Handbook on Micro Controller Based Governor fitted on Diesel Locomotives PDF

(Govt. of India) (Ministry of Railways) HAND BOOK ON MICRO CONTROLLER BASED GOVERNOR FITTED ON DIESEL LOCOMOTIVES (For official use only) CAMTECH/2012/M/MCBG/1.0 June 2012 Centre for Advanced Maintenance TECHnology...

(Govt. of India) (Ministry of Railways) HAND BOOK ON MICRO CONTROLLER BASED GOVERNOR FITTED ON DIESEL LOCOMOTIVES (For official use only) CAMTECH/2012/M/MCBG/1.0 June 2012 Centre for Advanced Maintenance TECHnology Excellence in Maintenance MAHARAJPUR, GWALIOR – 474005 egkjktiqj, Xokfy;j & 474005  HAND BOOK ON MICRO CONTROLLER BASED GOVERNOR FITTED ON DIESEL LOCOMOTIVES  FOREWORD Micro Controller based Governor has many advantages over conventional engine governors on diesel electric locomotive. However, since this is new technology, the awareness about its functioning and maintenance is not adequate amongst field staff. Proper knowledge is must for better reliability of this system. As a step to achieve this, CAMTECH has prepared this handbook. This handbook contains description, functions, displays and setting parameters for MCBG. I hope that this handbook will provide necessary knowledge to the concerned staff to achieve trouble free service of MCBGs. 29.06.2012 (A.R.Tupe) CAMTECH, GWALIOR Executive Director  PREFACE Governor is the vital part of a diesel electric locomotive. Various types of Governors are used in all diesel electric locomotives. Micro Controller based Governor is recently introduced in Indian Railway. Proper upkeeping and maintenance of MCB Governor is necessary to ensure reliability and availability of locomotives. This handbook on maintenance of MCB Governor of Diesel locomotive has been prepared by CAMTECH with the objective that those involved in maintenance of diesel electric locomotives in diesel loco sheds, must be aware of correct maintenance procedure of MCB Governor and must know how to investigate cause of failure and what remedial action is required. In preparation of this handbook Shri S.B.Sharma Sr. CTA/M/CAMTECH has given valuable contribution. I am also thankful to officers and staff of Railways and RDSO for their valuable comments. It is clarified that this handbook does not supersede any existing procedures and practices laid down in the maintenance instructions issued by manufacturers or by RDSO/LKO. Technological Upgradation and learning is a continuous process. Hence feel free to write to us for any addition / modification in this handbook or in case you have any suggestion to improve the handbook. Your contribution in this direction shall be highly appreciated. 29th June 2012 ( K.P.Yadav) CAMTECH GWALIOR Director/Mech  CONTENTS SNO Description Page No 1.0 Introduction 1 2.0 System installation 2 3.0 Advantages of MCB Governor 5 4.0 Salient features 7 5.0 Advanced features 8 5.1 Display Parameters 8 5.2 Faults Diagnosis 8 5.3 Test Facilities 9 5.4 Fail-Safe Features 9 6.0 System Specifications 10 7.0 System Description 12 7.1 Control Unit 12 7.1.12Control Card (MEGCC) 12 7.1.2 Input 7.3 Card (MEGIP) 15 7.1.3 Motor 7.4 Control Card (MEGMC) 16 7.1.4 Load and Clutch Control Card 16 7.1.5 Display Control Card 16 7.1.6 Power Supply Card 17 7.2 Actuator Card 20 8.0 Functional Details 22 8.1 Display Message 22 8.2 System Message 22 8.3 System Message that require to be 28 acknowledged 8.4 Faults Message 29 8.5 Status Message 34 8.6 User Settable parameter 35 8.7 List of Error Code with message 36 9.0 Setting of Settable Parameters 38 9.1 Brief Description of Configuration software 38 Menu Screens 9.2 Configuration 40 10.0 Principle of Operation 53 10.1 Block Diagrams for understanding function of 54 Governor 11.0 Maintenance 63 11.1 Fault Finding 64 11.2 Procedure for Calibration of Engine Fuel 71 Pump Racks with Micro Controller Based Electronic Governor (MCBG). 11.3 Procedure for Fuel Rack Position (FRP) 74 Auto Calibration 12.0 Drivers instruction 78 Annexure 1.0 80-81 Instruction Bulletins/Modification sheets issued by Motive Power Directorate of RDSO  CORRECTION SLIPS The correction slips to be issued in future for this handbook will be numbered as follows: CAMTECH/M/2012/MCBG/1.0/C.S. # XX date --------------- Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards). CORRECTION SLIPS ISSUED Sr. No. of Date of Page No. and Item Remarks C.Slip issue no. modified IRCAMTECH/2012/Mech/MCBG/1.0 1 MICRO CONTROLLER BASED GOVERNOR 1.0 INTRODUCTION The micro controller based governor Type MEG-601 is developed using state-of-art technology. A micro controller controlled DC stepper motor is used to control the fuel rack of diesel engine of the locomotive. The basic function of governor is speed control of engine, based on the throttle handle position (notch). A secondary function is to control load on the engine electrically, through an interface with E-type excitation system, for maintaining a pre-set constant horsepower at each notch. In addition to these functions, the equipment also does air manifold pressure based fuel limiting, and low lube oil pressure shutdown. A provision for reduction of excitation during wheel slip is also incorporated which can be enabled, if required, through user settable parameters. The system displays status of various engine parameters continuously on the Vacuum Fluorescent Display. CONTROL UNIT ACTUATOR UNIT Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 2 The system has built in fault diagnostic facility. In case of any fault, it takes appropriate action immediately, displays appropriate fault for information to driver, and also records the fault with date and time, to help the maintenance staff later. The governor has number of user programmable parameters, which permit the system to be used on various types of locomotives. Configuration of the system through user settable parameters for fine tuning of operation and reading fault messages of Error Log can be done, online on the loco, using a laptop PC, even while the engine is running. The equipment is modular in construction and has functionally separated plug in modules for ease of servicing. 2.0 SYSTEM INSTALATIONS The two sub assemblies of MCBG are to be mounted as follows: The control unit is to be mounted on short hood side just below the existing location of Booster Air Pressure, Lube Oil pressure and Fuel Oil Pressure gauges. A supporting mounting plate is provided to hold the control unit on the wall of the locomotive. Installation of Control Unit in Driver’s CAB S/H side in a WDM series Locomotive Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 3 Installation of Actuator Unit on a WW Governor base in a WDM series Locomotive The actuator unit must be mounted in place of present Governor with Wood Ward Governor's mounting base. In all, only three cables are used for system connections. All cables have shielded cores with inner PTFE sheathing and outer FRLS (fire retardant low smoke) sheathing. The two cables connecting the Control unit and the Actuator unit are enclosed in metal conduit. The other cable is enclosed with PVC conduit. All the cables connecting between the units have threaded MS connectors and ferrules with cable name on both the ends, for ease of installation. The cable with open ended leads has appropriate ferrules to match with the connections from the existing locomotive wiring. All the units have MS connectors with appropriate nameplates, so that corresponding cables can be connected to them. The MS connectors on the units match only with their corresponding mating connectors on the cable, so that wrong connection of cables is not possible. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 4 The Control Unit has 4 MS Connectors for following: a). Power to actuator unit anti sensor signals from actuator unit. b). Motor and Clutch drive to actuator unit. c). Input/Output Signals to terminal block in Locomotive Wiring. d). A spare RS485 Communication Port connector for future use. The actuator unit has the corresponding connectors for Power & Sensor signals and Motor & Clutch drive. SYSTEM INTERCOONECTONS POWER AND SENSOR SIGNALS 20x4 VFD CONTROL UNIT MOTOR & CLUTCH DRIVE ACTUATOR UNIT INPUT AND OUTPUT SIGNALS FROM LOCO WIRING Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 5 3.0 ADVANTAGES OF MCB GOVERNOR  Engine RPM is controlled without hunting.  Effective control for complete combustion of fuel, thus improving fuel efficiency and reducing pollution.  Load Control interface with Excitation system for constant Horse Power control.  User settable engine parameters for optimizing performance for different classes of locos.  16-bit micro controller based design.  Stepper motor used for high precision position control of fuel rack.  Digital PID control. Requires no adjustment through out its life, & no potentiometer settings.  No need of individual tuning for each engine. Once tuned digitally for a given class of loco, say WDM2, or WDG2 etc. the same parameters would be entered numerically for all the engines of that class.  Continuous display of engine status parameters.  Online fault diagnostics & fault message display  Error log with date and time stamp.  User settable Booster Air Pressure Vs Fuel Limit curve.  User-friendly menu driven software provided for laptop, to modifying any parameter/down loading ERROR LOG.  Electro magnetic clutch used for automatic shutdown of engine, in case of power failure and any major malfunctioning of the equipment.  Electronic and Mechanical Over speed trip testing through key lock Switch.  Switch to bypass Boost Air Pressure based Fuel Limit Control.  Functional plug in modules for ease of servicing.  Wiring minimized for high reliability.  Zero running maintenance up to 5 years  No oil and moving parts.  No Schedule maintenance up to 48 months – Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 6 Against 24 months of conventional governor.  Minimum overhauling time after 48 months- matter of 1 day against 3 to 4 days.  Easy break down maintenance without unloading – Being modular system, the defective module can be replaced.  Display of Engine related parameters for the driver.  Error log and Fault diagnostics.-Errors with real time and date are recorded in non volatile memory and can be down loaded to a Laptop  Notch wise run hours are recorded and can be down loaded to Laptop - to facilitate load factor calculation in a section  Low engine cranking time- 5 to 10 seconds as against 25 to 30 seconds. Saves battery life.  Precise control of Fuel rack trough stepper motor.  Against Hydraulic/Electro hydraulically operated pilot valve.  Practically no hunting. Increase fuel efficiency.  Independent Notch wise engine RPM setting/ - In other governor certain notch RPMS are interdependent on other notch RPMs.  Independent notch wise Low lube oil shut down Pressures.  Tuning of governor is digital setting through Laptop. - Against spring adjustments on trial and error.  Dry run test facility to test free travel of the rack -To test free travel of the fuel rack.  Mechanical OSTA test facility.  Electrical OST test facility. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 7 4.0 SALIENT FEATURES  Functionally plug-in modules. o Defective sub-assembly can be replaced in position  Minimum internal wiring to increase reliability.  A powerful 16 bit micro controller with stepper motor and digital PID control for precise positioning of fuel rack. o Smooth control of fuel rack and no hunting.  Electromagnetic clutch for automatic shutdown. o Immediate return of fuel rack to zero position.  On line tuning of parameters through LAPTOP to optimise the performance. o Very quick tuning of governor without down loading.  Adaptability for different class of locomotives. o All most all parameters are made user settable to suit for different class of locomotives.  Security against un-authorised access to governor parameters.  User friendly menu driven software for o view / set parameters o Down load error log to laptop / PC  Bigger display: o 20 character X 4 line VFD display for clear visibility.  Fuel rack position sensor failure made fault tolerant: o Loco can work without any problem even if fuel rack position sensor failed.  Failure of Booster Air Pressure (BAP) sensor, the governor automatically disables the BAP based rack limitation. o Manual bypass is also available in case of problem with loco. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 8 5.0 ADVANCED FEATURES 5.1 DISPLAY PARAMETERS Displays the following Diesel Engine parameters: – LOP (Lube Oil pressure) – FOP (Fuel Oil Pressure) – BAP (Booster Air Pressure) – Notch (Notch position) – Engine RPM – LCP(Load Control Position) These parameters are continuously monitored & displayed on the screen. 5.2 FAULT DIAGNOSIS On-line Fault Diagnostics. Display fault Message with Hooter Sounding. Error Log with Real Time and Date in Non Volatile Memory. The driver needs to Hooter press the acknowledge button for certain severe faults. Error log can be Down Loaded to a LAPTOP/ PC Acknowledge Notch wise diesel engine Button run time counter is provided to conduct Load factor trials. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 9 5.3 TEST FACILITIES Being micro controller based governor, electronic OSTA has OSTA been provided to shut down Test KEY the engine in case of engine over speeding. This electronic OSTA trips before the mech. OSTA. This is an additional feature. Facility to test Dry Run both electronic & mechanical Push button OSTA through key lock switch Dry run test through push button. 5.4 FAIL –SAFE FEATURES  Automatic shutdown of engine in case of  Lube oil pressure sensor failure.  Tacho signal failure.  Motor Over current.  Micro Controller, EPROM or Bus driver’s failure.  Software corruption  Power supply failure. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 10  Engine over Speed.  Booster air pressure Sensor failure automatically disables air pressure based fuel limiting.  Fault Tolerance for fuel rack position sensor failure.  Engine runs at notch 1 in case of notch input fault.  Runs with default parameters in case of EEPROM failure. 6.0 SYSTEM SPECIFICATIONS 1} Operating Supply Voltage Loco battery Supply of Nominal 72 Volts DC. Range 40 V to 90V DC. Voltage dip to 22 V DC for 0.8 Seconds permitted during cranking. 2} Speed (User Settable) Provision for setting 8 Engine Speed steps for the 8 notch positions. Speed settings are user settable as per RDSO specifications. 3} Governor Response time (User Settable) Time taken for speed adjustment from IDLE to FULL speed will be 15 to 20 seconds. For intermediate notch positions time to adjust engine RPM will be in the same proportion. 4} Load control Provision for load control to maintain constant horsepower output of the engine at each speed setting. Load control is achieved using equivalent of Load Control Potentiometer (LCP), for interfacing with the existing E-type excitation system on the locomotive. Load control timing (user settable) 1) From maximum to minimum field position change will be 8.5 to 11 seconds. 2) From minimum to maximum field position change will be 25 to 30 seconds. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 11 5} Air Manifold Pressure Bias Fuel Limiter Supply of fuel to engine is limited as per available Booster Air Pressure at any point of time. Provision is made for loading any curve (BAP Vs Fuel Rack Limit) through user settable parameters. A toggle switch is provided on control unit to bypass this feature. 6} Pressure Sensors a) Boost Air Pressure Sensor: Working range is 0-to 3-kg/cm2 gauge. b) Fuel Oil Pressure Sensor Working range is 0 to 5 Kg/cm2 gauge. c) Lube Oil Pressure Sensor Working range is 0 to 10 Kg/cm2 gauge 7) Display 20 characters X 4 line alpha numeric Vacuum Fluorescent Display. Following Engine parameters are displayed while engine is running. a) Notch Position b) Engine RPM c) Fuel Rack Position in mm. d) Boost Air Pressure in kg/cm2. e) Lube Oil Pressure in kg/cm2 f) Fuel Oil Pressure in kg/cm2 g) LCP position in hours: minutes format. System status messages and fault messages are also displayed as and when required. 8). Actuator Unit. a). Working capacity greater than 16.3 Nm. b). Rack travel 0 to 30 mm. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 12 7.0 SYSTEM DESCRIPTION 7.1 CONTROL UNIT The control unit is mounted on the wall on short Hood side, just below the existing location of Lube oil, Fuel oil and Boost air pressure gauges in the driver's cabin, or any other suitable location. The control unit houses all necessary electronic circuits for functioning of the governor and a Vacuum Fluorescent Display. All modules on control unit are plug in units. The control unit consists of following modules: 1. Control Card (MEGCC) 2. Input Card (MEGIP) 3. Load and Clutch control Card (MEGLC) 4. Motor Control Card (MEGMC) - 2 numbers. 5. Display Control Card (MEGDSP) 6. Power Supply Module (MEGPSM) 7.1.1 Control card (MEGCC) This card consists of a 16 bit micro controller; it's peripheral ICs and necessary system software for the control of governor. Control card interfaces with all other cards in the system. It has a nonvolatile memory (EEPROM) to store user settable configuration data and Error log. The control card receives various input signals like engine speed signal, notch position signai8, fuel rack position signal, pressure signals etc. from Input Card, and computes the required fuel rack position and provides output signals thru Motor control card, to drive Stepper Motor in the Actuator unit, which in turn drives the fuel rack accordingly. The control card also monitors stepper motor current through Motor control card. The control card also drives Electro magnetic Clutch in the Actuator Unit through Load and Clutch Control Card. It also monitors the status of front panel mounted "Boost Air Pressure Bypass" toggle switch and "Over Speed Test" Key Switch and initiates appropriate action". Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 13 CONTROL UNIT This card has one Digital to Analogue Converter (DAC), to provide Load Control output. This output is amplified in the Load and Clutch Control Card, for interfacing with E-Type excitation system. With this arrangement the micro controller can vary the load control output voltage between 24.4 volts and 68.8 volts. One Analog channel input of this card monitors the load control output voltage fed back from Load and Clutch Control Card. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 14 CONTROL UNIT Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 15 This feedback is used for closed loop control of Load Control output. The Load Control output (simulated LCP) position is displayed " in Hrs: Min: format on the display. This card also has a quartz crystal controlled, and battery backed Real Time Clock (RTC), to register date and time of occurrence of every error that is logged. Control card has two serial interfaces, one RS485 serial interface for communication with the Display Control Card And one RS232 serial interface for communication with lap top PC for programming of user settable parameters and viewing of error log. 7.1.2 Input card (MEGIP). This card is used for signal conditioning of, engine speed signal from Tacho generator, position and pressure signals from the actuator unit, notch input signals from throttle handle and all other high voltage (72VDC) input signals. This card provides 1.5KV electrical isolation, between locomotive circuits and micro controller circuits. All the inputs are optically isolated; surge protected, and reverses polarity protected. 7.1.3 Motor control card (MEGMC) This card drives the stepper motor in the actuator unit. Two identical cards are used. Each motor control card drives one Phase of the Two-phase stepper motor. This is a current controlled PWM drive. The stepper motor current level is received from Control Card continuously. The card also detects over current in the motor phase due to any fault. In case of over current it shuts down the drive and at the same time this condition ,is informed to Control Card for necessary control action. The drive circuit in this card uses 72 volts supply from loco battery. The motor drive works from 22 Volts to 100 Volts of Loco Battery supply voltage. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 16 7.1.4 Load and clutch control card (MEGLC) This card drives the clutch in the actuator unit and it also provides an interface for load control voltage output to E-type excitation system on the locomotive. The clutch drive circuit consists of a PWM controller and it generates 24 volts output from 72 volts locomotive battery supply. Clutch control signal from control card is optically isolated on this card from the locomotive battery supply and it is used to switch ON/OFF the clutch power supply. The clutch power supply output is short circuit protected. Another PWM controller on this card is used to generate Load Control Output. The variable voltage reference signal to this PWM controller, coming from control card, is optically isolated on this card. Proportional to this input reference signal, a load control output of 24.4 volts to 68.8 volts is generated in this card. The load control circuit draws power from 72 volts DC locomotive battery supply. The load control output is short circuit protected. The load control output voltage is proportionally scaled down and fed back to Control Card for closed loop control. 7.1.5 Display Control Card The main function of this card is to display the data received from micro controller on Vacuum Fluorescent Display (VFD). This Card has it's own micro controller whi.ch communicates with control card through serial communication. It has an RS485 interface circuit for this purpose. It also interfaces with the 20character X 4 line alphanumeric Display. This card uses 72 volts locomotive battery voltage to derive separate +5V DC Supply required for VFD. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 17 7.1.6 Power supply card This card converts the 72 volts locomotive battery voltage to variou8 low voltage supplies required by the system. The power supply card generates following voltages + 9 Volts DC for control circuits. + 12 Volts DC supply for Motor Control and Load & Clutch Control cards. + 9 Volts DC for control circuits. + 22 Volts DC for control circuits - 18 Volts DC for control circuits. The power supply has various protections for input over voltage, under voltage, reverse polarity and output short circuit. It has built in surge suppressors and filters to withstand surges on locomotive battery supply. Both Power supply Card and display control card are enclosed in one housing to form a combined module. The nameplate on this module is labeled as MEGDSP & MEGPSM. The control unit also has switches for various functions like Over Speed Test, Reset/Start operation and Boost Air Pressure bypass. Vacuum Fluorescent Display (VFD) The display is mounted on the Front side of MEGDSP&MEGPSM module. The Door of control unit has a cut out to enable the driver to conveniently read the display. This.is a 20 character X 4 line alphanumeric Vacuum Fluorescent Display (VFD). By default, this continuously displays status of engine parameters while the engine is running. Fault and status messages are displayed as and when required. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 18 CONTROL UNIT REAR VIEW Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 19 RACK SHAFT WITH FRP SENSOR CLUTCH MOTOR GEAR BOX FUEL RACK DRIVE SPRING GREASE NIPPLE BELLOW OUTPUT SHAFT Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 20 7.2 ACTUATOR UNIT The actuator unit is mounted on locomotive engine at the present position of the Woodward Governor. The actuator unit, houses the fuel rack drive consisting of stepper motor, gearbox, clutch, and a spring. This unit converts the electrical signals from control unit into mechanical movement of fuel rack. When the clutch is disengaged the spring pulls the fuel rack to "No Fuel" position, so that the engine is shut down. Fuel rack position sensor and pressure sensors are also housed in this unit. The electrical signals from these sensors are transmitted to control unit. ACTUATOR UNIT Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 21 Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 22 8.0 FUNCTIONAL DETAIL 8.1 DISPLAY MESSAGES The operation of the MCBG is user friendly as the system displays appropriate operational and fault messages along with an audio alarm. When the engine is running, the display unit will continuously show the following engine parameters.. 1) Lube oil pressure in Kg/ cm2 2) Boost air-pressure in Kg/cm2 3) Fuel oil pressure in Kg/cm2. 4) Fuel rack position in mm. 5) Notch position. 6) Engine RPM. 7) Load control output in Hours minutes format. The above parameters are accommodated on 20X4 VFD display unit as shown below LOP (Kg/cm2) FOP (Kg/cm2) BAP (Kg/cm2) L. L F. F B. B B N S S SS R R. R H H : M M NOTCH Engine Speed RPM FUEL RACK MM LCP HRS: Minutes The various system and fault messages and their interpretation are given in the tables below. 8.2 SYSTEM MESSAGES SNo Displayed Message INTERPRETATION 1. Power ON Check This message is displayed SUCCESSFUL whenever the system is Powered ON and peripheral components are found OK. 2. Press RESET/ Whenever the rack is at RESTART key to Zero position and, it is START Engine required to be opened for cranking the engine, this message is displayed. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 23 SNo Displayed Message INTERPRETATION 3. BUSY UserWhenever the Laptop PC Settable communication cable is Parameters connected to the control Programming ON. unit this message is displayed. 4. Setting up FUEL After pressing the RACK for RESET/START Key, while CRANKING the system opens fuel rack, for cranking the engine, this message is displayed. 5. READY This message is displayed for CRANKING when fuel rack is opened ENGINE for cranking. 6. CRANKING not After opening of fuel rack if done the engine is not cranked within 20 seconds the system displays this message & moves the fuel rack to no fuel position. 7. FAILED to CRANK During cranking of engine due to LOW if the engine RPM fails to ENGINE RPM reach minimum set RPM for the MCBG to take control, (within specified time) this message is displayed. 8. CRANKING While cranking if external Stopped due to shut down occurs this external SHUT message is displayed. DOWN. 9. ENGINE SHUT When external shut down DOWN Press occurs this message is RESET/START key displayed. to RESTART Engine. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 24 SNo Displayed Message INTERPRETATION 10 ENGINE SHUT After Low Lube Oil DOWN due to Low Pressure shutdown this Lube Oil Pressure. message is displayed. Press RESET/ START key to RESTART. 11 ENGINE SHUT While normal running of DOWN due to the engine if engine over OVER SPEED. speed occurs system shuts Press RESET/ down the engine and START key to display this message. RESTART Engine. 12 OVER SPEED While OST is in progress if TRIP test the OST or key switch is STOPPED. turned off this message displayed. 13 If OST tripped Whenever system detects Reset Else check motor over current, system Motor Press is shut down with this RESET/ START message. Motor over key to RESTART current may also occur if Engine. Fuel rack is moved by MCBG in case CST is not reset after it has tripped. 14 If OST tripped While cranking, due to rack Reset Else check obstruction or linkage fault fuel Rack Drive. or motor failure or motor Press RESET/ drive failure, if the fuel rack START key to does not move to required RESTART. position, this message is displayed. 15 If OST tripped While engine is running if Reset Else check engine bogs down due to for TACHO FAULT. OST trip or any other Press RESET/ reason or if Tacho fails, Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 25 SNo Displayed Message INTERPRETATION START key to engine is shut.down and RESTART. this message is displayed. 16 TESTING During electronic over Electronic OVER speed trip test this SPEED TRIP message is displayed. TRIP LIMIT XXXX ENGINE RPM XXXX 17 TESTING During mechanical over Mechanical OVER speed trip test this SPEED TRIP message is displayed. TRIP LIMIT XXXX ENGINE RPM XXXX. 18 SHUTTING DOWN This message is displayed ENGINE after External shutdown ENGINE RPM occurs due to energizing of XXXX. D solenoid. 19 CRANKING This message is displayed ENGINE. while engine cranking is in ENGINE RPM progress. Engine RPM that XXXX. is built up is continuously displayed. 20 FUEL RACK When Fuel Rack Position position Sensor recovers from fault Sensor Fault this message is displayed. Recovered 21 Ready for Engine This message is displayed Fuel Rack when Locomotive Fuel Calibration. Press Rack Calibration mode is RESET key to entered thru setting from move Fuel Rack. LAPTOP/PC for calibration 22 Engine Fuel Rack This message is displayed Calibration ON when Engine Fuel Pump Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 26 SNo Displayed Message INTERPRETATION Should not Crank Rack Calibration mode is Loco Now. active. 23 Calibrating Engine This message is displayed Fuel Rack with when Engine Fuel Pump MCBG.MCBG Rack Rack Calibration mode is positioned at xx.x active and fuel rack is mm Now. moved by the set distance. 24 Rack Position This message is displayed Sensor Calibration whenever Rack Position ON. Remove Sensor Auto Calibration Actuator Shaft Link mode is active' by setting and Press RESET through the Configuration key. Manager Software running on Laptop/PC. 25 Wait for 10 mins This message is displayed from Power ON, to whenever Rack Position start Rack Position Sensor Auto Calibration Sensor Auto mode is made active by Calibration. setting through the Configuration Manager Software running on Laptop/PC and Calibration is attempted earlier than 10 minutes time from Power ON. 26 Rack Position This message is displayed Sensor whenever the Rack Auto Calibration Position Sensor Auto ON. Calibration is in progress. 27 Lube Oil Pressure This message is displayed Sensor Faulty. whenever the Lube Oil Waiting for Pressure Sensor is Recovery declared faulty and MCBG is waiting for its recovery. 28. BATTERY weak or When Loco doesn’t get Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 27 SNo Displayed Message INTERPRETATION Tacho Faulty. cranked even after holding Stop Cranking the start button for a long duration this message is displayed. This message warns to stop the cranking when the start button is kept pressed for a long time to avoid deep discharge of the batteries 29. Check BATTERY When loco doesn’t achieve condition. Check the set RPM within the for Tacho fault. specified time, this Press START message is displayed. This Button to Restart may be either due to weak batteries, which are not able to crank, or Governor is not getting the Tacho / ESS signal properly. Check the battery voltages and if the batteries are found ok, check the Tacho/ESS signal wiring, Tacho / ESS, if found ok, the problem may be with MEGDIP or MEGCC card. 30. Reset OST. Check While normal running of free movement of the engine if engine over Fuel Rack Linkage speed occurs and with DRY RUN Mechanical OSTA is switch. tripped then engine shutdown and after Acknowledge this message will be displayed Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 28 8.3 SYSTEM MESSAGES THAT REQUIRE TO BE ACKNOWLEDGED Following messages remain on the display till they are acknowledged by pressing acknowledge switch on the display unit. SNo Displayed Message INTERPRETATION 1. Electronic O.S.T. After Electronic OST test is Test Successful successful this message is TRIP LIMIT XXXX displayed. TRIPPED AT XXXX 2. Mechanical O.S.T. After Mechanical OST test Test Successful is successful this message TRIP LIMIT XXXX is displayed. TRIPPED AT XXXX 3. Mechanical O.S.T This message is displayed Level while Mechanical OST To be increased testing, if the OST trip Trip Limit XXXX occurs at less than the set TRIPPED AT XXXX level and less than (electronic OST trip set level + 5 RPM). 4. Rack Position This message is displayed Sensor Calibration whenever the Rack Success. Position Sensor Auto Max. Error XX. XX Calibration is completed mm. AT xx. xx mm successfully. 5. Rack Position This message is displayed Sensor whenever the Rack Calibration Failed Position Sensor Auto Max. Error xx. xx Calibration fails. mm AT xx. xx mm. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 29 8.4 FAULTS MESSAGES Whenever any fault occurs it is displayed along with the Alarm. For normal faults the alarm buzzer is ON for a short duration and is turned OFF by the system without requiring any acknowledgement. For all major faults like faults leading to engine shutdown and OST test failure it is required to press the acknowledge key for clearing the messages on the display unit. a) Normal faults (not requiring acknowledgement for clearing of Display-Message). SNo Displayed message INTERPRETATION 1. Communication This is displayed whenever FAILED. communication to display module fails. 2. Boost air pressure Whenever a) BAP fuel fuel limiting limiting is bypassed with the BYPASSED use of toggle switch provided on control unit or b) Air pressure sensor / circuit fails this message is displayed. 3. Boost air pressure Whenever BAP fuel limiting fuel limiting now is made active with the use ACTIVE of toggle switch provided on control unit this message is displayed. 4. Load Control When load. Control circuit FAILED. fails this message is displayed. 5. FUEL RACK This message indicates fuel SENSOR FAILED rack sensor or its cable or interface circuit failure. 6. EEPROM FAILED. Failure of nonvolatile Running with configuration memory DEFAULTS (EEPROM) results in this PARAMETERS. message to be displayed. The engine still runs but with default parameters. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 30 SNo Displayed message INTERPRETATION 7. LUBE OIL If lube oil pressure sensor Pressure or its cable or interface SENSOR Faulty. circuit fails, this message is shown. 8. BAP Sensor If BAP sensor or its cable or Faulty. interface circuit fails, this message is shown. 9. FOP Sensor If FOP sensor or its cable or Faulty. its cable or interface circuit fails, this message is shown. 10. FUEL RACK Drive This message is displayed Motor Over when motor over current Current occurs during cranking. Check OST 11. Fuel Rack Position This message is displayed Sensor recovered whenever the Fuel Rack from fault. Position Sensor recovers from Fault. 12. LOP Sensor This message is displayed recovered from whenever the Lube Oil fault. Pressure Sensor recovers from faults. 13. BAP Sensor This message is displayed recovered from whenever the BAP Sensor Faults. recovers from fault. 14. FOP Sensor This message is displayed recovered from whenever the FOP Sensor Faults. recovers from faults. 15. Load Control Fault This message is displayed recovered. whenever Load Control Output circuit of MCBG recovers from fault. 16. Unable to This message is displayed Calibrate Rack whenever Rack Position Position Sensor. Sensor Auto Calibration mode is made active by Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 31 SNo Displayed message INTERPRETATION setting through the Configuration manager Software running on Laptop/ PC and due to any major problem the control unit and actuator are not matching with each other. 17. ESS1speed This message is displayed sensor when ESS-2 is fault and misbehaving. Engine RPM is varying or ESS-2 signal is fault and ESS-1 signal is mal- functioning. 18. ESS2speed This message is displayed sensor when ESS-1 is fault and misbehaving. Engine RPM is varying or ESS-1 signal is fault and ESS-2 signal is malfunctioning 19. ESS1speed This message is displayed sensor wire open when the Engine Speed fault. sensor-1 or its cable or interface circuit fails. 20. ESS2speed This message is displayed sensor wire open. when the Engine Speed sensor-2 or its cable or interface circuit fails. 21. ESS1 Sensor This message is displayed Recovered from when the Engine Speed Faults. sensor-1 signal recovers from fault. 22. ESS2 Sensor This message is displayed Recovered from when the Engine Speed Faults. sensor-2 signal recovers from fault. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 32 b) Faults requiring acknowledgement for clearing of display message SNo Displayed message INTERPRETATION 1. OST TRIPPED or This is displayed whenever FUEL RACK Drive shutdown is enforced due to OBSTRUCTED or continuous motor over Motor FAILED. current may be due to OST SHUTTING DOWN obstruction to fuel rack or ENGINE any other causes. 2. Low Lube Oil This message is displayed Pressure when Low Lube Oil Pressure SHUTTING DOWN is detected while engine is ENGINE running and shutdown is enforced. 3. OST TRIPPED or While engine is running if TACHO FAILED engine bogs down due to SHUTTING DOWN OST trip or any other reason ENGINE or if Tacho fails, engine shut down is enforced and this message is displayed. 4. OVER SPEED While normal running of the SHUTTING DOWN engine if engine over speed ENGINE occurs, system shut down the engine & display this message. 5. Electronic OVER When electric OST tests fails SPEED TRIP test this message is displayed. FAILED OST test failure occurs when engine does not shut down at the set RPM limit for test. 6. Mechanical OVER This message is displayed, SPEED TRIP test during mechanical OST test, FAILED if mechanical OST does not trip even after the engine has run at the set RPM limit for the OST, for 10 secs. 7. Switch OFF MB1 & If engine is unable to crank MB2 Wait for 5 for a long time, due to OSTA Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 33 SNo Displayed message INTERPRETATION Minutes. Switch ON trip or any obstruction to MB1 & MB2, to Fuel Rack Drive or loose Restart Engine. contact in LOP sensor wiring or any other reason, this message is displayed. Prior to the display of this message, the actual cause is displayed every time when cranking fails. Try to diagnose the problem. If unable to do anything else, switch OFF breakers MB1 & MB2. Wait for 5Minutes and then switch ON MB1 &MB2 again to Restart Engine. 8. OST TRIPPED or During cranking, if FUEL RACK Drive continuous motor over Motor FAILED current occurs due to OST CAN’T START obstruction to rack or any ENGINE other reason, this message is displayed. 9. Lube Oil Pressure Whenever lube oil pressure Sensor FAILED. sensor or its circuit or cable SWITCH OFF fails this message is Power & repair displayed, after shutting Sensor to restart down engine. engine. 10. FUEL RACK When Fuel Rack position Position Sensor sensor or its circuit or cable Faulty fails this message is displayed. 11. OST TRIPPED or While Cranking the engine, if FUEL RACK Drive any obstruction for fuel rack FAILED STOP movement is encountered CRANKING this message is displayed. ENGINE Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 34 8.5 STATUS MESSAGES SNo Displayed INTERPRETATION Message 1. Notch Fault If any illegal combination of A, B, C, D solenoid control Inputs, is received, this message is displayed. 2. BAP Limit Whenever Boost Air pressure sensing is active and rack is limited due to available boost air pressure this status message is displayed. 3. HP Limit Whenever load control action is enforced due to Horse Power Limit set for the Notch, this message is displayed. 4. RackPosErr This is displayed whenever fuel rack movement is not as desired while engine is running. 5. BAPLdCntrl Whenever load control action is enforced due to Booster Air Pressure is less than the Limit set for the fuel rack position, this message is displayed. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 35 8.6 USER SETTABLE PARAMETERS Various control parameters of the governor are made user settable. These parameters can be modified through any laptop computer. For this purpose, the "Governor Configuration Manager" software supplied by M/s Medha should be loaded in the laptop. This menu driven software for the parameter setting is extremely user friendly. The software displays the range and default value for any parameter that is selected for viewing or modification. Thus user is not required to carry any documentation for the same. The laptop interfaces with the MCBG through an RS232 serial port. User can set the parameters while the engine is running, which is very useful for tuning of engine and instantly checking its response for any modification. Following is the list of parameters that are user settable. 1) Notch wise engine speed 2) Notch wise minimum lube oil pressure for loco shutdown. 3) Maximum permissible fuel rack at each notch. 4) Boost air pressure wise fuel rack limit. 5) Over speed trip setting. 6) Engine acceleration and deceleration rates. 7) Load control minimum and maximum voltage and response time. 8) Fuel rack position for cranking. 9) Other miscellaneous parameters like BAP linked load control enable, etc. The software named Configuration Manager. MEG 601 is used for modifying configuration. The software can be used to Read/Load the user settable parameters from/into the MCBG, as well as read the error log contents from the MCBG. The software can be installed and run from the setup CD on a LAPTOP/PC. It can be run from the START menu or the short cut created on DESKTOP for running "meg 601 cfg.exe" from the installed directory. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 36 8.7 LIST OF ERROR CODES WITH MESSAGE Code Error Description 1. Tacho Faulty or Cable Noisy 2. Fuel Rack Pos. Sensor Faulty, showing High Position 3. LOP Sensor Faulty, showing High Pressure 4. BAP Sensor Faulty, showing High Pressure 5. FOP Sensor Faulty, showing High Pressure 6. Communication Link to Display unit failed 7. RTC Fault occurred @ Power On 8. EEPROM Faulty. Default CFG Record Loaded 9. Engine Shut Down Due to Over Speed 10. Fuel Rack Pos. Sensor Faulty or Cable Open 11. LOP Sensor Faulty or Cable Open 12. BAP Sensor Faulty or Cable Open 13. FOP Sensor Faulty or Cable Open 14. Engine Shut Down due to low Lube Oil Pressure 15. Engine Shut Down due to Motor Over Current 16. Tacho Faulty or Cable Open 17. LCP Circuit Faulty 18. Rack Obstructed by OST or Drive FAIL at CRANK 19. Fuel Rack Pos. Sensor Fault Recovered 20. NOTCH Time Count in RTC Faulty 21. NOTCH Time Count in RTC Faulty & RESE 22. LOP Sensor Fault recovered 23. BAP Sensor Fault recovered 24. FOP Sensor Fault recovered 25. LCP Circuit Fault recovered 26. Fuel Rack Pos. Sensor Faulty SHOWING Middle Position 27. FRP Sensor Tested by Clutch OFF 28. Electronic Over Speed Test Successful Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 37 29. Tacho Faulty or Cable Open while running 30. Mechanical OST Tested 31. Mechanical OSTA Tripped 32. ESS2 Faulty or Cable Noisy 33. ESS1 Cable Noisy Fault Recovered 34. ESS2 Cable Noisy Fault Recovered 35. Difference between two sensor speeds is high 36. ESS1 speed sensor misbehaving 37. ESS2 speed sensor misbehaving 38. ESS1 speed sensor wire open fault 39. ESS2 speed sensor wire open fault 40. ESS1 showing high RPM at zero speed 41. ESS2 showing high RPM at zero speed 42. ESS1 Faults Recovered 43. ESS2 Faults Recovered 44. Engine Shut Down due to LOP at Low Idle Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 38 9.0 SETTING OF SETTABLE PARAMETERS 9.1 BRIEF DESCRIPTION OF CONFIGURATION SOFTWARE MENU SCREENS The menu screen is as shown in the figure below when the software is run PPC Config: To select the Serial Communication Port for Communication with MCBG on the LAPTOP/PC. Click on this menu to see current port number selection or to make a change. This setting is requited to be done only once after the software is installed on the LAPTOP/ PC. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 39 Click on the button to select new port number and then click on Ok. To retain existing selection click Cancel. View Data: On clicking on View Data ERROR LOG is shown. Clicking on Error Log opens a screen with which one can use for reading the error log for MCBG. Error Log Manager Screen: This screen is used to read the error log contents from the MCBG or to view the previously stored error log files. The error log screen has the following commands. Read Gov: This commands read the records from the governor on the selected port. If no part has been previously selected then a port is to be selected now. Once the communication has been successful the records will be decoded & displayed for the user analysis. Read File: A previously stored error log file may now be loaded and viewed for analysis using this command. The error log files are be default saved with extension ‘erl’. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 40 Save Last Read Log As: Once the error log from the governor has been read, the save as command may be used to save the read data into a file for viewing again in future. The file-save dialog box will be displayed to select a folder and file name to save the current File with extension 'log' for future viewing (Text format). Open Prev Read Log: To open and view a previously stored file with 'log' 'extension (Text Format file). This file can be opened in 'NOTEPAD or WORDPAD for viewing and can be printed out. Exit: To return to the main menu screen. 9.2 CONFIGURATION On selecting this option from the main menu, two selections are shown "Governor" and "FRP Sensor Auto Calibration". Select Governor Option to configure Governor for routine setting. Select "FRP Sensor Auto Calibration" for calibration to match the Actuator and the Control Unit. A password is required for entry in to this menu and is meant for authorized personnel only. A} The Governor option selection shows following screen (Given on Next page) 1. The Configuration parameters Group: For convenience all the parameters are sub divided into smaller sub groups. Each sub group can be individually selected. 2. The command panel: All the Commands that can be executed are given as buttons at the bottom of the screen. Each command is described below. 3. The status bar: Located above the commands, has the following details a. The minimum value b. The maximum 'value c. The number of decimals allowed d. Default Value e. The status indicator indicating Busy when the system is busy. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 41 4. The Input region: In this block on the screen the actual parameter value can be entered. The commands available and their description 1} Send: The send command is used to transmit the changed values to the MCBG control unit. The send command works only when any parameter value is changed. If no changes have been done the command returns an error message. The send command sends only those parameters that have been changed so as to reduce the load on the communication lines and on the controller in MCBG. After the send command is chosen Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 42 (If changes are made). The LAPTOP/PC tries to transfer the data to the MCBG through the selected port. If the configuration is successful the message indicating the "configuration is successful” is shown on monitor. After this, user will be asked whether the configuration was successful or not. user has to respond with the dialog box with "Yes" when user sees the configuration successful message. If the user responds to "No” dialog box the software automatically tries to retransmit the data to the MCBG control unit. If cancel is selected the program stops trying to send the data. 2} Save: This button is used, to save the changes made to the screen. The software always initiates the values to the screen with the last saved data. 3} Read Config: This command has to be used when the user wants to read the values currently existing in the MCBG. Executing this command reads the parameters from the MCBG from the selected port and changes the values in the corresponding positions on the PC screen. These values may either be saved or discarded. Once the save option is selected it overwrites the old values in PC memory with the current ones. 4) Main Menu: This command may be used to exit from the selection and return to main menu. If any changes are made user will be prompted by the option of saving them. If the user selects 'No' option then the changed values will be discarded and the previously saved values will be retained. B) The Fuel Rack Position (FRP) Sensor Auto Calibration option is used to see the configurations to the Actuator unit and the Control unit. For details on FRP Sensor Auto Calibration, refer para procedure for calibration of Engine Fuel Pump Rack. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 43 Each of the sub menus of the "Governor" is given below in detail. 1) Notch Speeds This screen allows the user to set the notch wise engine RPM. NOTCH RANGE DEFAULT MINIMUM MAXIMUM IDLE 300 400 400 1. 300 400 400 2. 393 495 450 3. 486 595 550 4. 579 685 650 5. 672 783 750 6. 765 865 850 7. 858 963 950 8. 950 1050 1050 Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 44 2) Notch wise fuel rack limit User can set notch wise fuel rack limit in the following menu. NOTCH RANGE DEFAULT DECIMALS MIN. MAX ALLOWED IDLE 3 34 3.5 1 1. 3 34 14.3 1 2. 3 34 15 1 3. 3 34 16 1 4. 3 34 17.5 1 5. 3 34 19.5 1 6. 3 34 22.5 1 7. 3 34 27 1 8. 3 34 32 1 Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 45 3) LOPS Following is the screen for setting the notch wise Lube Oil Pressure Limit (LOPS) values and Time delays for engine shutdown. Parameter RANGE DEFAULT DECIMALS MIN. MAX ALLOWED LOPS delay @ notch 2 to 8 for 0 20 2 0 shut down 1. 0 10 1.3 2 2. 0 10 1.7 2 3. 0 10 2.1 2 4. 0 10 2.6 2 5. 0 10 3.0 2 6. 0 10 3.5 2 Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 46 Parameter RANGE DEFAULT DECIMALS MIN. MAX ALLOWED 7. 0 10 3.9 2 8. 0 10 4.4 2 Idle/ Notch 1 30 60 45 0 LOPS delay Notch 2 to 8 5 20 10 0 Notching UP delay 4) Boost air fuel limit Following is the screen for setting Fuel Rack opening limit as Boost Air Pressure. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 47 PRESSURE RANGE DEFAULT DECIMALS in Kg/ Cm2 ALLOWED MIN, MAX. 0.0 3 34 17 1 0.1 3 34 19.2 1 0.2 3 34 21 1 0.3 3 34 22 1 0.4 3 34 23 1 0.5 3 34 23.9 1 0.6 3 34 24.5 1 0.7 3 34 25.1 1 0.8 3 34 25.7 1 0.9 3 34 26.3 1 1.0 3 34 26.9 1 1.1 3 34 27.6 1 1.2 3 34 28.3 1 1.3 3 34 29.3 1 1.4 3 34 30.5 1 1.5 3 34 32 1 5) CRANKING AND LOAD CONTROL PARAMETER RANGE DEFAULT DECIMALS ALLOWED MIN. MAX Cranking to 100 900 200 0 control RPM Fuel rack 6 34 14 1 position @ Crank (mm) Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 48 Load control 20 30 24.4 1 minimum voltage 1 Load control 60 72 68.8 maximum voltage 0 Load control 6 15 10 max. to min. field change in seconds 0 Load control 20 40 28.1 min. to max. field change in seconds 0 Over ride 5 15 10 max. to min. field change time in seconds Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 49 6) OST and Miscellaneous control PARAMETER RANGE DEFAULT Decimals MIN. MAX allowed Electronic 1010 1220 1200 0 Over Speed Test RPM Mechanical 1010 1300 1220 0 Over Speed Test RPM Fuel Rack Set this FLAG to enable Engine Fuel Calibration Pump Calibration ON Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 50 7) Notch Time Counters: When these counters are read from MCBG gives values of running of Locomotive in different notch up to a period of 136 years. These can be set to 0 whenever required. PARAMETERS DEFAULT Notch 1 Time 0 Notch 2 Time 0 Notch 3 Time 0 Notch 4 Time 0 Notch 5 Time 0 Notch 6Time 0 Notch 7 Time 0 Notch 8 Time 0 Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 51 8) Fuel Rack Calibration: Fuel Pump Rack Calibration can be done as explained in Procedure at Annexure I. The following screen shows different values for data entry. Parameter RANGE DEFAULT DECIMALS ALLOWED Min. MAX. Fuel Rack Position 0 34 0 1 @ 0 mm of MCBG Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 52 Parameter RANGE DEFAULT DECIMALS ALLOWED Min. MAX. Fuel Rack Position 0 34 5 1 @ 0 mm of MCBG Fuel Rack Position 0 34 10 1 @ 0 mm of MCBG Fuel Rack Position 0 34 15 1 @ 0 mm of MCBG Fuel Rack Position 0 34 20 1 @ 0 mm of MCBG Fuel Rack Position 0 34 25 1 @ 0 mm of MCBG Fuel Rack Position 0 38 30 1 @ 0 mm of MCBG Move MCBG for 0 30 0.1 1 Calibration Set Data Time: This menu can be used to Set data and Time in MCBG as per system Data and time on Laptop/ PC. MCBG has an RTC that may need setting as MCBG records error log with Data and Time. Exit: Click this to exit from Configuration Manager Software and return to Operating System. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 53 10.0 PRINCIPLE OF OPERATION The micro controller in control unit continuously measures the frequency signal from the Tacho generator on the locomotive. The engine RPM is calculated from this frequency signal. Desired engine RPM is determined from the selected notch on throttle handle by monitoring status of control wires of speed signals A, B, C and D (Loco wire nos. 15A, 12A ,7lC, and 3A). Comparing these 'two RPMs in a PID control loop the micro controller drives fuel rack of the engine through the Actuator unit, so as to adjust the engine RPM equal to the set RPM for the given notch. PID parameters can be optimized for each class of engines through user settable parameters using a laptop, so as to maintain stable engine RPM free from hunting. When the notch is changed, the speed is varied linearly based on acceleration and deceleration rates, specified in user settable parameters. Booster air pressure is measured through a pressure sensor to limit the movement of fuel rack as a function of Booster air pressure. This ensures the supply of fuel to the engine proportional to available air pressure at any point of time, and prevents incomplete combustion, black smoke, excessive engine temperature, fuel wastage etc. The fuel limit curve in the form of Booster air pressure Vs Fuel rack limit can be entered through a laptop in user settable parameters. A toggle switch is provided on control unit to bypass this feature, incase there is any blockage in the pipelines or other fault. Even when this feature is bypassed, the speed variation between different notches is adjusted linearly based on acceleration and deceleration rates, configured in user settable parameters. A load control output is provided to maintain constant horsepower output of the engine at each notch. The load control is done thru E-Type excitation system, by changing -the generator field excitation, from maximum to minimum or vice versa at a rate specified in user settable parameters. Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 54 For this purpose Notch wise Fuel rack Limit can be specified through user settable parameters, Booster air pressure linked load control facility is also available, which can be enabled/disabled through toe user settable parameters. BAP Turbo Diesel Tr. HP LOP Engine Alt. Fuel Rack Governor Eng.RPM Excitation Control Notch Control Desk Lube oil pressure is continuously monitored and engine is shutdown if the lube oil pressure is less than the specified pressure at each notch position as set in the user settable parameters. Additional time delay is Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 55 allowed for pressure build up during acceleration and at Notch 1. These time delays can be specified through user settable parameters. To test over speed trip a three position key switch is provided. One position on this key switch selects a built in feature of MCBG to test electronic over speed trip, which shall be less than that of mechanical 05T. The second position of key switch selects mechanical 05T. This switch will be active only in 8th notch. In electronic over speed test the engine RPM is gradually increased above 8th notch RPM. When the engine RPM reaches the set RPM for electronic OST, the system should shut down the engine. A message on the display indicates whether the test is successful or failed and in case it is successful it indicates the APM at which the electronic 05T has operated. During mechanical 05T test the governor gradually increases the engine RPM to maximum set limit and waits for a specified time. By this time the external mechanical OST device should trip shutting down the engine. Even if it does not trip the Governor reduces the engine RPM to 8th notch RPM. Display indicates whether the test is successful or failed or needs adjustment, and also the RPM at which the OST has operated. The actuator unit has an electro magnetic clutch, which turns off, autocratically during loss of power and fuel rack is brought to "No Fuel" position, by the spring. It also gets deactivated in case of malfunctioning of the system. This will close fuel rack and shut down the engine. A built in fault diagnostic system continuously monitors the Ilealth of various peripherals. In case of major faults the engine is shut down automatically. In other cases appropriate action is taken. In all the cases appropriate message is displayed on the display unit, and the fault is registered with date and time stamp in error log, to help the shed based maintenance staff later, for ease of servicing. Handbook on Micro Controller Based Governor CAMTECH/GWL  IRCAMTECH/2012/Mech/MCBG/1.0 56 10.1 Block diagrams for understanding Function of Governor CONTROL UNIT The control unit is again functionally ACTUATOR UNIT divided into 6 modules. Display & The governor works on 72V DC. 72V Power Supply The power supply module derive low Card voltages required for other modules. Display loco parameters. Load & Clutch Provides supply for the clutch coil in the Control Card actuator unit. Provides load control signal to excitation. Stepper Motor There are two stepper motor control cards. Cards (2) Provides drive signal to the stepper motor. Input Card Receive notch signals from the locomotive. Receive pressure signals from actuator unit. Transmits these signals to control card Block Diagram No.1 CONTROL UNIT ACTUATOR UNIT The Control Card consists a Micro Controller with its peripherals. Display & Power Supply Card It receives various input signals Load & Clutch like Notch, Engine Speed, Fuel Rack Control Card position and pressure signals etc., from the input card. Control Stepper Motor Card Cards (2) It communicate these parameters to Input display unit. Card Block Diagram No.2 Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 57 The driver sitting at control desk Display & opens the notch to the required Power Supply position. Card The notch signal is communicated to the input card. Load & Clutch The control card decides Control Card the engine RPM for the selected notch. Existing RPM is compared Control Stepper Motor with new RPM level. Card Cards (2) Input The control card computes the Card stepper motor direction and the angular movement required for new fuel rack position. Eng. RPM Notch It gives signal to the stepper Tacho / Control motor cards to drive the ESS Desk motor. Block Diagram No.3 CONTROL UNIT ACTUATOR UNIT Display & 72V Power Supply Stepper motor Card Stepper Motor signal Load & Clutch Control Card Control Stepper Motor Card Cards (2) Input Card Eng. RPM Notch The stepper motor cards communicate Tacho / Control this drive signal to the stepper motor ESS Desk in the actuator unit. Block Diagram No.4 Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 58 Block Diagram No.5 CONTROL UNIT ACTUATOR UNIT Display & Power Supply Stepper motor Card Stepper Motor signal Gear Box Load & Clutch Control Card Control Stepper Motor Card Cards (2) Input Card Eng. RPM Notch The stepper motor slowly rotates in Tacho / Control steps as controlled by the control card. ESS Desk The motor torque is amplified through gear box. CONTROL UNIT ACTUATOR UNIT Display & 72V Power Supply Stepper Motor Stepper motor Card signal Gear Box Load & Clutch Control Card EM -Clutch Clutch signal Stepper Motor Rack & Pinion Control Card Cards (2) Input Card Eng. RPM Notch The clutch coil gets supply from the load Tacho / Control & clutch control card soon after the ESS Desk MCBG is powered up. Block Diagram No.6 Handbook on Micro Controller Based Governor CAMTECH/GWL IRCAMTECH/2012/Mech/MCBG/1.0 59 Block Diagram No.7 CONTROL UNIT ACTUATOR UNIT Display & Power Supply Stepper motor Card Stepper Motor signal Gear Box Load & Clutch Control Card EM -Clutch Stepper Motor Rack & Pinion Control Card Cards (2) Input Card Eng. RPM Notch The torque is transmitted to the rack Tacho / Control and pinion through an electro magnetic ESS Desk clutch. Block Diagram No.8 CONTROL UNIT ACTUATOR UNIT Display & Power Supply Stepper motor Card Stepper Motor signal Gear Box Load & Clutch Control Card EM -Clutch Output Clutch signal shaft Stepper Motor Rack & Pinion Control To Fuel Card Cards (2) Rack Input Card The rack & pinion converts this rotary motion into vertical motion. Eng. RPM Notch The output shaft moves the fuel rack to Tacho / Control the new position against over travel ESS Desk spring. Handbook on Micro Controller Based Governor CAMTECH/GWL  IRCAMTECH/2012/Mech/MCBG/1.0 60 Block Diagram No.9 CONTROL UNIT ACTUATOR UNIT Display & 72V Power Supply Stepper motor Card Stepper Motor signal Gear Box Load & Clutch Control Card EM -Clutch Output Clutch signal shaft Stepper Motor Rack & Pinion Control To Fuel Card Cards (2) Fuel Rack Position Rack Input Fuel Rack sensor Card Position sensor The fuel rack position sensor provide a feed back signal to the input card and Eng. RPM Notch from there it is communicated to the Tacho / Control control card. The cycle repeats till the ESS Desk required RPM is reached. Block Diagram No.10 CONTROL UNIT ACTUATOR UNIT Display & Power Supply Stepper motor Card Stepper Motor signal Gear Box Load & Clutch Control Card EM -Clutch Output Clutch signal shaft Stepper Motor Rack & Pinion Control To Fuel Card Cards (2) Fuel Rack Position Rack Input Fuel Rack sensor Card Position sensor The Control card de-en