LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ INSTRUCTION MANUAL MICRO PROCESSOR- BASED ELECTRONIC SPEED INDICATING CUM RECORDING & ENERGY MONITORING SYSTEM FOR 25KV AC EMU, MEMU’s AS PER RDSO SPEC.NO. RDSO/ PE/ SPEC/ EMU/0032 – 2002 REVISION .0 AMENDMENT NO:1 MODEL # LAX 2000 E-EMU FOR AC EMU’S. ************************************************************ 1 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ *** WARNING *** Information provided in the following pages is the sole property of M/s. Laxven Systems. These are not to be used, copied or reproduced without the express and written consent of M/s. Laxven Systems. The information provided does not bind or prevent M/s. Laxven Systems from further developing, improving or modifying their products without notice of change. ************************************************************ 2 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ MICRO PROCESSOR BASED ELECTRONIC SPEED INDICATING AND RECORDING & ENERGY MONITORING SYSTEM FOR 25 KV AC EMU & MEMU’S. Model : LAX 2000 E - EMU CONTENTS 1. 2. 3. 4. GENERAL SPECIFICATIONS OPERATING INSTRUCTIONS MAINTENANCE. 4.1 DO’S AND DO NOT’S 4.2 GUIDE TO TROUBLE SHOOTING 4.3 DRAWINGS 4.3.1 BLOCK DIAGRAM FOR AC EMU /MEMU 4.3.2 CONNECTION DIAGRAM FOR AC EMU / MEMU 4.3.3 DIMENSIONAL DRAWING OF RCI 4.3.4 CARD POSITION WHEN VIEWED FROM BACK 4.3.5 IDENTIFICATION OF MAIN PARTS OF ASSY. 4.3.6 DATA DOWN LOAD AND SPEED ANALYSIS 4.3.7 DIMENSIONAL DRAWING OF PULSE GENERATOR 4.3.8 JUNCTION BOX 4.3.9 SCB BOX ASSLY. 4.3.10 P.T. BOX ASSLY. 4.3.11 C.T. BOX ASSLY. 5. 6. APPENDIX FOR PROGRAMMING DOWNLOADING AND ANALYSIS ************************************************************ 3 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 1. GENERAL LAX 2000E-EMU is designed to provide a reliable and accurate record of speed, time, distance and energy parameters of an EMU under some given conditions. The system is powered from the DC voltage available in the EMU. It is suitable for voltage variations between 50 -140 V and is thus fit for application on all Indian Railway AC Electrical multiple Unit AC EMU, MEMUs . The system produces a record of speed Vs distance, Speed Vs Time, Energy Vs Time, Energy Vs Distance etc. traveled by the EMU. The above data, for the last six Hours of running at a resolution of 1 sec and for the last 45 days of running at a resolution of 20 sec are recorded in non-volatile flash PCMCIA memory, for any post-incident analysis. The system also provides digital display of the parameters (Parameters are laid in the specification). The parameters laid down in the specification are recorded in Internal and External memory module The Speed Recording System, Model LAX 2000E-EMU consists of the following units: A. AC EMU/MEMU’s Mounted Equipments: Qty 1. Speed Recorder cum Indicator LAX2000E- EMU - 1 No 2. Pulse Generator - 1 No. 3. Junction Box with cables -1 No. 4. Signal Conditioning Box - 1 No. 5. Potential Transformer -1 No. 6. Current transformer -1 No. 7. Set of cables -1 set B. EMU/MEMU Shed Equipments: Each shed should have at least one set of Loco shed equipment for AC EMU’s/ MEMU’s. ************************************************************ 4 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 1.1 1. Software on CD - 1 No. 2. Memory Down Loader -1 No. 3. Cables for downloading - 1 No. Speed Recorder Cum Indicator Unit. For AC EMU (RCI unit) RCI is a vital element of the system and consists of the following sub assemblies: 1. 2. 3. 4. 5. 6. 7. 8. 9. Power Supply Card Micro Controller Main CardMicro Controller Energy Card Memory Control Card /PCMCIA Card Stepper Card Display Card Key Board Mother Board Enclosure 1.1.1 Power Supply: It is a versatile DC to DC converter suitable for input supply of 50V to 140 V DC from the Battery of the EMU. Switching mode techniques are used to allow wide variations of input voltages and high electrical isolation between Input DC and Output DC Voltages. Surge suppression, reverse voltage protection and short circuit protections, filters are in-built. Output is sufficient for all requirements of Speed Recording and Indicating System. 1.1.2 Micro Controller Main Card: This sub assembly is factory programmed to perform the following functions. a) b) Run the real-time clock; a battery backup to last for minimum 10 years is provided . Records the Speed data received by the Pulse Generator along with the time, distance and energy parameters with the preconditions set by the driver and shed staff. The Controller updates the data every 250 milli- seconds. The calculated speed will be sent to the stepper card controller, which in turn drives the needle to the specific speed in analog form in the front panel. The speed and other parameters are ************************************************************ 5 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ displayed in digital form, apart from recording. The Main Control Card also interacts with Energy Card for obtaining energy , voltage and current data etc. c) Provides correct output signals for LCD display to display the required parameters and error signals including fault diagnosis. d) e). f). g). h). Interacts with Energy Card for obtaining energy parameters. Viz. Voltage, Current, Energy, Power Factor. Interacts with Micro controller based memory card Interacts with Key pad for programming the parameters by driver and shed staff . Multiplication factor of no. of motor coaches. Internal Memory: A non-volatile memory is provided in the main card to record the fine Of 6 Hours and 45 days of coarse memory @ 20 sec interval, of travel simultaneously with the PCMCIA recording. The data in this memory can be down loaded to the lap top directly through RS 232C port of PC. A separate RS 232 is provided on the unit to down load this data. i) Interact with PC/Laptop for down-loading of coarse and fine data. j) Display & Self Check Features: All the parameters are displayed sequentially with the press of DISPLAY key on the key pad. ALL ERROR MESSAGES WILL BLINK AT 0.25 SEC. Visual indication on exceeding the Memory occupation limit; Self check features are programmed for detection of Memory Status Memory freeze Auto check of zero speed k) Interaction with Stepper Card for driving the needle of the analog indicator. 1.1.3 Micro Controller Energy Card This Card receives the signals from PT and CT from Signal Conditioning Box and processed by Micro Controller and also interacts with the main card through a pre-defined protocol. ************************************************************ 6 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 1.1.4 Memory Control Card / PCMCIA Card The Micro controller based Memory card is an intelligent card and generates the status of the memory and communicates with the main controller card internally with a predefined protocol. The memory is divided in to three partitions, attribute memory, fine data and Coarse data. The fine data is stored at every second when the train is in motion in a loop form for the period of 6 Hours . When the train is in halt the fine data is not written into the memory. Like wise the coarse data is stored at every 20 sec during the EMU run and halt for 45 days in a loop form. In case of any accident, the authorized person has to break the memory freeze glass fitted on the front panel of the unit .and switch on the memory freeze switch. This prevents the fine data storing into the memory till the memory freeze switch is off. The PCMCIA card is a 68-pin, Type II is used and conforms to all International Standard s with push button ejector for easy loading and ejection. 1.1.5 Stepper Card The Stepper Card controls the stepper motor, and drives the needle of the analog speedometer in tune with the input signal received from the main card. Auto-Zero Check facility is provided. 1.1.6.LCD Display card The objective of this card is to display different parameters and Error signals on the 16character X 2 line LCD display. Detailed description of the Display parameters and Error signals are given in Parameter Setting and Viewing Protocol. 1.1.7. Key Board A 16 key membrane alpha numeric key pad is provided on the front panel to load the parameters by driver and the shed staff. It contains numerals 0-9 with alphabets , TRAIN NUM, TRAIN LOAD ,DRIVER ID, CANCEL, DISPLAY & ENTER keys. Some of the parameters like set over speed limits, wheel diameter, calendar, can not be accessible to the driver. The access to this parameters is through a switch which is under lock and key. The driver can access only to input his PF/ driver code, train number, train load, number of motor coaches and illumination level. ************************************************************ 7 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 1.1.8. Mother Board This Mother Board holds all the cards with 96 pin Euro connectors and provides the outputs to stepper card, keypad, display card and output card through lock and mate connectors. 1.1.9 Enclosure A robust steel enclosure for the Speed Recording System provides resistance to ingress of dust and moisture into the instrument. The enclosure is sealed to prevent unauthorized access and locking arrangements are provided from the front panel to insert the PCMCIA card and to set the parameters to the EMU. Provisions are made for connection of cables for input power, input from Pulse/speed sensor, output to LAP TOP/PC for downloading of data by suitable connectors. 1.2 Speed sensor: This unit is to be mounted on the axle cover available on the EMU. It is also able to bear all shocks and vibrations during the movements of the Vehicle. When mounted properly, the pulsar assembly of the speed sensor is driven by the loco axle with 1:1 speed ratio, through’ pin drive fork arrangement. The speed sensor is basically an optical sensor enclosed in a water tight enclosure, which is directly connected to the axle of the EMU with a pin drive as shown. The speed of the axle is directly transmitted to the sensor. The required supply for the sensor will come from the corresponding units. Two sensors are embedded in the housing. The required supply for the sensor will come from the corresponding units. The frequency of the output pulses from the speed sensor depends up on the axle rpm. The design generates 30 pulses per rpm of the axle, to ensure high system accuracy of the system. The electrical output from the speed sensor is conveyed to the system through multi-pin MS connector and a length of multi-core cable via junction box. 1.3 Junction Box A small rugged enclosure is provided for housing terminal strips used for establishing connections between cables routed to Speed Sensor, Recorders. This box is to be mounted on the chassis of EMU. ************************************************************ 8 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ Circular connector from the speed sensor will be terminated to one end of the junction box. The other side of junction box, terminals are ties up to the cables emerging from the Recorder Unit. 1.4 Signal Conditioning Box The Signal Conditioning box is used to isolate the high voltages and currents generated by the EMU and generate the suitable voltages acceptable to the Energy Monitoring systems. Inputs will come to one end of the box from Laxven CT and PT. 1.5 Potential Transformer For processing the energy parameters, OHE voltage is measured using a dual voltage Potential transformer which is provided in a PT box assembly. The input to the Potential transformer is a voltage signal corresponding to 22.5KV OHE voltage which is taken from 240V auxiliary winding of the main transformer. The output of the Potential transformer is 0-110V AC corresponding to the input 240V, which goes to the Signal-conditioning box. 1.6 Current Transformer For processing the energy parameters, OHE Current is measured using a ring type CT which gets its input from the primary of the main transformer. The input to CT is 0-150A AC and the output of the CT is 0-5A AC which goes to the signal conditioning box. 1.7 Cables Required for Interconnection All cables will be 1.5 sq. mm , PTFE Insulated, FRLS Jacketed and shielded cables. The cables are terminated either to the MS connector Or to the M5 lugs. 1.8 Memory Reader Unit: The Memory Reader unit is used to download the data from the PCMCIA card to the computer. For a detailed explanation refer chapter 6 on downloading and analysis. ************************************************************ 9 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 2. SYSTEM SPECIFICATIONS LAX 2000 E - EMU This system, confirms to RDSO Spec. No. RDSO/PE/SPEC/EMU/0032-2002 (REV . 0) 2.01 Power Supply voltage :50 to 140 V DC , from AC EMU’s. 2.02 Power :8 Watts. Resolution of recording In Static Memory :1 sec for fine data for the last 6 hours of . 2.03 run data. 20 Sec for course data for the last 45 2.04 2.05 days of run and halt data Accuracy of Speed Indication :Better than 0.8% of the full scale. Scale range :0 – 120KMPH or as per customer in 240 degrees 2.06 Display : 2.07 Temp. Range of Operation: -5 to +70 deg. C . Flash PCMCIA Memory : Last Six Hours data of travel at 1sec. Interval and last 45 days of run and halt data at 20 Sec interval in a loop form. This data is stored in a flash PCMCIA memory. The same data is also stored in Flash EEPROM on the main board as a stand by memory. This data can be down loaded through RS-232 port of the computer 2.08 2.09 Approximate weights :A 2 Row 16 character LCD display with back light is provided for viewing Speed, Time, Distance and other parameters. : Speed Recording unit < 3 Kg. ************************************************************ 10 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 3.OPERATING INSTRUCTIONS This appendix describes the step by step procedure of the operation of the unit. Recorder Unit: 1. Switch on the RCI units by giving 110V DC supply from EMU’s. 2. Connect the Interconnection cables as shown in wiring diagram. 3. As soon as the units are powered, the display shows “WELCOME TO LAXVEN SYSTEMS” 4. The unit self checks the Auto zero position of the Analog pointer. 5. The Display then checks the healthiness of the system, memory healthiness and other self checks. During this time the display shows “PLEASE WAIT PROCESSING”. This Operation may take about 30 seconds. 6. When once self check features are completed, the display shows Real time in HH:MM:SS, first line and other parameter date DD:MM:YY is displayed in next line. 7. Connect the speed signal to the Recorder unit and Pulse generator to the wheel of the EMU for speed signal The speed is displayed as analog speed on a dial is indicated by the pointer. 8. When the speed crosses the set over speed limit, Over speed alarm and LED are activated and the display shows “OVER SPEED”. 9. A memory freeze switch is provided on the unit to stop recording of fine data in case of any accident. When in operation Memory Freeze is displayed on the display. 10. The dial is illuminated with Aviation Green LED backlight to view the dial and pointer even in the night with the intensity control with the key pad provided on the front panel of the unit. With the zero option the backlight will be cut off and the 9 will be the maximum intensity, with a linear increase from 1 to 9. The LCD backlight will also change accordingly for better visibility to suit to individual driver. 11. The real time clock will continue to work in the event of power failure. It is powered by its own lithium battery which lasts for 10 years. 12. For Programming the parameters refer chapter5 13. For Downloading and analysis refer chapter 6 ************************************************************ 11 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 4.MAINTENANCE AND TROUBLE SHOOTING MAINTENANCE Monthly Maintenance: • Check physically the cables and clean the unit with soft cloth. Half-yearly check: • Pulse Generator – Check for any grease ingress in to the PG by opening the back cover and clean the dust in side the unit. Check the freeness of the unit by rotating the shaft with the hand to ascertain the proper functioning of the bearings and replace the Oil Seal. Maintenance every two years: Pulse Generator :- The maintenance of pulse generator has to take place every 24 months without fail for proper functioning of the unit and to prevent water/grease entering into the pulse generator. • Replace Oil seal • Replace front and back gaskets • Replace the bearings Recorder cum indicator • Replace the rubber gasket of the shell. • Replace the O ring and gasket of glass. • Replace the memory cassette compartment gasket and cushion sponge in RCI unit. • Replace the LCD display. • Replace the Keypad • Open the stepper motor and clean the dust in the rotor with the alcohol and ensure the proper re-fitment of the motor parts and re assemble the motor with zero setting adjustments of the needle. Change the cables exposed to outside atmosphere every two years. ************************************************************ 12 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 4.1 DO’S AND DON’T’S: Before installation and commissioning of the unit read the instructions carefully Before connecting the cables to the unit, ensure proper the connector and its polarity with the guide step for insertion. Do not apply more pressure on the connector which will result into bending of the male pins and puncture of the insulator in the female connector. Before connecting the power supply ensure the polarity of the battery and cable inscription. Connect the power cable lugs after the knife switch and circuit breaker. Ensure the alignment of the drive pin in the axle box and the fork of the pulse generator. If not properly matched, i.e the pin is outside the fork will result in the jump in speed signal and the readings will be erratic. Ensure proper mating of the PG connector and cable from PG to JB. Do not let the cable hang. Clamp at the neck of the cable at PG side. Program the unit carefully. Do not forget to Lock the memory cassette compartment door after the programming. Authorized person is only supposed to do the time adjustments. Any wrong/invalid date and time will cause the unit to malfunction and invalid recording which may not down load and every chance to loose the vital information. CAUTION: BEFORE DISMANTLING THE SYSTEM FROM THE EMU , PLEASE CHECK THAT THE SUSPECTED FAULTS ARE NOT ARISING OUT OF: Wrong Setting of Date and Time Wrong Setting of Wheel wear adjustments ************************************************************ 13 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ Wrong setting of Over speed limit Check supply of rated power and correct polarity to the units. Loose signal connections/ breakage in signal cable Improperly mated connectors outside/inside the unit. 4.2 GUIDE FOR TROUBLE SHOOTING SYMPTOMS OBSERVED / PROBABLE DEFECTS / REMEDY Recorder cum Indicator unit 4.2.1 Total system not working Power Cable defective- Check the power cable & connector and restore rated supply with the correct polarity. Power supply module may be Defective Check the incoming voltage, if the the voltage is available ; check the output of power supply by checking LCD power and motor movement. If these are not coming, replace the power supply module. 4.2.2 Speed not indicating Connections defective -Check signal cable and all connectors on the speed sensor, Junction Box, and units, and remove the defect. - Connect the speed simulator to the unit and verify the speed. If the speed does not come up, change the main control card. Main card defective 4.2.3 Speed, Time and Distance indications are OK, but no recording PCMCIA card not inserted Connector not mating - Ensure that the card is pressed properly into the slot. - Check for the connections between the mother board and memory card ************************************************************ 14 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 4.2.4 Date and Time not proper Programming Error - Ensure that proper date and time are loaded into the system. - Change the main card. Main card defective Date and time changing With out programming - RTC chip defective. Replace Main card. Pulse Generator 4.2.5 Pulse generator not working Bearing jam Water inside PG - Check for free rotation of the PG. If found hard, replace the bearings. - Replace oil seal, back and front gaskets ************************************************************ 15 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 5. PARAMETER VIEWING AND SETTING PROTOCOL The speed, Time, Distance Cum Energy Recording and Indicating is provided with a Analog Illuminated dial pointer display to indicate speed in KMPH. In addition a 16 character X 2 line backlight LCD is provided to view and set the parameters. The default display on LCD screen in recorder cum indicator unit is: H H : M M : S S D D - M M - Y Y Y Y The membrane Key pad which is used for viewing and setting of parameters contains 16 Multifunction keys, which can be used to load numeric digits 0-9, Alphabetical letters A to Z (Capital Letters), Alphabetical letters a to z (Small Letters), Space, Dot, Dash & Back Space. Description of Keys: ‘O’ key will be O Ц.‘1’ key will not have any letter ‘2’ key will be 2 ABC ‘3’ key will be 3 DEF ‘4’ key will be 4 GHI ‘5’ key will be 5 JKL ************************************************************ 16 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ ‘6’ key will be 6 MNO 7 ‘7’ key will be 7 PQRS ‘8’ key will be 8 TUV ‘9’ key will be 9 WXYZ CANCEL ‘CANCEL’ key will be ‘ENTER’ key will be To Accept the data ‘DISPLAY’ key will be To view or parameters ‘TRAIN NUM’ key will be To set the Train Number ‘DRIVER ID’ key will be To set the Driver Number ‘TRAIN LOAD’ key will be To set the train load & No. of coaches (Multiplication factor) modify the Functioning of Keys ‘2’ to ‘9’ On pressing the key ‘2’ first time numeric digit 2 will be entered. On pressing the key ‘2’ second time letter ‘A’ will be entered. On pressing the key ‘2’ third time letter ‘B’ will be entered. ************************************************************ 17 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ On pressing the key ‘2’ fourth time letter ‘C’ will be entered. On pressing the key ‘2’ fifth time letter ‘a’ will be entered. On pressing the key ‘2’ sixth time letter ‘b’ will be entered. On pressing the key ‘2’ eight time letter ‘c ‘ will be entered and the above will repeat. The same procedure is used for keys ‘3’ to ‘9 ‘ Functioning of key ‘0’ On pressing the key ‘0’ first time Numeric digit 0 will be entered. On pressing the key ‘0’ second time “ “ (space) will be entered. On pressing the key ‘0’ third time “ . ” (dot) will be entered. On pressing the key ‘0’ fourth time “– “ (dash) will be entered. On pressing the key ‘0’ fifth time Numeric digit 0 will be entered and the above will repeat Functioning of key ‘CANCEL’ ‘Cancel’ Key is used as backspace and to cancel total data entry. When the ‘Cancel’ key is pressed for the first time it is used as a backspace and latest entered character is removed. When the ‘Cancel’ Key is pressed for the second time it is used as a backspace and one more character is removed. When ‘Cancel’ key is pressed for the third time it is used as a backspace and one more character is removed. When ‘Cancel’ key is pressed for the fourth time the total data entry is cancelled displaying a message ‘Data Not Recorded’ for 3 seconds. Setting of dial Illumination. (During Run & Halt Conditions) The dial illumination level is changed by pressing the Numeric Keys 0 cum 1 cum 2 during Run and Halt conditions of the locomotives. When key ‘0’ is pressed the dial illumination will be switched off. ************************************************************ 18 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ When key ‘1’ is pressed the dial illumination level will be 50% When key ‘2’ is pressed the dial illumination will be maximum 100 %. When key ‘1’ is pressed again the dial illumination level will be again 50%. Viewing of the parameters using the display keys It is possible from RCI unit to view parameters using the display key when locomotive is standstill as well as in running conditions. The parameter as per the enclosed LCD display format are displayed in succession with every press of ‘Display’ key. The display will return to default display by pressing ‘Cancel ‘ key any time The display will return to default display if no key is pressed for 10 seconds. If the user wishes to see any desired data continuously a provision is made in such a way that pressing ‘ Enter ‘ Key in display mode shall freeze the displayed data on the screen. Pressing ‘Enter ‘ key again shall return default display. LCD display format for speedometer with energy measurement 1. OHE voltage V o l t a g e O H E X X . X K V 2. Speed S P E E D X X X k m p h 3. Speed limit for over speed alarm O v e r X X X S p e e d k m p h L i m i t ************************************************************ 19 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 4. Current Date D A T E d d : m m : y y y y 5. Total distance traveled (odometer) k m T r a v e l l e d X X X X X X X . X K m s 6. Energy consumed during run E n e r g y a t R u n X X X X X X X K W H 7. Energy consumed during halt E n e r g y a X X X X X X X K t H a l t W H 8. Energy consumed by present driver E N E R G Y C O N S U M E D X X X X X X X K W H 9. Energy consumed in a Trip T r i p E n e X X X X X X X K r g Y W H 10. Energy consumed during Coasting & Halt C o a s t & H a X X X X X X X K l t W H E n g . 11. Distance traveled by present driver K m b y C u r D r i v e R X X X X X X X K m s 12. Braking distance by present driver B R D i s t a n c e X X X X X X X . X K m s ************************************************************ 20 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 13. Dynamic Braking Application Duration by present driver B R X X : A p p l X X : X X D u r a t i o n H O U R S 14. Distance coasted by present driver D i s t a n c e C o a s t e d X X X X X X X . X K m s 15. Duration of coasting C o a s t i X X : X X : n g X X T i m e H O U R S 16. OHE current O H E C u r r e n t X X X X A m p 17.Memory Card capacity status M e m X X X . C a r d S t X X % F u l a t u s l 18. System fault Indication , if any occurred during operation S Y S T E M F A U L T S X X X X X X X X X X X X X X X X 19. Wheel Diameter W h e e l X X X X D i a m m 20 Driver ID D r i v e r I D X X X X X X X X X X X X X X X X ************************************************************ 21 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 21. No. Train 22. Train Load. N o . T r a i n X X X X X X L O A D i n X X X X X X T o n e s 23.EMU/MEMU No. E M U / M E M U X X X X X .24. No. of Motor coaches . N o o f X 25.Power Factor P o w e r X . X X M o. t N o . o r F a c t c o a c h o R .27.Total Energy (Cumulative Energy) . T o t a l E n e r g Y X X X X X X X K W H Parameters to be entered by Loco Crew. The parameter that can be set by locomotive crew are 1. Train Number (maximum 6 characters) 2. Driver ID (maximum 16 characters) 3. Train Load (maximum 6 characters) 4. Number of Motor Coaches/Multiplication Factor 5. Dial Illumination level ************************************************************ 22 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ A provision is made in both RCI & Indicator unit to set these parameters only at halt conditions of locomotives. Dial illumination can be set at run and halt conditions. Alphanumerical entry is accepted for the Train No., Driver ID and Train load parameters. 4. Setting of Train Number. The existing Train number can be changed by using ‘Train Num’ key After pressing ‘ Train Num’ key existing (previous entry stored in memory) Train No. shall be shown on display. The new Train Number can be entered using key pad. Acceptance of this entry shall be done by pressing ‘Enter’ key the display shall return to default display mode after displaying ‘New data recorded’ for 3 seconds. It is possible to discard any new data entered by pressing ‘CANCEL’ key and to retain earlier data. The functioning of ‘CANCEL’ key is described in Functioning of Cancel Key. 4. Setting of Driver ID The existing Driver ID can be changed by using ‘Driver ID’ key After pressing ‘Driver ID’ key existing (previous entry stored in memory) Driver ID shall be shown on display. The new Driver ID can be entered using key pad. Acceptance of this entry shall be done by pressing ‘Enter’ key the display shall return to default display mode after displaying ‘New data recorded for 3 seconds. It is possible to discard any new data entered by pressing ‘CANCEL’ key and to return earlier data The functioning of ‘CANCEL’ key is described in Functioning of Cancel Key. ************************************************************ 23 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 4. Setting of Train Load The existing Train load can be changed by using ‘Train Num’ key After pressing ‘ Train load’ key existing (previous entry stored in memory) Train load. shall be shown on display. The new Train load can be entered using key pad. Acceptance of this entry shall be done by pressing ‘Enter’ key the display shall return to default display mode after displaying ‘New data recorded for 3 seconds. It is possible to discard any new data entered by pressing ‘CANCEL’ key and to return earlier data The functioning of ‘CANCEL’ key is described in Functioning of Cancel Key. 4. Setting of Multiplication Factor/ No. of Motor coaches The existing Multiplication factor/ No. of motor coaches can be changed by using ‘Train load’ key twice. After pressing ‘Train load’ key for the first time existing train load shall be shown on display. By pressing ‘Train load’ key once again, the existing multiplication factor/ no. of motor coaches (previous entry stored in memory) shall be shown on display. The new value can be entered using key pad. Acceptance of this entry shall be done by pressing ‘Enter’ key the display shall return to default display mode after displaying ‘New data recorded for 3 seconds. It is possible to discard any new data entered by pressing ‘CANCEL’ key and to return earlier data The functioning of ‘CANCEL’ key is described in Functioning of Cancel Key. This parameter is most important to calculate the energy consumption and evaluations of the data. A ************************************************************ 24 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ wrong entry of the number of coaches will mislead the readings as well the analysis. Parameters to be entered by shed staff / Authorized persons. These parameters shall be entered from RCI unit only when locomotive is stand still i.e. speed is 0 kmph. Open the Memory Cassette compartment lid with the help of the key. In order to go from Display Mode to parameter setting mode/ configuration mode , a Push button Switch is provided inside the locked Cassette compartment of RCI. When the switch is pressed for 3 seconds the system automatically changes over from display mode to configuration mode At this moment a display of ‘ Configuration Mode’ will come on LCD display to indicate readiness of the system for configuration and the Program LED which is beside the push button switch will glow indicating that the system is in Configuration mode. Press ‘Display’ key on the keypad The following message is observed on the display. “Reset Counters” on the first line “Enter Password” on the second line If the user wishes to skip the parameter press ‘Display’ key and the display will show the next parameter (Speed limit) to be set. If the user wishes to load the parameter, load the new value using the keypad. Acceptance of this entry shall be done by pressing ‘Enter’ key . After pressing the Enter key the display will show the new value entered to confirm proper entry. Pressing the ‘Display’ key again will display the next parameter to be set. ************************************************************ 25 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ All the parameters shall be entered in same fashion as discussed above. If the parameters to be set have no change in the parameter value , pressing of ‘Display’ key retain the current setting and display the next parameter. Pressing ‘Enter’ key at this instant will change the system from configuration mode to Display mode after displaying “Display mode” on the LCD. When all parameters are set, pressing ‘Enter’ key after last parameter, the display returns to the first parameter . Whenever any wrong entry is made ’Invalid Value’ message is displayed on the LCD Screen and the data entered for that parameter will not be saved and the earlier data is retained. The ‘Cancel’ key function is same in setting of locomotive crew and setting by authorized persons. If no operation is performed for continuously 30 seconds, the system automatically goes from Configuration Mode to Display mode after displaying “Display Mode” on the LCD display for 3 seconds and the Program LED will turn OFF. If the locomotive starts moving , while the data entry is in progress, the data entry is aborted with a message ‘Loco Moving’ on the LCD display for 3 seconds and then display will return to default display with program LED turned OFF. The following parameters can be entered by Authorized persons. 1.Reset All counters R e s e t c o u n t e r 2. Speed for over speed Alarm S p e e d L i m i X X X K m p h t ************************************************************ 26 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 3. Current Time Setting T i m e S e t t i H H : M M : S S n g 4. Current Date Setting D A T E D D : M M : Y Y Y Y 5. Wheel Diameter Setting (600mm –1300 mm) W h e e l D i a X X X X m m s e t t i n g 6. EMU/MEMU Number setting L O C O N o X X X X X 7. Shed Name (Alphanumeric Entry) S h e d N a m e X X X X X X X X X X X X X X X X 8. EMU Type (Alphanumeric Entry) E M U T y p e X X X X X X 9. Equipment Number E q u I p m e n t X X X X X X X N u m b e r 10. PG Number P G N u m b e r X X X X X X X ************************************************************ 27 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 11. Dynamic Brake Resistor Status (0= Not Present, 1= Present) D B R X S t a t u s 12. PT input P T i n p u t X X X X X 13. PT output P T o u t p u t X X X X X 14. CT input C T i n p u t X X X X 15. CT output C T o u t p u t X X X X ************************************************************ 28 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ Error Messages/Indications There are 3 types of Error messages/indications available on the recorder cum indicator unit for attention of the driver/loco crew/shed staff apart from the error message logging in the memory. (a) LED indications: LED indications are provided in RCI to indicate (i)Fault in System/Memory full. (ii) Over speed indication (b) Blinking display of Error indication on LCD display to indicate reason for LED indication. This blinking display on LCD screen shall be resettable by pressing Display key on keypad but can be observed in the display in SYS faults indication (Refer LCD display format item 18 System Faults) (c) Audio Visual over speed alarm indication are provided in RCI Error Signals and their description 1.Over Speed: When the speed of the locomotive exceeds the set speed limit, an audible alarm sounds and an OVER SPEED LED glows up, OVER SPEED indication will blink on the LCD display, to have audio visual alarm. The audible alarm stops sounding and the Over Speed LED stops glowing when the loco speed comes below the set speed. 2.No PCMCIA Card : If PCMCIA is removed from the compartment, this error will blink up on the display and System Fail LED glows. Necessary action is to be taken by the shed staff to insert the PCMCIA in the slot. Keep the PCMCIA card properly and the error NO PCMCIA CARD will disappear on the display. 3. Internal Memory Fail : If by chance the display shows up the Internal memory fail continuously along with the SYS/FAIL lights up, i.e. system indicating that the internal memory is not writing due to memory fail condition existing in the memory card. Once this lights up Simply ************************************************************ 29 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ change the main card of the RCI unit, and send back the fail card to factory for repair/ replacement. CAUTION: THE SYSTEM IS HAVING THE CAPABILITY TO RECHECK THE INTERNAL MEMORY AND TRIES TO RECTIFY THE FAULT FOR 10 TIMES. IF IT IS NOT ABLE TO RECTIFY THE FAULT , THEN INDICATES INTERNAL MEMORY FAIL CONTINUOUSLY. 4. External Memory Fail : The fault is similar that of internal memory fail but it checks the conditions for External memory. In case the fault continuously appears on the display just remove the PCMCIA card and put the new PCMCIA. 5. Memory Freeze : A memory freeze switch is provided on the front panel of the speed recorder unit. A breakable glass is provided on the switch. In case the fine memory is to be freezed, to access the written data and not to be over written, then the option is to brake the glass and MEMORY FREEZE switch should be put to ON condition. Once the switch is ON fine memory is freezed and system will not write/ or access the Fine memory area till the Memory Freeze switch is put to OFF condition. As long as the MEMORY is freeze the fault indication appears on the display and a Red LED indication will appear in the memory freeze compartment. Only fine memory will be free zed during the memory freeze switch is in ON condition. Long term memory will however be written. 6. Memory Full : As per the specification if the data in the memory is more than 85% of occupancy, then the systems should indicate the user as full memory and cautions the user to down load the data at the earliest to avoid the loosing the earlier data because of the looping format of the data structure. During this time SYS FAIL /Memory full LED lights up and this is an indication to the user to verify the memory capacity on the display ************************************************************ 30 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ and the necessary actions to be taken to down load the data. The LCD display will show in blinking display mode “MEMORY FULL XX.XX %” In this case the SYS FAIL/ Memory Full LED glowing does not mean the system is failed, but a warning signal to the user. Please do not misunderstand this point. 7. No Energy Card If the Energy card is not present in the RCI unit, the display shows “NO ENERGY CARD” on the display and the SYS FAIL/ Mem Full LED glows. 8. No Memory Card If the microprocessor based Memory card in the main card in the RCI unit is not present/ not connected by the flat cable the display shows “NO MEMORY CARD” on the display and the SYS FAIL/Mem Full LED glows. ************************************************************ 31 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ 6. DOWNLOADING AND ANALYSIS This package is developed to provide a graphical view of the Locomotive data recorded by LAXVEN’s Speed Recording System. The recorded data is brought into PC's disk by RS232 serial port using the Download option on the menu. INSTALLATION: S/W ENVIRONMENT: IBM PC with Pentium processor Windows 95 or later VGA card with at least 640 X 480 resolution & 256 colors. Colour Monitor 64 MB RAM Windows Graphics Parallel PRINTER. One working 9 pin COMPORT. PROCEDURE: 1. 2. 3. 4. 5. 6. Switch on the computer. Go to My computer. Place CD in CD drive. Click on the CD drive. Select the Setup file from the Laxven2005 directory. Follow the instructions as they appear on the screen At the end of setup the item LAXVEN2005 will be added to the Program menu. 7. To run the program you will have to click this item. 8. You could create a shortcut to appear on the desktop. Clicking this shortcut will also start the program. 9. Creating the Shortcut: (a) Start Windows Explorer (b) Change directory to C:\Program Files\Laxven2005 (c) Right click the Laxven. Select Create Shortcut. (d) The shortcut will be created in C:\Program Files\Laxven2005 folder (e) Drag the shortcut on to the desktop (f) To Rename the shortcut right click on it. Select Rename. Change the name of your choice. ************************************************************ 32 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com LAXVEN SYSTEMS LAX2000 E-EMU MANUAL Third eye innovators…… Rev-1 January 2005 An ISO 9001 COMPANY ___________________________________________________________________ EXTERNAL DOWNLOADING PROCEDURE: Unlock the RCI and eject the PCMCIA CARD from the RCI. 1. Insert it into the MEMORY READER UNIT (MRU) unit placed at your PC. 2. Connect the MRU to PC serial port either in COM 1 or COM 2. 3. Power on the MRU with the help of a given 9 V DC battery or 9V DC adapter. 4. Power on PC/ If already working close the application program in use. 5. Click the LAXVEN2005 shortcut created on the screen. 6. On the screen select the OK button. 7. On the menu select the down button 8. A second screen will appear and you have to make sure that the port selected is correct. 9. Instructions will appear on the screen, follow them 10. Once you have satisfied click the PCMCIA button. 11. Once you have done this click the PCMCIA button. PC automatically down loads the data and creates its own file with respect to its locomotive number. 12. Once down loaded PC gives the graphic analysis chart, where in you have to select the data to be viewed/ data to be graphed etc on the screen, which are self explanatory. 13. Data will be stored permanently on the PC with a file named its locomotive number. INTERNAL DOWNLOADING PROCEDURE: 1. Unlock the RCI and insert the telephone jack in to the slot provided in the system along with the Internal Memory reader unit. 2. Connect the other end of the Internal Memory Reader unit to the PC comport. 3. Run the program LAXVEN2005 4. The LCD display will display “DOWNLOADING INTERNAL MEMORY” when downloading is taking place. Repeat the external down load procedure above from step number 6. ************************************************************ 33 Plot No.188/A, Phase-II, Sector-III, Cherlapally, Hyderabad - 500 051. (India) Phones: 91-40 27261137/38/39 Fax-91-40-27261176. www.laxven.com