********* ISSUES WITH IGBT LOCOS ********
BTIL
1 Software Issues
i Cable crimping Modification has been completed. No problem experienced afterwards.
ii Multiple software in VCU for BT make traction converter. Latest software version 1215 has nearly resolved...
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the pending software issues. After this software only one software for VCU for all locos having BT make traction converter.
iii Catenary voltage out of limit Problem experienced in Kalyan. Under study by BTIL.
2 Other Issues
i Availability of Spare Parts & maintenance Stocking has been done at ELS/Gomoh and Vadodara. Gomoh to confirm the adequacy of spares.

ABB
1 Hardware Issues
i Failures of Power Module PEBB Module failures high (25 in 14-15). Firm submitted analysis report indicating flaw in manufacturing process. Defective lot have been identified and replaced except 11 power modules in two locomotives in AQ & BIA sheds. Serial no. HKTX03 ans HKOD17 to be checked in 31470.
ii Duagon Cards Large no of Duagon card failures including modified Duagon card (D709). Firm mentioned failures due to Firmware malfunctioning. Firmware up-gradation has been done in 6 locos at AQ, TKD and GZB. Performance found satisfactory. So far, 52 locomotives have been modified. 12 Locos are pending for replacement by D709.
iii Failures of PEC800 cards There had been 11 cases of PEC 800 cards during 14-15. Firm indicated that DOS file management system has been replaced with Reliance system and implemented in s/w version 35a11. So far updated in 69 locos. Balance locos provided with s/w version 36. Railways to monitor the performance.
iv Breakage of cover support guide Replacement of hardened steel dowel pins with Stainless Steel pins. To be completed by 31.05.15 as per MOM of TKD. Completed in 30 locomotives only. Pins given to sheds for replacement.
v Replacement of voltage sensor by LEM make ABB make voltage sensors are to be replaced by LEM make. 3 locos are left for replacement.
2 Software Issues
i Implementation of DDS message in DIA card of VCU DDS implementation trial is going on in 6 locos at different sheds for traction converter only. Loco no 31611(TKD) has been provided with DDS implementation in SR and BUR. ABB to provide modified s/w version 36 in 3 locos at TKD (31545,30396, 30397) and 4 locos at BIA (30385, 30387, 31401, 31539) to monitor the performance for regular release of s/w ver.36.
ii Time out initialization/time out release shut down To be implemented in new software version. Issue to be resolved.ABB has captured data, analysis to be done.
iii Regenerative braking issue during first instant To be implemented in new software version. Implemented in Loco 31545 (TKD) and 30385 (BIA).
iv Time mismatch between converter & VCU Resolved in version 36.Under trial in TKD and BIA. Railways to monitor performance and give feedback to RDSO/CLW.
v LC Over-current (both bogie getting isolated) Resolved in version 36.Under trial in TKD and BIA. Railways to monitor performance and give feedback to RDSO/CLW.
vi FLG-1 is not in service, change over to FLG-2 To be studied in detail.
vii Initialization time to be reduced to less than 50 seconds Node 504 achieved in 60 seconds with modified PEC board on loco number 31471 at TKD and to be further reduced by 10 sec in second phase.
viii Individual TM isolation on account of faulty speed sensor not possible Resolved in s/w version 36. 7 locos have been modified in TKD and BIA. No problem experienced so far.
ix Converter redundancy demonstration for current measurement and DC link voltage measurement Demonstrated in AQ with Version 35 A11.Under observation. Completed in 68 locomotives.
x No Single point data down loading for traction converter and auxiliary converter ABB to upload modified s/w version 36 in 07 locos and monitor the performance.
xi Unwanted Events Resolved in version 36 except Invalid ID. Under trial in TKD and BIA.
xii In case of Individual TM failure on line, there is no defined cause on driver display Resolved in version 36.Under trial in TKD and BIA.
xiii Different software required with different make BUR Pending
xiv Sometimes message FLG1:0096 SS04 harmonic filter appear and filter cubicle isolate from service Resolved in version 36.Under trial in TKD and BIA.
xv Inspection and maintenance related issues Stocking done at Nagpur, Delhi, Bangalore. Sheds to give feedback.
3 Miscellaneous
i While removing traction converter for any reason, TC to TC OFC is required to be removed by cutting connector. Firm to examine and suggests remedial measures Pending
ii Repair manual according to DDS Not yet submitted.
i While removing traction converter for any reason, TC to TC OFC is required to be removed by cutting connector. Firm to examine and suggests remedial measures Pending
BHEL
1 Hardware Issues
i Failure of IGBT Power Module Root cause of failures of power modules to be ascertained. SEPL error to be analyzed by Sept. end. BHEL to use Hitachi/Mitsubishi devices in place of ABB devices.
ii Coolant leakage problem Leakage in SR having cooling circuit with threaded joints. RDSO advised BHEL for using flanged coupling on trial basis in 10 locos. Performance found satisfactory. Same system to be adopted in all new as well as in service converters by BHEL.
iii Coolant level fluctuation BHEL to provide air vent in locos where air trap problem has been reported.
iv Coolant pressure switch failures BHEl to use Honeywell make pressure switches on 5 locos at KYN shed and Danfoss make on 5 locos in LGD shed and monitor performance.
v High failure of DCU card in SR. 3 failures occurred in 2015-16. BHEL to submit detailed report to RDSO/CLW.
vi ACI card failure in AUX. converter. Increase in failures of ACI cards in Aux. Converters. Firm has improved FPGA software to prevent boot loader error. BHEL to submit field performance of modified s/w ver. 985 to RDSO/CLW.
2 Software Issues
i ASC pulsing stop. Problem has been reported with modified software in LGD shed. BHEL to find out root cause by 30.09.15. Performance of s/w ver. 366 to be watched before implementing in other locos.
ii Tripping of Aux. converter due to TFP oil pressure low BHEL to provide s/w ver. 985 in 1 loco at CLW during commissioning for its efficacy.
iii Healthiness of Battery charger Message of Battery charger not working does not appear until battery voltage falls to 92 volts. S/w ver. 985 has been uploaded in one loco ar RPM. BHEL to submit field performance report to RDSO/CLW.
3 Other Issues
i Availability of Spare Parts & maintenance Stocking has been done at three sheds having major population, lallaguda, kalyan and bhillai. Sheds to confirm the adequacy of spares.
ii Commissioning failure Commissioning failure still very high. 21 failures per 100 equipment commissioned at CLW during 2014-15.

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