NEW YORK AIR BRAKE CORPORATION

Transcription

1 NEW YORK AIR BRAKE CORPORATION A KNORR BRAKE COMPANY 748 Starbuck Avenue, Watertown, New York SERVICE INSTRUCTION NYS-104 SETUP, OPERATING, AND DIAGNOSTIC INSTRUCTIONS FOR CCB II EAB SELF TEST ISSUE NO. 2 PURPOSE The following instructions are intended to familiarize the user with the setup and operation of the selftest procedure for CCB II EAB (Electronic Air Brake) System. This document also describes the CCB II self test failure codes that are reported to the operator on the locomotive screens. The four digit failure codes may be seen in the Event/Fault log or on the self test status screen. This document describes each of the failure codes and its corrective action. Integrated Processor Module (IPM) three digit fault codes are not included (see NYS-105 for IPM fault code descriptions). A. Test Equipment Required: 1. Laptop Computer or PC with GE\Harris CCB II PTU Software installed. 2. RS-232 modem cable (9-pin male to 9-pin female). 3. Wheel Chocks. B. Set Up Of The System 1. Set the hand brake and chock the locomotive s wheels. 2. Ensure that the Air Brake (AB), Locotrol Electronic Brake (LEB), and the Integrated Locomotive Computer (ILC) circuit breakers are in the ON position. 3. Ensure that the locomotive compressor is operative and Main Reservoir is charged. 4. Disable Distributive Power (DP). DP must be disabled to run self test. a) To disable DP from Lead Locomotive (GE IFC sequence listed. Others are similar): Select Distr Power (F2) / Unlink (F5) / execute (F1) / End Dist Pwr (F7) / Execute (F1). b) To disable DP from Remote Locomotive: Go to remote Engineer s locomotive computer console and select End Dist Pwr / execute

2 5. Isolate the locomotive by removing Trainline Multiple Unit (MU) Cable and closing all MU Train end cocks. Set locomotive to Lead \ Cut-in operation. 6. Place the Automatic and Independent Brake handles to the Release' position. Once the system resets, place the Independent handle to the FULL position (BC must exceed 25 psi in order to run self test). 7. Make sure the Throttle handle is in the Idle' position and the Reverser handle is in the Neutral position. C. Running the Self-Test from the Engineer s Locomotive console: Note: Note: The Self-Test must be run from one of the Engineer s locomotive console screens. It cannot be run from the Conductor s locomotive screen or a laptop. A laptop computer or PC with GE/Harris PTU software must be connected to the IPM in order to save or print the Event Log or Trace Messages. 1. Select Operator Functions (F3) /Air Brake Setup (F2) / Remote Session (F6) and Air Brake Main Menu screen appears. 2. Select Self Test (F1) and the Self Test Authorization screen appears. Type Password then select Accept (F5) and Single-Unit Self Test screen appears. At this point, there are two options to choose from. Either: select RUN which will run a single loop self test on ALL LRUs, or select SETUP which allows the operator to choose which LRU(s) are to be tested (only the LRUs that have an X next to them will be tested). By default, all LRUs are selected when you enter the Single-Unit Self Test screen from the Main Menu. You can also choose Loop Continuously from the Setup screen options by placing an X in the box next to where it reads Loop Continuously. 3. To run a self-test on All LRUs: a) Select Run (F1). The system automatically starts the self test and the Abort (F2) option becomes available in case one wants to stop the self test at any time, for any reason. Note: The Self Test will test every LRU once. If all LRUs pass self test, a No Faults Detected and a Self Test Passed message will appear. If a self test failure occurs at any point in the test, the test is aborted. A failure code number and a description are posted (see section D). 4. To run a self test on selected LRUs: a) Select Setup (F3) and Single-Unit Self Test screen appears. b) Select which LRU(s) you want to be self tested and put an X in the box next to Loop Continuously if you want the self test to run continuously (follow the keyboard commands listed under Setup Options to choose desired setup)

3 c) Once the desired setup is entered, select Accept (F4) and Single-Unit Self Test screen reappears. Note: d) Select Run (F1) to start the self test of the custom setup that was just chosen. The system starts the self test. The Abort (F2) option is available to stop the self test at any time. If Loop Continuously was chosen, the computer will run a self test on the selected LRU (s) unless the Abort (F2) button is pressed (a message will appear indicating how many loops the self test completed and how many errors were detected during the self test procedure). The Loop Continuously cycle will also abort if five (5) consecutive, identical errors have been logged on any LRU. If Loop Continuously was NOT chosen, a single self test on the selected LRU(s) will be performed. If all selected LRU(s) pass, a No Faults Detected and Self Test Passed message will appear. If an LRU fails a self test, the test immediately aborts and a failure code number and description appear. D. EAB Self Test Steps, Failure Codes, and Corrective Actions: Step Test Performed Reason For Failure Resulting Fail Code Most Probable Cause Corrective Action If Still Bad, Try: 1 ER Release. Charge ER to Feed Valve pressure. 2 ER Drift at Release. For 5 seconds, verify ER +1, ER Full SVC. Set ER = FV ER Drift At Full Service. For 5 seconds, verify ER +1, MVER de-energized for 5 seconds, then MVER = energized. Wait 2 seconds for ERT pressure reading ER not within +/- 2 psi of Feed Valve (FV) pressure. ER not within +/- 1 psi of step 1 pressure (Drifted). ER not within +/- 2 of (FV-26 psi) air pressure. ER not within +/- 1 psi of step 3 air pressure reading. FS) MVER exhaust rate is not within limits ER Control Release ER Release ER Control FS ER FS MVER Deenergized Test (Service Rate Reduction) malfunction 'or' fault on ERCP malfunction 'or' fault on ERCP. malfunction 'or' fault on ER. malfunction 'or' fault on ER. Plugged choke on 13CP 'or' MVER stuck. Calibrate ERT in bad, replace ERCP. Calibrate ERT in bad, replace ERCP. Calibrate ERT in bad, replace ERCP. Calibrate ERT in bad, replace ERCP. Check 13CP exhaust choke (bottom). If clear, replace ERCP and calibrate ERT. Replace 13CP

4 6 MVER Energized. Wait 18 seconds; verify ER +3, Print TESTING BP LRU. ER pressure has drifted +/- 3 psi from step 5 air pressure MVER Energized Test. Leakage (Maintaining AW- 4 circuit is not activated). Check for leakage on ERCP and 13CP manifold gaskets. Leaks on hoses on rear of manifold. Check for leak at ERCP test fitting. Replace ERCP. Step Test Performed Reason For Failure Resulting Fail Code Most Probable Cause Corrective Action If Still Bad, Try: 8 Graceful Cut-in. ER target: BP+5, MV53 de-energized. 9 BP CHG. Set ER = FV- 40. Wait 30 seconds; verify BP +2, MV53/BPCO. Cut-out BP, Set ER = FV. BP should not increase with ER. 11 MV53/BPCO. Cut-in BP, verify BP > (FV-30) BP not in +/- 2 psi of (FV-40 psi) air pressure. BP not in +3/-8 psi of (FV-40 psi) pressure (allow 0.5 psi /sec. BP leakage). BP is not greater than (FV-30 psi) air pressure. 12 Wait 5 seconds. BP not in +/- 3 psi BP finish charge, verify of ER pressure. BP = ER +3, Low BP BPCO. Set ER = 0. Wait 60 seconds; verify BP is in (8.0, 14) BP is not within 8 to MVEM. Set BP = 40. Cut-out BP. Energize MVEM to create Emergency. Wait 5 seconds; verify BP <5 15 Wait 25 seconds for Vent Valves to reset. 16 EMV. Set BP = 40. Wait 5 seconds; verify BP <5 17 Wait 25 seconds for Vent Valves to reset. BP is greater than 5 BP is greater than BP Control Error (Charge) 1207 MV53/BPCO Will Not Cut Out MV53/BPCO Will Not Cut In BP Control Release 1209 BPCO No Cut Low Psi MVEM Fault 1211 EMV Fault BP leakage. ERT or BPT Calibration off. MV53/BPCO will not cut out. MV53/BPCO will not cut in. BP leakage. ERT or BPT Calibration off. BPCO did not low BP pressure. MVEM Fault. PVEM failure. Locomotive vent valves. EMV fault. PVEM failure. IPM I/O failure, cabling fault. Ensure end cocks are closed, and then calibrate ERT and BPT in EAB remote session. Check BPCP for leakage. Calibrate ERT and BPT in session. Rerun self test while monitoring trace messages. If BP is higher than allowable range, replace BPCP. Ensure MR is above FV pressure. Ensure end cocks are closed. Calibrate ERT and BPT. Rerun self-test. Ensure end cocks are closed. No BP or BPCP leakage. Calibrate BPT. Ensure end cocks are closed. No BP or BPCP leakage. If BP went to zero psi and vent valves didn't trip, check vent valves. Check cabling and connectors. Replace IPM, RIM. If still bad, replace BPCP. Replace BPCP. If BP is lower than allowable range, find BP leak on CCB II or locomotive. Replace BPCP. Replace BPCP. Replace BPCP Ring out cables from IPM to RIM to PSJB. Replace PSJB

5 18 Print TESTING 20 LRU. Set 20 pressure to 55 Wait 7 seconds for 20 to stabilize. 19 Exhaust 20 pipe pressure. Wait 7 seconds for 20 to exhaust. 20 pipe pressure is not between pipe pressure is greater than No 20 Charge 1302 No 20 Exhaust. fault on 20CP. fault on 20CP. Ensure end cocks are closed, no 20 leak. Calibrate 20T in EAB remote bad, replace 20CP. Ensure end cocks are closed. Calibrate 20T in bad, replace 20CP. at 20 test fitting. Possible manifold cross-port leak. Check normal operation outside remote session. Step Test Performed Reason For Failure Resulting Fail Code Most Probable Cause Corrective Action If Still Bad, Try: 20 MVLT. Set 20 = 55. Set to trail. Exhaust 20 AW4 pressure. Wait 5 seconds, read 20TT, verify > Line Exh. 22 Testing 13 LRU. 13 CHG. Set 13 = MR. Wait 5 seconds, verify 13 > MR EXH. Set 13 = 0. Wait 5 seconds, verify 13 < Exh. (Unpowered). Wait 15 seconds, verify 13 <15 25 Print TESTING 16 LRU. Release Auto and Ind. brakes. Set ER = /BC CHG. Set BC = 72. Wait 5 seconds; verify 16 is in (71, 77) psi range /BC CHG. Set BC = 72. Verify BC is in (69, 75) 28 16/BC EXH. Set BC = 30. Wait 5 seconds; verify 16 is in (28,34) psi range. 20 pipe less than pipe less than (MR- 5 psi) pressure. 13 pipe greater than pipe greater than pipe not between 71 and 77 BC is not between 69 and pipe not between MVLT Stuck In Lead No 13 Charge 1403 No 13 Exhaust 1402 No Un-powered Exhaust No 16 Charge No BC Charge 1504 No 16 Exhaust MVLT failure or PVLT stuck in lead. Leakage. 13T or MR calibration off. 13CP failure. 13T calibration off. MV13E failure. 13T calibration off. Restricted vents/chokes. fault on 16CP. fault on BCCP. BCT fault Ensure end cocks are Replace 20CP. closed, no 20 leak. Check for leakage in 20 pipe, 20CP manifold gasket. Calibrate MRT and 13T in session. Re-run selftest. Calibrate 13T. Re-run self-test. Check vents/chokes on bottom of 13CP. Calibrate 13T in EAB remote session. Rerun self-test. Check vents/chokes on bottom of 13CP. Re-run self test. If still bad, replace 16CP. Re-run self test. If still bad, replace BCCP. Re-run self test. If still bad, replace 16CP. Replace 13CP. Replace 13CP. Replace 13CP. and reservoirs on rear of at 16 test fitting. If passed 1503 but failed 1600, replace BCCP. and reservoirs on rear of

6 and 34 fault on 16CP. at 16 test fitting /BC EXH. Set BC = 30. Verify BC is in (27, 33) BC not between 27 and Set ER=Feed valve + 1. De-energize MVER. Pneumatic Penalty applies. Energize MVER. De-energize MV16 to switch to BC backup. 31 BC BKUP SVC. Switch to BC Backup (16TV to 16 Vol.). Wait 5 seconds, verify BC >35 BC is less than EXH. Wait 5 seconds, verify 16 < pipe greater than No BC Exhaust. fault on BCCP. BCT fault No Backup BC 1505 No 16 Exhaust To Zero. DBTV failure. Leaking type 2 DBI-MV on BCCP or BCCP failure. Calibration off. Re-run Self Test. If still bad, replace BCCP. Replace DBTV. Ensure that the system is not in Dynamic Braking. Replace BCCP. Re-run self-test. and reservoirs on rear of at BC test fitting. and reservoirs on rear of at 16 and/or BC test fittings. Replace 16CP. Step Test Performed Reason For Failure Resulting Fail Code Most Probable Cause Corrective Action If Still Bad, Try: 33 BC BKUP. Bail Off. Set 13 = MR, wait 10 seconds. Set 13 = 0; verify BC <5 34 Draining Aux <<ELV setting by repeatedly bailing off. 35 Aux << ELV Setting. Cut-out BP, Assert MVEM. Wait 20 seconds; verify BC is within 5 psi of ELV setting. BC is greater than 5 BC is not within +/- 5 psi of ELV setting. 36 Wait 20 seconds for Vent Valves to reset. Print TESTING BC LRU. 37 Energize MVER and MV16. Set BP=0, BC=0, and apply bail. 38 Set BP = 30 via ERBU (ERBU BP is not greater than ON, MV16 OFF). 25 psi or BC is not less than 2 Wait 10 seconds No Backup BC Bailoff ELV Fault. (typical setting is 62 psi) ERBU Will Not Energize. Expect BP = <30>, BC = <0> No BackUp BC Ensure end Bailoff. 13 pressure cocks are may not be greater closed, run 13CP than 25 self-test. If it passes, replace DBTV. ELV setting drift or failure. Calibration off. ERBU will not energize. Replace 16CP. Calibrate BPT, BCT, and 16T in bad, replace 13CP. Replace 16CP - 6 -

7 39 Remove ER Backup (MV16 ON, ERBU OFF). Wait 10 seconds. ER is greater than 5 psi or BC is less than ERBU Will Not Deenergize. Expect ER = <0>, BC >25. ERBU Will Not Deenergize. - or - Leaking or low brake cylinder pressure Replace 13 CP. - or - Repair brake cylinder leakage. Replace 16CP

8 REVISION PAGE: NYS-104 ISSUE NO. 1 DATE: MARCH 17, 1999 Original Issue ISSUE NO. 2 JANUARY 3, 2000 Added additional Probable Cause and Corrective DATE: Action text to Step 39, Section D