the information from all coaches and a 10.4” Touch Based TFT
display is provided for showing this information to the driver.
 Further an illuminated indication panel is provided for important driving related information for easy
viewing by the driver.
 Various gauges are also provided for driver viewing.
 The driver will also be able to control the Passenger Information System from the Driver Desk.
 The HT compartment consists of Traction Converter, Auxiliary Converter and other ancillary
equipment. On the roof of the HT compartment, there is a pantograph, Vacuum Circuit Breaker and
other ancillary equipment.
 Traction Transformer is under-slung mounted on the Motor Coach. Battery box and compressor are
also mounted underslung.
 Rest of the DMC apart from the Driver cab, HT compartment is Passenger saloon area. The
Passenger saloon area will be similar to Trailer Coach except for the space occupied by Driver Cab,
HT compartment.

2.2 TRAILER COACH (TC)

 Trailer Coach (TC) is a non-powered vehicle with only a Passenger saloon area.
 The Passenger saloon area will have lights, fans, emergency lights and Passenger Information
System consisting of LED displays, and speakers (for announcements).

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 TECHNICAL FEATURES

3.1 Following technical features are provided in MEMU.

• Use of 3- ph drive with air cooled IGBT based converter-inverters and maintenance
free & high power squirrel cage induction motors.
• Microprocessor based control system with built-in fault diagnostics for smoother control,
facilitating trouble shooting and easy maintenance.
• Inclusion of ADD (Automatic Drop Device) and ODD (Overreach Detection
Device) in pantograph to prevent damage to OHE and Pantograph. In case of
unusual, indication of fault as detected by ADD/ODD is provided on DDU.
• Train wide Ethernet communication between various control system for centralized
system configuration and data downloading.
• Frequency generator unit to drive the rake with full power in case of failure of
complete communication.
• Downloading of diagnostic data of TCMS through ERMS (EMU Remote Monitoring
system).
• Redundancy in communication bus is provided through WTB at train level & MVB
at unit level.
• There are four modes of working – Normal / Override (High priority) / Spl.RDM/
RDM.
• DDU is touch screen type.
• Provision of Air Spring failure indication on DDU & on the driver’s desk.
• DDU works in ON, OFF mode in both cabs. Commands from DDU cannot be
given when DCS is OFF.
• Control of Head Code through PIS from Guard’s compartment only.
• Unit numbering on DDU from CCG end in 8 car rake is Basic Unit 1, Basic Unit 4.
• Parking Brakes get applied automatically when DCS is Switch OFF and get released
when speed of the train is more than 10Kmph.
• Provision of 110V DC operated electric hooter.
• Selected actions/trouble shooting like isolation of one coach/one-unit EP brake
binding, Main Air Compressor (MAC) control, releasing Holding Brakes, BU isolation,
Bogie isolation, Panto/VCB setting, PB Override, Air Spring Override,
Light/Fan/Ventilation control, etc, can be done by giving command from HMI (DDU).
• Isolation of Basic Units is possible in Override mode also.
• Reduced Auxiliary Power (RAP) is a function by which 100 % Passenger Lights are
available even if only two Motor Coaches are working and 50% passengers’ lights
are available when only one Motor Coach is available in a 12 Car rake.
• Provision of LED based cab spot light, cab emergency light and step light for
ladder.
• Provision of energy efficient 18-Watt LED lights in place of 36-Watt Fluorescent
light in saloon area.
• Oil free compressor for less maintenance.
• Modular end wall control panels with user- friendly locks
• Provision of LED based Cab Spot Light and Emergency Light

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3.2 TECHNICAL DATA

SL
NO. PARAMETERS DESCRIPTION
1. Series 6000
2. Operating Voltage 25 KV AC
3. Operating system MAE675M -TCMS
4. Driver’s display DDU with touch screen
5. Rating of TM 268KW, 6 Pole, 1195V/175A, 71 Htz.
6. Rating of Main Transformer 1250 KVA
7. Primary / Sec. Voltage 22.5KV / 2 x 855V
1200KVA,
1800 V DC to 3Ph 1100 V to
1. 3ph 415 V
8. Auxiliary Supply
2. 1ph 3x110 V
3. 3ph110V to BC
BC- 110 V DC
1300 KVA,
9 Line Traction Converter Rating Input - 627V-1140V
Output – 3Ph 1430 V, 2x460A, 0-160Htz.
10 Gear Ratio 123/19(4.478)
Train control and
11 communication WTB at train level & MVB at unit level.
By push buttons. PB apply automatically
12 Parking Brake control when DCS is OFF and release
automatically at speeds above 10 Kmph.
13 Train Speed selection In cruise mode.
Through ERMS & Ethernet cable
14 Data downloading
connection.
15 GTO / IGBT / Diode cooling Forced air cooling
Unmanned Brakes when DCS
16 is OFF 1.2 Kg/cm2.
Release in traction mode as well as from
17 Holding Brake of 0.8Kg/sq.cm
DDU
18 Air Spring failure indication Provided
19 Max. speed in RDM 60Kmph.
Can be done from DDU as well as Switch
20 Single Unit operation
provided in EEC panel of CRW panel.
WBL 22.03 Schunk make with carbon
21 Pantograph
strips. With ADD and ORD protection.
1. Ambient Noise Measurement Unit
2. Network video recorder
3. PAPIS system
22 Special Features 4. ERMS system
5. Roll Down Protection.
6. Battery under voltage indication and
protection.

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3.3 Equipment Details

Transformer
Rated KVA 1300 KVA
Nominal Voltage primary 22.5 KV (25kV)
Nominal Voltage Secondary 855V (950V)

Line Converter
Nominal Input Voltage 855V, 50 Hz, single phase
Rated Current 760A
Rated DC Link Voltage 1800V DC

Traction Converter
Output Voltage 3-Ph 1430V AC
(Phase to Phase RMS)
Nominal current 468A

Traction Motor
Rated power 268 KW
Rated Voltage (Phase to phase) 1171 V
Rated current 175 A
Gear Ratio 103/23 (4.478)
Rated speed 1396 RPM
Insulation class 220

Auxiliary Converter
DC Input voltage 1800 V DC +/-10%
Control Supply 77 V to 137.5 V DC
Rated power of 415 V 3 phase output 79.2 KVA at 0.8 pf
Rated power of 110 V AC Single phase output-18.6 KVA at 0.8 pf
DC output 8.6 kW at 110 V DC
Battery charging 2.3 kW at 115 V DC
( current limited to 18 A)
Dry Battery 6x18
Battery Rating 120 Ah at 110 V DC

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 SAFETY FEATURES
4.1 PARTICULARS OF TRAIN:

Table 4.1 gives the leading particulars of MEMU stock, on which supplied equipment is fitted.

Track gauge 1,676 mm

Coach length over body 20,726 mm
Max. width over body side 3,660 mm
Inside length of existing HT compartment 3,500 mm
Inside width of existing HT compartment 3,300 mm
Maximum permissible axle load (any coach) 20.32 tonnes
Table 4.1

Table 4.2 gives few data about MEMU coach formation

Number of Coaches in Basic unit 4 per basic unit

Train formation 8, 12, or 16 coaches

Maximum Service Speed 110 km/ hr
Maximum Test Speed 120 km/ hr
OHE Line Voltage 25kV AC, 50 Hz
Normal variation: 19kV to 27.5kV
Occasional max (cut-off): 30kV
Variations in OHE Line
Occasional min: 16.5kV
Supply
Cut off voltage: 16kV
Frequency variation: 46 Hz to 54 Hz
Table 4.2

Table 4.3 Operating climatic conditions for MEMU Coaches:

0°C to 50°C
Temperature Average Annual Ambient of 35°C
Range
Temperature inside HT compartment can
reach 70°C
Altitude Coastal Area (Sea Level)
Very Heavy (up to 2500 mm during rainy
Rainfall
season)
Max speed of 8 km/ h in water up to 203 mm
Water flooding
above rail level with wave effect
Relative Up to 98% during rainy season which last 5
Humidity
months

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4.2 Train Propulsion Characteristics

active effort and braking effort curves based on the acceleration, deceleration and other requirements of
the specification, the following tractive effort and braking effort curves are arrived. Below is the tractive
effort and braking effort curve (electrical) Vs speed of the MEMU for a 12-car rake.

The braking effort of MEMU is a total sum of electrical (regenerative) and electro-pneumatic braking
efforts. Fig. 4.2 is the graph of Electrical (regenerative) braking effort and total braking effort (including
Electro-pneumatic braking effort) along with TE. The difference between the two graphs is the electro-
pneumatic braking effort that is required at different speeds.

DRIVING DESK LAYOUT EQUIPMENTS

Driver Desk is provided in driver cab for user interface. All equipment such as switches, lamps, master
controller, DDU, PIS interface which are required for driver interface are mounted on driver desk. Layout
of equipment are given in below sections.

5.1 DRIVING DESK OVERVIEW:

Cab view

Driver desk view Guard desk view

DRIVER DESK SIDE EQUIPMENTS: GUARD SIDE DESK EQUIPMENTS:

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Driver side Desk consist of following Equipment: Guard side Desk consist of following Equipment:
 Driver desk panel  BP Gauge
 TCMS Display  HMM Unit, Buzzer AV, Buzzer Fault
 Duplex pressure gauge (MR & BP) and BC gauge  Guard side Panel
 PIS HMI Unit.  Guard Emergency Brake
 Signaling Lamp Panel  Horn
 Auto Brake Valve Unit  AWS & DMH Panel Below Desk
 Master Controller Panel
 Speedometer

5.1.1 Driver Desk Panel:

Top Row from Left side:

1. Cab Light: Selector switch 2 positioned to switch on/off cab light.
2. Cab Fan: Selector switch 2 positioned to switch on/off cab fan.
3. Cab Light EMY: Selector switch to control the coach emergency light.
4. Major Fault Lamp: To indicate major faults. “RED” Colour.
5. Step Light: Selector switch to switch on/off step light guard side.
6. Lamp Test: Illuminated Push button to test all lamps available in driver desk.
2nd Row from Left side:
1. Audio visual: Push button(momentary) + Lamp. “Yellow” colour.
2. Flasher: Push button(maintain) + Lamp. Yellow” colour.
3. PB Release: Push button + Lamp. “GREEN” colour.
4. PB Apply: Push button + Lamp. “BLUE” colour.
5. Single Unit operation Lamp: To indicate single unit operation. “YELLOW” colour.
6. Head Light Failure: Lamp to indicate head light failure. “YELLOW” colour.
3rd Row from Left side:
1. HL Main: Switch to On/Off Main Head Light. 3 positioned OFF/Br/Dim.
2. Wiper: Switch to On/Off electrical wiper.
3. Wiper selection: Switch to select wiper speed. 3 positioned Low/Park/High.
4. Washer Pump: Push button to switch On/off washer pump.
4th Row from Left side:
1. Signal Bell: Push button + Lamp. For Signal bell code communication with Guard. “YELLOW”
colour.
2. EMY Bell: Push button + Lamp. For Signal bell code communication with Guard. “RED” colour.
3. USB Port: For maintenance purpose.

5.1.2 Auto Brake Valve Unit:

Auto Brake unit consists of Auto brake handle (on driving desk) and Brake isolation switch (BIV Key)
(below driver desk).
Auto brake valve handle has four positions.
1. Release 2. LAP 3. AUTO 4. Emergency.

5.1.3 Master controller Panel:

It consists of two portions:

1. Switch portion.
2. Throttle, Reverser and Cab activation key.

Switch portion consists of following items.:

1. EMY OFF: Push button (Maintain). Motoring prohibited. RED colour.
2. EMR OFF: LAMP to indicate emergency off.
3. Panto Switch: To raise or lower the pantograph.
4. ENS: Push button + Lamp. to be pressed while entering neutral section; Yellow colour.
5. MC switch: to switch on/off VCB.
6. Cruise Control: Push button+Lamp for constant speed control. YELLOW colour.
7. Fault Reset: Push button + Lamp. to reset fault. YELLOW colour.
8. Horn: Driver electric horn switch (Push Button). YELLOW colour.

Cab Activation Key:

It has three positions:
1. RDM: for rescue drive mode operation.
2. OFF: To inactivate cab.
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 3. ON: To activate Cab.

Reverser Switch:
It has three positions
1. Forward 2 Neutral or “O” 3. Reverse.
 If reverser is set in reverse direction than message will display in DDU “Reverse direction
selected, confirm that driving shall be enabled”. On confirming the fault message by pressing
confirm button on DDS, the Vmax will be set to 15Kmph.
Throttle handle ( PBC ):
It has four positions.
1. Driving 2. “0” ( COAST) 3. Electrical Braking 4. Emergency Braking
 The throttle handle holding lever is tilted at left side. For operating the handle towards driving
or braking side, driver has to keep the lever straight (horizontally). If while run driver leaves
the lever, DMH mode will get activated.
5.1.4 Signaling Lamp Panel:
It consists of following items:
1st Row from Left side:
1. EMR Brake: Lamp to indicate emergency brake application. RED colour
2. MIN 1 Panto UP: Lamp to indicate raising of min 1 Panto. Blue colour
3. Min 1 MC ON: Lamp to indicate min one VCB Closed. Blue colour.
4. TCN Failure: Lamp to indicate TCN failure. RED colour.
2nd Row from Left side:
1. Not all Panto UP: Lamp to indicate all panto DN. Yellow colour.
2. Not all MC ON: Lamp to indicate all VCB open. Yellow colour.
3. Min 1 BR applied: Lamp to indicate any one brake applied. RED colour.
4. Min 1 AS failed. Lamp to indicate 1 AS failed. Yellow colour.
3rd Row
1. RDM : Lamp to indicate RDM Mode. Blue colour.
2. OHE Available: Lamp to indicate OHE available. Red Colour.
Parking Brake Gauge: Single pressure gauge to indicate parking brake pressure.

5.1.5 PIS and HMM Unit:

This unit consist of:
1. Goose neck microphone and its switch.
2. HMM Unit display.
5.1.6 Gauge Panel:
Gauge panel consist of two gauges:
1. MR & BP Gauge both in one pressure gauge to show MR & BP pressure respectively in the
entire MEMU rake.
2. BC Gauge to show BC pressure in DMC.
5.1.7 Speedometer:
Beside parking gauge panel, speedometer is provided in driver’s desk for speed indication and
recording.

Driver Desk Panel Parking Brake Panel

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 5.2.1 Guard Side Panel:
Top Row from Left side:
1. Step Light: Selector switch to switch on/off step light guard side.
2. Cab Light: Selector switch 2 positioned to switch on/off cab light.
3. Cab Light EMY: Selector switch to control the coach emergency light.
4. Cab Fan: Selector switch 2 positioned to switch on/off cab fan.
5. Tail Light: Push button +Lamp to switch on/off the tail light. RED colour.
6. Marker: Push button+Lamp to switch on/off marker light. Yellow colour
2nd Row from Left side:
1. 100% Light ON: Push button to switch on/off coach light by 100%. Blue colour
2. 50% Lights On: Push button to switch on coach light by 50%. Blue colour.
3. Fans On: Push button+Lamp to switch on/off coach fans. Blue colour
4. EMR Light Off: Push button+Lamp to switch on/off the EMR light. RED colour.
5. Flasher: Push button+Lamp, to switch on/off flasher light of the train. Yellow colour.
3rd Row from Left side:
1. Signal Bell: Push button+Lamp. to communicate with pulse-based code. Yellow colour.
2. EMY Bell: Push button+Lamp to communicate with pulse-based code. Red Colour.
4th Row from Left Side:
1. Lamp Test: Illuminated Push button to test all lamps available in driver desk. Blue colour.
2. Test Battery Voltage: Push button to check battery voltage inn gauge.
3. Battery Voltmeter: To check battery voltage of DMC.

5.2.2 BP Gauge Panel (Guard Desk)

Contains BP gauge to show BP pressure in entire MEMU rake.

5.2.3 HMM Unit, Buzzer AV, Buzzer Fault

Consist of HMM display unit, 2 buzzers for fault and AV.

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DRIVER DISPLAY UNIT

6.1 Driver Display Unit Overview

TCMS DDU provides information for the TCMS system to support motor man in operating rake while
normal operation, as well as in case of malfunction of a subsystem.
DDU supports the maintenance staff in setting basic system parameters and fault finding. In case of
failure of TCMS DDU, train can still be operated. There is one DDU installed in each DTC cab. There
is no DDU in the shunting cabs.
DDU communicates with TCMS and performs the following basic functions:
Provide an interface to control train functions
● Display operational status of train functions
● Display diagnostic events
There are two user groups:
● Driver ID and
● Maintenance ID

Screen layout consists of 7 sections described below:

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Section 1: Head Line Area
Head Line area gives the information about train number configured, screen heading, date and time
fields.
Section 2: Soft Key Button Area
The soft key button area contains 10 touch sensitive buttons for different menu entries.
Section 3: Main Screen Area
The main screen area shows the actual content of the selected screen. If required, further touch
sensitive buttons are shown in the main screen area.
Section 4: High Priority Message Field
Active diagnostic events which require acknowledgement by motor man are present in high priority
message field area. For each event, the source of the event (basic unit number) and its event text are
displayed along with an acknowledge button. If no such event is present, the text field and acknowledge
button are not displayed. The events are presented in the order of their time of occurrence, across all
event sources. When the acknowledge button is pressed, the respective event is acknowledged and
disappears from this area. Clicking on the event is available at events list.
Section 5: Scrolling Event Area
All pending active events are presented in scrolling events area in a scrolling pattern. For each event,
the source of the event (basic unit, module details) and its event texts are displayed. If no such event
is present, the text field is not displayed. Motor man can manually scroll up and down the list with the
provided scroll buttons.
Section 6: Pop-Up Message Area
Pop up messages area is used to show informative (Popup) messages to motor man depending on the
operational status of the train. If no popup message is pending, the area shall be blank.
Section 7: Vmax Area
Vmax area indicates the maximum available/ allowed speed of the train. If traction interlock condition is
detected by CCC, then ‘Zero Force’ appears in this area.

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6.2 DDU Screen View:

6.2.1 Train Level View: Fig below shows the train level view of DDU. Rake level, all the important
symbols (basic unit wise), OHE voltage, OHE current, train speed, and train operational mode
information are displayed here.

6.2.2 Basic Unit View: Basic unit view shows a graphical representation of the front basic unit, which
consists DTC, MC, and TC cars. It provides a status overview of the major systems in the coaches. Fig
5.3 shows DDU front view for Basic unit 1.

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6.3 Soft Key Button Area:
The soft key button area has following different screens:

Driver brake screen: Drive/ Brake view screen shows the OHE line voltage, current as well as traction
effort values for each basic unit in the train. The small triangle type indicator indicates the set value for
tractive/ braking effort, as percentage of the maximum available tractive/ braking effort. The set value
is calculated by the function that distributes the desired efforts across the available basic units as a
function of available traction systems, basic unit weight and other parameters. Consequently, at a given
position of the master controller, the set values for different basic units can differ. The large level graph
and the value beneath indicate the achieved total tractive/ braking effort as percentage of the maximum
available tractive/ braking effort. The bar graph and value shown in orange color gives information about
braking effort whereas the blue color gives information about tractive effort. The maximum available
tractive and braking effort is dependent on the weight and speed of a basic unit. The braking e
fforts are combined values for electrical (ED) and pneumatic (EP) brakes. The solid bars in each basic
unit show the actual (achieved) traction/ braking effort values. The actual achieved value is displayed
in the label below the solid bars for each basic unit.

Air Spring Overview Screen: Air Spring Overview screen gives information about bellow wise air
suspension pressure values (in bars), end basic unit MR, and BP pressure values (in bars). The sensor
healthiness information is displayed in color decoding of sensor name field. In case of sensor failure,
corresponding value is shown in X, color of name field shall be differed. Basic unit level navigation can
be possible through ‘BU-x Suspension’ soft key. Sensor name field color coding is shown below:

Energy Overview Screen: Energy Overview screen, displays the energy consumption and energy
regeneration values for each basic unit and for the whole train. It also displays the total distance traveled
by train. Energy details of each basic unit is available in cumulative and trip wise. Trip wise data is
available for latest entered driver ID. Trip can be reset by using store track option in energy overview
screen or by entering a new user ID from login screen.

Login Screen: Login screen, is used to enter new user ID or to logout from existing user. Driver ID can
be logged out using reset ID/ logout button. This screen is available only in occupied cab. User can
change the train number from this screen.

Events Screen: Faults/ events are categorized into two types:

 Entire fault Archive Type – It consists of all logged events along with recovery details.
 Active Fault Archive Type – It consists of only the present active faults information.
All faults screen gives information about fault description, start time, end time (if recovered), basic unit
number, and module information along with fault category. In case of all active fault screen, same
information is available except ‘End Time’ column.

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Driver/Crew Message Screen: Driver Messages screen, displays only the active fault/ event
information which is required for motor man.

Brake Screen: Brake screen, gives information about basic unit level and brake cylinder pressures (EP
system) of train. This screen consists of two sections. First section consists all brake pressures status
and second section give option for enabling/ disabling holding brake to the train. This can be useful for
the motor man while brake test validation.

Brightness Control: When user press ‘Brightness’ soft key, then the brightness control appears on the
screen. Touch on the bar chart, controls the brightness of the screen. This brightness control disappears
when user touches again the same brightness button.

Maintenance Mode: This mode is mainly for maintenance purpose.

Legend Screen: Legend screen gives information about different icons available in the DDU.

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17
18
 CRW (CAB REAR WALL) CABINET DESCRIPTION

7.1 Cab Rear Side Equipment:

Driver Rear Side Equipment: Guard Rear Equipment:

 Cab Rear Wall (CRW) Panel  Cab AC

 DC-DC Converter (above CRW Panel)  LTC Earthing Switch
 Flasher Light Unit (above CRW Panel)  Panto Key (IG38),
 Grounding switch (HOM handle) above CRW  Panto pressure gauge with Isolating COC.

7.2 Description of Switch Panel (EEC):

7.3 Description of Switch Panel (EEC):

Top Row from Left side:

1. Cab Selector Switch: Two positioned switch to select Cab occupied loop in high priority if
normal loop is failed. Normal position-Normal, for Cab occupied Loop-High.
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 2. ICS By-Pass Switch: Two positioned switch to select ICS (BIV) interlock in cab occupied loop
to occupy the cab for testing or in case of ICS malfunction.
3. AAC Switch: Two positioned switch to select Auxiliary air compressor manual in case AAC
failed to work in Auto mode.
4. Single Unit Operation Switch: Two positioned switch to select ON to drive single basic unit.
5. Battery Supply: Two positioned spring-loaded switch. To give battery on/off pulse to turn on/off
BN supply.
6. Battery Protection: Two positioned switch to isolate battery protection when battery voltage is
less than 84V for initial power ON.
7. Mid BU Type: Two positioned switch. To be selected when basic unit connected in middle.
Bottom Row from Left side:

1. HTC Light: Two positioned switch to switch on/off HT compartment light.

2. HTC Fan: Two positioned switch to on/off HT compartment Fan.
3. EBL ISO: Two positioned switch to isolate the emergency brake applied loop in case of
malfunction.
4. BAL ISO: Two positioned switch to isolate the brake applied loop in case of malfunction.

5. PB ISO: Two positioned switch to isolate Parking brake in case of malfunction.

6. EOL ISO: Two positioned switch to isolate Emergency Off Loop in case of malfunction.
7. MAC: Two positioned switch to be operated for selection of main air compressor manually or
in case of MAC failed to work in Auto mode.
8. All MAC ON: Push button switch (Yellow Colour) to turn on all MAC units in case MAC not
working even MR pressure is low.
9. Battery Isolated: Indication Lamp (Yellow Colour), to indicate that the battery is isolated in the
basic unit.

7.4 Detailed description of MCB Panel of CRW:

SL
COMPONENT DESCRIPTION COMPONENT DESCRIPTION
NO
1 DMC SUPPLY (=061-F04) 30 HEAD CODE (=141-F03)
2 MCU1 SUPPLY (=061-F01) 31 CC TV CB (=141-F06)
3 MCU2 SUPPLY (=061-F02) 32 LRMS MCB (=134-F02)
4 RIO MCB (=061-F03) 33 TRAIN RADIO (=133-F01)
5 TCMS DISPLY (=131-F01) 34 SPEED INDICATOR (=134-F01)
6 ECN1 CB (=141-F04) 35 EMERGENCY LIGHTS (=102-F03)
7 ECN2 CB (=141-F05) 36 EMY LIGHTS LINE 1 (=102-F01)
8 ACU CB (=081-F01) 37 EMY LIGHTS LINE 2 (=102-F02)
9 LIC1 CB (=033-F01) 38 LIGHTS LINE 1 (=102-F04)
10 LIC2 CB (=033-F02) 39 LIGHTS LINE 2 (=102-F05)
11 TIC1 CB (=033-F03) 40 LIGHTS LINE 3 (=102-F06)
12 TIC2 CB (=033-F04) 41 FANS LINE 1 (=111-F01)
13 AAC SUPPLY (=071-F01) 42 FANS LINE 2 (=111-F02)
14 BATT CONTROL BD (=082-F02) 43 FANS LINE 3 (=111-F03)
15 CAB OCC1 (=021-F02) 44 HEAD LIGHT (=101-F01)
16 CAB OCC2 (=021-F03) 45 TAIL LIGHT (=101-F02)
17 EMY OFF LOOP (=091-F01) 46 FLASHER LIGHT (=101-F03)
18 EMY BRAKE LOOP (=092-F01) 47 DRIVER CAB LIGHTS (=103-F01)
19 EMERGENCY BRAKE VALVE (=092-F02) 48 DRIVER CAB EMY LIGHT (=103-F02)
20 BAL (=093F01) 49 DRIVER CAB FANS (=112-F01)
21 PANTO &MC SUPPLY (=011-F01) 50 HTC FANS & LTS CB (=112-F02)
22 DRIVE BRAKE SUPPLY (=021-F01) 51 STEP LIGHT (=101-F04)
23 MAC SUPPLY (=072-F02) 52 INSTRUMENT LIGHTING SUPPLY (=083-F01)
24 DMC EP CONTROL CB (=072-F03) 53 WIPER LEFT MCB (=135-F01)
25 PB SUPPLY (=074-F01) 54 WIPER RIGHT MCB (=135-F02)
26 SIGNAL BELL (=094-F01) 55 415V AC SOCKET (=084-X01)
27 EMY BELL CB (=095-F01) 56 230V SOCKET (=083-X01)
28 PIS SUPPLY (=141-F01) 57 SOCKET AC 230V (=083-F02)
29 DSD CB (=141-F02) 58 SOCKET DC 110V (=082-F01)
59 110V DC SOCKET (=082-X02)

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 7.5 Energising of 3 Phase MEMU

1. Switch on MCB for Battery Control (normally ON from shed) in CRW MCB panel.
2. In CRW switch panel, turn on battery supply to ‘ON’ (2 to 3 sec)
> MCU1, MCU2, DDU and control circuits ON.
3. Insert DCS Key (Cab activation key) in its slot and turn ‘ON’
4. Turn ICS to ‘OPEN’ fully (BIV Key)
> Self testing takes place with Lamp and Hooter sound.
> All test lamps will glow in Driver’s panel and guard’s panel for 5 sec. then extinguishes.
>Ensure CAB occupancy Icon in DDU glowing with blue background
colour (which means cab is occupied)
>Ensure all Panto icons in white background colour i.e. ready for operation.
5. Press Panto selector key towards UP briefly for 2 to 3 sec. and release.
> Ensure all Panto are raised (Panto Icon background colour changes to Blue).
>As soon as panto touches the contact wire, available voltage will be shown in the DDU
screen.
6. Press MC switch to ‘ON’ briefly for 2 to 3 sec. and ensure VCB icon
background colour changes to blue.
>Ensure the following Icons are changed to blue background.
TCMS, LCM, ACM, &MCP
7. Ensure Holding brake is applied 0.8Kg/Cm2.
> Minimum one bake lamp will glow if any one brake is applied.
>Ensure parking brake applied.
>Compressors are working now. MR & BP charges in the system.

7.6 Cab changing

procedure:

After stopping the train, apply auto brake via brake controller by
dropping BP 1.0Kg/Cm2. Ensure BC gauge show 1.2Kg/Cm2.
1. Turn ICS key (BIV) to CLOSE position and remove it.
2. Turn DCS key (BL key) to OFF position.
Ensure parking brake is applied while switching
off DCS or ICS key. Go to other Cab
3. Turn ICS key to OPEN
Ensure BP is charged and BC drops to 0.8Kg/Cm2.
4. Insert
DCS key
and Turn
ON. Self-
testing
takes
place.
Ensure Vmax value in DDU.
4.Before taking traction, release parking brake.

7.7 110Volt Battery Supply

MEMU has a 110 V DC on-board supply system. A battery is located under the
motor car. The battery charger supplies 110 V DC to batteries for charging
purpose. The battery charger only charges the battery in the own basic unit.
The battery main switch is located in the DMC cab. This switch completely
isolates the battery from the on-board supply system. One switch per unit is
provided. Before the battery can be switched on using the electronics cabinet in
the driver’s cab, all battery main switches in the shunting cab must be switched
on.
This is located in the CRW panel. The battery voltage is monitored by a
minimum voltage relay. When a specific voltage is reached, motor man can
override it for the preparation of the unit using the ‘Isolated Under voltage’

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switch on the driver's cab.
In the case of a defective battery, the unit continues to operate within the train
without any restrictions. This is ensured by a battery bus bar which leads
through the entire train. The emergency light in the driver's cab is connected
directly behind the battery main switch as a consumer. Therefore, it has to be
ensured that the emergency light is switched off when parking the train. (battery
main switch is not switched off, vehicle is shutdown).

END WALL PANEL

8.1 DMC End Wall Panel: One End Wall panel (DMC EWP)-2 is
located in left side on DMC non-driving end. End wall panel comprises of
following items.
1. Terminal Block for BN
2. Terminal Block for BD.

8.2 TC END WALL PANELS:

8.2.1 TC-1 & TC-2 End Wall Panels: One End Wall panel (TC EWP)-1 is
located in left side on TC driving end. It houses all electrical & electronics components
required for coach level control. It houses PCU, ECN switch, ETB Switch, MCB,
Relays & contactor for various application.
One End Wall panel (TC EWP)-2 is located in right side on TC non-driving end. It houses
PIS CC, NVR power supply, NVR, TBs, MCBs and Connectors for various application.

8.2.2 TC-3 End Wall Panels: One End Wall panel (TC3 EWP)-1 is
located in left side on TC driving end. It houses all electrical and electronic
components required for coach level control. It houses PCU, ECN switch,
ETB Switch, MCB, Relays and 415 V AC changeover and 110 V AC
Change contactor for various application.
One End Wall panel (TC3 EWP)-2 is located in right side on TC non driving end.
It houses PIS CC, NVR Power supply, NVR, 110V AC Changeover contactors,
415V Changeover contactor, Tbs, MCBS and connectors for various application.

ECN,ETB

PIS
CC
U

NVR
PCU

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