1

3
 6

TEST -BP DROP CHECKING

1. A9 HANDLE LEAD -LOCO IN WKG CAB
2. A9 LOCKING PIN TRL - LOCO IN NON WKG
3. MODE SWITCH CAB
4. SA9 HANDLE HLPR - KEPT IN THIS MODE
5. PTDC HANDLE DURING BANKING
6. EBV SCREEN OPERATION
4.0
ºy*m[(Tk p[nl

I IA/IB/IC
ºy*m[(Tk p[nl ki[ d[Kkr s&(n(Æct kr[> (k ki[e< Eyr (lk[j nh)> h].

Ii IA/IB/IC
ºy*m[(Tk p[nl ki[ bihr s[ c]k kr[>.ki[e< Krib) nh)> h].

iii IA/IB/IC
sB) COCs k) sh) pi[j)Sn c]k kr[>.

Iv IA/IB/IC
c]k kr[> sB) k[I
bl sh) f)T h]> ai]r unk[ kn[kSn sh) Tie<T h]> y(d ki[e< p(rxN
krni hi[ ti[ s>Àb>(Ft s[kSn ki[ s*(ct kr[>.

V IA/IB/IC
ºy*m[(Tk p[nl pr RS g[j lgi h] ai]r sh) kiy< kr rhi h].s&(n(Æct
kr[>.

Vi IA/IB/IC
ºy*m[(Tk p[nl pr ै न कोक खोले ओर पानी ै न करे
 1. SOLONOIDE
VALVE-30
2. SR-2 COC
3. HARMONIC
FILTER COC
4. SR-1 COC
5. SIFA COC(74)
6. FEED PIPE
COC(136)
7. PANTO SELECTOR
SWITCH(85)
8. PAN-1 COC
9. PAN-2 COC
10. IG-38 KEY
11. VCB COC
12. UNLOADER COC
13. SANDER-1 COC
14. SANDER-2 COC
15. P&G SWITCH
16. 16 CP
24
17. 20 CP
18. ERCP
19. C3W
20. PER-COS
21. DEAD LOCO
COC(47)
22. BPCP
23. BCCP
24. FEED VALVE

23 22
 ELECTRONIC
RELAY
VIGILIANCE
CONTROL
CONTROL
PORTION
Power supply
junction box
MPIO

Junction box
w/cables
Moisture Drain coc In CCB and E-70 Brake system

RS DRAIN COCK

RS DRAIN
COCK
5. b\[k aiesi[l[(T>g kik IA/I
0 B/IC

I BP/FP E>gl kik sh) kiy< kr rh[ h]> c]k IA/I

B/IC
kr[> . BP/FP pie<p kik aie<si[l[(T>g kik
pr bihr) ci[T k[ (nSin yi k\[k nh)> h].

6. b\[k hi[j pie<p IA/I

0 B/IC

I li[ki[ k[ trf b\[k hi[j pie<p D]m[j yi kT[-fT[ IA/I

B/IC
nh)> h] c]k kr[>.kp(l>g kik sh) kiy< krt[
h>].
FP ADD ISOLATION
COCK
 FP
FP HOSE HOSE
PIPE PIPE
HAND BOOK OF CCB PNEUMATIC PANEL

EBV

4
Prepared by: Ashish
Pandey
JUNCTION BOX WITH CABLES
The Junction Box Assembly provides a central termination point for interfacing the
Modular CCB Brake System with the locomotive electrical subsystems.
POWER SUPPLY JUNCTION BOX
The PSJB provides an isolated electrical power source for the Modular CCB Brake
System equipment. The PSJB receives supply voltage from the locomotive low
voltage battery system 110VDC and develops regulated 24 VDC supply voltage for
the Modular CCB Brake System electrical components.
MULTI-PURPOSE INPUT/OUTPUT NODE
The MPIO is a modular expansion element communicating with the core Modular
CCB Brake System via the LON network.
RELAY CONTROL PORTION
The RCP houses two high current relays with two sets of contacts,
capable of being wired normally open or normally closed on each set
of contacts.
ELECTRONIC VIGILANCE COMPUTER
The EVC is a modular expansion device providing an electronic interface between the
locomotive operator and the Modular CCB Brake System. The EVC system
exchanges various timed inputs and outputs between the operator and the brake
system. If the EVC does not receive the appropriate level of operator activity, the
Modular CCB Brake System will initiate an emergency brake command.
AUXILIARY MANIFOLD ASSEMBLY
The Air Brake System Control Rack also contains an Auxiliary Manifold Assembly to
perform the pneumatic auxiliary functions. This manifold includes magnet valves,
isolating cocks, pressure governors, check valves, feed valve and other components.
ELECTRO PNEUMATIC CONTROL UNIT
The Modular CCB Brake System is comprised of distributed electro-pneumatic devices
that are linked via a communication network. The EPCU mounted in the locomotive
machine room, consists of modularized line replaceable units (LRUs) that control the
development of all pneumatic control pressures (BP, BC & DP).

FLOW METER

The Flow Meter Valve is a pneumatic device that monitors main reservoir air flow
across an orifice within the EPCU to provide brake pipe flow indication via the flow
gauge located within the operator’s cab.

VENT VALVE

The 821 Vent Valve is a high capacity venting device to ensure rapid
propagation of BP reduction during emergency.

5
 HAND BOOK OF CCB PNEUMATIC
PANEL
AUXILIARY MANIFOLD - FUNCTION

 Feed Pipe Control

 MREP Control
 Pantograph Circuit control
 Parking Brake Control
 Air Supply to Traction Converters
 Air Supply to Filter Cubicle
 Sanding actuation 21 Magnet
valve for Vigilance

 Auto BC Pressure Switch

 Independent BC Pressure Switch

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 HAND BOOK OF CCB PNEUMATIC PANEL
ELECTRO PNEUMATIC CONTROL PORTION (EPCU)
 MR-F– MR Inlet Filter for ERCP, BPCP & 20CP
 20-F- 20CP Outlet Filter
 MR2-F - MR Inlet Filter for 16CP &BCCP
 BP-F- Filter/Strainer for BPCP
 16CP- 16 Control Portion provides pilotpressure for Loco BC
 20CP- 20 Control Portion provides BCEP pilot & PCEP Pressure
 ERCP- ER Control Portion provides Pilot pressure for BP
 BPCP- Brake Pipe Control Portion develops BP pressure.
 BCCP- Brake Cylinder Control Portion develops BC pressure for loco.
 KE-V- Distributor Valve provides back-up BC pilot.
 PER-COS - Pneumatic ER control change over cock

MR- 16- 20- ER-

F CP CP CP
PER-
20-
COS
ERCPF
- MR2- BP-
F F

KE- BC- BP
V CP -
C
P

ERCP- The ERCP electronically controls the eualizing reservoir pressure (ER) in response to EBV
automatic commands. The pneumatic and electrically control portion of the ERCP include emulation
of the #3, #10, and #26 pipes. Optional penalties magnet valves can be added to the #3 pipe port for
suppressible penalties, and to the #10 pipe port for non- suppressible penalties.

BPCP- The BPCP electronically controls the supply, exhaust maintaining and cut-of of trainline
brakepipe. The BPCP includes the brake pipe relay valve,emergency magnet valve and vent valve,
and brake pipe cur-out function as well as break-in –two detection and brake pipe pressure sensing.

16CP- The 16CP electronics develops brake cylinder control pilot pressure in response to brake pipe
pressure reductions, direct brake pipe pressure commands, and bail commands. 10

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 HAND BOOK OF CCB PNEUMATIC PANEL
20CP- The 20CP electronically develops the Direct Brake pipe pressure in response to EBV
independent handle commands. The 20CP includes the apply and release control valves, as well as
Lead/Trail interlocks to enable or disable pneumatic control.

BCCP- The BCCP is a pneumatically controlled valve that provides brake cylinder pressure based
upon the level of 16 and 20 pipe pilot pressure at a 1:1 ratio. The BCCP includes a high capacity
pneumatic relay valve and double check valve.

KEV- The KEV develops brake cylinder pilot pressure (16TV) during service brake applications as a
function of brake pipe pressure reduction. The KEV provides a pneumatic backup of 16 pilot
pressure to pilot the brake cylinder relay in the event of electronic failure. The KEV charges auxiliary
reservoir from brake pipe pressure.Upon brake pipe pressure reduction, the KEV ports air from
auxilary to the 16TV passage to a level proportional to the reduction.

PER-COS- The PER is amanually actuated peeumatic selector valve, which conditions the equalizing
reservoir control from electronic control to back-up pneumatic control. The PER includes a selector
knob and electronic feedback to identify the position of the valve.

ELECTRICAL INTERFACE

11

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 HAND BOOK OF CCB PNEUMATIC
PANEL
ELECTRONIC BRAKE
VALVE

The EBV is a Desktop arranged self – contained unit having all the controls required for
operation of the locomotive’s train brake. The control levers are arranged for minimum arm
and hand movement while providing support of the arm during normal operation.

 The EBV function to indicate the handle position to the computer. No direct action is
taken other than initiation of an emergency brake application.
 The knob type handle located to the right is the INDEPENDENT (DIRECT) BRAKE
leaver. Movement of the handle away from the operator will command the computer,
via network, to apply the independent brake variable from ‘min’ to ‘max’ application.
The independent brake may be released in like manner by pulling the handle toward
the operator.
 The BAIL-OFF feature is activated by lifting op on the ring of the knob on the
independent brake leaver.
 The handle located to the left is the AUTOMATIC BRAKE LEAVER . The automatic
brake handle commands the computer to the desired control of the brake pipe. The
automatic brake lever
has five position.

HANDLE POSITION

The EBV has five handle position:

1. Release
2. Run
3. Minimum
4. Full service
5. Emergency

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 HAND BOOK OF CCB PNEUMATIC PANEL
RELEASE (REL): In this position a message is transmitted to the ERCP and BPCP to charge
the brake pipe at a faster rate and to release the train brakes quicker. A secondary response to
release position is to overcharge Brake pipe to a slight overcharge pressure to assure complete
release of train brakes.

RUNNING (RUN): The EBV handle moved this position, a message is transmitted to the
ERCP to recharge brake pipe to the normal operating release pressure and to release
locomotive and train brake completely.

MINIMUM (MIN): The minimum position provides for a pre-determined light brake pipe
reduction to locomotive and train brakes with a guaranteed brake cylinder pressure.

SERVICE ZONE: Area between MIN and FS, the handle is placed in this zone to obtain a
service brake application dependent on the position of the handle, from minimum service to
full service.

FULL SERVICE: When in this FS position of this sector, a full service brake application is
commanded. This position is also used to recover a penalty brake application

EMERGENCY: This position is located farthest away from the operator. An electrical and
pneumatic emergency brake application is initiated. This position must be used for making
brake valve emergency brake application and for resetting after any emergency resulting from
any cause other than a brake valve initiated emergency brake application.

MODE SELECTOR SWITCH

Auto brake set-up for Lead, Trail, Helper, and Test modes. Set-up selection via rotary switch
mounted on EBV. Only one Brake Controller should be active at any time. If both the EBV
selected in Lead, penalty brake will be applied.

TRAIL: This position cut off automatic and independent brake control, except for the automatic
emergency. A trailing locomotive develops Auto Brake cylinder pressure based on Brake pipe
reduction a Lead locomotive. A Trailing locomotive develops Independent Brake cylinder
pressure based on Direct Brake pipe pressure from a lead locomotive. A Trail locomotive has
all four paramatic pipe connection (DB,FP,BP,MREP) with a Lead locomotive.

A trailing locomotive gets its Bail off Loco brake signal (BOLT) from the Lead locomotive
through the (Locomotive control computer) LCC and via the UIC cable which connects
locomotives in a consist.

TEST (Lead / Cut-out): This position cuts off brake pipe charging, but does not cut out the
independent brake oar automatic emergency brake. ER pressure follows handle position.
Locomotive Brake cylinder pressure automatically applies via DBP in this mode to test for
Brake pipe leakage. ‘Test’ mode is a stationary mode in which the Driver can check the leak
tightness of Brake pipe, and can only be performed at a zero speed condition of the
locomotive.

LEAD: This position has all automatic and independent brake function active. In this mode of
operation both Automatic and Direct Brake handles control BP and Direct Brake pipe pressure
which in turn controls the locomotive brake cylinder pressure. Direct Brake pipe pressure
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 HAND BOOK OF CCB PNEUMATIC PANEL
HELPER: This position cuts off brake pipe charging, but does not cut out Independent
brake or automatic emergency brake. ER pressure is exhausted to zero. A Helper
locomotive has only the BP connected to a Lead locomotive.

Back-up Functions (PER Function & BC Back up)

Loco running in Between section and a critical Brake system fault occurs which prevents the
Loco pilot from moving, the following steps may be taken to move the locomotive to the next
convenient location at a restricted speed (under control of Locomotive Computer control). It
should be noted that this mode, “Pneumatic ER” (PER) is intended as a back-up protection
and should not be used for normal operation.

To operate the Locomotive Brake system in PER mode:

 Switch off circuit breaker for pneumatic panel supply in locomotive electrical panel.
 Rotate PER-COS to ”Cut-In” position( vertical).
 Keep vigilance circuit breaker on.
 Charge brake pipe pressure by operating the Back-up Driver’s Brake valve in the active
cab. BP
will charge to 5.00± 0.1kg/cm2.
 BC pressure will reduce to zero. If not, briefly pull the quick release lever at the bottom
of the KE ( Distributor) valve.
 If Direct Brake also not getting released, press the 20-TP provided on 20-control portion.

In PER mode locomotive control system allows traction only up to10 KMPH (under control
of VCU software of loco). Other interlocks through various pressure switches will function
as normal.

During PER mode, the 21 magnet valve (Emergency valve) remains active thus still can be
controlled by the electronics, the Memotel (Over speed) contact or either Assistant Driver’s
Emergency Valves. The Auto Brake handle will still generate an Emergency brake but it will
not trip the 21 Magnet valve (SIFA MV). All other functions on the CCB Brake controller will be
inactive. Only during a 21 valve magnet failure should the SIFA cut-out valve handle to be
isolated.

After moving the locomotive to a safer place or from the main track, clear the critical CCB
fault. After clearing the fault, in order to resume normal mode of operation.

 Drop BP to ‘0’ kg/cm2.

 Rotate PER-COS to ‘cut-out’ position.
 Switch on circuit breaker for pneumatic brake panel supply in locomotive electrical panel
 Charge BP as normal and resume the normal operation.

BC Back up: Further in case of any problem with ’16-cotrol portion’ CCB itself will De-energize
the 16- Magnet valve and this will connect BC control pressure generated by KE DC Relay
valve. In this back-up mode, max. Auto BC pressure will be 3.8 kg/cm2 instead of 2.5 kg/cm2
due to Distributor Valve.

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 HAND BOOK OF CCB PNEUMATIC PANEL
MODULAR CCB BRAKE SYSTEM EBV CREW
MESSAGE
LINE 1 LINE 2 MEANING
Wait Powering up This system is booting up
Self hand brake PTU is ON PTU disabled the brake
Unable to boot Service xxCP During power-up a problem was detected
with the xxCP. perform maintenance.
Fireman Emer S/W Mismatch Display when software version check
fails on power-up.
Operator Emer Put Auto in Emer Display if emer and handle < emer
Trainline Emer Put Auto in Emer Display if emer and handle < emer
Fireman Emer wait Display if in emergency an handle In emer
and
timer<60 sec.
Operator Emer wait Display if in emergency an handle In emer
and
timer<60 sec.
Trainline Emer Wait Display if in emergency an handle In emer
and
timer<60 sec.
Fault penalty Put Auto in FS Display if penalty and auto is <FS
Safety penalty Put Auto in FS Display if penalty and auto is <FS
Fault penalty Keep in FS Display if in penalty and handle in FS, and
timer<10 sec.
Safety penalty Keep in FS Display if in penalty and handle in FS, and
timer<10 sec.
Fault xx Active Shut AB off
Fault xx Active Check BC gauge Display When fault 23 is active
Fault xx Active Trail use only Display when disabling fault is active
Fault xx Active Ind Full or Rel Display when fault 20 is active.
Okay to Run Service soon-xx Display when a non-critical fault is active.
Wait: Recharging Reservoirs Display unit auxiliary reservoir is 98%
charged,
based on formula developed from actual
hardware performance. Only displayed
while auto= REL
Okay to Run BP Target=xx psi This is the default screen.
Unable to Boot Factory Indicates computer problem contect field
Code:??? service.
Initializing System…

24

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 HAND BOOK OF CCB PNEUMATIC PANEL
EBV CREW MESSAGE FAULT CODES

Fault Description Detected Reason for Corrective action If still Bad, Try:
code by fault
001 ERCN Fault RCP,BP Loss of ERCN Insure LON cable is If not corrected, must be
heartbeat for 4 positively seated at used in Trail Mode until
sec. ERCP. Cycle AB repair. Replace ERCP
circuit breaker
002 ERCP AW4 fault ERCP ER>120 or Place mode switch IN If not corrected, must be
pressure not TRAIL, Automatic used in Trail Mode until
within+/- psi in handle in EMER, and repair. Replace ERCP.
10 sec. Independent handle in
Full to clear fault.
006 MVER Fault ERCP Output Must be used in Trail
feedback mode until repair,
indicates MV Replace ERCP.
fault
010 BPT Fault BPCP Xdcr output If Fault remains after
voltage> 4.5 or< power cycling AB
0.5. circuit breaker, replace
BPCP. Set power off
and use in trail in
pneumatic backup until
repair.
014 MV53 Fault BP Output Must be used in Trail
feedback mode until repair,
indicates MV Replace BPCP.
fault
016 BPCN Fault RCP Loss of BPCN Inspect LON cable Check for yellow light on BP
heartbeat for 4 connection to bpcp on control node. If steady or
sec. the EPCP and tighten blinking reprogram or
as needed. Cycle AB replace BPCP. If red light
circuit breaker. remains on after power
cycle, Replace BPCP. Must
be used in Trail mode until
repair
023 13T Fault Lo 16 Xdcr output Automatic BC pressure
voltage <0.5 may be direct release
only. No blending or
other special BC
controls will be active
.Replace 16CP.
036 16CP AW4 Fault 16 Pressure not Place mode switch to If not corrected, automatic
within+/- 5 psi Trail, Automatic handle BC pressure may be direct
in 10 sec. in EMER, and release only. No blending or
independent handle in other special BC controls
FULL to clear fault will be active. Replace 16CP
039 MV 16 fault 16 Output Automatic BC
feedback pressure may be
indicates MV direct release
fault only. No blending or
other special BC
controls will be active.
Replace 16CP.
052 16 CN Fault RCP Loss of BPCN Insure LON cable is If not corrected, automatic
heartbeat for 4 positively seated at BC pressure may be direct
sec. 16CP. Cycle AB release only. No blending or
circuit breaker other special BC controls
2
will be active. Replace 16CP
5
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 HAND BOOK OF CCB PNEUMATIC PANEL
Fault Description Detected Reason for Corrective action If still Bad, Try:
code by fault
055 20 CP AW4 20 Pressure not Place mode switch to If fault remains, use in Trail
Fault within+/- 5 psi Trail, Automatic handle mode until repair. Replace
in 10 sec. in EMER, and 20CP.
independent handle in
FULL to clear fault

062 20 CN Fault EBV Loss of 20CN Insure LON cable is Check yellow light on 20
heartbeat for 4 positively seated at control mode. If steady or
sec. 20CP. Cycle AB circuit blinking, reprogramming or
breaker. If fault replace 20CP. If red light
remains, set ABCB off remains on after power cycle,
and use in trail on replace 20CP.
pneumatic backup.

075 AUTO HANDLE EBV Potentiometer Set to Trail. Replace EBV

OPEN output voltage
< minimum

076 INDEP HANDLE EBV Potentiometer Set to Trail. Replace EBV

OPEN output voltage
< minimum

085 EBV CN FAULT ER,BP Loss of EBV CN Insure LON cable is Check yellow light on EBV
heartbeat for 6 positively seated at EBV control node 20 control mode.
sec. connector and PSJB J If steady or blinking,
100. Cycle AB circuit reprogramming or replace
breaker EBV. If red light remains on
after power cycle, replace EBV.

118 RCP on Fault BP Loss of RCP Must be used in Trail

heartbeat for 4 mode until repair,
sec. Replace RCP.

125 MV 26 De- ER Output Must be used in Trail

energized feedback mode until repair,
indicates MV Replace ERCP.
fault

136 16 CP BPT Fault 16 Xdcr output Automatic BC pressure

voltage> 4.5 or< may be direct release
0.5. only. No blending or
other special BC
controls will be active.
Replace 16CP.

140 MR/FL Dual BP Xdcr output AW4 diagnostics are

Transducer voltage> 4.5 or< disabled. Loss of MR
Fault 0.5 both MRT pressure indication for
and FLT display. Replace BPCP

141 LCI COMM LOSS RCP Loss of LCI Insure LON cable is Replace LCI
heartbeat positively seated at LON
message for 5 Converter and LCC.
sec Cycle AB circuit
breaker. Replace LON
convertor.
2
142 20 BMV Fault 16 Output Must be used in Trail
feedback mode until repair, 6
indicates MV Replace 16 CP.