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CITADIS EVOLUTION TRACTION SYSTEM TROUBLESHOOTING

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1. 9 O Pagina Page 36 Sesto S Giovanni ITALY Involved LRUs 4 4 2 4 4 2 1 TBCU Description AC3mini Fan speed control board LV contactor LC1D126BLS170 Power module fan MF Power module fan MF AGATE backplane layout 2 3 4 5 6 Pagina Page 37 CODICE CODE DISEGNO MOD ALSTOM EE b Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 MUT A 4 4 2 2 TBCU LV Scheme Name Description PM FAN1 BAT 1 pin to energize power module fan PM FAN1 0V 1 pin return for power module fan PM FAN2 BAT 1 pin to energize power module fan PM FAN2 0V 1 pin return for power module fan The FSCB board is used to generate two different voltage reference in order to change fans rotation speed based on an Agate digital output connected on pin10 Voltage controller output signals one for each fan are on pin 14 and 17 Main voltage supply is connected on X21 9 and X21 33 Rotation status of each fan is acquired by the Agate via two digital inputs The Agate in able to switch on and switch off the cooling fan trought K4 relay CODICE CODE DISEGNO A LSTOM Pagina Page 38 Esa Sesto S Giovanni ITALY di of 120 AY00000054545 4 4 2 3 Winscope Traintracer Use AutotestPMC tdb to support investigation Follow on screen notes in order to Start and stop cooling fan at low speed verifying correct feedback Start and stop cooling fan at
2. LST OM Pagina Page 24 CODICE CODE p Sesto S Giovanni ITALY di of 120 AY00000054545 Contactors test sequence starts Close precharge contactor If DCVoltage threshold AND precharge aux contact False trigger an error and stop test If DCVoltage threshold AND precharge aux contact True trigger an error and stop test If DCVoltage gt threshold close line contactor Open precharge contactor If line aux contact False trigger an error and stop test If line aux contact True precharge phase is correct Inhibit braking chopper2 and set braking chopper1 dutycycle to a fixed value If measured DCCurrPos is out of the expected range trigger an error and stop test If measured DCCurrNeg is out of the expected range trigger an error and stop test Switch off chopper1 and remove inhibition chopper2 Inhibit braking chopper1 and set braking chopper2 dutycycle to a fixed value If measured DCCurrPos is out of the expected range trigger an error and stop test If measured DCCurrNeg is out of the expected range trigger an error and stop test Switch off chopper2 and remove inhibition chopper1 Close M1 contactor and M2 contactor If M1 contactor aux contact false trigger an error and stop test If M2 contactor aux contact false trigger an error and stop test Open M1 and M2 contactors If M1 contactor aux contact true trigger an error and stop test If M2 contactor aux contact true trigger an error and stop test Close again M1 and M2 contac
3. Pagina Page 43 CODICE CODE DISEGNO MOD ALSTOM a Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 JA9UT A 4 5 2 2 TBCU LV Scheme PowerModule PowerModule Q Fri e G X 313 214 1216 1218 X 313 p12 D10 Two thermoswitches related to inverter1 are connected in series and acquired by an Agate digital input Two thermoswitches related to inverter2 are connected in series and acquired by an Agate digital input Gate drive status from Inverter1 Gate drive status from Chopper1 Gate drive status from Inverter2 Gate drive status from Chopper2 msom 4 5 2 3 Winscope Traintracer TDB Use AutotestPMP tdb to support investigation Follow on screen notes in order to Check correct feedback from Gate Drive inverter1 Check correct feedback from Gate Drive chopper1 Check correct feedback from Gate Drive inverter2 Check correct feedback from Gate Drive chopper2 Check correct feedback from thermoswitches inverter1 Check correct feedback from thermoswitches inverter2 LSTOM Pagina Page 44 CODICE CODE Sesto S Giovanni ITALY di of 120 AYO0000054545 4 5 3 Verifications Failure 301 Involved LRUs BCU AGATE AC3mini Power module ONIX850DLP3 ONIX850DLP3 4 5 3 1 Message xx 29 26 GU inverter1 not OK 4 5 3 2 Message xx 29 27 GU Braking chopper inverter1 not OK DISEGNO DRAW 1 9UT AC3mini read feedback status from gate units board inside the power module which cont
4. Start and stop cooling pump verifying correct feedback Start and stop cooling fan at low speed verifying correct feedback A Start and stop cooling fan at high speed verifying correct feedback LST OM Pagina Page 30 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 4 3 3 Verifications Failure 102 Involved LRUs AGATE AC3mini Thermal protection moto pump RM 11K3 Three phase contactor 11K3 Pump 11M3 4 3 3 1 Message xx 29 08 GRF pump UnableToStart or contactor Flt AC3mini controls 11K3 which activates GRF motor pump and read status of the contactor aux contact CHECK thermal protection of the motor pump RM 11K3 in case of thermal protection trip re arm it VERIFY that pump rotation is smooth REPLACE 11K3 activate the pump and VERIFY consistency between contactor command and feedback REPLACE AC3mini downloading the correct Traction SW version activate the pump and VERIFY consistency between contactor command and feedback CHECK internal and external cabling VERIFY that electrical connections are good REPLACE motor pump LST OM Pagina Page 3L CODICE CODE de Sesto S Giovanni ITALY di of 120 AYO0000054545 1 9UT 4 3 4 Verifications Failure 104 Involved LRUs TBCU AGATE hree phase contactor 11K3 4 3 4 1 Message xx 29 09 GRF pump UnableToStop or contactor Stuck AC3mini controls 11K3 which activates GRF motor pump and read s
5. Verifications Even if the text messages are generic the TrainTraceCode permits to identify which motor is supposed to have troubles as on the table presented before Mi is related to motor1 2 is related to motor2 RUN LOW POWER TEST EPR to discover possible faults on speed sensors REPLACE AC3mini downloading the correct Traction SW version VERIFY that no specific faults are recorded while performing a dynamic test REPLACE the supposely fault speed sensor resolver VERIFY that no specific faults are recorded while performing a dynamic test Pagina Page 99 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A Inverter cooling fan fault Description Power module cooling fans are essential for proper functionalities of the Traction Converter Without cooling Traction System is considered locked in order to avoid seriuos damages to the power module A less severe fault is when it is not possible to stop fans i e due to a stuck condition of the contactor K4 Here below the involved messages TrainTracerCode Stack Text message xx 27 35 Inverter cooling fan stuck 2 10 2 xx 27 36 Inverter cooling fan unable to start xx 2B 4E le Involved LRUs Power module cooling fans are fully tested by the Low Power Test specific sequence presented in 4 4 Please refer to it for all the details related to LV schemes and WinScope TDB Description AC3mi
6. 2 Run TrainTracerUTM on the PC 3 Import the traintracer project file etr file localed in USB data eTrain Menu File gt Import project gt Import project from TrainTracer TrainTracer UTM File Service Window es Open project Import project Import project from TCMS Workbench Import project from TrainTracer Export project Delete project 4 Atthe end of the process Open the previously imported project la TrainTracer UTM File Service Window Open project A Console Project ciladis2 mas iv Import project VIN No Filter ersion Export project 5 Connectthe PC to the ethernet Train network and then click the Connect icon B TrainTracer UTM citadis2 mas 3 0 1 File Service Bookmarks Window Connect to train d LSTOM Pagina Page 20 CODICE CODE Kon Sesto S Giovanni ITALY di of 120 AY00000054545 6 Amessage box appears select Train switch connection then press Ga r r Connect to train Connection type Train switch connection O Front panel connection C Detect onboard configuration 7 The Option window appears where you have to specify the IP address Train switch address of each Agate3mini available on the vehicle Use Ignore check button to exclude Agate units not available on the train this reduce connection times because TrainT
7. LST 6 M Pogino Poge 1 CODICE CODE Sesto S Giovanni ITALY di of 120 AY00000054545 149UT User Manual CITADIS EVOLUTION TRACTION SYSTEM TROUBLESHOOTING MANUAL TRACTION SyTM Verificare lo stato di aggiornamento prima dell utilizzo Check the revision status before use CONTROLLATO DA CHECKED BY APPROVATO DA APPROVED BY DATA D CITELLI System TLE M RIGOSELLI Product Monager Tramways DATE Firma Firma 27 09 10 K rs nm d Signature Dorala CALE LA Signature Riferimento Interno Internal References eng ses mon 001 Societ certificata ISO 9001 amp 14001 ISO 9001 amp 14001 certified Compon La propriet della presente nservato Lo riproduzione anche parziale e lo diffusione senza nostro autorizzazione sono vietate a termini di legge This document is reserved property Reproduction or use for ony purpose without our outhorization is strictly forbidden by law Ward2000 LST OM Pagina Page 2 CODICE CODE de Sesto S Giovanni ITALY di of 120 AYO0000054545 1 9UT AGGIORNAMENTI UPDATE Mod Data Descrizione Autore Iss Date Description Author A 27 09 10 First emission D CITELLI System TLE rs ALLEGATI ANNEX N Documento Descrizione Document Nr Description LST OM Pagina Page 3 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 INDICE INDEX als 2 Perimeter 3 References 4
8. additional speed information 2 4 2 3 PMM configuration Name Description X20 Pinout PMM1 6wire shield resolver installed on motor 1 54 55 56 RefH RefL Sh Remember to swap SENH and SENL connection on the 57 58 59 CosH CosL Sh vehicle other wires shall follow the table 60 61 62 SinH SinL Sh 6wire shield resolver installed on motor 2 64 65 66 RefH RefL Sh Remember to swap SENH and SENL connection on the 67 68 69 CosH CosL Sh vehicle other wires shall follow the table 70 71 72 SinH SinL Sh AXLEADD1 2wire shield speed sensor installed on a trailed axle for 49 50 52 15V IN Sh additional speed information ALSTOM Sesto S Giovanni ITALY 2 4 3 X21 Battery Level Signals Pagina Page 13 di of 120 CODICE CODE AYO0000054545 On X21 connector all the battery level signals and battery supply pin are mapped Traction Unit is designed to use 24V DC nominal battery voltage within a range between 16 8V to 30V specific pins are defined to energize the electronic control internal LV devices contactors relays and cooling fans 2 4 3 1 Layout NO SB L RESCUE L TRACTION L DIRI IN ENABLE Dian LV BAT IN PMFANI_BAT LV_BAT_IN2 LO SPARE LO SPARE L NOBRAKE LO BCUFAULT LO BCUFAULT L DIR2 LO TRACKBRAK RAKE m CO CO CO CO CO CO WINN IS ISIS IS D o eje e a e s s e 0
9. 4 5 6 7 Pagina Page 79 CODICE CODE DISEGNO MOD ALSTOM ME Sesto S Giovanni ITALY 1200 AY0000005 545 5 5 3 Verifications In case of Repetitive overcurrent on DC link do the following steps RUN LOW POWER TEST EPR to eventually discover faults on current sensors power module shortcircuit on DC bus REPLACE AC3mini downloading the correct Traction SW version VERIFY that these specific faults are no more recorded while performing a dynamic test In case of Differential Current fault do the following steps RUN LOW POWER TEST EPR to eventually discover faults on current sensors power module or the Agate itself CHECK dielectric isolation to ground VERIFY that dielectric resistance is not compromize otherwise check the HV circuit to detect which LRU is responsible of the fault ONIX850DLP3 LF1 LF2 KPRE1 RPRE1 REPLACE AC3mini downloading the correct Traction SW version VERIFY that these specific faults are no more recorded while performing a dynamic test Pagina Page 80 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A HW DC Overvoltage Description Traction converter is protected against overvoltage at DC side usually due to severe transients on the catenary voltage or HW faults inside the power module braking rheostats or Agate When DC voltage overpass a certain threshold inverter pulses are inhibited and braking chopper is used to clamp
10. 4 8 6 Verifications Failure 608 4 8 6 1 Message xx 29 3D Braking chopper2 KO or DC PosCurr Fault 4 8 6 2 Message xx 29 3E Braking chopper2 KO or DC NegCurr Fault 4 8 7 Verifications Failure 611 4 8 7 1 Message xx 29 20 Motor Contactor1 unable to close 4 8 7 2 Message xx 29 22 Motor Contactor2 unable to close 4 8 8 Verifications Failure 613 4 8 8 1 Message xx 29 21 Motor Contactor1 fault during open 4 8 8 2 Message xx 29 23 Motor Contactor2 fault during open Traction failures 5 1 Introduction 5 2 Anomalous vehicle behavior 5 3 Event list LST OM Pagina Page 5 CODICE CODE de Sesto S Giovanni ITALY di of 120 AYO000005 545 HW Phase Overcurrent Description Involved LRUS TBCU HV Scheme TBCU LV Scheme Verifications DC Overcurrent Differential Current Fault Description Involved LRUS Verifications HW DC Overvoltage Description Involved LRUS Verifications Motor contactors faults Description Involved LRUS Verifications Line Precharge contactors faults Description Involved LRUS Verifications Rheo Overtemperature Description Involved LRUS Rheostat Verifications Motor Overtemperature Description Involved LRUS Verifications GRF Pump and Fan faults Description Involved LRUS Verifications GRF water pressure water level Description Involved LRUS GRF TBCU LV Scheme Winscope Traintracer TDB
11. Active high as above L PRESSOSTAT Water pressure sensor from GRF Active low open circuit with low pressure L PUMP Pump aux cont from GRF Active high pump aux cont from GRF L FANHS Fan HS aux cont from GRF Active high fan HS aux cont from GRF L Fan aux cont from GRF Active high fan aux cont from GRF L WATERLVL1 Water level from GRF Active low open circuit with low level L WATERLVL2 Water level from GRF Active low open circuit with low level L SPARE1 Spare input avalable Not defined L SPARE2 Spare input avalable Not defined L SPARE3 Spare input avalable Not defined L SPARE4 Spare input avalable Not defined L BCURELAY Aux contact from BCU bypass relay Active high BAT when relay is energized L BCUAPP Mech brake applied from BCU Active high L BCUREL Mech brake released from BCU Active high L BCUISO Mech brake isolated from BCU Active high DISEGNO MOD DRAW ISS Pogino Page 15 CODICE CODE DISEGNO MOD ALSTOM DRAW ES Sesto S Giovanni ITALY di of 120 AY00000054545 2 4 3 4 Digital Outputs Name Description notes 21 GOOD DIR Direction request has been decoded Two NO contacts in parallel Active high 51 correctly congruent with DIR FORWARD BAT when direction has been correctly or DIR REVERSE decoded LO BCUFAULT
12. Message xx 29 33 Current sensor Motor2 phaseS offset flt 4 6 4 Verifications Failure 402 4 6 4 1 Message xx 29 2E Current sensor DC positive offset fault 4 6 4 2 Message xx 29 2F Current sensor DC negative offset fault 4 6 5 Verifications Failure 403 4 6 5 1 Message xx 29 34 Voltage sensor DC Bus offset fault 4 7 Autotest Speed Transducers 4 7 1 Description 4 7 2 Involved LRUs 4 7 2 1 4 7 2 2 4 7 2 3 TBCU LV Scheme 4 7 2 4 Winscope Traintracer TDB 4 7 3 Verifications Failure 501 4 7 3 1 Message xx 29 1A Speed channel 1 Fault 4 7 3 2 Message xx 29 1B Speed channel 2 Fault 4 7 3 3 Message xx 29 1C Speed channel 3 Fault 4 7 3 4 Message xx 29 1D Speed channel 4 Fault 4 7 3 5 Message xx 29 1E Speed channel 5 Fault 4 7 3 6 Message xx 29 1F Speed channel 6 Fault 4 8 Low Power Test Precharge and motor contactors 4 8 1 Description 4 8 2 Involved LRUs 4 8 2 1 Braking Rheostat 4 8 2 2 4 8 2 3 TBCU HV Scheme 4 8 2 4 TBCU LV Scheme 4 8 2 5 Winscope Traintracer TDB 4 8 3 Verifications Failure 602 4 8 3 1 Message xx 29 37 Precharge contactor doesn t close 4 8 3 2 Message xx 29 38 Short circuit during precharge 4 8 4 Verifications Failure 603 4 8 4 1 Message xx 29 39 Line contactor doesn t close 4 8 5 Verifications Failure 605 4 8 5 1 Message xx 29 3B Braking chopper1 KO or DC PosCurr Fault 4 8 5 2 Message xx 29 3C Braking chopper1 KO or DC NegCurr Fault
13. REPLACE K11 VERIFY motor contactor activation and feedback REPLACE AC3mini downloading the correct Traction SW version VERIFY contactor activation and feedback CHECK the cabling VERIFY that electrical connections are good REPLACE KMOT2 VERIFY contactor activation and feedback Pagina Page 71 CODICE CODE ALSTOM Sesto S Giovanni ITALY di of 120 AY00000054545 DISEGNO MOD DRAW ISS Traction failures Introduction During normal operation Traction Control SW always performs a complete monitoring of the Traction System behavior taking all the protective actions is case of faults detected on the internal components Both the supposed root cause as the protective action is traced in the event memory to support the maintenance team during troubleshooting analysis In any case Traction System is able to protect itself disabling part or the whole functionalities without specific operation of the driver or the master controller TCMS Anomalous vehicle behavior Notes and remarks reported by the driver during vehicle service could help to understand which kind of fault occurred The following table could guide to filter the events related to the main traction fault Vehicle behavior The Traction System is out of order A lock icon is showed on the DDU Filter for Lock During normal operation the driver reports that motor torque was missing for few seconds than reappeared Error T
14. n S S 3 S SS A MSN M NI NI NI A NN NS NS a Description AGATE CODICE CODE DISEGNO DRAW AYO0000054545 1 9UT AC3mini Braking rheostat connection RH1 Braking rheostat connection Verifications RH2 Even if the text messages are generic the TrainTraceCode permits to identify which rheostat is supposed to have troubles as on the table presented before R1 is related to RH1 R2 is related to RH2 RUN LOW POWER TEST EPR to identify possible faults related to the rheostat devices or voltage sensor CHECK the cabling between the traction converter and the rheostats VERIFY that electrical connections are good CHECK the ohmic value of the rheostat disconnecting power cables from the TBCU VERIFY that resistance value is around 1 150hm nominal value Pagina Page 88 CODICE CODE DISEGNO MOD ALSTOM RE D Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 10 Motor Overtemperature 5 10 1 Description Each motor are monitored using a thermal model that estimates the working temperature hot spot in realtime When the estimated temperature overpass a defined warning threshold a message is traced in the event memory and the motor torque is reduced by a fixed percentage to prevent additional troubles If the temperature overpass a successive higher threshold inverter pulses are inhibited until the temperature fall down to an acceptable
15. 4 8 6 Verifications Failure 608 Involved LRUs TBCU Power module ONIX850DLP3 ONIX850DLP3 Braking Rheostat Braking rheostat 1 2 rheostat RH2 4 8 6 1 Message xx 29 3D Braking chopper2 KO or DC PosCurr Fault 4 8 6 2 Message xx 29 3E Braking chopper2 KO or DC NegCurr Fault AC3mini activates with a fixed duty cycle the braking chopper 1 part of the ONIX850DLP3 power module and checks that DC current value measured by DC transducers TAL P1 and TAL_N1 is consistent with the rheostat RH2 ohmic value REPLACE AC3mini downloading the correct Traction SW version VERIFY that the low power test sequence is completed successfully CHECK the cabling to RH2 VERIFY that electrical connections are good LST OM Pagina Page CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 4 8 7 Verifications Failure 611 Involved LRUs AGATE hree pole motor contactor LTHS0320HFO0 KMOT1 2 LV contactor LC1D126BLS170 K10 K11 4 8 7 1 Message xx 29 20 Motor Contactor1 unable to close AC3mini commands motor contactor KMOT1 using an auxiliary relay K10 and checks correct functionality reading the auxiliary contact of KMOTI itself REPLACE K10 VERIFY motor contactor activation and feedback REPLACE AC3mini downloading the correct Traction SW version VERIFY contactor activation CHECK the cabling VERIFY that electrical connections are good REPLACE KMOT1 VERIFY contactor activation and f
16. Fan UnableToStop or contactor Stuck Message xx 29 10 GRF FanHS UnableToStop or contactor Stk Autotest PowerModule Cooling Description Involved LRUs TBCU LV Scheme Winscope Traintracer TDB Verifications Failure 202 Message xx 29 13 PMC Fan DO for High Speed fault Message xx 29 14 PMC Fan1 UnableToStart or contactor Fit Message xx 29 15 PMC Fan2 UnableToStart or contactor Fit Verifications Failure 204 Message xx 29 16 PMC Fan1 UnableToStop or contactor Stuck LST OM Pagino Poge 4 CODICE CODE x Sesto S Giovanni ITALY di of 120 AY00000054545 Message xx 29 17 Fan2 UnableToStop or contactor Stuck Autotest PowerModule Protections Description Involved LRUs Winscope Traintracer TDB Verifications Failure 301 Message xx 29 26 GU inverter1 not OK Message xx 29 27 GU Braking chopper inverter1 not OK Message xx 29 28 GU inverter2 not OK Message xx 29 29 GU Braking chopper inverter2 not OK Verifications Failure 302 Message xx 29 2A Thermoswitch inverter1 not OK Message xx 29 2B Thermoswitch inverter2 not OK Autotest PowerModule Transducers Description Involved LRUs 4 6 2 2 4 6 2 3 Winscope Traintracer TDB 4 6 3 Verifications Failure 401 4 6 3 1 Message xx 29 30 Current sensor Motor1 phaseR offset flt 4 6 3 2 Message xx 29 31 Current sensor Motor1 phaseS offset flt 4 6 3 3 Message xx 29 32 Current sensor Motor2 phaseR offset flt 4 6 3 4
17. LSTOM Pagina Page 64 Sesto S Giovanni ITALY di of 120 IL LINE CURRENT L LINE CURRENT SENSOR SENSOR DBBLONDIA CODICE CODE DISEGNO MOD DRAW Iss AY00000054545 UC INVERTER VOLTAGE SENSOR A TAL PI current positive standard current sensor Hall effect is directly acquired by the Agate B TAL N1 DC current negative standard current sensor Hall effect is directly acquired by the Agate C TVL1 DC voltage transducer is directly acquired by the Agate PowerModule D Chopperi gate drive power supply E Chopper IGBT pulse command and status feedback F Chopperi gate drive power supply G Chopperi IGBT pulse command and status feedback 4 8 2 5 Winscope Traintracer TDB Use AutotestLPT tdb to support investigation Follow on screen notes in order to Close and open precharge contactor and verify correct feedback Close and open line contactor and verify correct feedback Close and open motor contactors and verify correct feedback LST OM Pagino Page CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 4 8 3 Verifications Failure 602 Involved LRUs AC3mini Line voltage sensor AV100 1000 SP2 TVL1 Precharge contactor L TC 100 KPRE1 LV contactor LC1D126BLS170 K6 Power module ONIX850DLP3 ONIX850DLP3 4 8 3 1 Message xx 29 37 Precharge contactor doesn t close AC3mini commands precharge contactor KPRE1 using an auxiliary relay K6 and checks correct
18. Terminology and Acronyms 1 1 1 1 General characteristics Product Presentation Traction Converter Mechanical Layout HV Overview Electrical connectors HV inputs and Motor outputs Braking Resistors outputs HV Scheme Standard Configuration LV Overview Electrical connectors 4 2 X20 Speed Signals 2 4 2 1 2 4 2 2 MAS configuration 2 4 2 3 PMM configuration 2 4 3 X21 Battery Level Signals 2 4 3 1 2 4 3 2 Power Supply 2 4 3 3 Digital Inputs 2 4 3 4 Digital Outputs 2 4 4 X22 amp X23 Vehicle Communication Busses 2 4 4 1 2 4 4 2 MVB amp Ethernet Troubleshooting Process Introduction Replace and Test approach List of tools used for investigations How to download diagnostic messages Understanding diagnostic messages Event Stack Filtering Events Low Power Test 4 1 Low Power Test step codes 4 2 Main Test Sequence 4 2 1 Description 4 3 Autotest GRF 4 3 1 Description 4 3 2 Involved LRUs 4 3 2 1 4 3 2 2 4 3 2 3 4 3 2 4 Winscope Traintracer TDB Verifications Failure 102 Message xx 29 08 GRF pump UnableToStart or contactor Fit Verifications Failure 104 Message xx 29 09 GRF pump UnableToStop or contactor Stuck Verifications Failure 106 Message xx 29 0D GRF Fan UnableToStart or contactor Flt Verifications Failure 108 Message xx 29 0F GRF FanHS UnableToStart or contactor Flt Verifications Failure 110 Message xx 29 0E GRF
19. and read status of the contactor aux contact REPLACE 11K1 VERIFY consistency between contactor command and feedback 2 REPLACE AC3mini downloading the correct Traction SW version VERIFY consistency between contactor command and feedback 3 CHECK internal and external cabling VERIFY that electrical connections are good LST OM Pagino Page 35 CODICE CODE de Sesto S Giovanni ITALY di of 120 AYO0000054545 149UT 4 4 Autotest PowerModule Cooling 4 4 1 Description This sequence check proper functionalities of the powermodule cooling fans It controls fans and verify correct behaviour reading the available status signal Step Test TrainTracerCode PowerModule Cooling test sequence starts 29 11 201 Activate fans 202 If fan1 doesn t start aux contact false trigger an error and stop test xx 29 14 If fan2 doesn t start aux contact false trigger an error and stop test xx 29 15 If high speed static output is in fault trigger an error and stop test xx 29 13 203 Switch off fans 5 204 If fani continue to run aux contact true trigger an error and stop test xx 29 16 If fan2 continue to run aux contact true trigger an error and stop test 29 17 PowerModule Cooling test sequence complete xx 29 12 The following messages will trace in the diagnostic memory the test steps TrainTracerCode Stack Text message IS A DISEGNO DRAW Q O O
20. rT T DABLODIOGA Pagina Page 56 ALSTOM Sesto S Giovanni ITALY di of 120 Description 6wire shield resolver installed on motor 1 CODICE CODE AYO0000054545 X20 Pinout 54 55 56 RefH RefL Sh 57 58 59 CosH CosL Sh 60 61 62 SinH SinL Sh 6wire shield resolver installed on motor 2 67 68 69 CosH CosL Sh 64 65 66 RefH RefL Sh 70 71 72 SinH SinL Sh ECA4 ECA4 MAS configuration speed sensors related to motor1 two single channel sensor MAS configuration speed sensors related to motor2 two single channel sensor MAS and PMM configuration speed sensor from trailer bogie configuration syncro resolver relater to motor1 PMM configuration syncro resolver relater to motor2 4 7 2 4 Winscope Traintracer TDB Use AutotestSST tdb to support investigation Follow on screen notes in order to check diagnostic flags related to motor1 speed sensors check diagnostic flags related to motor2 speed sensors check diagnostic flags related to trailer axle speed sensor DISEGNO MOD DRAW ISS AGATE Pagina Page 57 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY 4i of 120 AY0000005 545 Verifications Failure 501 Involved LRUs AGATE AC3mini Speed sensor Synchro resolver Trailer bogie Speed sensor Message xx 29 1A Speed channel 1 Fault Message xx 29 1B Speed channel 2 Fault Message xx 29 1C S
21. specific winscope In case of Fault on BCU brake released feedback do the following steps REPLACE AC3mini downloading the correct Traction SW version VERIFY correct feedback of L_BCUAPP signal using the specific winscope CHECK the cabling from the Agate backplane to the X21 connector then to the external BCU VERIFY that electrical connections are good REPLACE BCU device VERIFY correct feedback of L_BCUREL signal using the specific winscope Pagina Page 107 CODICE CODE DISEGNO MOD ALSTOM RE i Sesto S Giovanni ITALY di of 120 AY00000054545 UT A 5 18 DC Current sensors offset fault 5 18 1 Description DC current sensors are monitored for offset errors When the line and precharge contactors are open a current value measured above a threshold is considered an offset error this condition lock the Traction System for maintenance verifications Here below the involved messages TrainTracerCode Stack Text message xx 27 74 Lock DC current positive sensor offset error xx 27 75 Lock DC current negative sensor offset error 5 18 2 Involved LRUs Current sensors offset are fully tested by the Low Power Test specific sequence presented in 4 6 Please refer to it for all the details related to LV schemes and WinScope TDB D32 B32 Z32 D2 B2 Z2 Description Line current sensor Line current sensor AGATE backplane layout 5 18 3 Verifications 1 RUN LOW POWER T
22. this energy After a while the traction system automatically try to restart itself In case of repetitive faults in a short time Traction system is declared unavailable and specific HW checks must be done Here below the involved messages TrainTracerCode Stack Text message xx 27 91 Error Overvoltage on DC link xx 27 18 Lock Repetitive overvoltage on DC link Involved LRUs DC HV circuit is tested by the Low Power Test specific sequence presented in 4 8 Please refer to it for all the details related to LV schemes and WinScope TDB Description AGATE AC3mini Line voltage sensor AV100 1000 SP2 TVL1 Power module ONIX850DLP3 ONIX850DLP3 Braking rheostat 1 2 rheostat RH1 Braking rheostat 1 2 rheostat RH2 Pagina Page SL CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY 12 AY0000005 545 5 6 3 Verifications RUN LOW POWER TEST EPR to eventually discover faults on current sensors power module braking chopper or rheostat REPLACE AC3mini downloading the correct Traction SW version VERIFY that these specific faults are no more recorded while performing a dynamic test Pagina Page 82 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 7 Motor contactors faults 5 7 1 Description PMM Traction Converter is equipped with motor contactors Correct behavior of these devices one for each
23. using a proper pressure transducer In case of low water pressure the Traction Unit is locked to prevent more serious troubles at the motors Water tank level is optionally acquired when the GRF unit is equipped with these sensors In case of low level a warning message is recorded preventing system restart Here below the involved messages TrainTracerCode Stack Text message xx 27 2E Lock GRF cooling water low pressure xx 27 2A Warning GRF cooling water low level 5 12 2 Involved LRUs 5 12 2 1 TBCU Description BT connector X21 AGATE AC3mini AGATE backplane layout Pagina Page 92 CODICE CODE DISEGNO MOD ALSTOM RE Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 JA9UT A 5 12 2 2 GRF Description Differential pressure switch Level detector 2 thresholds option 5 12 2 3 TBCU LV Scheme Description notes X21 L PRESSOSTAT Water pressure sensor from Active low open circuit with low pressure 77 L WATERLVL1 Water level from GRF Active low open circuit with low level 81 L WATERLVL2 Water level from GRF Active low open circuit with low level 82 5 12 2 4 Winscope Traintracer TDB Use AutotestGRF tdb to support investigation Follow on screen notes in order to Verify weter pressure acquisition while pump is running Verify w
24. 02 DA00702C DABLOOTOZA GNO X 310 F DC current positive standard current sensor Hall effect is directly acquired by the Agate G DC current negative standard current sensor Hall effect is directly acquired by the Agate 4 6 2 3 Winscope Traintracer Use AutotestPMT tdb to support investigation Follow on screen notes in order to Verify measured motor1 phase currents Verify measured motor2 phase currents Verify measured positive DC current Verify measured negative DC current Verify measured DC bus voltage Pagina Page 50 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY di of 120 AY00000054545 4 6 3 Verifications Failure 401 Involved LRUs BCU AGATE AC3mini TAM_U1 TAM V1 Motor phase current sensor LF505 S SP28 TAM U2 TAM V2 4 6 3 1 Message xx 29 30 Current sensor Motori phaseR offset flt 4 6 3 2 Message xx 29 31 Current sensor Motori phaseS offset flt AC3mini uses voltage and current transducers for inverter protection and motors control REPLACE AC3mini downloading the correct Traction SW version VERIFY that motori currents value are around zero CHECK cabling between Agate rack connectors and the measuring device removing AC3mini VERIFY that electrical connections are good REPLACE TAM 01 or TAM V1 depending on the diagnostic message phaseR is U1 phases is V1 VERIFY that motor1 currents value are around zero 4 6 3 3 Message xx 29 32 Current sensor Motor2
25. 30 AGATE 3 I I i i 1 x 8 6 EIO3 EIO5 lu uo 555 555 i x x x x x x EIO3 DONE E u a 5 8 318 X318 1832 X316 1224 X318 1212 X 316 2 D32 Faso X318 b24 526 Si Bi 8 E E zls zs zs us z amp dd s ale Bis Bis k 4 43 li 3 a 5 8 Ss S 8 8 4 E 2 Battery voltage to energize internal relays and contactors comes from X21 8 Agate controls K6 relay which energize precharge contactor KPRE coil Agate controls K5 relay which energize line contactor KL1 coil Agate controls K10 and K11 relays that energize main motor contactor KMOT1 and KMOT2 coils cov Pagina Page 63 CODICE CODE DISEGNO MOD ALSTOM ME b Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 MUT A Auxiliary contact from line contactor KL1 is acquired by the Agate Auxiliary contact from precharge contactor KPRE1 is acquired by the Agate PMM configuration only auxiliary contact from motor contactor KMOT1 is acquired by the Agate PMM configuration only auxiliary contact from motor contactor KMOT2 is acquired by the Agate Inside the FSCB board are installed specific load resistors in order to guarantee minimum current in the aux contacts F Line contactor KL1 main coil is energized by K5 contact G Precharge contactor KPRE1 main coil is energized by K6 contact only if line contactor is open
26. 51092 T aL VB CBT CM XHVI BCE1 M1 BCE3 M2 25A1 LVB CBT O 44 26 28b 30d 302 CODICE CODE AYO0000054545 C 28 25120 OPTION AXLE INDEPENDANCE OPTION INDEPENDANCE PAR ESS WIRING PREDISPOSITION ONLY PREDISPOSITION CABLAGE UNIQUEMEt TLS 0L2 RMS AGR LLP ExBrkRe lt LO BCEXBSErkSefPal LO BCExB4BrkSetPoi 22 DA E UE IN 2 ect en A Bypass relay controlled by Traction used to take 4 setpoint signals from Traction TCMS B BCU Unit C TCMS RIOM redundant to Traction digital outputs 5 17 2 3 TBCU LV Scheme notes Active high L BCURELAY Description Aux contact from BCU bypass relay X21 90 L BCUAPP Mech brake applied from BCU Active high 95 L BCUREL Mech brake released from BCU Active high 97 X317 AGATE DISEGNO MOD DRAW ISS 1 9UT A LSTOM Pagina Page 105 Sesto S Giovanni ITALY di of 120 LO BCURELAY Description Command to control BCU relay Internally connected to L BCU BAT CODICE CODE DISEGNO MOD DRAW ISS AYO0000054515 notes Static output Close circuit in order to energize external BCU relay LO LOCBRO Command for BCU Internally connected to BCU BAT Static output LO LOCBH1 Command for BCU Static output LO LOCBR2 Command for BCU Static output LO LOCBR3 Command for BCU Static output BCU
27. 612 Open M1 and M2 contactors 613 If M1 contactor aux contact true trigger an error and stop test xx 29 21 If M2 contactor aux contact true trigger an error and stop test xx 29 23 614 Close again M1 and M2 contactors Contactors test sequence complete xx 29 36 The following messages will trace in the diagnostic memory the test steps TrainTracerCode Stack Text message Start Low Power Test precharg End Low Power Test precharg Precharge contactor doesn t close Short circuit during precharge Line contactor doesn t close Precharge phase completed Braking chopperl KO or DC PosCurr Fault Braking 1 KO or DC NegCurr Fault Braking chopper2 KO or DC PosCurr Fault Braking chopper2 KO or DC NegCurr Fault otor Contactorl unable to close otor Contactorl fault during open otor Contactor2 unable to close otor Contactor2 fault during open LST OM Pagina Page 59 CODICE CODE dde Sesto S Giovanni ITALY di of 120 AY00000054545 4 8 2 Involved LRUs 4 8 2 1 Braking Rheostat Braking rheostat 1 Braking rheostat 1 Braking rheostat 2 Braking rheostat 2 A INTATTI Mea 4 a AVE ihe N gt Description Line contactor S cheron Precharge contactor LTC100 Line voltage sensor AV100 1000 SP2 Line current sensor Line current sensor Three pole motor contactor LTH
28. As for the TCMS Control Platform diagnostic events can be downloaded using the standard TrainTracer tool To approach the troubleshooting process the suggested way of working to should follow these steps Beginning of LRUs Trouble Shooting Procedure Run LowPowerTest Sequenze EPR and check results Download the Diagnostic Events Test passed NO Check diagnostic events For error lock messages Investigate the error code and solve the problem See 4 Error Lock message exists YES Investigate the error code and solve the problem See 5 Pagina Page 18 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 3 2 Replace and Test approach This troubleshooting manual follows a simple but effective approach to identify faults and fix them describing a list of activities which can be classified in Replace and Verify Replace the supposely broken LRU and make a specific test to validate the hypotesis If the test result is positive the replaced LRU was effectively in fault In the other case restore the original LRU and go ahead for the next troubleshooting step Q N REPLACE LRU VERIFY BROKEN LRU discovered GO AHEAD m Check and Verify Check wiring or measure electrical parameters If the acceptance criteria is passed go ahead for the next troubleshooting step In case of error fix the issue i e wiring repair LRU repla
29. BAT 1 pin to energize static output for BCU X1 BT 25 26 5 17 2 4 Winscope Traintracer Use MechBrake tdb to support investigation Follow on screen notes in order to Force setpoint to the mechanical brake Check correct feedback signals Check proper functionalities of the Bypass external Relay 25K1 LST OM Pagino Page 106 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 5 17 3 Verifications In case of Fault on BCU relay auxiliary contact do the following steps REPLACE AC3mini downloading the correct Traction SW version VERIFY correct functionality of the external bypass relay 25K1 using the specific winscope TDB CHECK the cabling from the Agate backplane to the X21 connector then to the external relay VERIFY that electrical connections are good REPLACE external relay the cabling from the Agate backplane to the X21 connector then to the external relay VERIFY correct functionality of the external bypass relay 25K1 using the specific winscope TDB In case of Fault on BCU brake applied feedback do the following steps REPLACE AC3mini downloading the correct Traction SW version VERIFY correct feedback of L_BCUAPP signal using the specific winscope CHECK the cabling from the Agate backplane to the X21 connector then to the external BCU VERIFY that electrical connections are good REPLACE BCU device VERIFY correct feedback of L_BCUAPP signal using the
30. CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY di of 120 AY00000054545 X22 amp X23 Vehicle Communication Busses Traction Unit uses MVB for realtime communication with TCMS and ethernet for diagnostic and maintenance activities moreover Alstom TrainTracer tool is compatible and fully supported by the Citadis Traction Control System 2 4 4 1 Layout X22A MVB AT DATAN MVB A2 DATAN ETH YELLOW ETH WHITE MVB AI DATAP A2 DATAP ETH ORANGE ETH BLUE MVB BI DATAN MWVB B2 DATAN MVB BI DATAP MVB B2 DATAP 2 4 4 2 MVB amp Ethernet Description MVB A1 DATAN MVB line A1 DATAN MVB A1 DATAP MVB line A1 DATA P MVB A2 DATAN MVB line A2 DATA N MVB A2 DATAP MVB line A2 DATA P ETH YELLOW ETH WHITE ETH ORANGE ETH BLUE Standard Ethernet 4 wire cable Description MVB B1 DATAN MVB line B1 DATAN MVB B1 DATAP MVB line B1 DATA P MVB B2 DATAN MVB line B2 DATAN MVB B2 DATAP MVB line B2 DATA P Pagina Page 17 CODICE CODE DISEGNO MOD ALSTOM DRAW S Sesto S Giovanni ITALY di of 120 AY00000054545 A Troubleshooting Process Introduction Citadis Traction SW stores in permanent memory events and fault messages in order to simplify maintenance and troubleshooting activities Events are stored with a time stamp and can be filtered to highlight faults or simple diagnostic events
31. EF IN 1 pin to energize LOC REF pins 37 L LOC1 Localization input 28 L LOC2 Localization input 27 L_LOC3 Localization input 30 LOC_REF 3 pins internally connecter to LOC_REF_IN 29 35 36 for strap configuration Please consider the drawing below taken from vehicle LV schemes to understand the way to configure each Traction Converter proper battery voltage is provided on pin37 after that a strap cable 10116 configures the traction converter position on the vehicle 8 59 50 ORWARD DR_F 10A1 ROOF TO OPENNG HSCB Description MVB A1 DATAN MVB line A1 DATA N MVB A1 DATAP MVB line A1 DATA P MVB A2 DATAN MVB line A2 DATA N MVB A2 DATAP MVB line A2 DATA P Description MVB DATAN MVB line B1 DATA N MVB B1 DATAP MVB line B1 DATA P MVB B2 DATAN MVB line B2 DATA N MVB B2 DATAP MVB line B2 DATA P MVB2 ABLOO3 3A D L oot AGATE LST OM Pagina Page 120 CODICE CODE de Sesto S Giovanni ITALY di of 120 AYO0000054545 1 9UT 5 24 3 Verifications In case of Incorrect TCU Id LOC configuration do the following steps REPLACE AC3mini downloading the correct Traction SW version VERIFY that the Traction System starts without faults CHECK the cabling between the rack and the X21 connector removing the Agate VERIFY that electrical connections are g
32. EST EPR to discover possible faults on DC current transducers Pagina Page 108 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 19 Motor currents faults 5 19 1 Description Motor current sensors are monitored in order to detect anomalous values in particular unexpected low current values when motor is running or unbalance currents between phases When the anomalous behavoir appears the Traction System is stopped for a while then it restart automatically In case of repetitive occurrences the system is locked for maintenance and will requires a maintenance check Here below the involved messages TrainTracerCode Stack Text message Unexpected low motor curr when running xx 2B 63_ M2 Repetitive low motor curr when running Xc2B64 m2 Motor current unbalance xx 2B 66 M2 Motor current unbalance repetitive fault xx2B 67 2 Motor current sensor fault xc2B65 M2 5 19 2 Involved LRUs 5 19 2 1 TBCU Motor current sensors are tested by the Low Power Test specific sequence presented in 4 6 Please refer to it for all the details related to LV schemes and WinScope Description Motor phase current sensor TAM_U1 Motor phase current sensor TAM_V1 Motor phase current sensor TAM_U2 Motor phase current sensor TAM_V2 AGATE AC3mini Pagina Page 109 CODICE CODE DISEGNO MOD ALSTOM ME b Ses
33. Fault detected on local mech brake NO contact Close circuit when BCU fault LO TRACKBRAKE Track brake control Static output Only for DROC project BAT shall be on X21 17 HSCB 2NC Contact for fast HSCB opening NC contact Close circuit to permit DJ close HSCB 1NC Contact for fast HSCB opening NC contact Close circuit to permit DJ close LOC REF 3 pins internally connecter to LOC REF IN for strap configuration LO ROLLBACK Rollback detected NO contact Close circuit when rollback LO ZEROSPEED Zerospeed information Equivalent NC contact static output in parallel with NC Close circuit when speed less than defined threshold BAT shall be on X21 53 LO APS Traction effort cut after APS request NC contact Close circuit when traction Optional for vehicles equipped with inhibited APS LO BCURELAY Command to control BCU relay Static output Close circuit in order to Internally connected to L BCU BAT energize external BCU relay LO LOCBRO Command for BCU Internally connected Static output to BCU BAT LO LOCBR1 Command for BCU Static output LO LOCBR2 Command for BCU Static output LO LOCBRS3 Command for BCU Static output LO FAN Fan command to GRF NO contact GRF is for standard MAS vehicle only LO FANHS Fan High Speed command to GRF Static output LO PUMP Pump command to GRF Static output LO SPARE 11 Available contact NO contact Pagina Page 16
34. LY di of 120 AY00000054545 MUT A DC Overcurrent Differential Current Fault Description Traction converter is protected against overcurrent at DC side usually due to HW faults inside the power module or severe transients on the catenary voltage When DC current overpass a certain threshold inverter pulses are inhibited and the line contactor opens After few seconds the traction system automatically try to restart itself In case of repetitive faults in a short time Traction system is declared unavailable and specific HW checks must be done Differential Current fault appears when the two measured DC currents by the related current sensors are not consistent Due to the severity of this fault i e loss of dielectric isolation to ground the Traction System is immediately Locked Here below the involved messages TrainTracerCode Stack Text message xx 27 90 Error Overcurrent on DC link xx 27 17 Lock Repetitive overcurrent on DC link xx 27 1B Lock Differential Current fault Involved LRUs DC current sensors are tested by the Low Power Test specific sequence presented in 4 8 Please refer to it for all the details related to LV schemes and WinScope TDB Description AC3mini Line current sensor 1000A 250mA TAL P1 TAL N1 Power module ONIX850DLP3 ONIX850DLP3 Inductor 2mH 200A LF1 Inductor 2mH 200A LF2 Precharge contactor LTC100 KPRE1 Precharge resistor 30 OHMS 280W 1 1 2 3
35. RO LI BCUAPP LO LOCBRI LI BCUREL LO LOCBR2 LI BCUISO LO LOCBR3 P BCU BAT2 LO LOCBRO2 LO LOCBRI2 LO LOCBR22 LO LOCBR32 L BCURELAY2 LO BCURELAY2 ALSTOM Sesto S Giovanni Pagina Page 14 ITALY di of 120 2 4 3 3 Digital Inputs NO SB Description Safety Brake command CODICE CODE AYO0000054545 notes Active low open circuit to SB L RESCUE Rescue Line Optional for vehicle with RESCUE line Active high L TRACTION Traction command Active high L DIR1 DIR1 command Active high L DIR2 DIR2 command Active high INV ENABLE Pulse enable Active high L NOBRAKE Service brake command Active low open circuit to brake L NOEMBR Emergency brake command Active low open circuit to brake L LOC1 Localization input Active high L LOC2 Localization input Active high L LOC3 Localization input Active high DIR FORWARD DIR1 selected by the driver Active high DIR REVERSE DIR2 selected by the driver Active high L APS Fast cut traction from APS computer Active high L TEMP31 Temperature sensor from GRF GRF is for standard MAS vehicle only Active high BAT when T gt 31 L TEMP85 Temperature sensor from GRF Active high as above L TEMP105 Temperature sensor from GRF Active high as above L TEMP105 2 Temperature sensor from GRF
36. S0320HFO0 Three pole motor contactor LTHS0320HFO0 NIOJ Q Po LSTOM Pagina Page 60 Sesto S Giovanni ITALY di of 120 CODICE CODE DISEGNO DRAW i mm RUM TALE A id Description LV contactor LC1D126BLS170 LV contactor LC1D126BLS170 LV contactor LC1D126BLS170 LV contactor LC1D126BLS170 AGATE AC3mini AGATE backplane layout D DODOOOO Kc D2 B2 Z2 LSTOM Pagina Page 6L CODICE CODE Kon Sesto S Giovanni ITALY di of 120 AY00000054545 4 8 2 3 TBCU HV Scheme wi 1 E3jE3jE3 E3 E ul ml d E3 wl XMOT 1 11 gs gE BE 1 FE Incoming DC line from HSCB Line and precharge contactors Inductors connected in parallel thanks to a bus bar inside the power module Power Module ONIX 850DLP3 PMM configuration only motor contactors Current transducers for motors phases DC voltage transducer ommooo5r Pagina Page 62 CODICE CODE DISEGNO MOD ALSTOM Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 MUT A 4 8 2 4 TBCU LV Scheme Name Description X21 LV_BAT_IN pin to energize internal LV devices contactors relays 8 821V a om 06 un TMPIASA a DG00821 8216 09 DF00821 s s amp amp nue A E E E as p18 318 1204 X 318 D28 _ _X 316 1 20 X318 1 4 __ __ _ X 318 1228 2
37. Traction SW version VERIFY fan rotation and correctness of the high speed DO valid flag REPLACE FSCB VERIFY fan rotation and related feedback status signal REPLACE M1PM or M2PM depending on the fault message VERIFY fan rotation and related feedback status signal LST OM Pagina Page 40 CODICE CODE de Sesto S Giovanni ITALY di of 120 AYO0000054545 1 9UT 4 4 4 Verifications Failure 204 Involved LRUs BCU AGATE AC3mini LV contactor LC1D126BLS170 K4 Power module fan MF M1PM M2PM 4 4 4 1 Message xx 29 16 PMC Fan1 UnableToStop or contactor Stuck 4 4 4 2 Message xx 29 17 PMC Fan2 UnableToStop or contactor Stuck AC3mini controls K4 which energize both power module fans and read rotation status feedback from each fan FSCB board is used to select two motor speeds low and high based on a digital output command from the Agate REPLACE K4 VERIFY fan rotation and related feedback status signal REPLACE AC3mini downloading the correct Traction SW version VERIFY fan rotation and correctness of the high speed DO valid flag REPLACE M1PM or M2PM depending on the fault message VERIFY fan rotation and related feedback status signal Pagina Page 41 CODICE CODE DISEGNO MOD ALSTOM DRAW S Sesto S Giovanni ITALY di of 120 AY00000054545 A 4 5 Autotest PowerModule Protections 4 5 1 Description This sequence check proper functionalities of the diagnostic information coming from gate drives and t
38. Unit this solution covers possible fault conditions and degraded modes also MOTOR BOGIE TRAILER BOGIE AGATE Standard configuration For each asynchronous motor a double speed sensor is required For each permanent magnet motor a position sensor is required From a trailed axle a single speed sensor is required 2 4 2 1 Layout MASI SPI 15V MAS2 SP1 15V MASI SP2 15V MAS2 SP2 15V AXLEADDI 15 SENL MAST SP IN MAS2 SP1 IN MASI SP2 IN MAS2 5 2 IN AXLEADDI SPD 62 SENSH MASI SPI GND MAS2 SPI GND MASI 5 2 GND MAS2 SP2 GND MASI SP1 SH MAS2 SP1 SH MASI SP2 SH MAS2 SP2 SH AXLEADD1 SH 2 PMM2 REFL AXLEADD2 15V 42 PMI 2 REFSH AXLEMI 15V AXLEM2 15V AXLEADD2 SPD PMI REFL 2 COSH AXLEMI SPD AXLEM2 SPD REFSH PMM2 COSL AXLEADD2 SH 45 1 COSH 2 COSSH AXLEMI SH AXLEM2 SH 34 1 COSL 2 SENH 35 COSSH 2 SENL Phil SENH PMIM2 SENSH 2 4 2 2 MAS configuration Description X20 Pinout MAS1 SP1 3wire shield speed sensor installed on motor 1 1 2 3 4 15V IN GND Sh MAS1 SP2 3wire shield speed sensor installed on motor 1 25 26 27 28 15V IN GND Sh MAS2 SP1 3wire shield speed sensor installed on motor 2 13 14 15 16 15V IN GND Sh MAS2 SP2 3wire shield speed sensor installed on motor 2 37 38 39 40 15V IN GND Sh AXLEADD1 2wire shield speed sensor installed on a trailed axle for 49 50 52 15V IN Sh
39. Verifications GRF water high temperature and temperature incoherence Description Involved LRUs GRF TBCU LV Scheme Winscope Traintracer TDB Verifications Motor overspeed fault Description Involved LRUs TBCU Motors Verifications Inverter cooling fan fault Description Involved LRUs Verifications Inverter overtemperature Description Involved LRUs Verifications BCU related faults Description Involved LRUs TBCU Train LV Scheme TBCU LV Scheme Winscope Traintracer TDB LST OM Pagina Page CODICE CODE Sesto S Giovanni ITALY di of 120 AYO000005 545 Verifications DC Current sensors offset fault Description Involved LRUs Verifications Motor currents faults Description Involved LRUS TBCU Motors Verifications Precharge sequence faults Description Involved LRUs Verifications Power module natural voltage discharge Description Involved LRUs Verifications Direction request Description Involved LRUs TBCU TBCU LV Scheme Verifications Manipulator request Description Involved LRUs TBCU TBCU LV Scheme Verifications MVB related faults Description Involved LRUs TBCU TBCU LV Scheme Verifications Pagina Page 7 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY di of 120 AY00000054545 Introduction Scope Scope of this document is to support troubleshooting activities for the T
40. age XX 27 15 xx 27 16 xx 27 17 xx 27 18 cu EXE ue 55 xx 27 19 DIRI amp DIR2 digital inputs both to TRUE XX 27 1A Main DIR error xx 27 1B 55 Lock Differential Current fault x 271D 58 Error Line or Precharge Contactor stucked 0271 520 Error Precharge sequence fault xx 27 1F 5 20 Lock Repetitive precharge sequence fault 27 20 5 7 Error Motor contactor stuck xx 2B 08 xx 27 21 Motor contactor unabletoclose xx 2B 09 5 7 Lock Repetitive motor contactor unabletoclose ue 5 9 Rheo overtemperatur Rheo overtemperatur 5 9 Lock Repetitive rheo overtemperatur Rp 0 Motor overtemperature 5 10 Error Motor overtemperature 5 10 Lock Repetitive motor overtemperature eeso e xen 2 11_ 27 2 5 12 Warning GRF cooling water low level xx 27 2B 5 13 Warning cooling water high temperature 85 x 272C 5 11 Warning GRF cooling pump or fan contactors stuck xx 27 2D 5 11 Lock GRF cooling pump contactor unabletoclose xx 27 2E 5 12 Lock GRF cooling water low pressure xx 27 2F 543 Error GRF cooling water very high temperature xx 27 30 543 Lock GRF repetitive water very high temp 271 Lock xx 27 32 5 14 Warning Motor overspeed xx 2B 1A xx 27 33 5 14 Lock Repetitive motor overspeed xx 2B 1B xx 27 34 5 16 Warning Inverter overtemperatur Xx 2B 1C 27 35 Inver
41. anni ITALY di of 120 AY00000054545 YUT A 27 7 5 19 Lock Repetitive low motor curr when running xx 2B 64 M2 x 27 7D 5 19 Lock otor current sensor fault xx 2B 65 27 7 5 19 Error otor current unbalance xx 2B 66 Lock otor current unbalance repetitive fault F 2780 521 Lock DC Bus discharge time too long xx 27 81 523 Message Elec effort incoherence MVB trainwires 27 82 Message xx 27 83 Lock xx 27 84 5 24 Message MVB Communication lost 2785 5 24 Message MVB Communication OK 27 86 Message 5 4 overcurrent 4 54 Error 30 27 80 L 84 Eror overcurrent 2780 54 Error overcurrent x278E 54 Eror overcurrent erst L 54 Eror 2790 55 Error i 2791 56 Ero xx 27 92 523 Message Cut traction due to mech brake eff xx 27 93 520 Message Precharge time too long xx 27 94 Message Precharge resistor overtemperature xx 27 95 Incorrect TCU Id LOC configuration xx 27 9E validity xx 27 9F I validity xx 27 A0 validity XX 27 A1 validity xx 27 A2 validity Pagina Page 75 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A HW Phase Overcurrent D
42. annot be in case to TRUE at the same time will generate a warning message If this anomalous condition persist for more than 20s a serious fault exists at Train or Traction level so the Traction Converter is locked because it is unable to correctly decodes direction requests Here below the involved messages TrainTracerCode Stack Text message xx 27 19 Warning DIR1 amp DIR2 digital inputs both to TRUE xx 27 1A Lock Main DIR error 5 22 2 Involved LRUs 5 22 2 1 TBCU Description AGATE AC3mini BT connector X21 Pagina Page 115 CODICE CODE DISEGNO MOD ALSTOM MEL Sesto S Giovanni ITALY di of 120 AY00000054545 5 22 2 2 TBCU LV Scheme Name Description notes L DIR1 DIR1 command Active high DIR2 command Active high 5 22 3 Verifications 1 CHECK the cabling between the rack and the X21 connector removing the Agate VERIFY that electrical connections are good REPLACE AC3mini downloading the correct Traction SW version VERIFY that the Traction System starts without faults Pagina Page 116 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 23 Manipulator request 5 23 1 Description sends to Traction an electrical and mechanical effort setpoi
43. ater level acquisition Pacina Page CODICE CODE DISEGNO MOD ALSTOM MEL Sesto S Giovanni ITALY gi of 120 AY0000005 545 5 12 3 Verifications In case of cooling water low pressure do the following steps CHECK that the GRF water tank is filled correctly REPLACE AC3mini downloading the correct Traction SW version VERIFY that the water pressure is correctly acquired running the water pump CHECK the cabling removing the Agate from the Agate backplane to the GRF unit VERIFY that electrical connections are good REPLACE pressure switch 11B1 VERIFY that the water pressure is correctly acquired running the water pump In case of GRF cooling water low level do the following steps CHECK that the GRF water tank is filled correctly REPLACE AC3mini downloading the correct Traction SW version VERIFY that the water levels are correctly acquired CHECK the cabling removing the Agate from the Agate backplane to the GRF unit VERIFY that electrical connections are good REPLACE level switch 11B6 VERIFY that the water pressure is correctly acquired running the water pump Pagina Page 94 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 13 GRF water high temperature and temperature incoherence 5 13 1 Description Water temperature of the motor cooling circuit is monitored using proper thermoswitches 31 C 85 C two reduntant 105 C Only repetitive water overtem
44. cement N VERIFY FAULT discovered GO AHEAD PELLI 3 3 List of tools used for investigations A standard Windows PC equipped with TrainTracer UTM Alstom Maintenance SW Tool The specific Train Tracer etr file related to the Traction SW version installed on the vehicle A standard Ethernet cable to connect the PC with the vehicle local network A multimeter Mechanical tools for mounting and dismounting stuffs Electrical HV and LV detailed schemes This Troublesooting Manual Pagina Page 19 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AYOO00005 5 5 MUT A How to download diagnostic messages On the next a detailed procedure to download diagnostic events is described Take care that the initial steps from 1 to 3 are required to configure for the first time the PC with the diagnostic messages database related to the SW version in use project importing If the TrainTracer database in the local PC is update you have just to download the event list following steps starting from 4 D The CarBuilder that manages TCMS could provides a merged TrainTracer Database which integrates TCMS and Traction equipment configuration In this case you can use this specific TrainTracer project file to download at the same time diagnostic events for all the devices 1 Unzip the zip file related to the SW version installed in the Traction Converter 2 folders will be generated C3USB data CjUSB image
45. count in case of fault of the water pump or motor fan of the GRF Without water cooling pump not running or water pressure low Traction Unit will be locked if pump or fan is always running i e due to a stucked relay a warning message is recorded Without air cooling a warning condition is recorded Here below the involved messages TrainTracerCode Stack Text message xx 27 20 Warning GRF cooling pump or fan contactors stuck xx 27 2D Lock GRF cooling pump contactor unabletoclose xx 27 3C Warning GRF cooling fan unable to start xx 27 3D Warning GRF cooling fan unable to pass in hi spd Involved LRUs GRF Subsystem is fully tested by the Low Power Test specific sequence presented in 4 3 Please refer to it for all the details related to LV schemes and WinScope TDB Description Thermal protection moto pump RM 11K3 Three phase contactor for pump 11K3 Thermal protection moto fan PV RM 11K2 Three phase contactor 11K2 Thermal protection moto fan GV RM 11K1 Three phase contactor 11K1 MOTOR PUMP 11M3 MOTOR FAN 11M2 AGATE AC3mini 5 11 3 Verifications 1 RUN LOW POWER TEST EPR to verify the specific fault on the GRF subsystem Pagina Page 91 CODICE CODE DISEGNO MOD ALSTOM ME b Sesto S Giovanni ITALY di of 120 AY00000054545 UT A 5 12 GRF water pressure water level 5 12 1 Description Water pressure of the motor cooling circuit is monitored
46. e HV circuit o control braking chopper with a fixed dutycycle and verify correct DC current measurements from transducers Step Test TrainTracerCode Contactors test sequence starts xx 29 35 601 Close precharge contactor 602 If DCVoltage threshold AND precharge aux contact False trigger an xx 29 37 error and stop test If DCVoltage lt threshold AND precharge aux contact True trigger an xx 29 38 error and stop test If DCVoltage gt threshold close line contactor 603 Open precharge contactor If line aux contact False trigger an error and stop test xx 29 39 If line aux contact True precharge phase is correct xx 29 3A 604 Inhibit braking chopper2 and set braking chopper1 dutycycle to a fixed value 605 If measured DCCurrPos is out of the expected range trigger an error and xx 29 3B stop test If measured DCCurrNeg is out of the expected range trigger an error and xx 29 3C stop test Switch off chopper and remove inhibition chopper2 Inhibit braking chopper1 and set braking chopper2 dutycycle to a fixed value If measured DCCurrPos is out of the expected range trigger an error and xx 29 3D stop test If measured DCCurrNeg is out of the expected range trigger an error and xx 29 3E stop test 609 Switch off chopper2 and remove inhibition chopper1 610 Close M1 contactor and M2 contactor 611 If M1 contactor aux contact false trigger an error and stop test xx 29 20 If M2 contactor aux contact false trigger an error and stop test xx 29 22
47. eedback 4 8 7 2 Message xx 29 22 Motor Contactor2 unable to close AC3mini commands motor contactor KMOT2 using an auxiliary relay K11 and checks correct functionality reading the auxiliary contact of KMOT 2 itself REPLACE K11 VERIFY motor contactor activation and feedback REPLACE AC3mini downloading the correct Traction SW version VERIFY contactor activation CHECK the cabling VERIFY that electrical connections are good REPLACE KMOT2 VERIFY contactor activation and feedback LST OM Pagina Page 70 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 4 8 8 Verifications Failure 613 Involved LRUs AGATE hree pole motor contactor LTHS0320HFO0 KMOT1 KMOT2 LV contactor LC1D126BLS170 K10 K11 4 8 8 1 Message xx 29 21 Motor Contactor1 fault during open AC3mini commands motor contactor KMOT1 using an auxiliary relay K10 and checks correct functionality reading the auxiliary contact of KMOT1 itself REPLACE K10 VERIFY motor contactor activation and feedback REPLACE AC3mini downloading the correct Traction SW version VERIFY contactor activation and feedback CHECK the cabling VERIFY that electrical connections are good REPLACE KMOT1 VERIFY contactor activation and feedback 4 8 8 2 Message xx 29 23 Motor Contactor2 fault during open AC3mini commands motor contactor KMOT2 using an auxiliary relay K11 and checks correct functionality reading the auxiliary contact of KMOT 2 itself
48. escription Traction converter is protected against phase overcurrent generally due to HW faults inside the power module or motor When phase current overpass a certain threshold inverter pulses are inhibited and the line contactor opens After few seconds the traction system automatically try to restart itself In case of repetitive faults in a short time Traction system is declared unavailable and specific HW checks must be done Here below the involved messages TrainTracerCode Stack Text message xc278A Error Phase U overcurrent motor x 278B Ero Phase V overcurrent motor xx 27 8C Error Phase W overcurrent motor 27 808 Error Phase U overcurrent motor xc278E Error Phase V overcurrent motor xx 27 8F Error Phase W overcurrent motor Lock Repetitive overcurrent on 9027 16 Lock Repetitive overcurrent on 5 4 2 Involved LRUs 5 4 2 1 TBCU Description Motor phase current sensor LF505 S SP28 Motor phase current sensor LF505 S SP28 TAM_V1 Motor phase current sensor LF505 S SP28 TAM_U2 Motor phase current sensor LF505 S SP28 TAM V2 Power module ONIX850DLP3 ONIX850DLP3 LST OM Pagino Page 76 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 Motor1 phase connections Motor1 phase connections Motor1 phase connections Motor2 phase connections Mo
49. ffset fault Message Current sensor DC negative offset fault e Message pem Message Pagina P a7 CODICE CODE DISEGNO MOD ALSTOM DRAW ES Sesto S Giovanni ITALY di of 120 AY00000054545 4 6 2 Involved LRUs 4 6 2 1 TBCU NI al ta UT a b d Ep Ni i D2 B2 Z2 Motor phase current sensor TAM U1 Motor phase current sensor TAM V1 Motor phase current sensor TAM U2 Motor phase current sensor TAM V2 Line current sensor TAL P1 Line current sensor TAL N1 Line voltage sensor TVL1 AGATE backplane layout LSTOM Pagina Page 48 CODICE CODE Kon Sesto S Giovanni ITALY di of 120 AY00000054545 4 6 2 2 TBCU LV Scheme 5 INIUUNO 3SWHd Bl V H3183ANI 8 8 8N HSLYSANI DACEMC MOSN3S INSHUNO 3SVHd SI 8 H3LESANI Motor1 phaseR standard current sensor Hall effect is directly acquired by the Agate Motor1 phaseS standard current sensor Hall effect is directly acquired by the Agate DC voltage transducer is directly acquired by the Agate Motor2 phaseR standard current sensor Hall effect is directly acquired by the Agate Motor2 phaseS standard current sensor Hall effect is directly acquired by the Agate Pagina Page 49 CODICE CODE DISEGNO MOD ALSTOM ME Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 MUT A DADOTOTA DA007018 DA00701C 1N38802 INN 11 DABLOOTO1A V10200188G 0 007
50. functionality reading an auxiliary contact of KPRET itself REPLACE K6 VERIFY precharge contactor activation and feedback 2 REPLACE AC3mini downloading the correct Traction SW version VERIFY contactor activation 3 REPLACE KPRE1 VERIFY precharge contactor activation and feedback 4 CHECK the cabling VERIFY that electrical connections are good 4 8 3 2 Message xx 29 38 Short circuit during precharge AC3mini detects that even if precharge contactor KPRE1 closes correctly the DC voltage doesn t rise as supposed to be REPLACE AC3mini downloading the correct Traction SW version VERIFY contactor activation running again the low power test sequence REPLACE TVL1 VERIFY that the low power test sequence is completed successfully CHECK the cabling VERIFY that electrical connections are good REPLACE ONIX850DLP3 VERIFY that the low power test sequence is completed successfully LST OM Pagina Page 66 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 4 8 4 Verifications Failure 603 Involved LRUs AGATE Line contactor S cheron LV contactor LC1D126BLS170 4 8 4 1 Message xx 29 39 Line contactor doesn t close AC3mini commands line contactor KL1 using an auxiliary relay Kb and checks correct functionality reading an auxiliary contact of KL1 itself REPLACE K5 VERIFY precharge contactor activation and feedback REPLACE AC3mini downloading the correct Traction SW version VERIFY contacto
51. hermo switches producing a specific diagnostic message in case of fault condition Step Test TrainTracerCode PowerModule Protections test sequence starts xx 29 24 301 If inverter Gate Unit is in fault trigger an error and stop test xx 29 26 If braking chopper Gate Unit is in fault trigger an error and stop test xx 29 27 If inverter2 Gate Unit is in fault trigger an error and stop test xx 29 28 If braking chopper2 Gate Unit is in fault trigger an error and stop test xx 29 29 If thermoswitch inverter1 detect overtemperature trigger an error and stop Xx 29 2A test If thermoswitch inverter2 detect overtemperature trigger an error and stop xx 29 2B test PowerModule Protections test sequence complete xx 29 25 The following messages will trace in the diagnostic memory the test steps TrainTracerCode Stack Text message xx 29 29 GU Braking chopper inverter2 not OK xx 29 2A Thermoswitch inverterl not OK xx 29 2B Thermoswitch inverter2 not OK IS A DISEGNO DRAW D32 B32 232 D2 B2 Z2 T a 00000000 CODICE CODE ONIX850DLP3 AC3mini X30 Pagina Page 42 Description Power module ONIX850DLP3 Power module BT connector AGATE backplane layout EE UPS IT ol doo pi i E i SERES apum x lai unn 4 Involved LRUs Sesto S Giovanni ITALY 4 5 2 1 TBCU 4 5 2
52. high as above L TEMP105 2 Temperature sensor from GRF Active high as above 5 13 2 4 Winscope Traintracer TDB Use AutotestGRF tdb to support investigation Follow on screen notes in order to Check correct water temperature acquisition Pagina Page 96 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY 4i of 120 AY0000005 545 5 13 3 Verifications In case of GRF water temperature incoherence do the following steps CHECK all temperature signals when traction converter is off no HV present just the Agate is switched on VERIFY that no incoherence exists at standstill temp85 true but temp31 false otherwise REPLACE AC3mini downloading the correct Traction SW version and check again temperature informations CHECK the cabling removing the Agate from the Agate backplane to the GRF unit VERIFY that electrical connections are good REPLACE termostat switch 11B1 VERIFY that temp85 FALSE when traction converter is off In case of GRF repetitive water very high temp do the following steps CHECK that GRF water tank is filled correctly CHECK all temperature signals when traction converter is off no HV present just the Agate is switched on VERIFY that the water levels are correctly acquired CHECK the cabling removing the Agate from the Agate backplane to the GRF unit REPLACE level switch 11B6 VERIFY that the water pressure is correctly acquired running the water pump Pag
53. high speed verifying correct feedback LST OM Pagina Page 39 CODICE CODE de Sesto S Giovanni ITALY di of 120 AYO0000054545 1 9UT 4 4 3 Verifications Failure 202 Involved LRUs BCU AGATE AC3mini Fan speed control board FSCB LV contactor LC1D126BLS170 K4 Power module fan MF M1PM M2PM 4 4 3 1 Message xx 29 13 PMC Fan DO for High Speed fault AC3mini sets low high speed fans to reduce noise when the vehicle is in standstill this is done by the FSCB board which set proper control voltage to the fans controlled by an Agate DO AC3mini itself is able to detect if the DO is unconnected reading the current flow REPLACE FSCB VERIFY fan rotation and correctness of the high speed DO valid flag CHECK cabling removing AC3mini VERIFY that electrical connections are good REPLACE AC3mini downloading the correct Traction SW version VERIFY fan rotation and correctness of the high speed DO valid flag 4 4 3 2 Message xx 29 14 PMC Fan1 UnableToStart or contactor Fit 4 4 3 3 Message xx 29 15 PMC Fan2 UnableToStart or contactor Flt AC3mini controls K4 which energize both power module fans and read rotation status feedback from each fan FSCB board is used to select two motor speeds low and high based on a digital output command from the Agate CHECK that battery voltage is available on X21 pins REPLACE K4 VERIFY fan rotation and related feedback status signal REPLACE AC3mini downloading the correct
54. in fault trigger an error and stop test xx 29 1F Speed transducers test sequence complete xx 29 19 The following messages will trace in the diagnostic memory the test steps TrainTracerCode Stack Text message hannel 2 Fault xx 29 1F Speed channel 6 Fault Pagina Page 54 CODICE CODE DISEGNO MOD ALSTOM DRAW ss Sesto S Giovonni ITALY di of 120 AY00000054545 4 7 2 Involved LRUs 4 7 2 1 TBCU D2 B2 Z2 Description AGATE AC3mini BT connector X20 AGATE backplane layout LST OM Pagino Page 55 CODICE CODE de Sesto S Giovanni ITALY di of 120 4 7 2 2 Motors 2 te FER 2 Description MAS motor Speed sensor RH1522 Synchro resolver 4 7 2 3 TBCU LV Scheme MAS1 SP1 Description 3wire shield speed sensor installed on motor 1 AYO0000054545 1 9UT X20 Pinout 1 2 3 4 15V IN GND Sh MAS1 SP2 3wire shield speed sensor installed on motor 1 25 26 27 28 15V IN GND Sh MAS2 SP1 3wire shield speed sensor installed on motor 2 13 14 15 16 15V IN GND Sh MAS2 SP2 AXLEADD1 3wire shield speed sensor installed on motor 2 2wire shield speed sensor installed on a trailed axle for additional speed information 37 38 39 40 15V IN GND Sh 49 50 52 15V IN Sh X 310 212 B12 D12 DABLOD306 DABLOO30 7A GNO X 310
55. ina Page 97 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 14 Motor overspeed fault 5 14 1 Description When the measured motor speed exceeds a specific overspeed threshold a warning event is recorded in the diagnostic memory in case of repetitive fault this occurrence of events is condidered a severe fault which lock the Traction System The overspeed threshold is used to protect the motor against possible mechanical damages at its value is above the maximum vehicle speed allowed Here below the involved messages TrainTracerCode Stack Text message Motot overspeed _ 2 Repetitive motor overspeed xc2B34B M2 5 14 2 Involved LRUs 5 14 2 1 TBCU Motor speed sensors are tested by the Low Power Test specific sequence presented in 4 7 Please refer to it for all the details related to LV schemes and WinScope TDB 3 D32 B32 232 Description BT connector 20 AGATE backplane layout Pagina Page 98 CODICE CODE DISEGNO MOD ALSTOM ME b Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 MUT A 5 14 2 2 Motors Description MAS motor 4HGA1433 Speed sensor RH1522 PMM motor 6LMS1052 Synchro resolver
56. ion SW version VERIFY that these specific faults are no more recorded while performing a dynamic test Pagina Page 86 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A Rheo Overtemperature Description Rheostats one for each inverter section installed in the same box are monitored using a thermal model that estimates the working temperature hot spot in realtime estimation is done by knowledge of DC voltage and the chopper dutycycle When the estimated temperature overpass a defined warning threshold a message is traced in the event memory and the motor power is reduced by a fixed percentage to prevent additional troubles If the temperature overpass a successive higher threshold inverter pulses are inhibited until the temperature fall down to an acceptable value In case of repetitive faults in a short time the complete Traction Unit is declared unavailable Here below the involved messages TrainTracerCode Stack Text message Rheo overtemperatur __ R2 Fheo overtemperatur xc2B0c R2 Repetitive rheo overtemperatur x 2B OD R2 5 9 2 Involved LRUs 5 9 2 1 TBCU Description AGATE AC3mini Line voltage sensor AV100 1000 SP2 TVL1 Power module ONIX850DLP3 ONIX850DLP3 LSTOM Pagina Page 87 Sesto S Giovanni ITALY di of 120 5 9 2 2 Rheostat a
57. ith the available upload scripts scenarios Select Upload code to TCU then da press Execute Scenario in the button bar A pop up window will show the progress ongoing Download clear events BA Name Description a Dowload trainset events Download all events from the trainset a Download TC2 events Downloads all events stored on the device E 100 Download TCU events Download TCU events g Download events Downloads all events stored on the device g Download TC4 events Downloads all events stored on the device gt Downloading in progress 100 a3 Download TC5 events Downloads all events stored on the device a Download events Downloads all events stored on the g Download events Downloads all events store amp Download TC8 events Downloads all events 3 Download TCU events Downloads all events stored on the device Close progress windows automatically on success specific scenarios can be created useful i e to download or clear events from many devices at the same time Expecially the possibility to have in the same list events from both the TBCU could be useful in many cases LST OM Pagino Page 22 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 3 5 Understanding diagnostic messages Event Stack The Traction SW contains ten event s stacks two are used by OPERA Libraries software four are used for s
58. l connectors All the different product versions share the same mechanical layout LV connectors are located close to the Agate rack compartment right bottom corner on the drawing below Sez e 1 Description Agate rack and LV compartment power module high voltage devices inductances compartment LST OM Pagina Paye CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 HV Overview 2 3 1 Electrical connectors 2 3 1 1 HV inputs and Motor outputs HV Pos From HSCB HV Neg To ground U2 V2 W2 U1 VI To motors 2 3 1 2 Braking Resistors outputs RH1 pos To braking chopper 1 RH1 neg To braking chopper 1 RH2 pos To braking chopper 2 RH2 neg To braking chopper 2 Pagina Page 10 CODICE CODE DISEGNO MOD ALSTOM me Sesto S Giovanni ITALY di of 120 AY00000054545 UT A HV Scheme Standard Configuration Here below the principle high voltage scheme of the Citadis traction converter in standard configuration single Agate control The ONIX850DLP3 power module is configured to have a single input precharge circuit Pantograph 10 Voltage sensor 19 PMM isolating contactors only Surge arrestor 11 Filter capacitor for PMM configuration High Speed Circuit Breaker 12 Braking chopper 13 Braking resisto
59. m ACCU2 ACCU2 HSCB_2NC ACCU ACCU NO_EMBR LOC2 LOCI LOC REF LOCI ee INV_ENABLE2 OVDC PMFAN2 BAT HSCB 2NC LOC REF LOC REF 2 4 3 2 Power Supply Name ACCU Description LOC_REF_IN LO_BCUFAULT2 LO_BCUFAULT2 LO_ROLLBACK LO_ROLLBACK LO_TRACKBRAKE 20 LO_TRACKBRAKEI 61 62 PMFANI Ov PMFAN2 Ov 4 LO SPAREI2 DIR REVERSE DIR FORWARD GOOD DIR LO ZEROSPEED LO ZEROSPEED 2 pins to energize Agate rack HSCB INC ACCU ACCU L_APS LO_APS LO_APS ACCU2 ACCU2 OVDC2 HSCB INC GOOD DIR2 _SPARE4 73 74 L TEMPB5 75 L_TEMP105 76 L_TEMP105_2 77 L PRESSOSTAT 78 L PUMP 79 L FANHS 80 L_FANI 81 L WATERLVLI 82 L_WATERLVL2 83 LO_GRFFAN 84 LO GRFFANHS 85 LO GRFPUMP 86 GRF BAT 87 SPA RE L SPARE2 L BCURELAY ACCU 2 pins return for ACCU LV BAT IN 1 pin to energize internal LV devices contactors relays OVDC 1 pin return for LV_BAT_IN PM_FAN1_BAT 1 pin to energize power module fan PM_FAN1_0V 1 pin return for power module fan PM_FAN2_BAT 1 pin to energize power module fan PM_FAN2_0V 1 pin return for power module fan LOC_REF_IN 1 pin to energize LOC_REF pins GRF_BAT 1 pin to energize output contacts for GRF control BCU_BAT 1 pin to energize static output for BCU control DISEGNO MOD DRAW ISS LO BCURELAY BCU BAT LO LOCB
60. motor is done acquiring the status of the related auxiliary contact In case of inconsistency between command that energizes an auxiliary relay which supplies the main coil and feedback an error is traced In case of repetitive faults in a short time the related motor is declared out of order Here below the involved messages TrainTracerCode Stack Text message 27 20 Motor contactor stuck ME xx 27 21 Motor contactor unabletoclose M2 xx 27 22 Repetitive motor contactor unabletoclose Involved LRUs Motor contactors are fully tested by the Low Power Test specific sequence presented in 4 8 Please refer to it for all the details related to LV schemes and WinScope TDB EUM Description AGATE AC3mini Three pole motor contactor LTHS0320HFO KMOT1 Three pole motor contactor LTHS0320HFO KMOT2 LV contactor LC1D126BLS170 K10 LV contactor LC1D126BLS170 K11 Pagina Page 83 CODICE CODE DISEGNO MOD ALSTOM ME Sesto S Giovanni ITALY 4i of 120 AYODO0005 545 Verifications Even if the text messages are generic the TrainTraceCode permits to identify which contactor is not working as on the table presented before 1 is related to K10 and KMOT1 M2 is related to K11 and KMOT2 RUN LOW POWER TEST EPR
61. motor current sensors VERIFY that electrical connections are good Pagina Page 110 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A Precharge sequence faults Description Precharge phase the usual way to energize the DC filter before starting the power module is monitored for faults or erroneous behaviors e Faults of the contactors line and precharge e Unexpected rising time of the voltage too long e Overtemperature of the precharge resistor monitored via a thermal model Here below the involved messages TrainTracerCode Stack Text message Mare enor Precharde sequence fault x 2741F Lock Repetitive precharge sequence fault 27 93 Message Precharge time too long _xx 27 94 Message Precharge resistor overtemperature Involved LRUs Precharge sequence is tested by the Low Power Test specific sequence presented in 4 8 Please refer to it for all the details related to LV schemes and WinScope TDB Description Line contactor S cheron Precharge contactor LTC100 Line voltage sensor AV100 1000 SP2 Line current sensor Precharge resistor 30 OHMS 280W Pagina Page LLL CODICE CODE DISEGNO DRAW ALSTOM Sesto S Giovanni ITALY di of 120 AY00000054545 N n Taa D2 B2 Z2 Description LV contactor LC1D126BLS170 LV contacto
62. nance activities without any risks The discharge phase is monitored to detect fault on these resistors a proper lock message is recorded when the DC voltage is still above 50V 300sec after the DC bus has been disconnected by the HV line Here below the involved messages TrainTracerCode Stack Text message 27 80 Lock DC Bus discharge time too long 5 21 2 Involved LRUs Description Power module ONIX850DLP3 ONIX850DLP3 AGATE AC3mini Line voltage sensor TVL1 5 21 3 Verifications 1 RUN LOW POWER TEST EPR to verify possible faults on the precharge phase 2 REPLACE ONIX850DLP3 VERIFY that the low power test sequence is completed successfully LST CM Pagino Page 1 4 CODICE CODE Sesto S Giovanni ITALY di of 120 AYO0000054545 1 9UT 5 22 Direction request 5 22 1 Description Direction requests comes from proper digital inputs directly connected to the selector on the driver desk Due to the traction architecture at train level direction request are crossed depending on the roof position n ct cc NPI C21I M2 avez ET CARE Ex SENVEE I H M NPJ CZI I Di 11 Il ji dia ii ii ii PN ti ili ii i ii H I W I il W ii ii H ji Il 11 ACTEM soa espais havs 26625659 IT Too d conte ot An inconsistent direction requests both digital inputs c
63. ni Fan speed control board FSCB LV contactor LC1D126BLS170 K4 Power module fan MF M1PM Power module fan MF M2PM Pagina Page 100 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY 4i of 120 AYODO0005 545 5 15 3 Verifications 1 RUN LOW POWER TEST EPR to verify the specific fault on the power module cooling system Pagina Page 101 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 16 Inverter overtemperature 5 16 1 Description Power module is monitored by proper thermoswitches installed on the heat sink When the thermoswitch detects an anomalous overtemperature condition a warning event is traced in the diagnostic memory and cooling fans are forced to run at high speed even if the vehicle is in standstill If this condition persists for more than 60sec an error is traced and the traction converter is switched off until the error condition disappears In case of repetitive overtemperature faults the system is locked due to a severe fault Here below the involved messages TrainTracerCode Stack Text message Inverter overtemperatur _ Inverter overtemperatur x2B4F i Repetitive inverter overtemperatur 2820 Involved LRUs Power module thermoswitches are tested by the Low Power Test specific sequence presented in 4 5 Please refer to it for all the details related to LV
64. nni ITALY di of 120 AYO0000054545 4 6 5 Verifications Failure 403 Involved LRUs BCU AGATE AC3mini Line voltage sensor AV100 1000 SP2 TVL1 4 6 5 1 Message xx 29 34 Voltage sensor DC Bus offset fault DISEGNO DRAW 1 9UT AC3mini uses voltage and current transducers for inverter protection and motors control REPLACE AC3mini downloading the correct Traction SW version VERIFY that DC voltage value is around zero CHECK cabling between Agate rack connectors and the measuring device removing AC3mini VERIFY that electrical connections are good REPLACE TVL1 VERIFY that DC voltage value is around zero Pagina Page 53 CODICE CODE DISEGNO MOD ALSTOM Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 4 7 Autotest Speed Transducers 4 7 1 Description This sequence check correctness information coming from speed position sensors producing a specific diagnostic message in case of fault condition Step Test TrainTracerCode Speed transducers test sequence starts xx 29 18 501 If speed sensor channel 1 is in fault trigger an error and stop test xx 29 1A If speed sensor channel 2 is in fault trigger an error and stop test xx 29 1B If speed sensor channel 3 is in fault trigger an error and stop test xx 29 1C If speed sensor channel 4 is in fault trigger an error and stop test xx 29 1D If speed sensor channel 5 is in fault trigger an error and stop test xx 29 1E If speed sensor channel 6 is
65. nt via MVB moreover the Traction System acquires some digital information wires line TRACTION NOBRAKE NO EMERGENCY BRAKE NO SAFETY BRAKE directly from the manipulator and perform consistency checks to detect faults As a general rule braking request always override any traction request in case of inconsistency a specific message is recorded Here below the involved messages TrainTracerCode Stack Text message XX 27 81 Message Elec effort incoherence MVB trainwires xx 27 92_ Message i 5 23 2 Involved LRUs 5 23 2 1 TBCU 032 B32 232 2 2 22 Description AC3mini BT connector X21 AGATE backplane layout Pagina Page 117 CODICE CODE DISEGNO MOD ALSTOM ME Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 23 2 2 TBCU LV Scheme Name Description notes NO SB Safety Brake command Active low open circuit to SB L TRACTION Traction command Active high L NOBRAKE Service brake command Active low open circuit to brake L NOEMBR Emergency brake command Active low open circuit to brake 5 23 3 Verifications 1 CHECK the cabling between the rack and the X21 connector removing the Agate VERIFY that electrical connections are good REPLACE AC3mini downloading the correct Traction SW version VERIFY that the Traction System starts without faul
66. nverter2 detect overtemperature trigger an error and stop test PowerModule Protections test sequence complete PowerModule Transducers test sequence starts If M1R current sensor measured value is above a threshold trigger an error and stop test If M1S current sensor measured value is above a threshold trigger an error and stop test If M2R current sensor measured value is above a threshold trigger an error and stop test If M2S current sensor measured value is above a threshold trigger an error and stop test If DCCurrPos sensor measured value is above a threshold trigger an error and stop test If DCCurrNeg sensor measured value is above a threshold trigger an error and stop test If DCVoltage sensor measured value is above a threshold trigger an error and stop test PowerModule Transducers test sequence complete Speed transducers test sequence starts If speed sensor channel 1 is in fault trigger an error and stop test If speed sensor channel 2 is in fault trigger an error and stop test If speed sensor channel 3 is in fault trigger an error and stop test If speed sensor channel 4 is in fault trigger an error and stop test If speed sensor channel 5 is in fault trigger an error and stop test If speed sensor channel 6 is in fault trigger an error and stop test Speed transducers test sequence complete
67. ons are good REPLACE ONIX850DLP3 Pagina Page 46 CODICE CODE DISEGNO MOD ALSTOM Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 4 6 Autotest PowerModule Transducers Description This sequence check correctness information coming from current and voltage sensors when inverter pulses are switched off and no voltage on DC link is present thanks to the open line contactor producing a specific diagnostic message in case of fault condition Step Test TrainTracerCode PowerModule Transducers test sequence starts 29 2 401 If M1R current sensor measured value is above a threshold trigger xx 29 30 error and stop test If M1S current sensor measured value is above a threshold trigger xx 29 31 error and stop test If M2R current sensor measured value is above a threshold trigger xx 29 32 error and stop test If M2S current sensor measured value is above a threshold trigger xx 29 33 error and stop test If DCCurrPos sensor measured value is above a threshold trigger xx 29 2E error and stop test If DCCurrNeg sensor measured value is above a threshold trigger xx 29 2F error and stop test If DCVoltage sensor measured value is above a threshold trigger xx 29 34 error and stop test PowerModule Transducers test sequence complete xx 29 2D The following messages will trace in the diagnostic memory the test steps TrainTracerCode Stack Text message Message Current sensor DC positive o
68. ontactor 11K1 4 3 6 1 Message xx 29 0F GRF FanHS UnableToStart or contactor Fit AC3mini controls 11K1 which activates GRF high speed motor fan and read status of the contactor aux contact CHECK thermal protection of the motor fan RM 11K1 in case of thermal protection trip re arm it VERIFY that fan rotation is smooth REPLACE 11K1 activate the fan and VERIFY consistency between contactor command and feedback REPLACE AC3mini downloading the correct Traction SW version activate the fan and VERIFY consistency between contactor command and feedback CHECK internal and external cabling VERIFY that electrical connections are good REPLACE motor fan 11M2 LST OM Pagina Page 34 CODICE CODE dde Sesto S Giovanni ITALY di of 120 AYO0000054545 1 9UT 4 3 7 Verifications Failure 110 Involved LRUs GRF Three phase contactor 11K1 hree phase contactor 11K2 4 3 7 1 Message xx 29 0E GRF Fan UnableToStop or contactor Stuck AC3mini controls 11K2 which activates GRF motor fan and read status of the contactor aux contact REPLACE 11K2 VERIFY consistency between contactor command and feedback 2 REPLACE AC3mini downloading the correct Traction SW version VERIFY consistency between contactor command and feedback 3 CHECK internal and external cabling VERIFY that electrical connections are good 4 3 7 2 Message xx 29 10 GRF FanHS UnableToStop or contactor Stk AC3mini controls 11K1 which activates GRF motor fan
69. ood CHECK the strap cable on the external X21 connector vehicle side and the battery voltage on X21 37 VERIFY that electrical connections are good In case of MVB Communication lost do the following steps CHECK the cabling between the rack and the X22 X23 connector removing the Agate VERIFY that electrical connections are good REPLACE AC3mini downloading the correct Traction SW version VERIFY that these specific faults are no more recorded while performing a dynamic test
70. otection moto fan PV RM 11K2 Three phase contactor 11K2 Thermal protection moto fan GV RM 11K1 Three phase contactor 11K1 MOTOR PUMP 11M3 MOTOR FAN 11M2 Pagina Page 28 CODICE CODE DISEGNO MOD ALSTOM DRAW S Sesto S Giovanni ITALY di of 120 AY00000054545 4 3 2 2 TBCU Description BT connector X21 AGATE AC3mini Internal BT connector X1 BT AGATE backplane layout Pagina Page 29 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 4 3 2 3 TBCU LV Scheme Description notes LO FAN Fan command to GRF NO contact LO FANHS Fan High Speed command to GRF Static output LO PUMP Pump command to GRF Static output BIEX gie X DIGI siex 11134 DADINI 1 ag 1 Description L_PUMP Pump aux cont from GRF Active high pump aux cont from GRF L FANHS _ Fan HS aux cont from GRF Active high fan HS aux cont from GRF L_FANI Fan aux cont from GRF Active high fan aux cont from GRF 12 AGATE A Battery voltage shall be present on X21 86 in order to energize the digital outputs which controls pump and fan low and high speed B GRF relays status are acquired directly by specific digital inputs of the Agate board 317 4 3 2 4 Winscope Traintracer TDB Use AutotestGRF tdb to support investigation Follow on screen notes in order to
71. peed channel 3 Fault Message xx 29 1D Speed channel 4 Fault Message xx 29 1E Speed channel 5 Fault Message xx 29 1F Speed channel 6 Fault AC3mini is able to verify correctness of the electric signal coming from each speed and or resolver transducer Take into account the following notes Speed channel 1 and 2 are related to motori Speed channel 3 and 4 are related to motor2 Speed channel 5 is related to trailer axle REPLACE AC3mini downloading the correct Traction SW version VERIFY that diagnostic information from sensors are correct no faults anymore CHECK the cabling between the rack and the speed sensor connector removing the Agate VERIFY that electrical connections are good REPLACE the broken speed sensor VERIFY that diagnostic information from sensors are correct no faults anymore D The TSP Troubleshooting Guide R4 provided detailed information regarding speed sensors fault detection Pagina Page 5B CODICE CODE DISEGNO MOD ALSTOM Sesto S Giovanni ITALY di of 120 AY00000054545 UT A 4 8 Low Power Test Precharge and motor contactors 4 8 1 Description This sequence tests the correct behaviour of the precharge circuit with high voltage motor contactors in case of PMM Traction configuration and braking choppers In details the following tests are performed o check proper functionalities of the contactors using the information from the related aux contact o check proper charge phase of th
72. perature triggered when two amongs three high temp thermoswitches are active will lock the Traction System Before that a torque reduction is request to prevent completely loss of traction capabilities If an inconsistency temperature information is acquired 85 is detected 31 C not a message is recorded to highlight this anomalous behavior of the temperature sensors Here below the involved messages TrainTracerCode Stack Text message 2 72 _ Warning cooling water high temperature 85 xx 27 2F Error cooling water very high temperature xx 27 30 Lock repetitive water very high temp xe3E Message GRF water temperature incoherence 5 13 2 Involved LRUs 5 13 2 1 TBCU D32 B32 232 D2 B2 Z2 Description BT connector X21 AGATE AC3mini AGATE backplane layout Pagina Page 95 CODICE CODE DISEGNO MOD ALSTOM Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 MUT A 5 13 2 2 GRF Description Thermostat 31 C 11B5 Thermostat 85 C 11B4 Thermostat 105 C 11B2 11B3 5 13 2 3 TBCU LV Scheme Description notes L TEMP31 Temperature sensor from GRF Active high BAT when T gt 31 L TEMP85 Temperature sensor from GRF Active high as above L TEMP105 Temperature sensor from GRF Active
73. phaseR offset flt 4 6 3 4 Message xx 29 33 Current sensor Motor2 phaseS offset flt AC3mini uses voltage and current transducers for inverter protection and motors control REPLACE AC3mini downloading the correct Traction SW version VERIFY that motor2 currents value are around zero CHECK cabling between Agate rack connectors and the measuring device removing AC3mini VERIFY that electrical connections are good REPLACE TAM 02 or TAM V2 depending on the diagnostic message phaseR is U1 phases is V1 VERIFY that motor2 currents value are around zero Pagina Page 51 CODICE CODE DISEGNO MOD ALSTOM RE Sesto S Giovanni ITALY di of 120 AY00000054545 JA9UT A 4 6 4 Verifications Failure 402 Involved LRUs BCU AC3mini Line current sensor 1000A 250mA TAL P1 TAL N1 4 6 4 1 Message xx 29 2E Current sensor DC positive offset fault 4 6 4 2 Message xx 29 2F Current sensor DC negative offset fault AC3mini uses voltage and current transducers for inverter protection and motors control REPLACE AC3mini downloading the correct Traction SW version VERIFY that DC currents value are around zero CHECK cabling between Agate rack connectors and the measuring device removing AC3mini VERIFY that electrical connections are good REPLACE TAM P1 or TAM N1 depending on the diagnostic message DCPositive is P1 DCNegative is 1 VERIFY that DC currents value are around zero LSTOM Pagina Page 52 CODICE CODE Sesto S Giova
74. r 14 Inverter Line contactor 15 Electronic control AC3mini Precharge circuit 16 Filter inductor 17 Motor current sensor Line current sensor 18 Traction motors MAS or PMM cog P On MAS and PMM architecture a single AGATE rack controls both inverters LST OM Pagina Page 11 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 2 4 LV Overview 2 4 1 Electrical connectors Here below a front view drawing of the electrical LV connectors plate X20 72pin connector for resolver and speed sensor signals X21 108pin connector for all LV interfaces power supply command and feedback signals for single and double Agate configuration X22 MVB and Ethernet X23 MVB redundant line and Ethernet for 2AC3 configuration Not used in standard single Agate configuration On the next paragraphs for each connector the complete signal list and electrical caracterictics is detailed Pagina Page 12 CODICE CODE DISEGNO MOD ALSTOM uni Sesto S Giovanni ITALY di of 120 AY00000054545 149UT A X20 Speed Signals Speed informations come from proper speed sensors and or resolvers in case of PMMs speed measuring devices are used for motor close loop torque control and vehicle speed estimation To guarantee good performance of the antislip antislide control Citadis speed architecture has been designed in order to have 4 independent speed information available for each Traction
75. r LC1D126BLS170 K6 AGATE AC3mini AGATE backplane layout Power module ONIX850DLP3 ONIX850DLP3 Pagina Page 112 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY di of 120 AY00000054545 5 20 3 Verifications In case of Precharge sequence fault or Repetitive precharge sequence fault which appears when precharge phase is not completed successfully do the following steps RUN LOW POWER TEST EPR to verify possible faults on the precharge phase In case of Precharge resistor overtemperature which appears when precharge is overheated i e due to too many precharge operation in a short time do the following steps RUN LOW POWER TEST EPR to verify possible faults on the precharge phase CHECK ohmic value of the resistor RPRE1 VERIFY that value is around 300hms In case of Precharge time too long which appears when precharge phase is not completed successfully do the following steps RUN LOW POWER TEST EPR to verify possible faults on the precharge phase Pagina Page 113 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 UT A 5 21 Power module natural voltage discharge 5 21 1 Description When the line contactor opens as request by the TCMS or due to a traction converter internal fault the DC filter discharges naturally thanks to some internal resistors installed in the power module This is a safe design solution in order to perform mainte
76. r activation REPLACE KL1 VERIFY precharge contactor activation and feedback CHECK the cabling VERIFY that electrical connections are good Pagina Page 67 CODICE CODE DISEGNO MOD ALSTOM RE Sesto S Giovanni ITALY di of 120 AY00000054545 JA9UT A 4 8 5 Verifications Failure 605 Involved LRUs AC3mini TBCU Line current sensor 1000A 250mA TAL P1 TAL N1 Power module ONIX850DLP3 ONIX850DLP3 Braking Rheostat Braking rheostat 1 2 rheostat RH1 4 8 5 1 Message xx 29 3B Braking chopper1 KO or DC PosCurr Fault 4 8 5 2 Message xx 29 3C Braking chopper1 KO or DC NegCurr Fault AC3mini activates with a fixed duty cycle the braking chopper 1 part of the ONIX850DLP3 power module and checks that DC current value measured by DC transducers TAL P1 and TAL 1 is consistent with the rheostat RH1 ohmic value REPLACE AC3mini downloading the correct Traction SW version VERIFY that the low power test sequence is completed successfully CHECK cabling between Agate rack connectors and the measuring device TAL P1 or TAL N1 depending on the diagnostic message removing AC3mini VERIFY that electrical connections are good REPLACE TAL P1 or TAL N1 depending on the diagnostic message VERIFY that the low power test sequence is completed successfully CHECK the cabling to RH1 VERIFY that electrical connections are good LST OM Pagina Page 6B CODICE CODE dde Sesto S Giovanni ITALY di of 120 AYO0000054545 1 9UT
77. racer skip these units After all settings press OK button ED Options woe General Connection settings Project import export todetection settings Functions Dataplug manager Project citadis2_mas in Password Culture Connection Device information Software upload Dataplug manager Download cl t T T 1 Dechbead TCU root 101154881 192 168 0 111 Tracer toot 10 115 48 81 192 168 0 111 Qnx root 10 115 48 81 192 168 0 111 Qnx root 10 115 48 81 192 168 0 111 Qnx root 10 115 48 81 192 168 0 111 Qnx root 10 115 4881 192 168 0 111 root 10 115 48 81 192 168 0 111 nx root 1032866 1921680111 Qn Train Front Device Login Passwon switch panel DS type Ignore address address 3 x IS STET Jx Jiz jx jix s J Restore Connection 8 Press OK button in the already open Connect to Train window after few seconds TrainTracerUTM will inform about the established connection with the icon 9 Press Download Cleareventson the left Menu m TrainTracer UTM citadis2 mas 3 0 1 Connected File Service Bookmarks Window Train information Device information Software upload Parameters Dataplug manager Events faults Download clear events Pagina Page 21 CODICE CODE DISEGNO MOD ALSTOM DRAW S Sesto S Giovanni ITALY di of 120 AY00000054545 A 10 The following window appears w
78. raction System CITADIS EVOLUTION This guide based on diagnostic events recorded on the Agate3mini control electronic describes operations to identify the broken LRU The related replacement procedures are described in the Maintenance Manual Perimeter The role of the Traction System is to control and monitor one motorized bogie and the related devices mechanical brake unit motor cooling system GRF The context of the Traction System is the new CITADIS EVOLUTION platform a family of vehicles based on a modular architecture able to fulfill different requirements using a standardized set of subsystems Following the same philosophy the traction box is part of these module library and will be used across a wide range of tram composition ie vehicle with two or three motorized bogie different gear ratio and wheel diameters AS or PM motors type by a simple SW configuration TBCU1 GRF1 RHEO1 GRF2 TBCU2 UNA HOR ZINTA N M2 rr MEN P EA L L 1600 4935 5 Example of CITADIS EVOLUTION 302 type vehicle with 2 motorized bogie 1 3 References R1 Citadis Evolution Traction SyUM 145UT AY39405 R2 Citadis X02 MAS 1AC3 detailed LV scheme AY32185 R3 Citadis X04 PMM 1AC3 detailed LV scheme AY30287 R4 Citadis Evolution TSP TROUBLE SHOOTING GUIDE TRV1306LB17228 3 Terminology and Acronyms DSP Digital Signal Processor IGBT Insulated Gate Bipolar T
79. raction system was working correctly but after a change of cabin it didn t restart Warning Mechanical brake of the motorized bogie is not working Check for fault messages listed in 5 17 Motor torque is missing sometimes for a while electrical values related to the Traction System reported on the DDU are set to zero or frozed Troubles on MVB communication Check for fault messages in 5 24 Anomalous behavior of the manipulator no traction effort or no electrical effort in service brake Remember the possibility to filter events using the related button Code w Event 26 2B 1F 09 27 37 26 2B 1E 09 27 36 09 27 34 Occurence date 21 07 2010 10 16 05 607 21 07 2010 10 16 05 607 21 07 2010 10 15 20 607 21 07 2010 10 15 20 607 21 07 2010 10 15 05 627 Inverter overtemperature Inverter overtemperature Inverter cooling fan unable to start Inverter cooling fan unable to start Inverter overtemperature Troubles on manipulator wiring Check for fault messages in 5 23 Device Severity w TCU TCU TCU TCU TCU Error r 2 Cooling Control Error Lock Lock Inverter Inverter 1 Cooling Control Warning Inverter 1 Cooling Control 72 CODICE CODE DISEGNO MOD ALSTOM DRAW S Sesto S Giovanni ITALY di of 120 AY00000054545 A Event list Here the complete event list generated by the Traction SW when the system is in Operational Mode TrainTracer Ref Stack Text mess
80. rain scheme but controlled by Traction plus the related auxiliary contact used for diagnostic When inconsistency is detected e between effort setpoint and feedback e or between bypass relay command and aux contact feedback Mechanical Brake control pass to TCMS until the end of the braking phase At standstill Traction try to reset this fault in case of repetitive faults in a certain time mech brake is considered out of order and controls pass definitively to TCMS Agate must be switched off to recover this fault Here below the involved messages TrainTracerCode Stack Text message xx 27 50 Message Fault on BCU relay auxiliary contact xx 27 52 Message Fault on BCU brake applied feedback xx 27 57 Message Fault on BCU brake released feedback xx 27 58 Message Repetitive fault on BCU 5 17 2 Involved LRUs 5 17 2 1 TBCU Description BT connector X21 AGATE AC3mini Pagina Page 10 ALSTOM Sesto S Giovanni ITALY di of 120 5 17 2 2 Train LV Scheme 21101 PREPARED LV PREPAREE OPTION BOGIE INDEPENDANCE OPTION INDEPENDANCE PAR BOGIE 2501 TLS OL2 RMS AGR Y LVST 23K1b 231A 07 Q MZ231A 016 LVB CBT 038 4 losco 10341 lt 1 103811 25 1 125102 AL VB CBT ua cy 903 811 10342 25K5 125501 ALVB CST 25K1b 17
81. ransistor IO Input Output LV Low Voltage MAS Asynchronous motor PMM Permanent Magnet Motor TCMS Train Control and Monitoring System BCU Mechanical Braking Control Unit MVB Multifunction Vehicle Bus DC Direct continuous Current HV High Voltage APS Ground power supply GRF Motor Cooling Unit HW SW Hardware Software NC Normally Close contact NO Normally Open contact HSCB High Speed Circuit Breaker Pagina Page 8 CODICE CODE DISEGNO MOD ALSTOM me Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A General characteristics Product Presentation The main characteristics of the CITADIS EVOLUTION Traction basic unit are 850DLP3 power module low power IGBT inverter AGATES8mini electronic control unit able to control 2 AS or PM motors Interface with Train Control System TCMS via MVB network and LV logic train lines Control SW design process meets SSIL2 safety requirements Different product versions are available 1 850 R STD MAS DLP 1AC3 standard architecture two asynchronous motors 850 R STD PMM DLPAACS standard architecture two permanent magnet motors Each version shares the same functional interface LV train lines and MVB message structure in order to minimize modification at train level Traction Converter Mechanical Layout Here below a top view of the Citadis Traction cubicle useful to understand the main subsystems location and physical position of the electrica
82. rol and monitor IGBTs REPLACE AC3mini downloading the correct Traction SW version VERIFY Gate unit diagnostic feedbacks CHECK the cabling between the rack and the power module LV connector removing the Agate VERIFY that electrical connections are good REPLACE ONIX850DLP3 4 5 3 3 Message xx 29 28 GU inverter2 not OK 4 5 3 4 Message xx 29 29 GU Braking chopper inverter2 not OK AC3mini read feedback status from gate units board inside the power module which control and monitor IGBTs REPLACE AC3mini downloading the correct Traction SW version VERIFY Gate unit diagnostic feedbacks CHECK the cabling between the rack and the power module LV connector removing the Agate VERIFY that electrical connections are good REPLACE ONIX850DLP3 LSTOM Pagina Page 45 CODICE CODE Sesto S Giovanni ITALY di of 120 AYO0000054545 4 5 4 Verifications Failure 302 Involved LRUs BCU AGATE AC3mini Power module ONIX850DLP3 ONIX850DLP3 4 5 4 1 Message xx 29 2A Thermoswitch inverter1 not OK 4 5 4 2 Message xx 29 2B Thermoswitch inverter2 not OK DISEGNO DRAW 1 9UT AC3mini detects overtemperature faults reading status from specific thermoswitches mounted on the power module heat sink REPLACE AC3mini downloading the correct Traction SW version VERIFY thermoswitches status signals CHECK the cabling between the rack and the power module LV connector removing the Agate VERIFY that electrical connecti
83. schemes and WinScope TDB Description AC3mini Power module ONIX850DLP3 ONIX850DLP3 Power module BT connector X30 Power module fans M1PM M2PM Pagina Page 102 CODICE CODE DISEGNO MOD ALSTOM Sesto S Giovanni ITALY 4i of 120 AY0000005 545 5 16 3 Verifications 1 RUN LOW POWER TEST EPR to verify the thermoswitches status at standstill and the correct functionality of the power module fans CHECK visually the power module cooling fans VERIFY that no obstruction exist that could reduce air flow REPLACE AC3mini downloading the correct Traction SW version VERIFY that no specific faults are recorded while performing a dynamic test Pagina Page 1B CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AY00000054545 MUT A 5 17 BCU related faults 5 17 1 Description Each traction unit controls the BCU mechanical brake control unit related to its own motorized bogie Mechanical brake effort setpoint is provided through 4 digital outputs 16 possible effort levels BCU provides to Traction a feedback for brake applied and brake release 2 digital inputs which commutates at a predefined effort level these signals are used for diagnostic control Finally at train level a specific LV circuit permits to control mechanical brake through TCMS when Traction Unit is in fault this is done by a bypass relay part of t
84. stop test 103 Switch off pump 104 If pump doesn t stop aux contact true trigger an error and stop test 105 Activate fan 106 If fan doesn t start aux contact false trigger an error and stop test 107 Activate high speed fan 108 If fan doesn t run at high speed aux contact false trigger an error and stop test 109 Switch off fan 110 If fan continue to run at normal speed aux contact true trigger an error and stop test If fan continue to run at high speed aux contact true trigger an error and stop test GRF test sequence complete PowerModule Cooling test sequence starts 201 Activate fans 202 If fan1 doesn t start aux contact false trigger an error and stop test If fan2 doesn t start aux contact false trigger an error and stop test If high speed static output is in fault trigger an error and stop test 203 Switch off fans 204 If fan1 continue to run aux contact true trigger an error and stop test If fan2 continue to run aux contact true trigger an error and stop test PowerModule Cooling test sequence complete PowerModule Protections test sequence starts If inverter1 Gate Unit is in fault trigger an error and stop test If braking chopper1 Gate Unit is in fault trigger an error and stop test If inverter2 Gate Unit is in fault trigger an error and stop test If braking chopper2 Gate Unit is in fault trigger an error and stop test If thermoswitch inverter1 detect overtemperature trigger an error and stop test If thermoswitch i
85. tatus of the contactor aux contact REPLACE 11K3 VERIFY consistency between contactor command and feedback REPLACE AC3mini downloading the correct Traction SW version VERIFY consistency between contactor command and feedback CHECK internal and external cabling VERIFY that electrical connections are good LST OM Pagino Page 32 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 4 3 5 Verifications Failure 106 Involved LRUs AGATE AC3mini Thermal protection moto fan PV RM 11K2 Three phase contactor 11K2 Motor fan 11M2 4 3 5 1 Message xx 29 0D GRF Fan UnableToStart or contactor Fit AC3mini controls 11K2 which activates GRF reduced speed motor fan and read status of the contactor aux contact CHECK thermal protection of the motor fan RM 11K2 in case of thermal protection trip re arm it VERIFY that fan rotation is smooth REPLACE 11K2 activate the fan and VERIFY consistency between contactor command and feedback REPLACE AC3mini downloading the correct Traction SW version activate the fan and VERIFY consistency between contactor command and feedback CHECK internal and external cabling VERIFY that electrical connections are good REPLACE motor fan 11M2 LST OM Pagino Page 3B CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 4 3 6 Verifications Failure 108 Involved LRUs TBCU AGATE GRF Thermal protection moto fan GV RM 11K1 hree phase c
86. ter cooling fan stuck xx 27 36 5 15 Lock Inverter cooling fan unable to start xx 2B 1E XX 27 37 5 16 Error Inverter overtemperatur 2 1 xx 27 38 5 16 Lock Repetitive inverter overtemperatur xx 2B 20 LST OM Pagino Page 73 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 x 27 3C 511 Warning GRF cooling fan unable to start xx 27 3D 511 Warning GRF cooling fan unable to pass in hi 27 5 13 Message GRF water temperature incoherenc o274F Message xx 27 50 517 Message Fault on BCU relay auxiliary contact _xx 27 51 Message xx 27 52 5 17 Message Fault on BCU brake applied feedback 2753 Message 2754 Message 2755 Message xx 27 57 5 17 Message Fault on BCU brake released feedback xx 27 58 5 17 Message Repetitive fault on BCU DC current positive sensor offset error DC current negative sensor offset error xx 27 7A_ Lock xx 27 7B 5 19 Error Unexpected low motor curr when running xx 2B 63 LST Pagina Page 74 CODICE CODE DISEGNO MOD DRAW KS Sesto S Giov
87. to S Giovanni ITALY di of 120 AY00000054545 MUT A 4 3 Autotest GRF 4 3 1 Description This sequence check proper functionalities of the GRF unit It controls pump and fan and verify the correct behaviour reading the available auxiliary contacts information Step Test TrainTracerCode GRF test sequence starts 29 06 101 Activate pump 102 If pump doesn t start aux contact false trigger an error and stop test xx 29 08 103 Switch off pump 104 If pump doesn t stop aux contact true trigger an error and stop test xx 29 09 105 Activate fan 106 If fan doesn t start aux contact false trigger an error and stop test xx 29 0D 107 Activate high speed fan 108 If fan doesn t run at high speed aux contact false trigger an error and xx 29 0F stop test 109 Switch off fan 110 If fan continue to run at normal speed aux contact true trigger an error xx 29 0E and stop test If fan continue to run at high speed aux contact true trigger an error xx 29 10 and stop test GRF test sequence complete xx 29 07 The following messages will trace in the diagnostic memory the test steps TrainTracerCode Stack Text message Message IRE LSTOM Pagina Page 27 CODICE CODE Kon Sesto S Giovanni ITALY di of 120 AY00000054545 4 3 2 Involved LRUs 4 3 2 1 GRF Description Thermal protection moto pump RM 11K3 Three phase contactor for pump 11K3 Thermal pr
88. to S Giovanni ITALY di of 120 AY00000054545 MUT A 5 19 2 2 Motors Description MAS motor 4HGA1433 MAS motor electrical connections PMM motor 6LMS1052 PMM motor electrical connections 5 19 3 Verifications In case of Motor current sensor fault which appears when measured current is not zero with pulses inhibited do the following steps RUN LOW POWER TEST EPR to verify possible offset faults of the motor current transducers In case of Motor current unbalance repetitive fault which appears when phase currents are not balanced correctly do the following steps RUN LOW POWER TEST EPR to verify possible offset faults of the motor current transducers CHECK phase to phase impedance value of the motor M1 if the diagnostic message is related to this one M2 otherwise disconnecting it from the motor contactors or output connection in case of MAS motors VERIFY that impedance value are equals amongs phases In case of Repetitive low motor curr when running which appears when measured currents is unexpected low while motor is running do the following steps REPLACE AC3mini downloading the correct Traction SW version VERIFY that these specific faults are no more recorded while performing a dynamic test CHECK motor current sensors acquisition while performing a dynamic test VERIFY which sensor detects anomalous low current and REPLACE it CHECK the cabling between the rack backplane rack and the
89. to identify possible root cause fault REPLACE AC3mini downloading the correct Traction SW version VERIFY that these specific faults are no more recorded while performing a dynamic test Pagina Page 84 CODICE CODE DISEGNO MOD ALSTOM Sesto S Giovanni ITALY di of 120 AY00000054545 UT A 5 8 Line Precharge contactors faults 5 8 1 Description Precharge contactor and line contactor are monitored using the status of the related auxiliary contact In case of inconsistency between command that energizes an auxiliary relay which supplies the main coil and feedback an error is traced Here below the involved messages TrainTracerCode Stack Text message xx 27 1D Error Line or Precharge Contactor stucked Involved LRUs Line and precharge contactors are fully tested by the Low Power Test specific sequence presented in 4 8 Please refer to it for all the details related to LV schemes and WinScope TDB Description AC3mini Line contactor S cheron KL1 Precharge contactor LTC100 KPRE1 LV contactor LC1D126BLS170 K5 LV contactor LC1D126BLS170 K6 LST OM Pagina Page 85 CODICE CODE dde Sesto S Giovanni ITALY di of 120 AY00000054545 5 8 3 Verifications 1 RUN LOW POWER TEST EPR to identify possible root cause fault 2 REPLACE AC3mini downloading the correct Tract
90. tor2 phase connections Motor2 phase connections Description MAS motor 4HGA1433 MAS motor electrical connections PMM motor 6LMS1052 PMM motor electrical connections 5 4 2 3 TBCU HV Scheme Please refer to chapter 4 8 for details related to motor current sensors interface with the Agate 5 4 2 4 TBCU LV Scheme Please refer to chapter 4 6 for details related to motor current sensors interface with the Agate Pagina Page 77 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY di of 120 AY00000054545 5 4 3 Verifications RUN LOW POWER TEST EPR to eventually discover faults on motor current sensors or power module gate drives CHECK phase to phase impedance value of the motor M1 if the diagnostic message is related to this one M2 otherwise disconnecting it from the motor contactors or output connection in case of MAS motors VERIFY that impedance value are equals amongs phases CHECK phase to ground impedance value of the motor M1 if the diagnostic message is related to this one M2 otherwise disconnecting it from the motor contactors or output connection in case of MAS motors VERIFY that impedance value are equals amongs phases REPLACE AC3mini downloading the correct Traction SW version VERIFY that these specific faults are no more recorded while performing a dynamic test Pagina Page 78 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITA
91. tors Contactors test sequence complete Pagina Page 25 CODICE CODE DISEGNO MOD ALSTOM b Sesto S Giovanni ITALY di of 120 AY00000054545 UT A 4 2 Main Test Sequence 4 2 1 Description Here below the detailed state diagram related to the main autotest function that prepares the Traction Unit for test execution and perform a reboot at the end of the test in order to put again the Traction System in normal mode 2 P 7 p 1 Traction LI Precondition MVB IReducPowrTest local variable 3 _ j 4 NoBrake LI MVB IReducPowrDone 4 5 TrainStopped MVB IReducPowrRes local variable TCMSCom local variable 1 6 MVB CReducPowrTest MVB lAutoTestStep Precondition TRUE AND Precondition FALSE AND Faults FALSE AND TCMSCom TRUE TCMSCom TRUE t P gt 2 2s discharge filter Toff Delay command Discharge error DCVoltage lt threshold fault during test execution last step completed OR 3 discharge filter Discharge error DCVoltage lt threshold The following messages will trace in the diagnostic memory the test steps TrainTracerCode Stack Text message 10 29 68 10 29 69 29 6 10 29 68 29 66 10 29 6D 10 29 6E Pagina Page 26 CODICE CODE DISEGNO MOD ALSTOM Ses
92. ts Pagina Page 118 CODICE CODE DISEGNO MOD ALSTOM RE li Sesto S Giovanni ITALY di of 120 AYOO00005 5 45 MUT A 5 24 MVB related faults 5 24 1 Description All the traction converters installed on vehicle roof are identical and takes the unique MVB address by specific cable configuration In case of erroneus configuration i e due to a broken connector or Agate internal fault the traction converter lock itself in order to avoid unexpected behaviors due to the errors in the Instead in case of trouble in the MVB communication after initialization monitored using a life signal exchanged with TCMS for safery reasons the torque setpoint is clamped to zero and the unexpected event is recorded in the diagnostic memory Here below the involved messages TrainTracerCode Stack Text message xx 27 84 Message MVB Communication lost xx 27 85 Message MVB Communication OK xx 27 95 Incorrect TCU Id LOC configuration 5 24 2 Involved LRUs 5 24 2 1 TBCU Description BT connector X21 BT connector X22 BT connector X23 AGATE AC3mini LST OM Pagina Page 119 CODICE CODE de Sesto S Giovanni ITALY di of 120 AY00000054545 5 24 2 2 TBCU LV Scheme Here below the X21 pin out related to the MVB address configuration Description X21 LOC R
93. value In case of repetitive faults in a short time the motor is disabled until a system reboot Here below the involved messages TrainTracerCode Stack Text message xx 27 26 Motor overtemperature BOE xx 27 27 Motor overtemperature xx 2B 0F M2 xx 27 28 Repetitive motor overtemperature xx 2B 10 M2 5 10 2 Involved LRUs Description AGATE AC3mini Motor phase current sensor TAM 01 TAM V1 LF505 S SP28 TAM U2 TAM V2 GRF Motors M1 M2 Pagina Page 89 CODICE CODE DISEGNO MOD ALSTOM i Sesto S Giovanni ITALY 4i of 120 AY0000005 545 5 10 3 Verifications Even if the text messages are generic the TrainTraceCode permits to identify which motor is supposed to have troubles as on the table presented before M1 is related to motor1 M2 is related to motor2 RUN LOW POWER TEST EPR to eventually discover faults on GRF in case of MAS configuration or motor current sensors CHECK phase to phase impedance value of the motor M1 if the diagnostic message is related to this one M2 otherwise disconnecting it from the motor contactors or output connection in case of MAS motors VERIFY that impedance value are equals amongs phases Pagina Page 90 CODICE CODE DISEGNO MOD ALSTOM RE i Sesto S Giovanni ITALY di of 120 AY00000054545 UT A 5 11 GRF Pump and Fan faults 5 11 1 Description Different protective actions are taken into ac
94. verity w Function 21 07 2010 10 15 05 507 26 2B 1F Inverter overtemperature TCU Error r 2 Cooling Control 21 07 2010 10 16 05 607 09 27 37 Inverter overtemperature TCU Error 21 07 2010 10 15 20 607 26 2B 1E Inverter cooling fan unable to start TCU Lock 21 07 2010 10 15 20 607 09 27 36 Inverter cooling fan unable to start TCU Lock Inverter 1 Cooling Control 21 07 2010 10 15 05 627 09 27 34 Inverter overtemperature TCU Warning Inverter 1 Cooling Control Pagina Page 23 CODICE CODE DISEGNO MOD ALSTOM E s Sesto S Giovanni ITALY gi of 120 AY0000005 545 Low Power Test Several hardware faults can be identifed executing the Low Power Test Sequence EPR then checking the final result anomalous behavior is traced highlighting on the DDU the related faulty step code Refer to the TCMS UserManual for detailed information regarding Low Power Test activation procedure Low Power Test step codes When the Low Power Test start command comes from TCMS via DDU button accessible on the maintenance page Traction SW checks that the necessary precondition are verified vehicle stopped manipulator in coasting before activating the test sequences During the test phase the driver is informed on the DDU screen about the progress of the sequence by a numeric code related to the test actually ongoing Step Test Ref GRF test sequence starts 4 8 101 Activate pump 102 If pump doesn t start aux contact false trigger an error and
95. ystem monitoring four are used by ControlBuild application Event Stack Comment System Systeme Information STR 3 0 information or error Bue STR 3 1 information CB ventil MONITORING TCU or COOLING FAN Tray Error CB system TCU Error CB powerup Information CB error Reserved for application contact TCE for detail CB warning Reserved for application contact TCE for detail APPLICATION CB message Reserved for application contact TCE for detail CB lock Reserved for application contact TCE for detail CB alarm Recorded events don t necessarily traduce an error it could also represent an information or a message In example CB powerup stack is used to record at each power up the FLT syst power up event which stores information about CPU temperature working hours cumulative kilometres and so on Filtering Events When diagnostic messages have been downloaded in the PC memory you can analyze them immediately or save and sent to colleagues Many features are available in particular the possibility to filter events in order to highlight message related to a specific functionality i e messages related to the mechanical brake control or based on a severity criteria i e messages related to a Lock event A small button is used for filtering Mouse click on a colums title permits to order events ccurence date Code w Event Device Se

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