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of India)
(Ministry of Railways)
HAND BOOK
ON
MICRO CONTROLLER BASED GOVERNOR
FITTED ON DIESEL LOCOMOTIVES
Centre
for
Advanced
Maintenance
TECHnology Excellence in Maintenance
29.06.2012 (A.R.Tupe)
CAMTECH, GWALIOR Executive Director
PREFACE
SYSTEM INTERCOONECTONS
POWER AND SENSOR SIGNALS
20x4 VFD
CONTROL
UNIT
MOTOR &
CLUTCH DRIVE
ACTUATOR UNIT
CONTROL UNIT
CONTROL UNIT
CLUTCH
MOTOR
GEAR BOX
BELLOW
OUTPUT SHAFT
Handbook on Micro Controller Based Governor CAMTECH/GWL
IRCAMTECH/2012/Mech/MCBG/1.0 20
7.2 ACTUATOR UNIT
ACTUATOR UNIT
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.
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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.
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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
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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
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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
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
BAP Turbo
Diesel Tr.
HP
LOP Engine Alt.
Fuel
Rack
Governor
Eng.RPM
Excitation
Control
Notch
Control
Desk
Display &
72V Power Supply Stepper motor
Card Stepper Motor
signal
Input
Card
Display &
Power Supply Stepper motor
Card Stepper Motor
signal
Gear Box
Load & Clutch
Control Card
Input
Card
Display &
72V Power Supply Stepper Motor
Stepper motor
Card
signal
Gear Box
Load & Clutch
Control Card EM -Clutch
Clutch signal
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.
Display &
Power Supply Stepper motor
Card Stepper Motor
signal
Gear Box
Load & Clutch
Control Card EM -Clutch
Input
Card
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.
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
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
TROUBLE SHOOTING
Faults Driver Attention
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.