Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
of India)
(Ministry of Railways)
IRCAMTECH/M/GWL/15-16/CCB-II
April 2015
FOREWORD
The Hand Book of CCB-II has been prepared by CAMTECH for
loco running as well as Diesel shed maintenance staff.
The failure of Brake system has a great impact on the reliability of
the diesel locomotives. Due to various modifications and alterations,
CCB-I.5 has now been upgraded to CCB-II with some additional
features in the system.
I hope that this Hand book will definitely enhance the knowledge of
concerned staff to do faster restoration of troubles pertaining to brake
system while working on line.
April- 2015
(A.R.Tupe))
EXECUTIVE DIRECTOR
CAMTECH/GWALIOR
PREFACE
Brake system is the vital part of diesel electric locomotives. CCB1.5 has now been upgraded to CCB-II with additional features.
Knowledge of new system and trouble shootings is necessary to
running/maintenance staff to ensure reliability and availability of
locomotives in sheds as well as on line.
This Hand Book contains trouble shootings of CCB-II fitted
locomotives for Diesel Loco Pilots. Loco pilots should understand
the steps of trouble shooting sequentially to save time during fault
findings enroute.
The purpose of Hand Book is to enhance knowledge and competence
of loco pilots in dealing with the problems of Diesel locomotive on
run.
This book will be useful to the maintenance staff and loco inspectors
also for counseling running staff about CCB-II system.
It is clarified that this Hand Book does not supersede any existing
procedures and practices laid down in the maintenance instructions
issued by manufacturers or by RDSO/LKO.
April- 2015
(K.P.Yadav)
Director/Mech
CAMTECH/ Gwalior
CORRECTION SLIPS
The correction slips to be issued in future for this handbook will
be numbered as follows:
IRCAMTECH/M/GWL/15-16/CCB-II/1.0/. # XX date ------------Where XX is the serial number of the concerned correction
slip (starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr. No. of
C.Slip
Date of
issue
Remarks
Contents
S.No.
Description
Page No.
1.0
General Description
2.0
Component Description
2.1
2.2
2
3
2.3
2.4
KE Valve
2.5
3.0
System Back-ups
07
4.0
07
5.0
Operating Pressure
23
6.0
Additional Features
24
7.0
25
8.0
26
9.0
30
10.0
37
11.0
Abbreviations
39
2.6
IRCAMTECH/M/GWL/15-16/CCB-II
1. General Description:
CCB II-IR is a microprocessor based electro-pneumatic
brake control system. A CCB II-IR equipped locomotive
can LEAD or Trail a multiple unit consist and can be
operated as a Helper unit. CCB II-IR is comprised of
distributed
electronics
for
improved
reliability,
IRCAMTECH/M/GWL/15-16/CCB-II
IRCAMTECH/M/GWL/15-16/CCB-II
IRCAMTECH/M/GWL/15-16/CCB-II
The EBV is the Man Machine interface to the CCB II-IR Brake
System. The EBV communicates ER and BCEP commands (handle
movements) by the driver to the Air Brake System via the LON
network.
EBV communicates via an intelligent Node. The EBV is designed
for installation as a desktop mount. It is used by the Engineer to
control the Independent Brake, Automatic Brake and Bail-off.
The EBV includes a Target Display that allows the Engineer to
know, immediately, how much reduction is requested when the
handle is moved. Faults are annunciated to the operator via an LCD
screen mounted on the Drivers Brake Valve (EBV). This screen is
also used for routine advisory instructions such as penalty reset and
emergency reset.
Selector switch on EBVs have four Positions
IRCAMTECH/M/GWL/15-16/CCB-II
IRCAMTECH/M/GWL/15-16/CCB-II
2.6 Direct Brake Handle:-The Direct Brake Handle has two positions
namely Release and FULL.
Automatic brake Handle: - Automatic brake Handle has five positions
1. Release position.
IRCAMTECH/M/GWL/15-16/CCB-II
2. Run position.
3. Minimum reduction brake application.
4. Full service application.
5. Emergency application position.
IRCAMTECH/M/GWL/15-16/CCB-II
IRCAMTECH/M/GWL/15-16/CCB-II
IRCAMTECH/M/GWL/15-16/CCB-II
10
Direct Brake Handle FULL When Stopped & REL for Moving the
Locomotives
Mode selector switch on EBV- Lead
EBV Setting in Trailing Loco on Both Control Stands .
(Both EBV are Non Working)
Auto Brake handle - Full service application.
Direct Brake Handle Release
Mode selector switch on EBV- Trail
(c) EBV Setting in Banker Loco Operation:
1. Non Working Control Stand:Auto Brake handle - Full service application.
Direct Brake Handle Release
Mode selector switch on EBV- Trail
2. Working Control Stand: Auto Brake handle - Full service application.
Direct Brake Handle FULL When Stopped & REL for Moving the
Locomotives
Mode selector switch on EBV- HLPR
NOTE:- With above setting in Banker Loco , attach BP hoses
between formation & Banker Loco , open BP angle COCS to charge
BP. BP in the Banker Loco may drop immediately once angle COC
is opened and PCS will knock-out (no message on LCC Screen ).
IRCAMTECH/M/GWL/15-16/CCB-II
11
Once, BP is charged from Leading loco, PCS in the Banker loco will
reset automatically and loco is ready for operation.
CAUTION:- Do not change any setting on Banker Loco Control
Stand except Releasing Direct Brake i.e. Bringing Direct Brake
Handle to Release Position for loco movement.
(i)
(ii)
(iii)
(iv)
IRCAMTECH/M/GWL/15-16/CCB-II
12
IRCAMTECH/M/GWL/15-16/CCB-II
13
IRCAMTECH/M/GWL/15-16/CCB-II
14
IRCAMTECH/M/GWL/15-16/CCB-II
15
IRCAMTECH/M/GWL/15-16/CCB-II
16
IRCAMTECH/M/GWL/15-16/CCB-II
17
IRCAMTECH/M/GWL/15-16/CCB-II
18
IRCAMTECH/M/GWL/15-16/CCB-II
19
NOTE: Air Brake self test will not pass if controller Faults are
active, under such condition, Switch over to other controller and
work informing concerned shed.
(n) Effect on WDG4/WDP4/CCB fitted Alco Loco after
Emergency Brake Application & steps to be followed by Crew to
Recover
Effect on Locomotives
Whenever Loco Pilots moves the Auto Brake handle to more than FS
& keep in Emergency position or operates Firemen Emergency valve,
then,
PCR trips and PCS Open light indicates on the indication
panel
Engine speed comes to Idle
IRCAMTECH/M/GWL/15-16/CCB-II
20
IRCAMTECH/M/GWL/15-16/CCB-II
21
IRCAMTECH/M/GWL/15-16/CCB-II
22
IRCAMTECH/M/GWL/15-16/CCB-II
23
.
5.0 Operating Pressure -HHP LOCO
EBV Handles
ER
BP
BCEP
BC
Positions
Kg/cm
Kg/cm
Kg/cm
Kg/cm
Release
5.7.07
5.7.07
Run
5.2.07
5.2.07
MIN
0.4 reduction
0.4 reduction
0.4.14
0.4.14
FS
1.5 reduction
1.5 reduction
1.8.14
1.8.14
EMER
<1.4
1.8.14
1.8.14
Release
n/a
n/a
FS
n/a
n/a
5.2.14
5.2.14
Automatic brake
Independent brake
Other Pressures
IRCAMTECH/M/GWL/15-16/CCB-II
24
EBV
Handles
Positions
ER
BP
BCEP
BC
Kg/cm
Kg/cm
Kg/cm
Kg/cm
Release
5.5.07
5.5.07
Run
5.0.07
5.0.07
MIN
0.4 reduction
0.4 reduction
0.4.14
0.4.14
FS
1.5 reduction
1.5 reduction
1.8.14
1.8.14
EMER
<1.4
1.8.14
1.8.14
Independent
brake
Release
n/a
n/a
FS
n/a
n/a
3.5.14
3.5.14
Automatic
brake
Other Pressures
IRCAMTECH/M/GWL/15-16/CCB-II
25
IRCAMTECH/M/GWL/15-16/CCB-II
26
ii) Isolate locomotive (close end angle cocks) and repeat step (i). If
BP charges now but wouldnt before, check train for leakage or decoupling.
iii) Place Electronic Brake Valve (EBV) Automatic handle sharply
into and out of emergency EMER position at least ten times. Reset
emergency and move Automatic brake handle to RUN. If BP
pressure rises, the problem was a stuck 21 vent valve on the EBV.
iv) If BP rises partially toward ER but fails to reach ER (and a blow
of air is heard at EPCU), replace BPCP (there may be contamination
in the relay or emergency valve). If problem persists, replace
locomotive vent valve.
(3) Automatic brake cannot be bailed off on the locomotive.
i) Ensure EBVs mode selector switch is set to "Lead".
ii) Replace EBV. If problem persists, replace 16CP.
(4) Cannot build brake cylinder pressure.
i) Ensure locomotive is set-up to Lead Ensure truck brake cylinders
are cut-in (angle cocks).
ii) Make a brake application with the Automatic brake handle. Note
that brake pipe pressure reduces.
iii) Check for blow of air at the brake cylinder control portion
(BCCP). If no leakage is heard, check integrity of locomotive piping
from manifold of EPCU to truck brake cylinders.
8.0 CCB II-IR EBV Crew Messages
The following messages are transmitted to the EBV display. These
crew messages are provided to assist the Loco Pilot in operating the
brake system. They are not intended to be maintenance instructions.
Line 1
Line 2
Meaning
Wait
Powering Up
The system is booting
up.
IRCAMTECH/M/GWL/15-16/CCB-II
Line 1
Line 2
Set
Hand Test in Progress
Brake
Unable to Service xx CP
Boot
Fireman
Emer
Operator
Emer
Trainline
Emer
Fireman
Emer
Operator
Emer
Wait
Trainline
Emer
Wait
Fault
Penalty
Safety
Penalty
Put Auto in FS
Put Auto in FS
27
Meaning
PTU disabled the
brakes
During power-up a
problem was detected
with
the
xxCP.
Perform maintenance.
Display if emer and
handle < emer
Put Auto in Emer
Display if emer and
handle < emer
Display
if
in
emergency and handle
in Emer., and timer <
60 sec
Display
if
in
emergency and handle
in Emer., and timer <
60 sec.
Display
if
in
emergency and handle
in
Emer., and timer < 60
sec.
Display if penalty and
auto is < FS
Display if penalty and
auto is < FS
IRCAMTECH/M/GWL/15-16/CCB-II
Line 1
Fault
Penalty
Line 2
Keep in FS
Safety
Penalty
Keep in FS
Fault
Active
xx Shut AB Off
Fault
Active
xx Check BC Gauge
Fault
Active
Fault
108 Check Setup
Active
Okay
Run
Okay
Run
to Service Soon - xx
to BP Target = x.xx
28
Meaning
Display if in penalty
and handle in FS,
and timer < 10
seconds
Display if in penalty
and handle in FS,
and timer < 10
seconds
A system fault exists,
which requires the air
brake power to be shut
off and used in trail
Use pneumatic gauge
for
BC
pressure
indication
Display
when
a
disabling
fault
is
active
Both
EBV
mode
switches are set to
same switch position
and one of them is not
in
the
Trail
position
Display when a noncritical fault is active.
This is the default
screen
IRCAMTECH/M/GWL/15-16/CCB-II
Line 1
Line 2
Unable to Factory Code:???
Boot
Initializing
System...
Self
test
Passed
S/T
1xx
F/C= Service xx CP
29
Meaning
Indicates
computer
problem contact field
service.
Displayed
during
system
power-up
checks
Display when Self test
complete with no
failures
Display when Self test
failure occurs for the
xxCP, where xxx is
the last 3 digits of the
self test failure code
Line 2
FREIGHT
LEAD IN
TRAIL
Meaning
Display for 2 seconds after mode
switch defines a lead position
Display for 2 seconds after mode
switch defines a Trail position
EBV TEST Display for 2 seconds after mode
MODE
switch defines a Test position
HELPER
Display for 2 seconds after mode
MODE
switch defines a Helper position
IS
Display when EBV is not active
INACTIVE
IRCAMTECH/M/GWL/15-16/CCB-II
30
Line 1
Line 2
Meaning
<SYSID< Rev=<Date <SYSID< is the parts list number of
-26-EBV Code>
the EBV software
<Date Code> is the EBV software
revision build date defined ass
MM/DD/YYYY
Meaning
<M> - Current Month
<D> - Current Day
<Y> - Current Year
<YR> - Current Hour
<HR> - Current
Minute
<SEC> - Current
Second
Corrective Action
IRCAMTECH/M/GWL/15-16/CCB-II
31
002
ERCP
AW4
Fault
ERCP
ER > 120
or
pressure
not
Within +/5 psi in 10
seconds
006
MVER
Fault
ER
010
BPT
Fault
BPCP
Output
feedback
indicates
MV fault
Xdcr
output
voltage >
4.5 or
< 0.5.
014
MV53
Fault
BP
Output
feedback
indicate
MV fault
IRCAMTECH/M/GWL/15-16/CCB-II
016
BPCN
Fault
RCP,ER,
20,EBV
036
16CP
AW4
Fault
16
32
Loss of
BPCN
heartbeat
for 5
seconds.
IRCAMTECH/M/GWL/15-16/CCB-II
33
039
MV16
Fault
16
Output
Feedback
indicates
MVfault.
052
16CN
Fault
RCP,20
Loss of
16heartbe
at for 5
seconds
055
20CP
20
AW4
FAULT
Pressure
not
within +/5 psi
in 10
other special BC
controls will be
active. Replace
16CP at Shed.
Automatic BC
pressure may be
direct release only.
No blending or
other special BC
controls will be
active. Replace
16CP at shop.
Inspect LON cable
is positively seated
at 16CP. Cycle AB
circuit breaker. If
not corrected,
automatic BC
pressure may be
direct release only.
No blending or
other
special BC
controls will be
active. Replace
16CP at
Shed.
Place Mode switch
to TRAIL,
Automatic handle
in EMER, and
Independent
IRCAMTECH/M/GWL/15-16/CCB-II
34
seconds
062
20CN
Fault
EBV,ER,
BP,RCP
Loss of
20CN
heartbeat
for 5
seconds
075
AUTO
HAND
LE
OPEN
EBV
076
INDEP
HAND
LE
OPEN
EBV
CN
Fault
EBV
Potential
meter
output
voltage <
minimum
Potentiom
eter output
voltage <
minimum
Loss of
EBV CN
heartbeat
for 5
seconds
085
ER,BP,
20 RCP
handle in FULL to
clear fault. If fault
remains, use in
Trail Mode until
repair. Replace 20
CP.
Insure LON cable
is positively seated
at 20CP. Cycle AB
circuit breaker. If
fault remains, set
ABCB off and use
in trail on
pneumatic backup
Set to TRAIL.
Replace EBV.
Set to TRAIL.
Replace EBV.
IRCAMTECH/M/GWL/15-16/CCB-II
108
Cab
Mismat
ch
Fault
RCP
118
RCP
CN
Fault
BP,20,
EBV
125
MV26
Deenergiz
ed
ER
35
Both Cab
switches
are set to
switch
position
and one of
them is
not in the
TRAIL
position.
Loss of
RCP
heartbeat
for 5
seconds
Output
feedback
indicates
MV
fault
node. If steady or
blinking,
reprogram
or replace EBV. If
red light remains
on after power
cycle, replace
EBV.
Correct setup,
recover penalty. If
not corrected, must
be used in Trail
Mode until repair.
replace EBV
Must be used in
Trail Mode until
repair. Replace
RCP.
Must be used in
Trail Mode until
repair. Replace
ERCP
IRCAMTECH/M/GWL/15-16/CCB-II
36
136
16CP
BPT
Fault
16
Xdcr
output
voltage >
4.5 or
< 0.5
140
MR/FL
Dual
Transd
ucer
Fault
BP
141
LCI
Comm
Loss
RCP
Xdcr
output
voltage >
4.5 or
< 0.5 for
both
MRT and
FLT
Loss of
LCI
heartbeat
for 5
seconds
142
20
BMV
Fault
16
Output
feedback
indicates
MV
fault
Automatic BC
pressure may be
direct release only.
No blending or
other special BC
controls will be
active. Replace
16CP at shed.
AW4 diagnostics
are disabled. Loss
of MR pressure
indication for
display (if
equipped). Replace
BPCP at shed
Ensure LON cable
is positively seated
at LON convertor
and LCC
Cycle AB circuit
breaker.
Replace LON
convertor, Replace
LCI
Must be used in
Trail Mode until
repair. Replace
IRCAMTECH/M/GWL/15-16/CCB-II
37
IRCAMTECH/M/GWL/15-16/CCB-II
38
If one EBV faults are logged and are not clearing, work from
other EBV (may be operated to clear the section till the other
EBV is attended duly observing safety)
While Auto Handle at FS position while changing LT switch
position (other than Test position selection CCB will apply
FS penalty if not followed.
Recycle CCB Circuit Breaker to clear any faults logged. If
not cleared then please contact respective shed.
Ensure proper working of Air Dryer and MR Drain valves.
In case the Air Dryer is by passed, then manually drain MR
Auto Drain Valves when times permits and inform shed.
If Air Dryer by passed inform to shed and also pass the
remarks in loco repair book.
DONTs
IRCAMTECH/M/GWL/15-16/CCB-II
39
Do not spill liquid like tea, coffee, water on the Brake Valve
Controller
Do not keep Non-working Auto handle beyond FS position.
11.0 ABBREVIATIONS
ABCB.................... AIR BRAKE CIRCUIT BREAKER
ALR ..................... ALARM RELAY
BO ........................ BAIL OFF
BC....................
BRAKE CYLINDER
BCCO................ BRAKE CYLINDERCUT-OUT PIPE
BP......................... BRAKE PIPE
BPCN................... BRAKE PIPE CONTROL NODE
BPCO................... BRAKE PIPE CUT-OFF VALVE
BPCP.................... BRAKE PIPE CONTROL PORTION
CN........................ CONTROL NODE
COC..................... CUT OFF COCK
COMM................. COMMUNICATION
COS...................... CUTOFF SWITCH
EAB...................... ELECTRONIC AIR BRAKE
EBV...................... ELECTRONIC BRAKE VALVE
EMER................... EMERGENCY
ER........................ EQUALIZING RESERVOIR
ERCP................... EQUALIZING RESERVOIR CONTROL
PORTION
ERCN................... EQUALIZING RESERVOIR CONTROL NODE
FV ......................... FEED VALVE
IND ....................... INDEPENDENT
LON ...................... LOCAL OPERATING NETWORK
LRU ...................... LINE REPLACEABLE UNIT
MIN ...................... MINIMUM
MR ........................ MAIN RESERVOIR
MREP ...................MAIN RESERVOIR EQUALIZING PIPE
IRCAMTECH/M/GWL/15-16/CCB-II
40
IRCAMTECH/M/GWL/15-16/CCB-II
OUR OBJECTIVE
To upgrade maintenance technologies
and methodologies and achieve
improvement in productivity and
performance of all Railway assets and
man power which inter-alia would
cover reliability, availability, utilization
and efficiency?
If you have any suggestions and any specific comments,
please write to us.
Contact person
: Director (Mech.)
Postal address
: Indian Railways,
Centre for Advanced
Maintenance Technology,
Maharajpur, Gwalior.
Pin code - 474 0050
Phone
:
0751- 470890, 0751-2470803
Fax
:
0751- 2470841
41