CCB2 (E) Pneumatic - Feb 2020

Rail Service – Field Service
Engineer’s Meet
24th – 26th February, 2020
Knorr-Bremse Group │1
Rail Service – Field Service Engineer’s Meet
Agenda
❑ CCB Overview
❑ Loco Pneumatic Circuit
❑ CCB Pneumatic Circuit – EPCU Panel
❑ CCB Pneumatic Circuit – Auxiliary Panel
❑ Routine maintenance
▪ CCB Overview
Knorr-Bremse Group 3
CCB-Electric Advantages
➢ Improved BP monitoring
▪ Rate monitoring
▪ Level monitoring
▪ Flow monitoring
➢ Improved Bail-off control
▪ Non-resetting in service modes unless deeper reduction made
▪ Resetting in Penalty and Emergency modes
➢ Back-up mode for BC control (P16)
➢ Back-up mode for ER control (PER)
➢ Simpler Lead/Trail set-up through a single switch located on the
controller
➢ Flexibility to system parameters through software modifications
without hardware additions
➢ Adaption of Future upgrades possible
➢ Provision for both Goods and Passenger modes.
➢ Advanced diagnostics for Air Brake system
▪ Operation monitoring
▪ Fault code history storage
▪ PTU HELP menu for trouble shooting assistance
CCB-Electric Brake Rack Assembly
The Brake Rack Assembly is a vertical, wall-mounted rack

arrangement which is comprised of the following elements:
➢ Electro Pneumatic Control Unit (EPCU)
➢ Auxiliary Panel including Park Brake Functions
➢ Mounting Frame
➢ EPCU Header Bar
➢ Locomotive Interface Header Bar
➢ Electronic Vigilance Computer (EVC)
➢ Relay Control Portion (RCP)
➢ MPIO
➢ PSJB
➢ Electrical Junction Box
FRONT VIEW OF CCB RACK REAR VIEW OF CCB RACK
Electro Pneumatic Control Unit (EPCU)

MR-F 16-CP 20-CP ER-CP
➢ EPCU consists of 6 LRUs (Line Replaceable Units) 20-F
➢ LRUs that contain an electronic portion NODE on it are called as an MR2

BP-F
Intelligent LRU KE-V BP-CP
➢ Each LRU (Line Replaceable Unit) contains the pneumatic components BC-CP
associated with the locomotive function it controls
➢ EPCU manages the pneumatic interfaces between the locomotive brake

system and the consist.
➢ It controls the locomotive's brake cylinders, brake pipe, independent

application and release pipe, and the actuating pipe.
➢ The heart of an EPCU's pneumatic circuit is Knorr's patented Analog System Redundancies / Back-ups
Converter. These converters utilize pulse-width modulation to provide
highly accurate and stable control of equalizing reservoirs, brake cylinder ➢ Brake Cylinder Back-up – If the computer controlled BC
pilots, and independent application and release pipe pressures. pilot controller (16CP) fails, the system will automatically
switch over to using the KE valve output for BC pilot.
➢ A redundant pneumatic backup system is integrated into the EPCU, which ➢ Pneumatic ER Back-up (Optional) – The system is
provides backup for partial loss of computer control in the lead locomotive provisioned to optionally allow use of a back-up pneumatic
or functions in the trail mode when the system is unpowered. ER controller and switchover cock.
ERCP (EQUALISING RESERVOIR CONTROL PORTION)
➢ FUNCTION:
➢ Responsible for controlling the Equalising Reservoir Pressure, the pilot for BP
pressure in response to EBV Automatic Handle.
➢ MAJOR COMPONENETS:
➢ ER-APPLY
➢ ER-RELEASE
➢ MVER
➢ DEAD ENG COC
➢ DEAD ENG REGULATOR,
➢ ERT
➢ BPT
➢ BCT
➢ 10T
➢ PVSU.
BPCP (BRAKE PIPE CONTROL PORTION)
FUNCTION:
Responsible for controlling the Brake Pipe Pressure as per the pilot Equalising
Reservoir Pressure received.
MAJOR COMPONENETS:
BP Relay Valve
ACMV
ACMV PILOT VALVE
MV53
BPCO
MVEM
PVEM
BPT
MRT
FLT
16CP (16 CONTROL PORTION)
FUNCTION:
Responsible for controlling the 16 Pilot Pressure in response to BP
reduction and EBV IND handle movement.
MAJOR COMPONENETS:
16-APPLY
16-RELEASE
MV16
PVTV
16 BMV,
PVE
16T
BPT
MREPT
DCV2
20CP (BRAKE CYLINDER EQUALISING CONTROL PORTION)
FUNCTION:
Responsible for controlling Direct Brake Pipe Pressure in response to
EBV IND handle movement.
MAJOR COMPONENETS:
20-APP
20-REL
20 RELAY VALVE
MVLT
PVLT-1
PVLT-2
20TT
20TL
BCCP (BRAKE CYLINDER CONTROL PORTION)
FUNCTION:
Responsible for controlling BC Pressure as per the 16 Pilot Pressure or
the KE valve Pilot Pressure or the 20CP Pressure.
MAJOR COMPONENETS:
BC RELAY VALVE
DCV-1
KE VALVE
FUNCTION:
KE Valve develops BC Pilot Pressure due to reduction in the BP Pressure for the BC
Relay Valve in the event of electronic failure and during power loss.
PER COS (Pneumatic Equalizing Actuator)
FUNCTION:
PERCOS is manually actuated pneumatic selector valve which connects the
pneumatic
equalizing reservoir pressure to the CCB system for controlling the BP pressure in the
PTDC functioning mode.
PSJB (POWER SUPPLY JUNCTION BOX)
FUNCTION:
PSJB provides an isolated electrical power supply for the CCB II LRUs. It receives the
input power supply from the locomotive and develops regulated 24V output for the CCB II
LRUs to function.
RELAY CONTROL PORTION
FUNCTION:
RCP houses relays which are used for following logics:
PCS Relay (Electronic Mode)
PCS Relay (PTCDC Mode)
EFR Relay
CCB Health Signal
WIRING JUNCTION BOX
FUNCTION:
Wiring Junction Box acts as interface between the VCU and the CCB system. It carries
input power supply for the CCB and the components on the Auxiliary Panel, and provides
the output signals from the CCB / Auxiliary panel to the VCU.
ELECTRONIC VIGILANCE COMPUTER
FUNCTION:
EVC exchanges various timed input output signals between the locomotive and the
CCB system to indicate whether the operator is active or incapable to control the train. If
the EVC does not receive the operator activity signals the CCB will initiate an emergency
brake command and drop BP pressure to zero
MULTI PURPOSE ANALOG INPUT OUTPUT NODE (MPIO)
FUNCTION:
The MPIO is the signal interface between the VCU and the CCB system. It has both input
and output channels between the two.
INPUT : DB signal, Bail Off Trainline signal, BC Request (Regenerative), Zero Speed signal
for mode change
OUTPUT : ER/BP signal
CCB-Electric Auxiliary Manifold Functions
Auxiliary Manifold incorporates the following functions:

➢ Feed Pipe Control
➢ MREP Control
➢ Pantograph Circuit
➢ Parking Brake Control
➢ Air Supply to Traction Converters
➢ Air Supply to Filter Cubicle
➢ Sanding actuation
➢ 21 MV (Vig Mag Valve)
➢ Auto BC Pressure Switch CCB-Electric Auxiliary Manifold Ports
➢ Independent BC Pressure Switch  FP  ADV/UL
 Pan 2  MREP
CCB-Electric Auxiliary Manifold Interfaces  Pan 1  FC
The electrical interface provides a means for receiving Locomotive  CB (Vacuum Circuit Breaker)  TC 2
signals for energizing the various magnet valves as well as sending  AC  TC 1
pressure switch information to the Locomotive control.  MR 2  Sand 2
All the Pneumatic connections are connected to Locomotive interface  #1 MR(240Lit)  Sand 1
Header Bar thru metal tubing from back of the Brake Rack Assembly
 PB
Auxiliary Manifold with Valves
Electronic Brake Controller (EBV)
The EBV controller is a desk-top model which is ergonomically

designed & is the interface between the brake system and the
locomotive Driver
 Uses “Push-to-Brake” configuration.
 Consisting the Vent Valve for exhausting the Pilot Pressure of
NB11 Emergency Valve.
 Contains the following controls:
− Automatic Brake Handle (incorporates Accelerated Charging)
− Independent Brake Handle with Bail-Off Ring
− Lead/Trail Mode Selector
(Four position switch)
Easy to read Digital Display: Provides 2 line 16 character instant
information on the BP target pressure and limited crew advisory and
diagnostic messaging (in English only)
CCB-Electric Normal Mode - Lead/Trail Switch
In normal control mode, the L/T selector switch performs

the following functions:
 Lead
− Control as Lead, or only Single Locomotive
 Helper (Banking mode Operation)
− BP control cut-out
− Independent (direct brake) control for Banking
Locomotive BCP
 Trail (Multiple Operation)
− No handle controls other than emergency brake
− Response to T/L pipes and electrical signals only
 TEST
− BP control cut-out
− To TEST BP leakage in the loco / formation.
▪ Loco Pneumatic Circuit
MR PRESSURE CIRCUIT FROM COMPRESSOR TO AUX PANEL/MR1 FOR CREATION OF FP, MREP, UL CIRCUIT & SANDERS
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
MR PRESSURE CIRCUIT FROM COMPRESSOR TO MR2 / AUX PANEL / 240L TANK FOR CREATION OF BP, BC & BCEP AND FOR
PARKING BRAKE & SIFA MV
COLOUR SCHEME
21 Pipe
TO AUX
PANEL
16 Pilot FOR
PARKING
BRAKE &
SIFA
VALVE
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
▪ CCB Pneumatic Circuit – EPCU Panel
ER Control Portion: ER Charging (Automatic BC Release)
MR
ERG
COLOUR SCHEME
10P
21 Pipe ER Pilot
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
ER Control Portion: ER Reduction(Automatic BC Application)

EX
MR
ERG
COLOUR SCHEME
10P
21 Pipe ER Pilot
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
ER Control Portion: Dead Engine Cut-In

EX
MR
ERG
COLOUR SCHEME
10P
21 Pipe ER Pilot
BP
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
BP Control Portion: BP Charge (Automatic BC Release)
MR
FL
ER Pilot
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
BP
MR
ER
20 Pilot
BCEP/DBP
EX
10 Pipe
BP Control Portion: BP Accelerated Charge (Automatic BC Release)
MR
ER Pilot
FL
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP BP
MR
ER
20 Pilot
BCEP/DBP
EX
10 Pipe
BP Control Portion: BP Reduction (Automatic BC Application)
MR
FL
ER Pilot
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP BP
MR
ER
20 Pilot
BCEP/DBP
EX
10 Pipe
BP Control Portion: Emergency Application (Engineer Induced)
MR
FL
ER Pilot
COLOUR SCHEME
EX
21 Pipe
821VV
16 Pilot
BC
BP
BP
MR
ER
20 Pilot
BCEP/DBP
EX
10 Pipe
16 Control Portion: BP Reduction(Auto/IND 16/BC Application)
MR
16 Pilot
COLOUR SCHEME 16TV
21 Pipe BP
MREP
16 Pilot
BC
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
16 Control Portion: BP Charge(Auto/IND 16/BC Release)

EX
MR
16 Pilot
COLOUR SCHEME
16TV
21 Pipe BP
MREP
16 Pilot
BC
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
BC Control Portion: BP Reduction(Auto/IND 16/BC Application)
MR
16 Pilot
COLOUR SCHEME
21 Pipe
20 Pilot
16 Pilot
BC
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
BC Control Portion: BP Charge(Auto/IND 16/BC Release)
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
20 Control Portion: BCEP Application
Volume
MR
COLOUR SCHEME
21 Pipe BCEP
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
20 Control Portion: BCEP Release

EX
Volume
MR
COLOUR SCHEME
21 Pipe BCEP
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
One EMV provided inside BPCP for future use by an external control system
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
Back-up Mode - PER

➢ Provides a pneumatic means to control the train brake in the event that
the CCB electronically controlled brake system is non-functional. Allows
use of pneumatic driver’s backup brake valve in case of critical failure.
➢ Activation of the PER back-up control circuit is performed as follows:

CCB is always in EER mode (electronic control of ER/BP) unless the DBV PER-COS
PER Cut-out Switch on the manifold is selected for pneumatic operation.
➢ To cut in the PER circuit, turn off the Air Brake circuit breaker.
Select the PER-COS for PER mode by turning the knob from
horizontal to vertical position.
➢ When the PER-COS is selected for PER control of BP, the Pneumatic
ER is created to control BP, the COR relay will be energized when BP is
greater than 4.0 Bar, closing the PCR relay and thereby allowing tractive
power generation.
Configures the system for normal operation

or pneumatic backup of equalizing reservoir
control in the event of an ERCP failure.
Back-up Mode - PER
PER EX
MR
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
ER
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
▪ CCB Pneumatic Circuit – Auxiliary Panel
MR PRESSURE CIRCUIT FROM COMPRESSOR TO AUX PANEL/MR1
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
AC MR
MR PRESSURE CIRCUIT FROM COMPRESSOR TO MR2 / AUX PANEL / 240L TANK
COLOUR SCHEME TO AUX

PANEL
FOR
PARKING
21 Pipe BRAKE &
SIFA
VALVE
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
PANTO & CIRCUIT BREAKER
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
ER
20 Pilot
DJ CB PAN1 PAN2
AUX PRESS IN
OUT OUT OUT BCEP/DBP
10 Pipe
AC MR
UNLOADER CIRCUIT
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
ER
UNLOADER
VALVE 20 Pilot
MR PRESS
OUT
IN
BCEP/DBP
10 Pipe
AC MR
FILTER CUBICLE & TRACTION COVERTER CIRCUIT
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
47
ER
20 Pilot
TC1 TC2 FC BCEP/DBP

MR PRESS OUT OUT OUT
IN 10 Pipe
AC MR
TC1, TC2 & FC AIR
FEED PIPE & SANDER CIRCUIT
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
MREP FP SAND1 SAND1 10 Pipe
OUT OUT OUT OUT
AC MR
MR PRESS
IN TC1, TC2 & FC AIR
FP & SAND AIR
PARKING BRAKE & 21 SIFA MAGNET VALVE
COLOUR SCHEME
21 Pipe
16 Pilot
BC
BP
MR
ER
20 Pilot
BCEP/DBP
10 Pipe
AC MR
TC1, TC2 & FC AIR
BP PARKING MR2
BRAKE IN
FP & SAND AIR
IN
10 Pipe Circuit: Provides fully pneumatic method of applying a penalty brake application (non-suppressible penalty).
External MV
controlled by Loco
EX
10 PIPE
EPCU
3 Pipe Circuit: Provides pneumatic method of applying a penalty brake application that can be handle suppressed.
External MV
controlled by Loco
EX
3 PIPE
EPCU
Periodic maintenance for WAP-5 & WAP-7 Locomotives
Periodic maintenance for WAP-5 & WAP-7 Locomotives
Periodic maintenance for WAG-9 Locomotives
Periodic maintenance for WAG-9 Locomotives
Thank you for your kind attention

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Rail Service – Field Service

24th – 26th February, 2020

❑ Loco Pneumatic Circuit

❑ CCB Pneumatic Circuit – EPCU Panel

❑ CCB Pneumatic Circuit – Auxiliary Panel

CCB-Electric Brake Rack Assembly

The Brake Rack Assembly is a vertical, wall-mounted rack

➢ Auxiliary Panel including Park Brake Functions

➢ EPCU Header Bar

➢ Locomotive Interface Header Bar

➢ Electronic Vigilance Computer (EVC)

➢ Relay Control Portion (RCP)

➢ Electrical Junction Box

FRONT VIEW OF CCB RACK REAR VIEW OF CCB RACK

Electro Pneumatic Control Unit (EPCU)

➢ LRUs that contain an electronic portion NODE on it are called as an MR2

➢ EPCU manages the pneumatic interfaces between the locomotive brake

➢ It controls the locomotive's brake cylinders, brake pipe, independent

ERCP (EQUALISING RESERVOIR CONTROL PORTION)

BPCP (BRAKE PIPE CONTROL PORTION)

16CP (16 CONTROL PORTION)

20CP (BRAKE CYLINDER EQUALISING CONTROL PORTION)

BCCP (BRAKE CYLINDER CONTROL PORTION)

PER COS (Pneumatic Equalizing Actuator)

PSJB (POWER SUPPLY JUNCTION BOX)

RELAY CONTROL PORTION

WIRING JUNCTION BOX

ELECTRONIC VIGILANCE COMPUTER

MULTI PURPOSE ANALOG INPUT OUTPUT NODE (MPIO)

CCB-Electric Auxiliary Manifold Functions

Auxiliary Manifold incorporates the following functions:

Auxiliary Manifold with Valves

Electronic Brake Controller (EBV)

The EBV controller is a desk-top model which is ergonomically

CCB-Electric Normal Mode - Lead/Trail Switch

In normal control mode, the L/T selector switch performs

▪ Loco Pneumatic Circuit

▪ CCB Pneumatic Circuit – EPCU Panel

ER Control Portion: ER Charging (Automatic BC Release)

ER Control Portion: ER Reduction(Automatic BC Application)

ER Control Portion: Dead Engine Cut-In

BP Control Portion: BP Charge (Automatic BC Release)

BP Control Portion: BP Accelerated Charge (Automatic BC Release)

BP Control Portion: BP Reduction (Automatic BC Application)

BP Control Portion: Emergency Application (Engineer Induced)

16 Control Portion: BP Reduction(Auto/IND 16/BC Application)

COLOUR SCHEME 16TV

16 Control Portion: BP Charge(Auto/IND 16/BC Release)

BC Control Portion: BP Reduction(Auto/IND 16/BC Application)

BC Control Portion: BP Charge(Auto/IND 16/BC Release)

20 Control Portion: BCEP Application

20 Control Portion: BCEP Release

Back-up Mode - PER

➢ Activation of the PER back-up control circuit is performed as follows:

Configures the system for normal operation

Back-up Mode - PER

▪ CCB Pneumatic Circuit – Auxiliary Panel