Electronic Interlocking

S 18 ELECTRONIC INTERLOCKING

Issued in November 2009

INDIAN RAILWAYS INSTITUTE OF SIGNAL ENGINEERING & TELECOMMUNICATIONS SECUNDERABAD - 500 017

S-18 ELECTRONIC INTERLOCKING CONTENTS S. No

Chapter

Page No

1

Introduction to Electronic Interlocking

1

2

MICROLOK-II EI system

14

Annexure-I

Electronic Interlocking Spec. No: RDSO / SPN / 192 / 2005

49

Annexure-II

Items of Microlok-II EI system (Centralised version) for a typical 4- Road Station

65

Annexure-III

Items of “ All Indoor Works for provision of Microlok-II EI system (Distributed version with OFC) at Stations of Indian Railways”

70

Annexure-IV

Technical Specifications of E.I.

72

Annexure-V

Failure summery of Electronic Interlocking system at Stations of Indian Railways

81

Annexure-VI

Factory Acceptance Test and Site Acceptance Test of Microlok II

85

Annexure-VII

SIMIS S EI system

101

Annexure-VIII

ESA11- IR Electronic Interlocking System Manufactured by AZD Praha

122

Annexure-IX

GE system of Electronic Interlocking

131

Annexure-X

Pre-commissioning Checklist

136

Annexure-XI

Review Questions

144

Drafted By

P. Raju, IMS-2 , S.V.K. Hanuman, IES-5

Checked By

Jyotirmoy Ray, Asst Prof /Sig

Approved By

Ch. Mohan, Sr. Prof / Sig

DTP and Drawings

P.V. Surya Narayana, JE I (D)

No. of pages

145

Date of Issue

November 2009

Version No

A4

© IRISET “ This is the Intellectual property for exclusive use of Indian Railways. No part of this publication may be stored in a retrieval system, transmitted or reproduced in any way, including but not limited to photo copy, photograph, magnetic, optical or other record without the prior agreement and written permission of IRISET, Secunderabad, India”

http://www.iriset.ac.in

INTRODUCTION OF ELECTRONIC INTERLOCKING

CHAPTER 1 : INTRODUCTION 1.1

Introduction of Electronic Interlocking :

The era of interlocking started with mechanical lever frames. As the size of yards & train movements increased, size of lever frames also increased. These lever frames not only increased in size occupying more space but also required intensive maintenance. With the advent of Electro-mechanical relays, these lever frames gave way to relay interlocking based installations. This development resulted in relatively faster operation, fail safety in operation and reduced size of buildings required for housing of interlocking installations. With further increase in traffic and expansion of railway network, large number of Route Relay Interlocking and Panel Interlocking installations were commissioned. Route Relay interlocking (RRI) and Panel Interlocking (PI) installations use Electromechanical relays requiring complex wiring and Inter-connections. The wiring diagrams for such installations run into hundreds of sheets. Individual relays, wiring and interconnections along with thousands of soldered joints are required to be physically examined and certified. This exercise requires traffic blocks of long durations and large manpower to manage the traffic during blocks. Even for small yard re-modeling like addition of a loop line, all the above activities are required to be redone. Therefore, the advantages of relay based interlocking installations are being nullified. With development of modern fault tolerant and fail safety techniques, electronics and particularly microprocessors have found acceptance in the area of railway Signalling world over. Railways in advanced countries of Europe, North America & Australia have gone for large scale introduction of microprocessor based Electronic Interlocking system (EI). This system occupies considerably less space, consumes less power, is more reliable and is easy to install and maintain. Also, initial commissioning & changes due to yard re-modeling can be carried out in negligible time requiring skeleton manpower for traffic management during the blocks. EI is a computer based electronic interlocking system, used for controlling points, signals, level crossing gates etc, through a centralized control panel or through VDU, like existing relay based/ mechanical interlocking systems. (Microprocessor or Micro controllers are used in EI’s.) . Based on a proposal for development of Electronic Interlocking System, submitted by IIT Delhi to DOE, a project was started at IIT Delhi in July 1983. Two Officers from Railways were posted on this project to IlT, Delhi. Two industries (M/s DCM & CGL) were also associated in development and fabrication of the prototype. A design of the system was evolved in March 1985. The design was evaluated through software simulation at IIT Delhi and a prototype based on this design was fabricated in 1987. RDSO and DOE funded the project for design, development and prototype fabrication jointly. The prototype was installed at Brar Square Station of Northern Railway for field evaluation. Based on field trial results, it was decided by Railway Board to manufacture four engineering models incorporating necessary improvements. Railways and DOE funded these jointly on 50:50 basis. Thereafter, design and fabrication of SSI Mark-II system was taken up by RDSO in association with lIT, Delhi. Brief history of EI s in Indian Railways is follows. (a) First EI (Microlok I ) is installed at Srirangam (SR) in 1987. (b) First indigenous EI – Installed at Brar Square (NR) – (Parallel operation)-1987-88 (c) First indigenous EI – Installed at Dushkheda (CR) – Stand alone – October, 1995 DCM. (d) Second indigenous EI – Installed at Bhadli (CR) – Stand alone – March, 1997 CGL. (e) Third indigenous EI – Installed at Uppugunduru (SCR) – Stand alone – Warm standby - April, 1998 - RPIL. More than 350 EI have been installed in Indian Railways so far of various makes and 75 more in various stages as on 2009-10.

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INTRODUCTION

1.2 Advantages of Electronic Interlocking System: (a) System can be tested at factory level using simulation panels. (b) Non-Interlocking period is less (Typically few hours instead of few days.) both for initial installation and also for yard alterations (which can be done using application software compiler which is user friendly.) (c) Modular in design and easy for maintenance, thus requiring less staff . Expertise of hardware and software is not much needed for maintaining the equipment at initial stage. (d) Requires less number of relays - vital EI replaces interlocking circuits Thus less space required for signal equipment room (Relay rooms). (e) Less power supply as compared with existing PI/ RRI’s. Less failures, less wiring, less soldering, less complexity in the circuit. (f) Enables usage of OFC (with Object Controller) which reduces requirement of Copper cables , their cost & maintenance. (g) Remote operation of signals, points, and level crossings controls is feasible. Thus Compatible with centralized traffic Control. (h) All EI’s are designed and manufactured as per the international safety committees – such as CENELEC STANDARDS (European countries). (i)

Standard of safety and reliability is higher as compared with existing relay interlocking systems (PI/RRI).

(j)

Datalogger / Event logger is an integral part of EI.

(k) Self-diagnostic in feature: i.e. error code/ alarm code messages will be displayed on display cards or on the front panel of printed circuit boards. Hence easy for rectification of failures and reduces the failure duration.

Policy on type of Interlocking to be adopted : Board has decided the following policy to be adopted on IR vide Board’s letter Nos. 2003/Sig/G/5 dt. 10-09-2003 and 2003/Sig/G/5/Pt. Dated 30th January, 2006 Up to 50 routes

Relay based interlocking of Metal to Carbon or Metal to Metal type according to the expertise available on the railway. (In special cases, EI may also be adopted in installations below 50 routes on a case to case basis. Such proposals for EI at signalling installations below 50 routes have to be justified on a case to case basis based on life cycle cost including capital cost, annual maintenance cost, depreciation provision, saving due to avoidance of repeated relay wiring due to anticipated yard remodeling etc. and concurrence of the associate finance obtained.)

50 to 200 routes

Electronic interlocking.

Above 200 routes

RRI with relay based interlocking of Metal to Carbon or Metal to Metal type according to the expertise available on the railway. ( Note : Bd has directed RDSO to finalise new Specification for EI for above 200 routes also vide Lr No .2008/SIG/SGF/4 /EI /GEN dt 29/07/09)

Note :- The above policy will be applicable to all new works and such of those sanctioned works where detailed estimates are not yet sanctioned.

IRISET

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VARIOUS TERMS USED IN E I

1.3 Various Terms used for EI’s:(a) CPU – Central Processing Unit ( Micro processor or Micro controller) (b) RAM – Random Access Memory (used for vital data processing and event / error logs) (c) EPROM –Erasable Programmable Read Only Memory. (used for storing Executive and Application software) (d) EEPROM – Electrically Erasable Programmable Read Only Memory. (used for storing Executive and Application software) (e) OBJECT CONTROLLERS (OC): (i) Object controller is the equipment which drives the field function through conventional Relay or directly through its own electronic circuitry. It also takes inputs from the field. (ii) Object Controllers drive the field gears (Points, Signal etc.,) through relays and take feedback (input) from various field gears (Track, Point Indication, Aspects etc) through concerned relay contacts. (iii) Object Controllers are used as slave unit of Main system . (iv) Object controller and Main system can be connected by copper cable or Optical Fiber Cable (OFC) or wireless. (v) By using Object Controllers Main signalling cables between Equipment Room (Relay Room) and Location Box of field functions can be eliminated.

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INTRODUCTION

Different types of Electronic Interlocking Systems currently used in Indian Railways.

Manufacturer

MODEL

RDSO/SPN/ 192/2005 clause No

Hardware Redundancy

Software Diversity

Standby arrangement HotWarm standby standby

US & S

MICROLOK-II

7.1 (a)

NO

YES

NO

YES

SIEMENS

SIMIS S (See Annexure-VII)

-

NO

YES

YES

YES

WESTING HOUSE

WESTRACE

7.1 (a)

NO

YES

YES

YES

AZD-PRAHA

GE ALSTOM KYOSAN

IRISET

ESA 11- IR (See Annexure-VIII)

VHLC (See Annexure-IX) ASCV SMARTLOK

-

2 out of 2

YES

At control level Processor

At command level and I/O cards level processor cold stand by

7.1(b)

YES

YES

NO

YES

-

NO

YES

YES

YES

2 out of 2

NO

KB-5

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Some of the installations ECoRly, Walter division of Kottavalsa - Vizianagaram Palasa section, Pundi, Naupada, Kotabomalli, Tilaru, etc., SCRly, Mahaboob Nagar (HYB division); WRly, Rajkot Division of Sabli Road, Leelapur Road, Lakhtar, Bala Road, Vani Road, etc., SERly, CKP division, Mahalimarup station.

SC division, BZA-BBQ Section SCRly,-12 Nos

CRly, PA division, KOP-KRD section, SNE, Shirwade, etc., DMRC On BRC Division, Western Railway, 7 Kyosan Systems of have been installed in 2005-2008

CLASSIFICATION OF EI’S

1.4 Classification of EI’s: Depends on redundancy EI’s are classified as : (a) Software Redundant. (b) Hardware Redundant. 1.4.1

Single Hardware with software redundancy. Ex: (i)

MICROLOK -II US&S.

(ii)

WESTRACE – WESTING HOUSE

(iii)

VPI – Vital Processing Interlocking – ALSTOM.

(iv)

ASCV (SMARTLOK) – ALSTOM.

(v)

SIMIS S - SIEMENS EI

With this configuration hot standby or warm standby with auto changeover arrangement is required. 1.4.2 Dual Hardware with Hardware redundancy – 2 out of 2 system. Ex: (i) VHLC – GE Transportation (ii) SICAS S5 – SIEMENS EI (iv) ESA 11 – AZD Praha (vi) ESA 12 – AZD Praha (vii) EBI LOCK 850 – Bombardier Transportation. With this configuration hot standby or warm standby with auto changeover arrangement is required. Software used in both hardware may be identical or diverse. 1.4.3 Triple Modular redundancy - Hardware redundant - 2 out of 3 system Ex: (i)

ALSTOM – SSI

(ii)

SIMIS –W - SIEMENS

(iii)

SICAS – SIEMENS

(iv)

ESTWL90 – ALCATEL

In this TWO out of THREE hardware (identical) system Software used in hardware may be identical or diverse.

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INTRODUCTION

1.5 TYPICAL HARDWARE USED IN EI 1.5.1 Any computer-aided systems require the study of both hardware and software of the system. Study of hardware involves the study of components; printed circuit boards (PCB’s) provided in the computer aided Signalling system. Software (Program) is a set of instructions given to a microprocessor (computer). A brief description of common hardware features for different Electronic Interlocking Systems are discussed as follows. 1.5.2

Common Features of Hardware: (a)

Electronic Interlocking System is a microprocessor based electronic device with fail-safe information processing used in place of conventional relay interlocking systems.

Fig.No.1.1 (a) Input Cards : All the field conditions (i.e. Field relay contacts) are connected to these input cards of EI system. The maximum inputs capacity of each RI card will depend on design of the RI cards by different manufacturers. The total number of inputs will depend on the yard layout. Total inputs means: (i) Field inputs (ii) Panel inputs

:

ECRs, TPRs, NWKR etc.

:

GNs , UNs, NWNs, RWNs, etc.

(iii) Read back inputs :

HR, DR, WNR, WRR etc

Opto couplers are provided to isolate field optically from the system in Input cards. These cards will read the conditions of inputs and passes the information to EI system.

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COMMON FEATURES OF HARDWARE

(b) Processor card: This card is also called as central processing unit card of the System. This is provided with microprocessor, RAM, ROM, EPROM, EEPROM Memory IC’s. These EEPROMS or EPROM’s (ROM’s) are programmed with software required for executing the system commands. System software consists of the following: -

Executive software programmed in system EPROM’s

-

Application software programmed in DATA EPROM’s.

Executive Software

Application Software.

This software is common to all EI’s for the This software is specific to each station. same company manufacturing. Different for different stations. Factory installed software

This is as per table of control of specific station

Performs all operations

Can be installed at site by signal engineers.

Cuts off vital supply voltage to output Logic installed through Boolean expressions relays, in case of unsafe failures. or user-friendly equations. In all EI installations, DATA EPROM’s are to be replaced with new DATA EPROM’s at the time of yard alteration works. i.e. yard data as per new table of control software is to be programmed in the EPROM’s For doing yard alterations as per the new table of control (interlocking) EI compiler software is used. Some manufacturers are providing EEPROMs, in which program can be erased electrically and reprogrammed with new software as per new changes using a debug port. Function of CPU Card : This card will execute the commands given by the user (station master/panel operator). Whenever the panel operator operates the push buttons, the relevant push buttons will be operated. Processor card will sense the operation of the panel operation of the panel operator (through inputs cards) and process according to the program available in EPROMS and finally gives output if the conditions are favorable (i.e., field condition relays are favorable as per principle of interlocking). The output voltage generated by the CPU card will be connected to Relay output cards. Before sending the output-to-output relays safety checks will be done internally. Output card (Relay Drive Card): This card receives the output of CPU card as input and picks up relevant output relay as per the panel operators’ request. The output of this card is terminated on phoenix terminals from there the output relays are connected.

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1.5.3

Basic Principle of Hardware design :

The Basic principle of design is shown in Fig.No.1.2. Input/output cards, and CPU card with RAM and ROM are inter connected.

Fig No: 1.2 System Bus for information (data) exchange. Input cards gives information of all inputs to system Bus. CPU card will read the status of inputs and output cards are connected to output relays for operating the circuits (i.e., signal lamp circuit, point operation circuit, CH slot circuit etc). CPU will execute the panel commands as per the program stored in the memory chips. During execution of commands it reads the status of all inputs and writes on the RAM. After processing the interlocking logic the output is written in RAM and then according to a fixed program, these are written to the output registers of the output cards through which output relays are actuated. 1.5.4

Safety and Reliability of Hardware :

Prime objective of EI design for Railway Signalling shall be, to obtain fail safe features similar to that obtainable in relay interlocking systems which are already existing. Microprocessor based equipment cannot be designed to work on fail safe principle at all times. Therefore, reliability has a much more importance role to play which is achieved by redundancy. Fail-safe EI system can be obtained only when it is made possible to detect any fault in the system instantly on occurrence to apply remedial measures. The output of the system should be cut off whenever the system detects any unsafe condition. So, all the EI’s should have self-diagnostic features so as to achieve fail to safety condition. To ensure safety and reliability there are three approaches to the hardware (redundancy) design of EI’s globally. (a) Single processor system – with extensive safety checks. (b) System with redundancy (two out of two) – failsafe (c) System with redundancy (two out of three) failsafe and failure tolerance.

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TESTING AND VALIDATION

1.6

TESTING AND VALIDATION

Testing and validation of a microprocessor based safety system is carried out in four stages as described below: Stage-1 Theoretical design of the hardware and program structure of the software are examined for reliability and fail-safety at the initial design level. Stage-2 Each card or the circuit module of the hardware is tested under normal as well as fault conditions. In the case of software, each routine is tested with diverse test data. Stage-3 Overall system, after integration of hardware and software is tested under different input data conditions. Testing at this stage can be carried out by simulation for accelerated testing using computers. Stage-4 Exhaustive field trials of the equipment is conducted under the field conditions.

1.7

REQUIREMENTS FOR ORDERING OF ELECTRONIC INTERLOCKING SYSTEM

While ordering EI, purchaser is required to furnish the following documents to the supplier: (a) Approved Interlocking Plan (b) Approved Panel / Front Plate Diagram (c) Selection table. After installation at the station, functional testing shall be done by the purchaser as per the Selection table.

1.8 CRITERIA FOR THE SELECTION OF EI SYSTEM The main criterion for the selection of EI System is its reliability, availability, maintainability & safety apart from meeting full functional requirements. The main features are: (a) System should meet functional requirements and have future expandability. (b) Meet the requirements of environmental conditions, electromagnetic interference, etc. (c) System should be user friendly and economical (example – object controller for yards). (d) System architecture should be such as to give very high overall availability while ensuring high degree of safety. (e) System validation to international standards to meet safety integrity level 4 (defined in CENELEC Standards). To meet above main requirements, various architectures have been suggested in Para 7.1 of the specification No. RDSO/SPN/192-2005.

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INTRODUCTION

1.8.1 Block diagrams of various available systems is given below: (a)

Single Hardware with software redundancy:

Fig : Single Processor without any Standby

SINGLE PROCESSOR WITH STANDBY (TWO EI’S CONNECTED IN PARALLEL) Fig No :1.3 (b) Dual Hardware with Hardware redundancy – 2 out of 2 system:

DUAL HARDWARE WITHOUT STANDBY Fig No : 1.4

IRISET

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BLOCK DIAGRAM OF VARIOUS AVAILABLE SYSTEMS

DUAL HARDWARE WITH WARM STANDBY Fig No : 1.5

DUAL HARDWARE WITH HOT STANDBY Fig No : 1.6

DUAL HARDWARE WITH OBJECT CONTROLLERS Fig No : 1.7

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c) Triple Modular Redundancy (TMR) - Hardware redundant - 2 out of 3 system:

TMR WITH RELAY INTERFACE Fig No : 1.8

TMR WITH OBJECT CONTROLLERS Fig No : 1.9

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VARIOUS DESIGN ASPECTS OF SYSTEM

1.8.2 Various Design aspects of the System to achieve viability & safety: Design of electronic Railway Signalling Equipment based on processor and/or software has to ensure that safety integrity of whole system/sub-system is maintained through out the life of the equipment. Safety integrity is specified as one of 4 discrete levels by IEC/CENELEC Standards. Level-4 has highest level of safety integrity. For Safety Integrity Level - 4, dangerous failure rate per hour for continuous mode of operation should be less than 10-10. Safety integrity of any system covers mainly two components: (a) Systematic failure integrity. (b) Random failure integrity. It is necessary to specify both the Systematic & Random failure integrity requirements of the system if adequate safety is required to be achieved. 1.9 European Committee for Electro technical Standardization (CENELEC) has come up with several Standards, out of which, the following are to be considered for any Electronic component – based Railway Signalling equipment. EN 50121

--- Electromagnetic Compatibility (EMC).

EN 50126

--- Railway applications - The Specification & Demonstration of Reliability, Availability, Maintainability and Safety (RAMS).

EN 50128

--- Railway applications - Software for Railway Control and Protection Systems.

EN 50129

---

Railway applications - Safety Related Electronic Systems for Signalling.

Besides these Standards if Communication Line is used in Railway Signalling as in the case of Block Signalling or Axle Counter, another Standard. EN 50159 --- Signalling and Communications — Safety-related Communication -- is also to be considered. EN50126 for RAMS fail-safe systems like EI, ATP, AFTC are verified and validated to SIL- 4 standard of EN50129 and EN50128.

***

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MICROLOK - II : EI SYSTEM

CHAPTER 2: MICROLOK - II - EI SYSTEM 2.1

Introduction:

Microlok is a trade name of US&S currently known as Ansaldo STS India Pvt Ltd. Initially Microlok I was introduced in early 1990 s . The current version is Microlok II , which is a multipurpose monitoring and control system for line side interlocking equipment. With this system we can have Direct control of wayside signals, Control and monitoring of Point Machine, Control and monitoring of track circuits Vital communication to other compatible interlocking systems and Cab signalling. The hardware used in Microlok II (MLKII), various aspects of design, installation, testing, commissioning and maintenance of MLKII with the update post commissioning changes in yard is detailed as under :-

2.2

Hardware used in this system: Microlok II equipment consists of : (a) (b) (c) (d) (e) (f) (g) (h)

2.3

Card file. CPU PCB. Power Supply PCB. Vital Output PCB. Vital Input PCB. Non-Vital-Input / Output PCB. VCOR- Vital Cut Off Relay. Wiring hardware

Software used in this system:

2.3.1 Executive Software: Executive software used in this system does the following functions. (a) Monitoring all Vital and Non-vital cards. (b) Processing inputs, decision making and issuing commands. (c) Continuous internal and external diagnostics. (d) Management of serial data ports. (e) Execution of application software. All Microlok II CPU boards are shipped with executive software loaded in memory. Upgrade is possible using Maintenance Tool. 2.3.2 Application Software: User develops Application Software based on Interlocking requirement and Yard Size.

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HARDWARE USED IN THIS SYSTEM

FRONT VIEW OF MICROLOK-II SYSTEM Fig No : 2.1

REAR VIEW OF MICROLOK-II SYSTEM Fig No : 2.2

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MICROLOK - II : EI SYSTEM

2.4

Hardware:

2.4.1 Card File:

Power Supply card

1

2

CPU card

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Vital Input, Vital Output, Nonvital I/O cards.

CSI card

20

Microlok-II Card file layout Fig No: 2.3 Each card file is like a shelf having 20 Slots to accommodate various PCBs that are used in a system. Slot nos.1 to 15 and 20 are used to accommodate Non-vital Input-output or Vital Input or Vital Output PCBs. Slot no.16&17 are used to accommodate Power supply PCB. Slot no.18&19 are used to accommodate CPU PCB. In this cardfile a mother board is available in the rear side connecting all the 20 Slots. This cardfile is suitable to mount on a 19” rack. 2.4.2 CPU PCB Each card file to have one CPU PCB and always placed in slot no.18&19. In this card Micro Controller used is Motorola 68332 and its speed is 21 MHz. In this card, 4 nos. of flash EPROMs of 8 MB are used to store executive and application software, Two nos. of fast Static RAM (each 64KB) are used to process the vital data and Four nos. of Static RAM (each 64KB) are used to store events and errors. It has Five serial ports to communicate with peripheral devices. Ports 1 & 2 are RS 485 types to interface with vital control system such as MLKII. Port 3 is RS 432 type for other Nonvital control systems such as operators PC. Port 4 is RS 232 type for other Non-vital control systems such as indication panel / Genesys. Port 5 is used to interface with Maintenance PC provided with maintenance tool software, exclusively for diagnostic purpose. The main functions of CPU is described as under: It monitors continuously status of Vital Boards. It also monitors system internal operation for faults and responds to detected faults. It processes application logic based on inputs received and deliver outputs to drive external gears. It records system faults and routine events in user-accessible memory. It monitors and controls the serial communication ports. It controls power to vital outputs through external VCOR relay.

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CPU PCB

CPU Board Front Panel Layout Fig No : 2.4

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Various indications/buttons available on front side of the CPU card is tabled below. CPU Printed Circuit Board ( Refer Fig : 2.4 )

Fig No:2.2

LABEL

DEVICE

1,2

(None)

4 – Character alpha numeric displays

3

A,B,C,D,E

Yellow LED s

4

1,2,3,4,5,6,7,8

Red LED s

5

ON LINE

Green LED s

When lit , indicates normal system operation (successful diagnostics)

6

VPP ON

Yellow LED

When Lit , indicates FLASH + 5 V or +12 V programming voltage enabled (via board jumper)

7

RESET

Red LED

8

RESET

Momentary Push Button

When Pressed , RESETs the CPU. Also used to replace the CPU in the RESET mode.

9

MENU

3 – Position (Return to Centre) toggle switch

Used to search main program menu items shown on displays.

3 – Position (Return to centre ) toggle switch .

Used to select main program menu items shown on displays.

3 – Position (Return to Centre) toggle switch

Used to cycle through configuration values to be selected with ACTION switch.

3 – Position (Return to Centre) toggle switch

Executes or Cancels configuration value selected with ADJUST switch.

L-R 10

MENU UP- DOWN

11

ADJUST UP-DOWN

12

IRISET

ACTION ACCEPTREJECT

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PURPOSE

On site Configuration programming menus and options Reserved for serial link status User- defined in application software

When Lit , Indicates that the system is in RESET mode.

POWER SUPPLY PCB

2.4.3

Power Supply PCB:

Each card file to have one Power Supply PCB and always placed in slot no.16&17. Power supply PCB is basically a DC-DC converter that converts 12V DC input supply is +12V, -12V and +5V required for various board functioning. Based on diagnostic check by CPU, Power Supply Card receives 250Hz signal from CPU and extends supply to VCOR relay. This card provides isolated supply to internal circuit. System Operating Power Power Input to System Cardfile Voltage Range

Nominal Voltage

9.5 to 16.5 12V dc VDC

Min. Sys. Maximum Start-Up Ripple

Current Draw

11.5V dc

Determined by Installation (No. of signal lamps, cab carrier frequency, etc.)

0.5V P-P

Cardfile Power Supply Printed Circuit Board Outputs* For System Cardfile PCB 5V Internal Circuits

For System Cardfile PCB 12V Internal Circuits

To VCOR Relay

+5V @ 3A

+12V @1A, -12V @ 1A

+12V into 400 Ω Coil

* Not used to power vital or non-vital external devices or circuits

The table below is a list of the worst-case current draws for Microlok-II system boards:

BOARD

CONDITION

+ 5V

+ 12 V

- 12 V

IN16 N17061001

16 LEDs

170 ma

-

276ma

OUT16 N17060501

16 LEDs

155 ma

6 ma

-

IN8.OUT8 N17061601

16 LEDs

150 ma

4 ma

147ma

CPU N17061301

No serial links ON 840 ma

4 ma

12 ma

CPU N17061301

Serial link ON

1000 ma

4 ma

12 ma

NV.IN32.OUT.32 N17000601

64 LEDs ON

576 ma

-

-

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POWER SUPPLY CARD Fig No : 2.5

IRISET

OUTPUT CARD Fig No : 2.6

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VITAL OUTPUT PCB

2.4.4 Vital Output PCB: Each Vital Output PCB has 16 Outputs. It is available in 12V and 24V DC applications. Each Vital Output can drive an output device such as any Q-series relay. This output relay in turn controls signals, points, crank handle, siding control, level crossing etc. Since Vital Output drives the relay, which controls important outdoor gears, all the Vital Output boards are continuously diagnosed by a CPU. Any abnormality in any of the outputs will shut down the system to ensure safety. The status of vital output is known from LEDs available in front of the PCB. Vital Output PCB

VCOR Relay

Standard Vital Output card (24V)

B 24

Output “X”

Controlled External Relay

Poly switch Protected Output “Contact”

N24 Analog Ground

CPU Control Standard Vital Output Fig No : 2.7

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2.4.5 Vital Input PCB: Each Vital Input PCB has 16 Inputs. It is available in 12V and 24V DC applications. Each Vital Input is assigned to read the status of outdoor gears such as Track circuits, Point detectors, Crank handles, Siding controls, level crossing etc. Since the Vital Inputs read the status of outdoor gears, they are normally configured with double cutting arrangement using relay contacts. The status of Vital Input is known from LED indications available in front of the PCB.

INPUT CARD Fig No : 2.8

IRISET

Non-Vital Input-Output Card Fig No : 2.9

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NON-VITAL INPUT/OUTPUT PCB

2.4.6 Non-Vital Input/output PCB: Each Non-vital I/O has 32 inputs and 32 outputs in one PCB. It is available in 12V and 24V DC applications. Non-vital inputs are Panel push buttons and keys. Non-vital outputs are Panel indication LEDs, counters and buzzers. The status of Non-vital Input/output is known from LED indications available in front of the card. 2.4.7

Vital Cut off Relay- VCOR:

Each card file will have one VCOR to ensure the healthiness of the system. VCOR has 6 F/B dependent contacts each rated for 3 Amps. When system is healthy the coil receives voltage from PS PCB, which in turn controlled by CPU. Power to Vital output board is controlled by VCOR, thus ensuring safety.

Vital Cut-Off Relay (VCOR) Fig No : 2.10 2.4.8 Lightning & Surge protection arrangements in MicrolokII •

The interfacing of CCIP with I/O gatherer cardfile is on PIJF cable. GD tubes have been provided at T1 rack for protection of Non-vital Input /output boards against surge, transient / lightning. GD tubes (EPCOS EC90) have been connected at non-vital input from panel and non-vital output to panel and grounded with system equipotential earth.

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Microlok Non Vital Output Filter is a surge protective device which protects the non vital output board from electrical surges caused by lightning or power faults in Microlok system.

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An augmented surge protection arrangement (external protection box) introduces surge suppression for the Non Vital Board output lines safeguard the system against lightning surges & other switching surges:

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(S18) ELECTRONIC INTERLOCKING

MICROLOK - II : EI SYSTEM

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Every Non Vital Board output line is provided with 30V Tranzorb (1.5KE30A) and MOV (V36ZA80). The Tranzorb is connected to the +24V DC signal line & MOV is connected to the 24V DC Common line.

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Every Non Vital Board output line is provided with GD Tube (CG2 145L) and MOV (V36ZA80). GD Tube is grounded to the earth & MOV connected to the 24V DC Common line. The RS-5 Resistor is provided in each of the output lines which is capable of withstanding 5 joules energy.

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The external protection box also provides protection to the 24V common line for every Non Vital board. Every 24V common line is provided with 30V Tranzorb (1.5KE30A) and MOV (V36ZA80). The Tranzorb connected to the +24V DC signal line & MOV connected to the 24V DC Common line. The RS-5 Resistor is provided in each of the output lines which is capable of withstanding 5 joules energy.

(* Extract of RDSO Guidelines vide L.No.STG/IH/ML dt.10.07.09) Consequent to damage of Microlock-II EI due to lightning at a few stations on ECoR, implementation of an earthing improvement scheme comprising of following three stages was decided. Zonal Railways and the firm were accordingly advised vide this office letter of even no. dated 14.03.2008. Stage 01 -

Shielded cable between Termination Rack and Control Panel is to be properly grounded at the Termination side. Microlock-II Racks which are having epoxy coating will be provided with copper foil. Separate DC 24V supply to be used for Microlock-II cooling fan. Ensuring proper copper connection of Room Earth Bar and Earth points Ensuring earth resistance value