MASTER CONTROLLER FOR

3-PHASE LOCOMOTIVES
ARC/MCU/V1.0
USER MANUAL
Release V.1.0
January, 2019

ADVANCED RAIL CONTROLS PRIVATE LIMITED

#59/1-2, 1 & 2 FLOOR (ABOVE BANK OF INDIA), G-BLOCK,
80 FEET MAIN ROAD,SAHAKARANAGAR
BANGALORE-560092
 MASTER CONTROLLER FOR 3-PHASE LOCOMOTIVES

INDEX

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IMPORTANT NOTICE
This is a sophisticated microprocessor based equipment and can
be serviced only by trained skilled personnel. Opening the
equipment by any unauthorized person will make the warranty
null and void

1.0 Introduction
Master controller used in three phase locomotives class
WAG9, WAP5 & WAP7 Locomotives provides tractive effort
& braking effort reference (TE/BE Demand) to the traction
converter. This equipment is also referred as Throttle. The
TE/BE Demand is generated by the driver by moving the
handle up or down smoothly. While moving in ‘UP’ direction,
TE demand is generated and while moving in ‘DOWN’
direction, BE demand is generated. The TE/BE demand is
generated in the form of 4-20 mA current signal, which is sent
to control electronics (VCU1 and VCU2) through Analog I/O
interface viz Analog I/O card and signal routing printed circuit
boards. This current signal is further converted into digital
data and sent to converter control after conditioning and
processing, based on the locomotive operating status.
There are 3 main functions in the Master controller which are
mentioned below:
(a) TE/BE Reference signals Generation (4-20mA)
(b) CAM output Signals(Boolean 110VDC:TE, BE, 1/3, 2/3TE/BE)
(c) Forward & Reverse direction selection (Boolean 110VDC:
For X2: REVX2)

1.1 TE/BE Reference Signal

The TE/BE reference is 4-20 mA current loop, both during
traction & braking. The mode viz. traction or braking, is
determined within the VCU by the Boolean signal depending
upon whether the throttle handle is in traction region or
braking region. The output signal variation with respect to the
CAM shaft angle is illustrated in Fig-1 for reference.
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The throttle handle movement is converted into encoder

shaft through gear train. Hence, the throttle angle and
encoder shaft angle will be at a ratio corresponding to the
gear ratio.
When the throttle is at zero position, the signal is 2 mA, which
is the active zero. Between 0˚ and 135˚, the signal varies
linearly. At 15˚(TE) & at 15˚(BE), the signal is 4 mA, which is
mapped in the vehicle software as 0%. When the signal is 20
mA, the TE/BE reference is mapped as 100% in the vehicle
software.

1.2 CAM Output Signals

CAM switches are needed to detect the position of Angle
Transmitter (Throttle). Four cam switches are used to detect
the position like TE region, BE region, ZERO position, 1/3 of
Full TE/BE and 2/3 of Full TE/BE. ZERO position is sensed by
sensing the combination of four CAMs. The position of CAM
switches in different regimes are as follows:
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When the throttle handle is at zero position, all the four

switches are pressed, and all the contact outputs are open (i.e.
outputs are zero). The CAM switch related to TE region gets
released at 15˚ movement of the encoder shaft in TE region,
and the contact will close. Similarly, the CAM switch related to
BE will close when the encoder moves 15˚ into the BE region.
Similar action will take place for the CAM switches
corresponding to 1/3 & 2/3 of TE/BE maximum. The
mechanical arrangement of the CAM and the corresponding
angle is given in Fig-2.

The CAM switches used are of high durability suitable for

lakhs of repeated ON/OFF operations during the lifetime, with
load. The switch mechanism is totally enclosed type to avoid
any dust ingress. The interface of Cam switches with vehicle
control is given in Fig-3.

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1.3 FORWARD/REVERSE Selector Switch

The master controller is integrated with a forward/reverse
selector switch, which is used by the driver to select the travel
direction. This selector switch is mechanically interlocked with
the throttle handle, so that, throttle movement is possible only
after selecting the direction. Also, once the direction is
selected, it cannot be changed unless the throttle is brought
back to zero position.

The CAM switch arrangement for the selector switch is given

in Fig-4:

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There are four switches in the direction selector. When the

selector is thrown in forward direction (F), two switches gets
pressed, thus establishing a contact and supplying 110V DC
signal to the digital I/O cards of VCU. Similarly, another two
switches gets pressed when the selector is thrown in the
Reverse direction (R), thereby establishing contacts and
extending 110V DC supply to the digital I/O cards of VCU. At
zero position, all the switches gets released and the switches
will be open, and hence, the digital I/O cards will sense a zero
voltage. The switches used are similar to the ones used in
conjunction with the throttle handle.

2.0 Pin assignment

There are two types of connectors used in the Master
Controller,

1) 13 pin Circular: Panel mount connector, Male

2) 9 pin D-Sub: Panel mount connector, Male

with coding plate

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2.1 13 pin Circular connector Pin assignment

TE/BE

TE/BE

2.2 9 pin Sub-D connector Pin assignment

Signal
Signal

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3.0 Mechanical Dimensions

The master controller is made using components milled
through CNC machines with high level of precision and
accuracy. The assembly views are given below. The
dimensions interfacing with the locomotive will be exactly as
per CLW drawings & specifications.

126.5
47
121

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4.0 Functional Test

Master Controller Functional test to be followed as per
Specification:(Ref: CLW approved test Protocol No.
71/16/1075/(4t)/10999. Dated 28-02-17)
(a) Throttle Movement test
(b) Direction Movement test
(c) Mechanical inter-lock test between direction handle
and throttle
(d) Angle transmitter output (4-20mA) test proportional to
the angle position of the throttle handle with direction set
4.1 Throttle Movement Test
Throttle must move smoothly in TE and BE region without
any obstruction.

4.2 Direction Movement Test

Direction handle must rotate in forward and reverse.

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4.3 Mechanical inter-lock test between

Direction and Throttle Handles
Throttle should not move if direction switch is in Zero Position.
If direction is selected in forward, throttle must move in TE
and BE region. If we want to change the direction to Reverse,
then throttle handle should be brought back to Zero position.

4.4 Angle Transmitter Output (4-20mA) Test

The TE/BE reference is 4-20 mA current loop, both during
traction & braking. The mode viz. traction or braking, is
determined within the VCU by the Boolean signal depending
upon whether the throttle handle is in traction region or
braking region.
The output signal variation with respect to the CAM shaft is to
be followed as per the process mentioned below : CURRENT

OUTPUT (observation using Digital Multimeter)

CURRENT (in mA)

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CURRENT (in mA)

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5.0 Master Controller overall Specification

(from VCU1 and VCU2 Rack)

Output Signal Interface

Estimated Life 10,00,000 Operations

of CAM Switches

mm

(IEC 61373:2010, Category 1, Body Mounted)

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6.0 Scope of supply (per Unit)

7.0 Spare items and accessories (for Ordering)

ARC UID Number Quantity Required
(per Unit)

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8.0 Contact Details

For any warranty/service related queries, please contact:

Mr. M Mariappa.
Head, Service Department,
Advanced Rail Controls Private Limited,
# 59/1&2, Above Bank of India,
G- Block, Sahakara Nagar,
Bangalore- 560092.
Phone: +91 80 42401212, +91 80 42401226
Fax : +91 80 42401213
Cell: +91 9743715600
E-Mail : [email protected], [email protected]
Website: www.arc.net.in

Contact Details of service Personnel:

Chaitanya M (Base station : Kazipet)

Cell: +91 7989247708

Chaitanya S (Base station : Lallaguda)

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For any warranty / service related queries, please contact :

Subhash Kumar ( Base Station : New Delhi)

Ravikumar Vishwakarma (Base station : Gomoh) Cell : +91 7050029319

Anchal Kumar Cell: +91 8092793337

ADVANCED RAIL CONTROLS PRIVATE LIMITED

#59/1-2, II FLOOR (ABOVE BANK OF INDIA)
G-BLOCK, SAHAKARANAGAR
BANGALORE-560 092
Tel: 080-42401212 Fax: 080-42401213
E-mail: [email protected]

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