(Govt.

of India)
(Ministry of Railways)

Handbook
On
Wheel Slide Protection Device(WSP)
Speed Sensor WSP-Electronic WSP-Valve

UBatt. Vehicle-Bus

Electric

Pneumatic

(For official use only)

IRCAMTECH/2011/Mech/WSP/1.0
August 2011

MAHARAJPUR, GWALIOR -474005

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 Foreword
WSP system is the vital part of LHB & other FIAT fitted
bogie coaches. WSP system is recently introduced in
Indian Railways. Proper up keeping and maintenance of
WSP system is necessary to ensure reliability and
availability of coaches. This Handbook on WSP system
has been prepared by CAMTECH with the objective that
those involved in maintenance of LHB & other FIAT
bogie fitted coaches, must be aware of WSP system and
its function with correct maintenance. This Hand Book
not only describes in WSP system but care has been taken
to explain basic thing about WSP system including
introduction, working principle, testing procedure etc.

Technological up gradation and learning is a continuous

process. Hence feel free to write to us for any
addition/modifications or in case you have any suggestion
to improve the Hand Book, your contribution in this
direction shall be highly appreciated.

Date:
Place: (K.P.Yadav)
Director(Mech)
 CORRECTION SLIPS

The correction slips to be issued in future for this handbook will

be numbered as follows:

CAMTECH/2011/Mech/WSP/1.0/C.S. # XX date …………….

Where “XX” is the serial number of the concerned correction slip
(Starting from 01 onwards)

CORRECTION SLIPS ISSUED

Sr.No. of Date of Page No. and Item Remarks

C.Slip issue no. modified
Speed Sensor WSP-Electronic WSP-Valve

UBatt. Vehicle-Bus

Electric

Pneumatic

Wheel Slide Protection Device

(WSP)
 Index

Chapter Description Page No

1 Wheel Slide Protection Device 1-35

1.1 Introduction 1

1.2 Working Principle 2

1.3 Details of FAIVELEY WSP System 6

1.4 Testing procedure (Faiveley) 13

1.5 Defects analysis & trouble 16

shooting (Faiveley)
1.6 Details of KNORR BREMSE WSP 26
System
1.7 Testing procedure (Knorr Bremse) 29

1.8 Defects analysis & trouble 32

shooting (Knorr Bremse)

II
No.IRCAMTECH/2011/Mech/WSP/1.0 1

1.1 Introduction
LHB coaches have been introduced in services on some of the
premier trains on Indian Railways with state of art features.
One of the important feature provided in these coaches are
WHEEL SLIDE PROTECTION DEVICE (WSP).
Initially, coaches turned out by production units were having
two types of WSP’s namely supplied by (a) M/s Knorr Bremse
India limited & (b) M/s SAB WABCO India ltd. During initial
supplies Parrizi type processor was received with M/s Knorr
Bremse air brake system whereas Sab Wabco with its own.
During further developments, railways started using processors
manufactured by M/s Knorr Bremse with its own air brake
system & in the mean time, M/s Faiveley has taken over M/s
Sab Wabco. Therefore, presently railways is having three types
of processors (WSP’s) in service:
1. M/s Knorr Bremse India Ltd.
2. M/s Knorr Parrizi India Ltd.
3. M/s Faiveley India Ltd. (earlier known as M/s Sab
Wabco)

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After introduction in services, it is noticed that, performance of

WSP specifically Knorr Parrizi system was not up to the mark
& even firm was not able to give service support due to poor
response from the OEM. In view of above, Parrizi type WSP
are being replaced with Knorr Bremse system. Presently,
railways is having mainly two types of WSP System.
WSP control unit is a combination of various electronic cards.
This unit is housed in electrical control panel units. This unit is
connected by means of various cables through various
equipments
1.2 Working Principle
During the course of brake application, there are possibilities
of skidding/sliding/locking of individual axle. In these cases
adhesion between the rails & wheels plays vital roll. Above
situations are likely to cause damage to wheel sets with
increased braking distance. The main purpose of using the
WSPs is to utilize the available adhesion. The WSPs provided
in the system avoids wheel sliding, also cuts the maintenance
cost. Speed sensors, the part of the system detect the speed of
the wheel & sends signal to the processor unit.
The processor unit evaluates the received signal from speed
sensor of the vehicle & generates signals enabling the dump
valve/antiskid valves to control the brake cylinder pressure in
case of any locking/skidding. The control on the brake cylinder
pressure is instantaneous to the wheel to rail adhesion, keeping
the wheels within their optimum range of skidding.
The WSP has some of the major parts.
1.2.1. Speed Sensor.
1.2.2. Phonic wheel.
1.2.3. Microprocessor.
1.2.4. Dump valves.
1.2.5. Pressure switch.

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1.2.1 Speed Sensor:

The speed sensors are fixed on one end of the axle box cover
with the help of two bolts. During fitment the gap between
sensor probe & phonic wheel plays vital role. The gap can be
adjusted with the help of shims & measured through the
peephole in axle box cover. The other end of the speed sensor
i.e. cable is connected to junction box in car.
The sensor system provided on coaches is based on non contact
type of counting of RPM. This is ensured with the help of
phonic wheel & sensor probe fitment with some air gap.
The main function of speed sensor is to pickup the signals with
the rotation of phonic wheel mounted on axle end & convey to
microprocessor.

The air gap between the rotating gear (Phonic wheel) & speed
sensors probe should be
Knorr Bremse = 0.4 to 1.4 mm
Faiveley = 1.5 + 0.5 mm

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Criteria gap between speed sensor and toothed wheel

1.2.2 Phonic wheel:

A phonic wheel is installed on one end of each axle. The
phonic wheel is a toothed wheel (gear type). The purpose of
this toothed wheel is to alter the internal inductance of the
adjacent sensor. The change in internal inductance is evaluated
as axle speed of various axles on a coach. During fitment,
concentric movement of phonic wheel should be ensured. The
eccentric movement of phonic wheel may cause signal errors,
damage of speed sensor probe.
1.2.3 Microprocessor:
Microprocessor is the heart of the WSP system. This gathers
the signals from phonic wheel & speed sensors, evaluates the
vehicle speed. Moreover, during brake application, it monitors
& bridges the sharp drop of speed of a particular axle/wheel,
enabling the dump valve to control/adjust the brake cylinder
pressure.

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Each processor is provided with LED display & some test

buttons. This LED displays various codes which can be
decoded & the health of WSP system can be evaluated.
1.2.4 Dump valve/Anti skid valve:
A dump valve is provided for each axle of the vehicle. These
dump valves are a type of solenoid valves, connected with the
air pressure line of brake cylinder. Dump valve/antiskid valve
should be fitted close to the brake cylinders. These dump
valves allow to deplete the air available in brake cylinder line
during brake application based on the signals from WSP
microprocessor.

1.2.5 Pressure switch:

Pressure switch is provided on brake control panel. The
purpose of pressure switch is to activate the WSP when the
pressure reaches as given below.

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System make Working on pressure Pressure range

Knorr Bremse BP Pressure 0.2 Kg/cm2 – 0.5

Kg/cm2

Sab Wabco FP Pressure 1.5 Kg/cm2 – 1.7

Kg/cm2

Pressure switch
1.3 Details of FAIVELEY WSP Systems:
This electronic unit (SWKP AS 20 R) is housed in a 19”
cabinet consisting of various electronic cards. The details are
as under:
1.3.1 Internal Module of WSP System
This system is separated into various components such as :
1.3.1(a). N1 (Power pack 1):
This unit supplies energy to the dump valves. This unit enables
independent functioning of the control unit and dump valves.
 Input voltage ranging from 16.8 V to 150 Vdc
 Output voltage 24 V + 3% dc

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1.3.1(b). N2 (Power pack 2):

This unit supplies energy to all measurement & data
processing units.
 Input voltage ranging from 16.8 V to 150 Vdc
 Output voltage 24 V + 3% dc
 EMC – Filter
 Pressure switch input
 Low-voltage shut-off

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1.3.1(c). OP (Optocoupler input): (Not in Use)

 8 Potential-free inputs from 16 V to 150 Vdc

From these inputs, only 8th input is used for monitoring of

pressure switch & remaining 1-6 inputs remain unused.
1.3.1(d). RE (Relay output):
 6 potential-free outputs of 16 V to 150 Vdc

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Out of 06 outputs, one output is used. Remaining 5 are not

used by system.
Output 5: Toilet discharge: close at V>30km/h; open at
V<28km/h
1.3.1(e). ST (Status display):

 Used for monitoring of all Inputs & outputs (OP & RE).
 Used for monitoring dump valves and four supply
voltages (BV= charging of brake cylinder; EV= exhausting
of brake cylinder).
1.3.1(f). MV (solenoid amplifier):
 Four solenoid amplifiers per assembly.
 4 independent safety shut-off points as extra safety
devices.
 Both sides switch-off of solenoids in the case of watch
dog time-out
 Constant voltage supply of 24 volts for solenoids
irrespective of battery voltage.

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This module is used for controlling the dump valves via

bipolar output amplifier.
1.3.1(g). CPU (Central processing unit)

 Selective regulation of brake cylinder pressure of the

wheel set.

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 Date received & is stored permanently for diagnostic

purpose.
 Error recording with date, time & frequency.
 9-channel SUB-D plug for connecting PC (RS 232)
 4-digit 7-segment display for service & maintenance.
1.3.1(h). GE (Speed recording):
 Energy supplier for the speed sensors.
 Dynamic test for each speed sensor.
 Analogue output of reference speed.
The GE module acquires the speed sensor data. The sensors
are supplied & tested continuously by this module.

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Schematic diagram for the Component overview

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Component Overview
1.4 Testing procedure (Faiveley):
CPU Front panel
Step 1: Diagnostic of Faults
As push button 1 is pushed &
the code displayed is different to
99 (ie. 95 or 72 or 73) or the
system is switched off. The CPU
will switch on & by pressing the
push button 1 for minimum
3sec, the faults can be displayed.
The following functions also
take place:

 Indication “88” for 3 sec (7-segment LED test)

 Indication of all faults in a sequence of 3 sec.
Step 2: Test
To test the system, push button 2 (Test) to be pressed for atleast
3sec. The indication “89” appears and following functions take
place:
All the brake cylinders of axles 1 - 4 are vented in succession.
The correct alignment of dump valve and speed sensor of all the
axles starting from axle 1 is checked. Any failure in this will
result in inaccurate axle speeds being measured which causes
false pressure values are set in the dump valves.
Note: The axles are measured as 1 & so on from opposite side,
where the microprocessor is fitted.
Step 3: Clearing of failure memory
By pressing the push button 3 for minimum 3 sec, the following
function takes place
 Indication of “cLr”

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 Clearing of all historical faults.

Step 4: Door test (Not in use)
Step 5: X/ Kilometer counter
By pressing the push button for minimum 3 sec, the distance
will be shown on the display. The distance is value with 8
positions and is divided into two parts. At first, most significant
part is shown on display followed by the least significant part.
1.4.1 Wiring Diagram (Faiveley):
Wiring plays vital role of working of system & to diagnose the
fault in system during maintenance of the WSP system. Wiring
diagram is place on next page.

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1.5 Defects analysis & trouble shooting (Faiveley):

LED display of WSP displays information about the
working/failures of system. The displays are in numerical
form. Each figure code describes different type of failure &
their probable cause. Details of code in display & cause are as
under:
Defect codes with Troubleshooting:

Code
Failure
in Failure cause Corrective action
code
Display
Hardware
Acknowledge the
watchdog of
72/73 10 failure, continue the
solenoid valve of
operation.
axle 1 is triggered.
Short circuit or
Check the wires for
interruption of
72/73 11 short circuit or
speed sensor of
interruption
axle 1
Wires or solenoid of
the dump valve
Short circuit of
should be checked
72/73 13 solenoid valve of
for short circuits,
axle1
acknowledge the
failure.
Wires or solenoid of
the dump valve
Interruption of
should be checked
72/73 14 solenoid valve of
for interruption,
axle 1
acknowledge the
failure.

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Code
Failure
in Failure cause Corrective action
code
Display
Hardware
Acknowledge the
watchdog of
72/73 20 failure, continue the
solenoid valve of
operation.
axle 2 is triggered.
Short circuit or
Check the wires for
interruption of
72/73 21 short circuit or
speed sensor of
interruption
axle 2
Wires or solenoid of
the dump valve
Short circuit of
should be checked
72/73 23 solenoid valve of
for short circuits,
axle2
acknowledge the
failure.
Wires or solenoid of
the dump valve
Interruption of
should be checked
72/73 24 solenoid valve of
for interruption,
axle 2
acknowledge the
failure.
Hardware
Acknowledge the
watchdog of
72/73 30 failure, continue the
solenoid valve of
operation.
axle 3 is triggered.
Short circuit or
Check the wires for
interruption of
72/73 31 short circuit or
speed sensor of
interruption
axle 3

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Code
Failure
in Failure cause Corrective action
code
Display
Wires or solenoid of
the dump valve
Short circuit of
should be checked
72/73 33 solenoid valve of
for short circuits,
axle 3
acknowledge the
failure.
Wires or solenoid of
the dump valve
Interruption of
should be checked
72/73 34 solenoid valve of
for interruption,
axle 3
acknowledge the
failure.
Hardware
Acknowledge the
watchdog of
72/73 40 failure, continue the
solenoid valve of
operation.
axle 4 is triggered.
Short circuit or
Check the wires for
interruption of
72/73 41 short circuit or
speed sensor of
interruption
axle 4
Wires or solenoid of
the dump valve
Short circuit of
should be checked
72/73 43 solenoid valve of
for short circuits,
axle 4
acknowledge the
failure.

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Code
Failure
in Failure cause Corrective action
code
Display
Wires or solenoid of
the dump valve
Interruption of
should be checked
72/73 44 solenoid valve of
for interruption,
axle 4
acknowledge the
failure.
Hardware
Acknowledge the
watchdog of
95 10 failure, continue the
solenoid valve at
operation.
axle 4 is triggered.
1. Check the wires
Short circuit or
for short circuit or
interruption of
interruption.
connection
95 11 2. Replace speed
between speed
sensor,
sensor at axle 1 and
acknowledge the
WSP
failure.
1. Check the wires
and valve for short
circuit,
Short circuit at
acknowledge the
95 13 solenoid valve of
failure.
axle 1.
2. Replace solenoid
valve, acknowledge
the failure.

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Code
Failure
in Failure cause Corrective action
code
Display
1. Check the wires
and valve for
interruptions,
Interruption of
acknowledge the
95 14 solenoid valve of
failure.
axle 1
2. Replace solenoid
valve, acknowledge
the failure.
Hardware
Acknowledge the
watchdog of
95 20 failure, continue the
solenoid valve of
operation.
axle 2 is triggered.
1. Check the wires
Short circuit or
for short circuit or
interruption of
interruption.
connection
95 21 2. Replace speed
between speed
sensor,
sensor of axle 2
acknowledge the
and WSP
failure.
1. Check the wires
and valve for short
circuit,
Short circuit at
acknowledge the
95 23 solenoid valve of
failure.
axle 2.
2. Replace solenoid
valve, acknowledge
the failure.

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Code
Failure
in Failure cause Corrective action
code
Display
1. Check the wires
and valve for
interruptions,
Interruption of
acknowledge the
95 24 solenoid valve of
failure.
axle 2.
2. Replace solenoid
valve, acknowledge
the failure.
Hardware
Acknowledge the
watchdog of
95 30 failure, continue the
solenoid valve of
operation.
axle 3 is triggered.
1. Check the wires
Short circuit or
for short circuit or
interruption of
interruption.
connection
95 31 2. Replace speed
between speed
sensor,
sensor of axle 3
acknowledge the
and WSP
failure.
1. Check the wires
and valve for short
circuit,
Short circuit at
acknowledge the
95 33 solenoid valve of
failure.
axle 3.
2. Replace solenoid
valve, acknowledge
the failure.

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Code
Failure
in Failure cause Corrective action
code
Display
1. Check the wires
and valve for
interruptions,
Interruption of
acknowledge the
95 34 solenoid valve of
failure.
axle 3.
2. Replace solenoid
valve, acknowledge
the failure.
Hardware
Acknowledge the
watchdog of
95 40 failure, continue the
solenoid valve of
operation.
axle 4 is triggered.
1. Check the wires
Short circuit or
for short circuit or
interruption of
interruption.
connection
95 41 2. Replace speed
between speed
sensor,
sensor of axle 4
acknowledge the
and WSP
failure.
1. Check the wires
and valve for short
circuit,
Short circuit at
acknowledge the
95 43 solenoid valve of
failure.
axle 4.
2. Replace solenoid
valve, acknowledge
the failure.

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Code
Failure
in Failure cause Corrective action
code
Display
1. Check the wires
and valve for
interruptions,
Interruption of
acknowledge the
95 44 solenoid valve of
failure.
axle 4
2. Replace solenoid
valve, acknowledge
the failure.

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Table of Failure Codes:

Axle Code Description

1 10 Safety shut - down MV (Dump Valve)
Short circuit / interruption GE (Speed
11 Sensor)
13 Short circuit MV (Dump Valve)
14 Interruption MV (Dump Valve)
2 20 Safety shut - down MV (Dump Valve)
Short circuit / interruption GE (Speed
21 Sensor)
23 Short circuit MV (Dump Valve)
24 Interruption MV (Dump Valve)
3 30 Safety shut - down MV (Dump Valve)
Short circuit / interruption GE (Speed
31 Sensor)
33 Short circuit MV (Dump Valve)
34 Interruption MV (Dump Valve)
4 40 Safety shut - down MV (Dump Valve)
Short circuit / interruption GE (Speed
41 Sensor)
43 Short circuit MV (Dump Valve)
44 Interruption MV (Dump Valve)
Failure in electronic card RE (relay
70/71 output)

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Axle Code Description

72 WSP disturbance, one axle
73 WSP disturbance, several axles
HF Global hardware failure
Pr Processor
EP EPROM
EE EEPROM
Hd Hardware watchdog
8888 Segment test
89 Test run
95 Intermittent fault
99 Good indication

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1.6 Details of KNORR BREMSE WSP Systems:

This electronic unit (MGS2 WSP System) is mounted in a rake
case & housed in the electrical controlled panel. This system
consists of following parts:
1.6.1. Power board:
The power boards are fitted in a closed box. Its front panel
has two yellow LED’s indicating the operating state. This
board supplies the voltage for powering the boards, actuators
and speed sensors. For powering the anti-skid valve a 24 V
source is used from MGS2 control unit. Input Supply voltage
– 24V + 30% DC to 110 + 30% DC.

PB03 A (Power board)

1.6.2. Boards MB04

MB04 Board

Wheel Slide Control (i.e. acceleration & slip control) is

implemented entirely on board MB04.

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MB04 contains all the electronic peripherals for individual

wheel slide control up to four wheels. MB04 board has a
man-machine interface (MMI) integrated in its font panel.
MB04 supply 24 V Dc to all the Dump valve.
Features:
 Four configurable input circuits for the speed sensors.
 Eight semiconductor output stages for four anti skid valves
with two magnets each.
 Two mechanical relays to cut off the magnet valves for
safety in response to a malfunction.
 Short circuit proof power supply to all four speed sensors
 Four input circuit for analog frequency sensors.
 Micro controller monitoring & fail safe mode.
Man–Machine interface (MMI) comprises of:
- a 9-pin sub-D female connector for the RS 232
interface (to connect a PC terminal).
- a 4-character alphanumeric display
- Four control key.
1.6.3. Board EB01
It is an extension board in MGS2 control unit. It provided
digital inputs & outputs which are utilized for supplementary
functions such as door control, toilet criteria.

EB01 Board
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Features:
 It serves as watchdog.
 Eight digital inputs, galvanically isolated from MGS2
potential, outputs and one another. Two of the inputs can
be configured as frequency inputs via software.
 Eight relay outputs, galvanically isolated from MGS2
potential, inputs and one another. Four of the relays can
be used as both make & break switches. The other four
relays have just a make contact function.
 Two galvanically isolated frequency outputs.

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1.7 Testing procedure (Knorr Bremse):

1.7.1. Test run:

By pressing the keys on MMI, three different test runs can be
performed. The test runs are terminated automatically when a
speed signal higher than 03 kmph is identified.
Step 1 - “Valve control” test run
By pressing the key “S2” on MMI for about one sec, the
valve control test run starts.
The display will show “8888” for the first three seconds &
then switches to “89”. Faults found by the test are displayed
at the end of the run. Volatile faults that have occurred at
some time on the move and disappeared again in the
meantime (e.g. loose contacts), are displayed as number
“95”. After the test run has been completed, the code “99” is
again shown on the display.
All the brake cylinders of axles 1 - 4 are vented in
succession. The alignment of anti skid valve and speed

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sensor of all the axles starting from axle 1 are checked. Any
failure will result in inaccurate axle speeds being measured
which causes false pressure values are set in the anti skid
valves.
Step 2 –“Door control” test run (Not in use)
1.7.2. Fault memory:
1.7.2(A) Retrieving faults from memory
The display return code “99” if the fault memory is empty
& no keys are pressed. The display shows code number
“95”, if any volatile faults are in memory.
Press key “S1” to start the query. To begin with, the
display reads “8888”.
All current faults are displayed for three seconds each.
The display subsequently reads “95” & then shows the
volatile faults.
1.7.2(B) Erasing faults from memory
The fault memory is erased when the erase key “S3” is
pressed for about one second. However, persistent faults
will be entered instantly again in the fault memory.
1.7.3. Service Terminal:
An interface PC can be connected with port on MMI RS 232
for monitoring diagnostic output of the system.
1.7.4 Wiring Diagram (Knorr Bremse):
Wiring plays vital role of working of system & to diagnose
the fault in system during maintenance of the WSP system.
Wiring diagram is place on next page.

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1.8 Defects analysis & trouble shooting (Knorr Bremse):

LED display of WSP displays information about the
working/failures of system. The displays are in numerical
form. Each figure code describes different type of failure &
their cause. Details of code in display & cause are as under:
Defect code with Trouble shootings:

Problem Connected
Display Fault
Source with
Board
02 Digital I/Os
EB01A
Board
03 Central processing unit
MB04A
Board Wheelset 1
10 Time out
MB04A
Speed
Short circuit / open
11 sensor
circuit
1/feeder
Speed
12 Signal error sensor
1/feeder
Dump Valve
13 Short circuit
1/feeder
Dump Valve
14 Open circuit
1/feeder
Safety monitor Board
15
defective(test run) MB04A

Handbook on WSP System CAMTECH/GWL

No.IRCAMTECH/2011/Mech/WSP/1.0 33

Problem Connected
Display Fault
Source with
Board Wheelset 2
20 Time out
MB04A
Speed
Short circuit / open
21 sensor
circuit
2/feeder
Speed
22 Signal error sensor
2/feeder
Valve
23 Short circuit
2/feeder
Valve
24 Open circuit
2/feeder
Safety monitor Board
25
defective(test run) MB04A
Board Wheelset 3
30 Time out
MB04A
Speed
Short circuit / open
31 sensor
circuit
3/feeder
Speed
32 Signal error sensor
3/feeder
Valve
33 Short circuit
3/feeder

Handbook on WSP System CAMTECH/GWL

No.IRCAMTECH/2011/Mech/WSP/1.0 34

Problem Connected
Display Fault
Source with
Valve
34 Open circuit
3/feeder
Safety monitor Board
35
defective(test run) MB04A
Board Wheelset 4
40 Time out
MB04A
Speed
Short circuit / open
41 sensor
circuit
4/feeder
Speed
42 Signal error sensor
4/feeder
Valve
43 Short circuit
4/feeder
Valve
44 Open circuit
4/feeder
Safety monitor Board
45
defective(test run) MB04A
Speed signal fault, door
70
control
Speed signal fault, Board
71
electromag track brake EB01A
72 Fault at one wheelset
Fault at several
73
wheelsets

Handbook on WSP System CAMTECH/GWL

No.IRCAMTECH/2011/Mech/WSP/1.0 35

Problem Connected
Display Fault
Source with
Board
74 Safety monitor fault
MB04A
Activation fault,
Board
c8 cumulative fault
EB01A
signaling
Connector defect board Board
S2
EB01A EB01A
Connector defect board Board
S3
MB04A MB04A
8888 Display test
89 Test running
95 Volatile faults
99 System good

Handbook on WSP System CAMTECH/GWL