Lockout of emergency ventilation system will occur in the third round of fault after repeated twice automatic retry.
Table 15 – Protection device an Protection Device Related relay Fault State Possibility Cause Fault State Possibility Cause ACCP ACB11 trip •Over loaded equipment •Short circuit ----- ----- ACB12 trip ACB21 trip ACB22 trip CFCPK11 off • Coil open Disconnection Short circuit •Mechanical lock of contact CFCPK12 off CFCPK21 off CFCPK22 off
d related fault relay and parts (normal operation) Stopped Equipment by Fault ACU1 ACU2 EF1 CF1 & CP1 EF2 CF2 & CP2 EF1 CF1 & CP1 EF2 CF2 & CP2 Stop X X X Stop X X Stop X X X Stop X Stop X X X X Stop X X X Stop X X X X Stop
ACU1 EFK1 off • Coil open Disconnection Short circuit •Mechanical lock EF11FR • Coil: No.13-14 open • Contact: No.5-9 open • Disconnec • Short circu • Mechanica lock EFOCR1 active •Over loaded equipment •Mechanical lock of contact CPOCR1 active •Over loaded equipment •Mechanical lock of contact LPR11 • Coil: No.13-14 open • Contact: No.5-9 open • Contact: No.6-10 open • Disconnec • Short circu • Mechanica lock IOL1 active CF1Th active LPS1 active HPS1 active Over loaded equipment HPR11 Coil: No.13-14 open • Disconnec • Short circu
ction uit al Stop X X ction uit al X Stop X X ction uit X Stop X X
Table 15 – Protection device an Protection Device Related relay Fault State Possibility Cause Fault State Possibility Cause Mechanical lock of contact • Contact: No.5-9 open • Contact: No.6-10 open Mechani lock EFK2 off • Coil open Disconnection Short circuit •Mechanical lock of contact EF11FR • Coil: No.13-14 open • Contact: No.5-9 open • Disconnec • Short circu • Mechanica lock EFOCR2 active •Over loaded equipment
d related fault relay and parts (normal operation) Stopped Equipment by Fault ACU1 ACU2 EF1 CF1 & CP1 EF2 CF2 & CP2 EF1 CF1 & CP1 EF2 CF2 & CP2 cal ction uit al X Stop X
•Mechanical lock of contact CPOCR2 active •Over loaded equipment •Mechanical lock of contact LPR12 • Coil: No.13-14 open • Contact: No.5-9 open • Contact: No.6-10 open • Disconnec • Short circu • Mechanica lock IOL2 active CF2Th active LPS2 active HPS2 active •Over loaded equipment •Mechanical lock of contact HPR12 • Coil: No.13-14 open • Contact: No.5-9 open • Contact: No.6-10 open • Disconnec • Short circu • Mechanica lock ACU 2 EFK1 • Coil open Disconnection Short circuit EF21FR • Coil: No.13-14 open • Contact: No.5-9 open • Disconnec • Short circu • Mechanica lock
ction uit al X X Stop X ction uit al X ction uit al X Stop X
•Mechanical lock of contact Table 15 – Protection device and re Protection Device Related relay Fault State Possibility Cause Fault State Possibility Cause EFOCR1 •Over loaded equipment •Mechanical lock of contact CPOCR1 active •Over loaded equipment LPR21 • Coil: No.13-14 open • Disconnec • Short circu IOL1 active
elated fault relay and parts (normal operation) Stopped Equipment by Fault ACU1 ACU2 EF1 CF1 & CP1 EF2 CF2 & CP2 EF1 CF1 & CP1 EF2 CF2 & CP2 tion uit X X Stop X
CF1Th active •Mechanical lock of contact • Contact: No.5-9 open • Contact: No.6-10 open • Mechanica lock LPS1active HPS1 active •Over loaded equipment •Mechanical lock of contact HPR21 • Coil: No.13-14 open • Contact: No.5-9 open • Contact: No.6-10 open • Disconnec • Short circu • Mechanica lock EFK2 off • Coil open Disconnection Short circuit •Mechanical lock of contact EF22FR • Coil: No.13-14 open • Contact: No.5-9 open • Disconnec • Short circu • Mechanica lock EFOCR2 active •Over loaded equipment
al tion uit al X X Stop X tion uit al X X Stop
•Mechanical lock of contact CPOCR2 active LPR21 Disconnecti Table 15 – Protection device and Protection Device Related relay Fault State Possibility Cause Fault State Possibility Cause IOL2 active •Over loaded equipment •Mechanical lock of contact • Coil: No.13-14 open • Contact: No.5-9 open • Contact: No.6-10 open • Short circu • Mechanica lock CF2Th active LPS2 active
on X X X Stop d related fault relay and parts (normal operation) Stopped Equipment by Fault ACU1 ACU2 EF1 CF1 & CP1 EF2 CF2 & CP2 EF1 CF1 & CP1 EF2 CF2 & CP2 uit al
HPS2 active •Over loaded equipment •Mechanical lock of contact HPR21 • Coil: No.13 -14 open • Contact: No.5 -9 open • Contact: No.6 -10 open • Disconnect• Short circu• Mechanica lock
tion uit al X X X Stop
50 Outline of relay Followings are outline of relay installed in ACU and ACCP used for the control of air conditioning. 1. Relay for evaporator fan (EFKR11, 12, 21, 22) EFKR1, 2 control ON-OFF of electromagnetic contactor for evaporator fan (EFK1, 2) Function: To turn on EFKR1, 2 by closing contact No.8-12. Fault: Unable to close contact No.8-12 Fault influence: Stop or unable to start the associated evaporator fan and related condenser-fan/compressor 2. Relay for evaporator fan (EFKR13, 14, 23, 24) EFKR13, 14, 23, 24 control ON-OFF of electromagnetic contactor for emergency ventilation fan (EFK3, 4). Function: To turn on EFK3, 4 by closing contact No.8-12. Fault: Unable to open contact No.8-12 Fault influence: Stop or unable to start the normal ventilation of associated evaporator fan and stop or unable to start related condenser-fan/compressor. 3. Relay for the operation mode selection (TMS) Relay TMS set the operation mode of air conditioning to “TCMS”. Function: To set the operation mode of air conditioning to “TCMS” by closing contact No.5-9 when the mode select switch is positioned at “TCMS”. Fault: Unable to close contact No.5-9 Fault influence: Stop or unable to start the VAC system of one car.
4. Relay for the operation mode selection (VENT) Relay VENT set the operation mode of air conditioning to the mode with ventilation only “VENT”. Function: To set the operation mode of air conditioning to “VENT” by closing contact No.5-9 when the mode select switch is positioned to “VENT”. Fault: Unable to close contact No.5-9. Fault influence: Stop or unable to start all condenser-fans/compressors of one car. 5. Relay for the prohibition of compressor start (ACCSTR) ACCSTR controls the start or restart of compressors of ACU when air compressor of train starts. Function: To start the prohibition mode of compressor start by closing contact No.5-9 when train line “Air Compressor Start Signal” is electrified. Fault: Unable to open contact No.5-9. Fault influence: Stop or unable to start all condenser-fans/compressors of one car. 6. Relay for the “Load Shed” mode (LSR) LSR controls the start of “Load Shed” mode for the reduction of power consumption in the event of one APS fault. Function: To inform the activation of “Load Shed” mode signal to CPU by closing contact No.5-9. CPU sops two condenserfans/compressors
Fault Unable to open contact No.5-9 Fault influence: Stop or unable to start 2 condenser-fans/compressors per car are. 7. Relay for the “Outside fire” mode (OUTFR1) Relay OUTFR1 is used for the start of outside fire mode. Function: To inform the outside fire signal to CPU by closing contact No. 7- 11. Closing of contact No5-9 shut all fresh air inlet of F/R dampers of car. Fault: Unable to open contact No.5-9 Fault influence: Fresh air volume of one car is lost due to the shut of fresh air inlet of F/R dampers 8. Relay for the “Outside fire” mode (OUTFR2) Relay OUTFR2 is used for the start of outside fire mode of own car by using the detection of own outside smoke sensor. Function: To shut the fresh air inlet of F/R damper of own car by closing contact No.8-12 To send information for state of outside smoke sensor to the TCMS by closing contact No.7-11 Fault: Unable to open contact No.7-11 and/or 8-12 Fault influence: All fresh air inlet of own car is shut off by closing contact No.8-12 All fresh air inlet of train set is shut off by closing contact No.7 – 11. 9. Relay for the “Inside fire” mode (INFR)
INFR is used for the start of inside fire mode when train line for “Inside fire” is electrified. Function: To shut the return air inlet of F/R damper, to open emergency damper and to start the emergency ventilation by closing contact No.5-9. To inform the inside smoke signal to CPU by closing contact No.5-9 Fault: Unable to open contact No.5-9 Fault influence: Stop or unable to start of all condenser-fans/compressors of one car. 10.Relay for the emergency damper (DMR) DMR is used for the control of emergency damper and start the emergency ventilation in the event of inside fire. Function: To open all emergency dampers of one car and to start the emergency ventilation by closing contact No.5-9 and 8-12. Fault: Unable to open contact -No.5-9 and/or 8-12. Fault influence: Possibility of frozen evaporator coil and reduction of cooling capacity since return and fresh air volume pass through evaporator coil is reduced by open of emergency damper. 11.Relay for the CPU healthy check (RUNR) RUNR is used for the check of CPU healthy and start of the auxiliary control system to continue the operation of VAC system. Function: To start auxiliary control system by closing contact No.2-4 when CPU is malfunction. Fault: Unable to open contact No.2-4.
Fault influence: VAC control changes to simple control of stopgap until the withdrawal Table 16 – Control relay and fault influence to normal operation Fault relay State of relay fault & Possibility cause Stopped Equipment by Relay Fault ACU1 ACU2 EF1 CF1 & CP1 EF2 CF2 & CP2 EF1 CF1 & CP1 EF2 CF2 & CP2 ACCP EFKR11 • Coil: No.13-14 is open Disconnection Short circuit • Contact: No.8-12 is open Mechanical lock Stop X X EFKR12 X Stop X EFKR21 X Stop X EFKR22 X X Stop EFKR13 Contact: No.8-12 close Mechanical lock Welded contact Stop X X EFKR14 X Stop X EFKR23 X Stop X EFKR24 X X Stop TMS • Coil: No.13-14 is open Disconnection Short circuit • Contact: No.5-9 is open Mechanical lock Stop Stop VENT • Coil: No.13-14 is open Disconnection Short circuit X Stop X Stop X Stop X Stop
• Contact: No.5-9 is open Mechanical lock ACCSTR Contact: No.5-9 is close Mechanical lock Welded contact X Stop X Stop X Stop X Stop LSR Contact: No.5-9 is close Mechanical lock Welded contact X X X Stop X X X Stop OUTFR1 Contact: No.7 -11 is close Mechanical lock Welded contact X X Wrong information of outside fire informs to ACCP Contact: No.5-9 is close Mechanical lock Welded contact X X Loss of fresh air of own car. Recirculation of ventilation and cooling can continue. ACCP OUTFR2 Contact: No.8 -12 is close Mechanical lock Welded contact X X Loss of fresh air of own car. Recirculation of ventilation and cooling can continue. Table 16 – Control relay and fault influence to normal operation Fault relay State of relay fault & Possibility cause Stopped Equipment by Relay Fault ACU1 ACU2 EF1 CF1 & CP1 EF2 CF2 & CP2 EF1 CF1 & CP1 EF2 CF2 & CP2 X X
Contact: No.7 -11 is close Mechanical lock Welded contact Wrong information for outside fire is informed to TCMS. Loss of fresh air of train set. Recirculation of ventilation and cooling can continue. ACCP INFR Contact: No.7 -11 is close Mechanical lock Welded contact X X Cooling capacity reduction Possibility of stop Cooling capacity reduction Possibility of stop DMR Contact: No.5-9 and/or No.8-12 is close Mechanical lock Welded contact X X Cooling capacity reduction Possibility of stop Cooling capacity reduction Possibility of stop RUNR • Coil: No.1-5 is open Disconnection Short circuit • Contact: No.2-4 is open Mechanical lock X X Setting point of interior temperature : Fixed Fresh air volume: Fixed Fault information: Non Transmission between TCMS: Non 51 Control equipment for CAHU 1. Miniature circuit breaker (MCB) (CAHMCB in ACCP) This MCB protects the cab air handling unit from overload and short circuit.. 2. Electromagnetic contactor for fan (VFC1, VFC2 in CAHU) VFC controls ON-OFF of fans by the activation of control relay RY1, 2. 3. Control Relay (RY1, 2 and DR) RY1 is energized and contact No.3-5 is closed to operation both fans VAC1 and VAC2 when personnel set the position of mode switch of CAHU to “HIGH”.
And RY1 turns on the indication lamp for fan’s operation by closing contact No.2- 6. RY2 is energized when personnel set the position of mode switch of CAHU to “MID” or “LOW”. RY2 closes contact No.3-5 to operate both fans and to shut damper by closing contact No.2-6 when it is energized. And RY2 turns on the indication lamp for fan’s operation by closing contact No.2- 6. DR is energized when personnel set the position of mode switch of CAHU to “LOW”. DR open contact No.6-9 to stop fan VAC2 and open damper DM by opening contact No.4-5when it is energized. 4. Over current relay for fan (VFOCR1, VFOCR2 in CAHU) Over current relay VFOCR in circuit for fan stops fans when motor is overloaded. VFOCRs energize the related relay for fault (RY3) to stop both fans and to turn on the fault indicator lamp of CAHU. 5. Relay for fault (RY3 in CAHU) Relay RY3 is energized when VFOCR1 or VFOCR2 is activated. RY3 stops both fans by opening contact No.4-5 and keep the fault state/turn NOT off fault lamp by self-holding function with closing contact No.2-6. Operation of fans is locked out. Table 17 – Control relay and fault influence to normal operation Fault equipment State of relay fault & Possibility cause Operation mode Stopped Equipment by Fault VF1 VF2 DM Indication lamp Operation Fault
Normal state “HIGH” X X OPEN ON OFF “MID” X X CLOSE ON OFF “LOW” X --- OPEN ON OFF CAHMCB Contact is open Mechanical lock “HIGH” NOT UC NOT UC NOT UC NOT UC NOT UC “MID” NOT UC NOT UC NOT UC NOT UC NOT UC “LOW” NOT UC --- NOT UC NOT UC NOT UC VFC1 • Coil: No.A1-A2 is open Disconnection Short circuit • Contact: main circuit is open Mechanical lock “HIGH” NOT UC X OPEN ON OFF “MID” NOT UC X CLOSE ON OFF “LOW” NOT UC --- OPEN ON OFF VFC2 • Coil: No.A1-A2 is open Disconnection Short circuit • Contact: main circuit is open Mechanical lock “HIGH” X NOT UC OPEN ON OFF “MID” X NOT UC CLOSE ON OFF “LOW” X NOT UC OPEN ON OFF Relay RY1 • Coil: No.1-11 is open Disconnection Short circuit • Contact: No.3-5 open Mechanical lock Welded contact “HIGH” NOT UC NOT UC OPEN NOT UC OFF “MID” NOT UC NOT UC CLOSE NOT UC OFF “LOW” NOT UC NOT UC OPEN NOT UC OFF Relay RY2 • Coil: No.1-11 is open Disconnection Short circuit • Contact: No.3-5 open • Contact: No.2-6 open Mechanical lock Welded contact “MID” NOT UC NOT UC NOT UC (open) NOT UC OFF “LOW” NOT UC NOT UC NOT-UC Open NOT UC OFF Table 17 – Control relay and fault influence to normal operation
Fault equipment State of relay fault & Possibility cause Operation mode Stopped Equipment by Fault VF1 VF2 DM Indication lamp Operation Fault Relay DR • Coil: No.1-11 is open Disconnection Short circuit • Contact: No.4-5 open Mechanical lock Welded contact • Contact: No.6-9 open Mechanical lock Welded contact “LOW” X NOT UC (Operatio n) NOT UC (close) ON OFF VFOCR1 Contact: No.97-98 close Mechanical lock Welded contact “HIGH” NOT UC NOT UC OPEN ON ON “MID” NOT UC NOT UC NOT UC (open) ON ON “LOW” NOT UC --- OPEN ON ON VFOCR2 Contact: No.97-98 close Mechanical lock Welded contact “MID” NOT UC NOT UC OPEN ON ON “LOW” NOT UC --- NOT UC (open) ON ON 52 Fault diagnosis and symptom analysis 53 ACU and ACCP 5.5.1.1 Two ACUs stop or unable to start Table 18 – Two ACUs stop or unable to start
Step Result Perform Go To Step 1 Check the fault indication lamp of ACCP Turn off ------ 2 Turn on both fault indication lamps ------ 3 2 Check relay TMS in accordance with Table 16 Fault Replace ----- Table 18 – Two ACUs stop or unable to start Step Result Perform Go To Step 3 Check ACB11, 12, 21, 22 and electrification of 400V for secondary side of ACB. Turn ON and energized ------ 4 Tripped or deenergized Check the cause of trip or deenergized. And replace, if necessary ----- 4 Check evaporator fans EF1, 2 of both ACUs. Fault of all EFs Check the cause of fault. And replace, if necessary ----- Normal ------ 5 5 Check relay and electrification of DC110V for coil and contact of EFKR11, 12, 13, 14, 21, 22, 23, 24 and EF11FR, EF12FR, EF21FR, EF22FR in accordance with Table 16 Energized Normal ------ 6 De-energized Fault Check the cause of fault. And replace, if necessary ------
6 Check EFK1,2,3,4, EFOCR1,2, in ACU Fault Check the cause of fault. And replace, if necessary ------ 5.5.1.2 One ACU stop or unable to start Table 19 – One ACU stop or unable to start Step Result Perform Go To Step 1 Identify the fault ACU This table shows the case of ACU1 ----- 2 2 Check ACB11, 12, and electrification of 400V for secondary side of ACB. Turn ON and energized ------ 3 Tripped or deenergized Check the cause of trip or deenergized. And replace, if necessary ----- 3 Check evaporator fans EF1, 2 Fault of two EFs Check the cause of fault. And replace, if necessary ----- Normal ------ 4 4 Check relay and electrification of DC110V for coil and contact of EFKR11, 12, 13, 14, EF11FR, EF12FR in accordance with Table 16 Energized ------ 5 De-energized Fault Check the cause of fault. And replace, if necessary ------ 5 Check of EFK1,2, EFOCR1,2 in ACU Fault Check the cause of fault. And replace, if necessary ------ 5.5.1.3 One EF and related CF/CP of an ACU stop or unable to start
Table 20 – Four CPs of two ACUs stop or unable to start Step Result Perform Go To Step 1 Check the fault indication lamp of ACCP Turn off ------ 2 Turn on both fault indication lamps ------ 4 2 Check relay ACCSTR in accordance with Table 16 Normal ------ 3 Fault Replace ----- 3 Check relay VENT in accordance with Table 16 Normal ------ 4 Fault Replace 4 Check relay and electrification of DC110V for coil and contact of HPR11, 12, 21, 22, LPR11, 12, 21, 22. Energized Normal ------ 5 De-energized Fault Check the cause of deenergized. Repair wiring, if necessary. Replace relays, if necessary ----- 5 Check CFCPK11, 12, 21, 22 in accordance with Table 15. Check electrification of DC110V Check electrification of AC400V Energized Normal ------ 6 De-energized Fault Check the cause of deenergized. Repair wiring, if necessary. Replace relays, if necessary ------ 6 Check four CFs/CPs. Normal ------ 7 Fault of four CFs and CPs Check the cause of fault. And replace, if necessary ----- 7 Check CPOCR 1,2 , CFTh Normal ------ 8 Fault Check the cause of fault. ------
1,2, IOL 1, 2 in both ACUs And replace, if necessary 8 Check HPS1,2 , LPS1, 2 in both ACUs Fault Check the cause of fault. And replace, if necessary ------ 5.5.1.4 Two CPs of one ACUs stop or unable to start Table 21 – Two CPs of one ACUs stop or unable to start Step Result Perform Go To Step 1 Identify the fault unit This table shows the case of ACU1 ----- 2 2 Check CFCPK11, 12 in accordance with Table 15. Check electrification of DC110V Check electrification of AC400V Energized Normal 3 De-energized Fault Check the cause of deenergized. Repair wiring, if necessary. Replace relays, if necessary ------ Table 21 – Two CPs of one ACUs stop or unable to start Step Result Perform Go To Step 3 Check relay and electrification of DC110V for coil and contact of HPR11, 12, LPR11, 12. Energized Normal 4 De-energized Fault Check the cause of deenergized. Repair wiring, if necessary. Replace relays, if necessary ----- 4 Check two CFs/CPs Normal 5
Fault of two CFs and CPs Check the cause of fault. And replace, if necessary ----- 5 Check CFCPOCR1,2 CFTh1,2, IOL1, 2 in ACUs Normal 6 Fault Check the cause of fault. And replace, if necessary ------ 6 Check HPS1,2 , LPS1, 2 in ACUs Fault Check the cause of fault. And replace, if necessary ------ 5.5.1.5 Two CPs of two ACUs stop or unable to start Table 22 – Two CPs of one ACUs stop or unable to start Step Result Perform Go To Step 1 Identify the fault unit This table shows the case of CP1 of ACU1 and CP1 of ACU2 ----- 2 2 Check the fault indication lamp of ACCP Turn off ------ 3 Turn on both fault indication lamps ------ 4 3 Check relay LSR in accordance with Table 16 Normal ------ 4 Fault Replace 4 Check CFCPK 11, 21 in accordance with Table 16. Check electrification of DC110V Check electrification of Energized Normal ------ 5 De-energized Fault Check the cause of deenergized. Repair wiring, if necessary. Replace relays, if necessary ------
AC400V 5 Check relay and electrification of DC110V for coil and contact of HPR11, 21, LPR11, 21. Energized Normal ------ 6 De-energized Fault Check the cause of deenergized. Repair wiring, if necessary. Replace relays, if necessary ----- 6 Check two CFs and CPs Normal ------ 7 Fault of all CPs Check the cause of fault. And replace, if necessary ----- 7 Normal ------ 8 Table 22 – Two CPs of one ACUs stop or unable to start Step Result Perform Go To Step Check CFCPOCR1, CFTh1, IOL1, in ACUs Fault Check the cause of fault. And replace, if necessary ------ 8 Check HPS1, LPS1, in ACUs Fault Check the cause of fault. And replace, if necessary ------ 5.5.1.6 One CP of ACU stop or unable to start Table 23 – One CP of one ACU stop or unable to start Step Result Perform Go To Step 1 Identify the fault unit This table shows the case of CP1 of ACU1. ----- 2 2 Energized Normal ------ 3
Check CFCPK 11 in accordance with Table 15. Check electrification of DC110V Check electrification of AC400V De-energized Fault Check the cause of deenergized. Repair wiring, if necessary. Replace relays, if necessary ------ 3 Check relay and electrification of DC110V for coil and contact of HPR11, LPR11. Energized Normal ------ 4 De-energized Fault Check the cause of deenergized. Repair wiring, if necessary. Replace relays, if necessary ----- 4 Check associated CF and CP Normal ------ 5 Fault of CF or CP Check the cause of fault. And replace, if necessary ----- 5 Check CPOCR 1, CFTh 1, IOL 1, in ACU Normal ------ 6 Fault Check the cause of fault. And replace, if necessary ------ 6 Check HPS1, LPS1, in ACU Normal ------ 7 Fault Check the cause of fault. And replace, if necessary ------ LPS continues the state of detection Check refrigerant leakage ------ 7 Check the state of evaporator coil and condenser coil Dust clogging Remove dust and clean ------
5.5.1.7 Transmission error between TCMS and ACCB Transmission error is able to check on the monitor of TCMS or monitor of PTE When transmission error occurs, ACCP continues air conditioning using the stored data which is transmitted from TCMS just before error. Table 24- Transmission error between TCMS and ACCP Step Result Perform Go To Step 1 Identify Car No. ------ ------ 2 2 Turn-off and Turn-on of ACCPCB Fault recovery To see the state of affairs ---- Non-recovery ------ 3 3 Change the printed circuit board for transmission in CPU unit of ACCP Fault recovery Replace ---- Non-recovery ------ 4 4 Check the disconnection of wiring, electric connector pin, etc. Disconnect Repair or replace ---- 5.5.1.8 Damper fault Table 25 – Damper fault Step Result Perform Go To Step 1 Check the state of damper using “Test” mode of TCMS. “ACU fault” indicates Identify the trouble damper group. One group consists of Fresh/Return air damper 1 and Emergency damper 1, or Fresh/Return air damper 2 and Emergency damper 2 2
2 Check the movement of associated F/R damper flap using “Test” mode of TCMS. Active ----- 4 Inactive Replace F/R damper or replace motor, if No.3 is no problem. 3 3 Check relay “DMCR11”, DMCR12”, “DMCR21” or “DMCR22” of ACCP. Normal Possibility of motor or control PCB fault 2- inactive Fault Replace ----- 4 Check relay “DMFR11”, DMFR12”, “ DMFR21” or “DMFR22” of ACCP. Normal ----- 5 Fault Replace ----- 5 Check activation of position switch. Check the electrification between terminal 13 and 14 of “DMFR11”, “DMFR12”, “DMFR21” or “DMFR22”, when the state of associated damper is “Close of return air inlet”. Active F/R damper is “No problem”. 6 Inactive Replace of position sensor or adjust the sensor position. ----- 6 Check the movement of associated Emergency damper flap using “Test” mode of TCMS. Active ----- 8 Inactive Replace Emergency damper. Replace motor, if No.3-No.7 are no problem. 7 7 Check relay “EMR1” or “EMR2” installed in the electric parts box of ACU Normal Possibility of motor fault. 6inactive Fault Replace. ----- Table 25 – Damper fault
Step Result Perform Go To Step 8 Check the position switch installed in geared motor of damper Fault Replace the geared motor ----- 5.5.1.9 Unable to operate both ventilation fans of CAHU Table 26- Unable to operate both fans of CAHU Step Result Perform Go To Step 1 Check Indication lamp for fault(RED) Turn-on 2 Turn-off 7 2 Check CAHMCB of ACCP Tripped Check insulation resistance between ACCP and fan motor of CAHU. Repair or replace, if necessary. ---- Not trip 3 3 Check insulation resistance of fan motor circuit between VFOCR and fan motor. Outlier Check a fault of fan and wiring. Repair or replace. ---- Normal value 4 4 Check VFOCR Abnormal Replace. ---- Normal 5 5 Check VFOCR auxiliary contact No.97-98 Abnormal Replace. ---- Normal 6
6 Check coil and contact of RY3 Abnormal Replace. ---- 7 Check coil and contact of RY1 Abnormal Replace. ---- Normal 8 8 Check coil and contact of RY2 Abnormal Replace. ---- 5.5.1.10 Unable to operate both ventilation fans of CAHU Table 27- Unable to operate one fan of CAHU Step Result Perform Go To Step 1 Check VFC1 and 2 Abnormal Replace. ----- 5.5.1.11 Unable to operate damper of CAHU Table 28- Unable to operate both fans of CAHU Step Result Perform Go To Step 1 Energization 2
Change position switch to “MID”, and turn off CAHMCB. Disconnect the electric connector. Turn on CAHMCB. Check the electrification of electric connector PIN NO.23 De-energized 4 2 Check printed circuit board for confirmation of the DC 24V electrification for motor De-energized Repair or replace ----- Energization 3 3 Check geared motor Abnormal Repair or replace ----- 4 Check relay RY2 contact No.3-5 Open Replace ----- Close 5 5 Check relay DR contact No.35 Open Replace ----- 54 Locating fault - refrigerant leakage detection The best method for checking of refrigerant leakage is with an electric leak detector. A Halide torch can also be used, but may not be as effective. Testing with soap suds at joints can reveal large leaks, but is ineffective in determining if the system is properly sealed. Only test with electronic leak detector is recommended. The procedure is illustrated as follow: 1. Use an electronic leak detector for detecting refrigerant R407C leakage.
2. Turn off all power to the air conditioning unit. Install safety tags on system power sources to alert other personnel work is in progress on the air conditioning unit. 3. Clean off any dirt or grease from fittings or joints before beginning test. Note any oil spots. 4. Connect the electronic leak detector to power source and switch ON the detector. (Refer to the instrument manual for the detail handling of electric leak detector.) 5. Place the probe as close as possible to test area, moving tip at a speed of about 2 cm per second along entire surface. 6. Test bottom of parts carefully as refrigerant is heavier than air. 7. Pay attention to areas showing accumulation of fresh oil. Leaking refrigerant carries oil with it. 8. Determine size and amount of leak by audio pitch and flashing rate of probe lamp. Both will continue at increased rate until probe removes away from leak area. (Indicator sound and flashing lamp change with the type, please refer to its manual.) 9. As necessary, adjust leak size switch and balance control settings in order to detect much larger or smaller leaks. 10.Turn leak detector switch to OFF position and disconnect the detector from power source. 11. Mark area of leak, recover refrigerant, repair leak and leak check before charging unit with refrigerant (R-407C).
Figure 42 – Electronic leak detector 55 Locating fault – HPS fault investigation at workshop Although it is recommended to send back to supplier if it detects a High Pressure Switch (HPS) defect, following is an example of checking the functionality of HPS. 1. Place healthy SACU, such as spare SACU, on Bench Test Equipment for SACU (BTE). 2. Install a High Pressure Switch (HPS) in question onto the refrigerant cycle 1 of SACU on BTE. 3. Connect a pressure gage to Charge Port 1. 4. Operate SACU on BTE. 5. While Compressor 1 (CP1) is operating, place some card boards or equivalent onto the inlet of Condenser Fan 1 (CF1) and CF2 so that cooling air from CF will not reach to the condenser coils. 6. Confirm CP1 stops when pressure of refrigerant cycle 1 becomes in the range of approximately 2.94 ~ 3.04 [MPa]. 7. Remove the card board on CF1 and CF2, and confirm CP1 restarts. 56 Equipment shutdown / start-up procedures Please refer to Volume 2 of TCMS Operation Manual for equipment start-up and shutdown procedure. 57 Hardware replacement procedures 58 Air conditioning unit 5.7.1.1 Replacement of saloon air conditioning unit 1. Turn off all power to the air conditioning unit.
2. Install safety tags on system power sources to alert other personnel of the air conditioning unit are being replaced. 3. Disconnect all electric connectors. 4. Remove the ground wire in return air opening. 5. Remove the connection ducts. 6. Remove the bolts securing the unit to the car. Keep the hex head bolts (M10x25mm, 17mm head), hex head nuts, flat washers (bolt side OD: φ26.0 mm, ID φ11.0 mm; nut side OD: φ20.0 mm, ID φ10.5 mm), spring washers for reuse. Figure 43 – Air conditioning unit mounting fasteners (red circled) 7. Secure shackles to the four lifting brackets on the air conditioning unit. 8. Attach the hook of lifting jig to the shackles. 9. Use a lifting jig and a crane to lift the air conditioning unit. 10. Lift the air conditioning unit from the roof of rolling stock and place it on a cart for moving to a storage area. 11. Use the lifting jig and the crane to place a spare air conditioning unit on the rolling stock.
Figure 44 – Replace air conditioning unit with a jig 5.7.1.2 Refrigerant recovery 1. Turn off all power to the air conditioning unit. Install safety tags on system power sources to alert other personnel work on the air conditioning unit is taking place. 2. Loosen bolts and remove cover of compressor / condenser section. 3. Locate the compressor suction and discharge connection points. 4. Connect a recovery machine, a refrigerant recovery tank and a gauge manifold. All apparatus should use the type only for refrigerant R407C. 5. Before connecting hose, check whether stop valve is closed. Charge port of discharge line will be automatically opened, if a hose is connected. 6. Connect hose A (High pressure side) to the discharge line process ports (Charging port) near the compressor. 7. Connect hose B (Centre hose) to recovery machine. 8. Connect recovery machine and refrigerant recovery tank with proof pressure type hose. 9. Open the stop valves and open refrigerant recovery tank valve. 10.Operate the recovery machine to recover the R-407C refrigerant. 11.Shut all valves and stop recovery machine after completion of recovery. 12.Disconnect recovery machine from charging hose B.
13.For evacuation, keep Hose-A connected. Figure 45 – Connection for Refrigerant Recovery 5.7.1.3 Refrigerant charge This procedure is to be used when adding to an empty system or to a system that needs a large charge. 1. This service procedure is done after refrigerant recovery. 2. Ensure all power to the air conditioning unit is off and the safety tags on system power sources are in position. 3. Obtain a high vacuum pump with evacuation hose connection and a vacuum gauge capable of reading microns. 4. Connect Hose B to the vacuum pump. 5. Operate the vacuum pump and open the valve of gauge manifold. 6. Operate the vacuum pump until the vacuum gauge reads 200 microns or less, then close valve on vacuum pump. 7. Wait 1 hour and then observe the vacuum gauge. If the reading is below 400 microns proceed to step 10. If reading is 400 microns or above, repeats step 6 and then this step is an effort to achieve 400 microns.
8. If a steady reading of 400 microns or below cannot be achieved, this service procedure has failed and other service action is required. Check system for leakage. 9. Close the valve of gauge manifold and immediately change into the charge system. 10. For charging of refrigerant, keep Hose-A connected and change vacuum pump to refrigerant tank. Figure 46 – Connection for evacuating refrigerant 11. Place a tank of R-407C on a weight scale (meter) and record reading. 12. Connect the Hose B of gauge manifold to R-407C tank. 13. Determine the scale reading that will indicate that the desired R-407C charge has been accomplished and then open valve of tank of R-407C and valve of gauge manifold. Regulate the flow of R-407C with this valve and close it when the proper charge has been introduced. If the conditions of ambient temperature, system temperatures and pressures do not allow the full quantity of R-407C to be introduced, warm R-407C tank by hair drier gradually. 14. Continue to monitor the weight displayed on the scale. Close the valve on the R-407C tank when the desired scale reading has been achieved. 15. Make sure that both valves are closed. Remove refrigerant charging equipment. 16. Check leakage again. 5.7.1.4 Compressor replacement (6.0 man-hours)
Brazing kit is necessary to replace the compressor and other parts for refrigerating circuits. WARNING Temperature of the compressor and discharge tube to the condenser coil immediately after operation has stopped is very high. Wait and replace the compressor after it has cooled. Follow hot work procedure for brazing work. 1. Turn off all power to the air conditioning unit. Install safety tags on system power sources to alert other personnel of work is in progress on the air conditioning unit. 2. Loosen bolts of the outside cover, and remove the cover. Keep the removed bolts for reuse. 3. Recover refrigerant from charging port of discharge pipe using refrigerant recovery machine. 4. Remove the terminal cover of the compressor, and remove the connecting wiring. 5. Record 6. Use brazing tools to disconnect the discharge pipe and the suction pipe. 7. Remove the bolts fixing the compressor. 8. Remove the compressor with a crane. 9. Install a new compressor to the air conditioning unit with a crane. 10. Use bolts, resilient isolators, resilient blocks, spacers, washers, and spring washers to fix the compressor to the unit. Tighten the bolts to proper torque. 11. Remove condenser fans. (Refer to 5.7.1.5 for details.) 12. Replace the filter-dryer. • Remove the dryer band.
• Remove the pipes before and after the filter-dryer with the brazing, and replace the filter- dryer with a new one. • Fix the filter-dryer with the dryer band. 13. Connect the suction pipe and discharge pipe to the compressor with brazing. Check the brazing material is applied completely around the pipe. 14. Charge refrigerant (R407C). • Connect the charge port of discharge pipe to the refrigerant tank with gauge manifold, and charge the refrigerant (About 300g) • Use an electronic leak detector to probe for leaks. • If there is no leaks, recover the refrigerant and evacuate the system. If there are leaks recover the refrigerant and repair the leaks before going to evacuation. • Open the valve and evacuate the system. The evacuation level needs to be 200-micron vacuum maximum held for two hours and a maximum of a 200- micron leak back after one hour. • After evacuation close the valve and connect the end of the valve to the refrigerant tank. Purge the air between the tank and the charge port. • Open the valve, and charge the liquid refrigerant (R407C) in the high side of the system only. • Charge the refrigerant cycle to the rated capacity. • After charging the refrigerant into the system, remove the hose of gauge manifold and attach the cap. 15. Connect wiring to the terminal box of the compressor. 16.Fix the terminal box cover to the compressor and tighten the bolts. 17. Install condenser fans. (Refer to 5.7.1.5 for details.) 18. Mount the cover of air conditioning unit and fix with bolts. 5.7.1.5 Condenser fan replacement (0.6 man-hours)
1. Turn off all power to the air conditioning unit. Install safety tags on system power sources to alert other personnel work is in progress on the air conditioning unit. 2. Keep all removed bolts and screws for reuse. 3. Loosen bolts on the outside cover, and remove the cover. 4. Cut and remove cable ties on the cable linking the blower. 5. Disconnect the electric connector for condenser fan 6. Remove the mounting bolts securing the condenser fan. 7. Remove the condenser fan from the air conditioning unit with crane. 8. Place a new condenser fan in the air conditioning unit. Fix it with bolts and tighten the bolts to rated torque. 9. Plug the condenser fan cable to the electric connector. If the lead wire is cut, replace the whole lead wiring including terminals at both ends. Do not connect the wiring by splicing the broken wire. 10. Fix the condenser blower cable with cable ties. 11. Secure the bell-mouth support plate with bolts and tighten the bolts to rated torque. 12. Mount the outside cover. Fix it with bolts and tighten the bolts to rated torque. 5.7.1.6 Evaporator fan replacement (0.8 man-hours) 1. Turn off all power to the air conditioning unit. Install safety tags on system power sources to alert other personnel work is in progress on the air conditioning unit. 2. Keep all removed bolts and screws for reuse. 3. Loosen bolts on the inside cover, and remove the cover. 4. Cut and remove cable tie fixing the cable to the blower. 5. Loosen M5 screw and remove the cover for terminal box of motor 6. Disconnect wire from the terminal stand. 7. Remove the bolts securing the evaporator fan.
8. Lift the evaporator fan with crane and remove it from the air conditioning unit. 9. Place a new evaporator fan in the air conditioning unit. Fix the evaporator fan with bolts and tighten the bolts to rated torque. 10. Connect wiring to terminal in accordance with the recorded order. 11. Fix wiring with cable ties and reattach the cover for terminal box of motor. 12. Mount the evaporator cover. Fix with bolts and tighten the bolts to rated torque. 5.7.1.7 Fresh/Return air damper and emergency damper replacement (0.6 man-hours) 1. Turn off all power to the air conditioning unit. Install safety tags on system power sources to alert other personnel work is in progress on the air conditioning unit. 2. Keep all removed bolts and screws for reuse. 3. Loosen bolts on the evaporator cover, and remove the cover. 4. Cut and remove cable ties on the cable linking the damper. 5. Disconnect the electric connector for damper. 6. Remove the fixing bolts securing damper. 7. Remove damper from ACU. Use crane, if necessary. 8. Place a new damper at correct position in ACU and fix with bolts and tighten the bolts to rated torque. 9. Connect the electric connector. 10. Fix wiring with cable ties and reattach the cover for terminal box of motor. 11. Mount the evaporator cover. Fix with bolts and tighten the bolts to rated torque. 5.7.1.8 Emergency inverter replacement (1.0 man-hours) 1. Turn off all power to the air conditioning unit. Install safety tags on system power sources to alert other personnel work is in progress on the air conditioning unit.
2. Keep all removed bolts and screws for reuse. 3. Loosen bolts on the evaporator cover, and remove the cover. 4. Cut and remove cable ties on the cable fixing frame, if necessary. 5. Loosen bolts fixing the inverter support plate to frame and lift up inverter. 6. Remove wiring and the electric connector from inverter 7. Loosen bolts fixing the inverter and remove inverter. 8. Place a new inverter on the inverter support plate. Fix with bolts and tighten bolts with rated torque. 9. Remove the inside cover. 10. Remove inverter with an installation board. 11. Check the unusual state such as the burn marks, deformation, etc. 12. Replace to new one, if unusual state is detected. 59 Air Conditioning Control panel (ACCP) 5.7.2.1 CPU unit replacement (0.4 man-hours) 1. Turn off all power to the ACCP. Install safety tags on system power sources to alert other personnel work is in progress on the air conditioning unit. 2. Keep all removed bolts and screws for reuse. 3. Remove all electric connector on the front of CPU unit 4. Cut and remove cable ties used for the cable fixing. 5. Loosen bolts fixing the frame of CPU unit and remove CPU unit with frame. 6. Install new CPU unit, fix with bolts and tighten bolts. 7. Connect all electric connector. 8. Connect PTU unit. 9. Turn on all power to ACCP and check the lighting of indication lamp “CPU RUN” at the switch/display panel which shows the health of CPU. 10. Check that there is not “Transmission error” information on the display of TCMS and PTU.