BPAC WITH UFSBI GENERAL PRESENTATION 18_05_2017-1.pptx

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1. A Presentation On Block Working Using Push Button Type Block Proving With Axle Counter Using UFSBI & SSDAC

2. Introduction It is a non-co-operative, user-friendly push button type Block Instrument capable of providing the last vehicle detection in both single & double line sections. The Block Panel provided, offers audio-visual indications for all vital information. The interlocking circuits and input/output through Q-series relays provide galvanic isolation, making the system suitable in both RE & Non-RE sections. The system is media independent i.e. it works on Copper cable, OFC or microwave without hampering the fail-safety of the operation . The system is triple modular redundant which means increase in availability. This system also holds the final status using latch relays so that during Power supply or any failure it remains in last operating state.

3. Why do we need a New Block Instrument to work in multiple communication media like OFC / Microwave & Copper conductor on long Block Section ? With increased traffic density, there is a need for Block Instruments that can work in these different communication media for high reliability as cable cuts are the major cause of prolonged block failures. The most important part is the total system (Including UFSBI, Axle Counter and Telephone) can now work on DARK FIBRE also. We need 3 cores (out of 24 Cores) for Single Line and 4 cores for double line Block operation. Hence it requires no STM or Primary Multiplexers . Introduction

4. What is the advantage of having a Push Button type Block Panel for operation ? A. It is basically non cooperative type and Easy to operate & maintain . What is the use of Axle Counter in Block Proving ? A. The main use of Axle Counter is Block Occupation / Free verification & Last Vehicle Check .

5. Brief System Description & Working The system works as per Absolute Block system, incorporating the features of Block Proving by Axle Counter to control the movement of trains on block section from one block station to another. Principle of working The trains are worked on Absolute Block system. Each block section is provided with an Axle Counter to verify the occupation or clearance of block section and indicated on Block Panel. It is not possible to obtain Last Stop Signal to ‘OFF’ unless “LINE CLEAR” has been obtained from the station in advance. It is not possible to take “LINE CLEAR” unless block section and an adequate distance beyond first stop signal of station in advance is clear of trains.

6. The Last Stop Signal assumes ‘ON’ aspect automatically on entry of train into block section and retains this ‘ON’ position, till a fresh “LINE CLEAR” is obtained. Block section automatically shows “TRAIN ON LINE” on block panel when a train enters into the block section on “LINE CLEAR”. Audio – Visual alarms for Train entry/exit, to/ from block section are provided and are to be acknowledged. “LINE CLOSE” feature is automatic after complete arrival of train. “LINE CLEAR” cannot be taken without taking consent of receiving station. “LINE CLEAR” cancellation is Co-operative.

7. Comparison between different block instruments Double Line SGE Type Single Line IRS type Push Button Block Instrument Single Line Tokenless Handle Type TLBI (IRS S 98-2001) BPAC (Block Panel & UFSBI) RDSO/SPN/188/2004 Block Operation Rotary Commutator Type Push Button Type Rotary Handle & Block Needle type Push Button Type Block Media Copper Cable Copper Cable Copper Cable Copper Cable / Voice channel of P-Mux / Microwave / E1/ Dark Fiber Block Commication DC earth return type Electrical Pulse Coding Analog FM TX-RX Fail-safe Digital Communication at 2400 bps . Optional Media fall-back with Auto Media C/O Block Length 10-12 Km (typically) 10-12 Km (typically) 10-12 Km (max.) on 0.9mm Quad cable Upto 25 Km (typically) on 6Q-Cable Upto 50 Km typically on OFC Upto 30 Km typically on mW Radio

8. Double Line SGE Type Single Line IRS type Push Button Block Instrument Single Line Tokenless Handle Type TLBI ( IRS S98-2001 ) BPAC (Block Panel & UFSBI) RDSO/SPN/188/2004 RE Compatibility workable in RE area Non- workable in RE area Workable in RE area Workable in RE area Time for taking Line Clear, TOL & Line Close 1 – 2 min. (approx.) 20 – 30 sec. (approx.) 2 to 3 min. (approx.) 1-2 sec. (max.) Last Vehicle Verification & Line Close Manual Manual Manual Automatic (Auto TOL & Auto Line Close) Operator Involvement per train movement 3 times (taking Line Clear, Putting system to TOL and then Line Closing) 2 times (taking Line Clear and then Line Closing) 2 times (taking Line Clear and then Line Closing) Only once ( for taking Line Clear) Comparison between different block instruments

9. System Components The System comprises of the following items as per RDSO/SPN/188/ 2004 BLOCK PANEL (As per drawing no. RDSO/S 32019 ) (1 PAIR) UFSBI (As per RDSO/SPN/147/2005 with ammdt . 1 ) (1 PAIR) RELAY RACK (As per drawing no. RDSO/S 32020) (1 PAIR) Block Telephone (As per RDSO/SPN/191/2006 ) (1 PAIR) Single Section Digital Axle Counter (As per RDSO/SPN/177/2003 ) (1 PAIR)

10. System Components The System comprises of the following items as per RDSO/SPN/188/2004 BLOCK PANEL (As per drawing no. RDSO/S 32017) (1 PAIR) UFSBI (As per RDSO/SPN/147/2005 with ammdt . 1 ) (1 PAIR) RELAY RACK (As per drawing no. RDSO/S 32018) (1 PAIR) Block Telephone (As per RDSO/SPN/191/2006 ) (1 PAIR) Single Section Digital Axle Counter (As per RDSO/SPN/177/2003 ) (2 PAIRS)

11. LINE CLOSE Indication : Yellow TRAIN COMING FROM Indication: Green TRAIN GOING TO Indication: Green TOL Indication: Red Cancel CO-OP Indication: Yellow Cancel Indication: Yellow SNK Indication: Yellow SNOEK Indication: Yellow LSS Indication: Red LSS Indication: Green LINE FREE Indication: Green LINE OCCUPIED Indication: Red SHK IN Indication: Green SHK OUT Indication: Red MUX / UFSBI Status OK Indication:Green MUX / UFSBI Status Fail Indication: Red Communication Link Fail Indication: Yellow INDICATIONS 445 350 550

12. PUSH BUTTONS,KEYS & COUNTER “Bell” Button: Black “Train Going To” Button: Red “ACKN” Button: Black “Cancel Co-op” Button: Green “Cancel” Button: Yellow “ Shunt Release” Key SMs Key Counter Cancellation Call attention Buzzer Intermittent Train Entry / Exit Buzzer Continuous

13. LINE CLOSE Indication (UP & DN): Yellow TRAIN COMING FROM Indication: Green TRAIN GOING TO Indication: Green TOL Indication (UP & DN): Red Cancel CO-OP Indication: Yellow Cancel Indication: Yellow SNK Indication (ADVANCE & HOME): Yellow SNOEK Indication: Yellow LSS Indication: Red LSS Indication: Green LINE FREE Indication (UP & DN): Green LINE OCCUPIED Indication (UP & DN ): Red MUX / UFSBI Status OK Indication: Green MUX / UFSBI Status Fail Indication: Red Communication Link Fail Indication: Yellow INDICATIONS (DL)

14. PUSH BUTTONS,KEYS & COUNTER (DL) “Bell” Button: Black “Train Going To” Button: Red “ACKN” Button (UP & DN): Black “Cancel Co-op” Button: Green “Cancel” Button: Yellow “LCB” Key SMs Key Counter Cancellation Call attention Buzzer Intermittent Train Entry / Exit Buzzer (SENDING) Continuous Train Entry / Exit Buzzer (SENDING) Intermittent

15. UFSBI The UFSBI system is a digital multiplexer used for communicating the status of relay(s) between stations in a fail safe manner. The communication is full duplex. The medium of communication is voice / data channels on Optical fibre or copper cable. The multiplexer with its accessories, relays and power supply are housed in a cubicle. Parts of UFSBI : DC-DC Converter UFSBI-DS Relay Rack

16. UFSBI CUBICLE FRONT VIEW BACK VIEW

17. DC - DC CONVERTER Input 24V DC +20% - 10%, 10 Amps Output 24V DC 4 Amps 5V DC 4 Amps +12V DC 1.5 Amps –12V DC 1.5 Amps DC – DC CONVERTER FRONT VIEW DC – DC CONVERTER BACK VIEW 24V INPUT -12V OUTPUT UTPUT +12V OUTPUT 5V OUTPUT 24V OUTPUT PSMON Fuses ON / OFF Switch

18. The features of the power supply are : Input-output isolation. Input over voltage and under voltage protection. Output short circuit and over load protection. 24V DC output is isolated from other outputs. Ripple is less than 50mv at rated value. Efficiency is more than 70%. Works on “HOT STAND-BY” mode. PSMON(Power Supply Monitoring Unit) is provided to initiate audio visual alarm in SM’s room on UFSBI ALARM PANEL discussed in a later chapter.

19. PARTS OF UFSBI UFSBI-DS consisting of the following parts Input card CPU card Control cum Communication Card (CCC) Output Card Reset Box. MODEM. UFSBI Alarm Panel

20. PARTS OF UFSBI Input Card 1-6 CPU Card 1-3 Output Card 1&2 CC Card Reset Box MODEM Version Display

21. INPUT CARD OF UFSBI I/P RELAY 1- 8, O/P RELAY 1-8 & BIPR1 & BIPR2 INPUT CARD 1 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V INPUT CARD 3 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V INPUT CARD 5 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V I/P RELAY 9 - 16, O/P RELAY 9 – 16 INPUT CARD 2 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V INPUT CARD 4 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V INPUT CARD 6 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V It is responsible for complementary sensing of the relay status of UFSBI. i.e. for sensing one pick up and one drop contact of each input relays.

22. Physical Connection between Relay & Cards FRC CONNECTOR (Flat Cable) I/P RELAY, O/P RELAY & BIPR1 & BIPR2 INPUT CARD 1 & 2 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V INPUT CARD 3 & 4 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V INPUT CARD 5 & 6 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V WAGO TERMINAL FRC TERMINAL FRC TERMINAL

23. CPU CARD OF UFSBI INPUT CARD 1&2 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V I/P RELAY O/P RELAY & BIPR1 & BIPR2 INPUT CARD 3&4 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V INPUT CARD 5&6 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V CPU CARD A a. Input de-bouncing b. Input Data validation after inter-processor communication c. adding CRC code CPU CARD B a. Input de-bouncing b. Input Data validation after inter-processor communication c. adding CRC code CPU CARD C a. Input de-bouncing b. Input Data validation after inter-processor communication c. adding CRC code The UFSBI system is works on a 2 out of 3 majority voting logic i.e. if one CPU card or its corresponding Input cards goes bad then also system can work. CPU – A read the Inputs through Input Card 1&2, CPU – B read the Inputs through Input Card 3&4& CPU – C read the Inputs through Input Card 5&6. Thereafter validates the data by Inter-processor communication, adds CRC code and send this to CC card for transmission. On the other end after receiving the data from CC card it decodes it and sends that to Output card to pick up the Output relay.

24. CC CARD OF UFSBI Input Card 1 & 2 1. Opto Isolation of Relay Inputs 2. Noise & Surge suppressor Input Card 3 & 4 1. Opto Isolation of Relay Inputs 2. Noise & Surge suppressor Input Card 5 & 6 1. Opto Isolation of Relay Inputs 2. Noise & Surge suppressor CPU A 1. Input De-bouncing 2. Input data validation by Inter Processor communication 3. Adding CRC codes CPU B 1. Input De-bouncing 2. Input data validation by Inter Processor communication 3. Adding CRC codes CPU C 1. Input De-bouncing 2. Input data validation by Inter Processor communication 3. Adding CRC codes PICK UP DROP OUT TO MODEM Control & Communication Card 1. Data received from 3 CPUs on Time Division basis 2. TTL to RS232 level conversion Complementary sensing of an Input Relay State

25. OUTPUT CARD OF UFSBI FROM MODEM OUTPUT RELAY Output Card 1. Hardware 2/3 Voter Unit 2. Output through DC to DC converter 3. Decesion Read back by each CPU CPU A 1. Received data validation by Processor 2. Performing 2 out of 3 Software Voting Control & Communication Card 1. RS232 toTTL level conversion 2. Data sent to 3 CPUs CPU B 1. Received data validation by Processor 2. Performing 2 out of 3 Software Voting CPU C 1. Received data validation by Processor 2. Performing 2 out of 3 Software Voting 2 numbers of such cards are provided for driving Output relay. 1 st Output card drives Output relay 1 to 8 and rest 9 - 16 number output relay is driven by Output card 2.

26. Failsafety 2 out of 3 logic BIPR1 & BIPR2 - For health monitoring Output card voltage is extended through BIPR1 & BIPR2 contacts Force picking up and unsafe conditions BIPR1 & BIPR2 will drop Makes all the outputs are withdrawn

27. How BIPR1 & BIPR2 works when system is switched on Both will be in pick up state for 1 minute BIPR2 will be down After 15 minutes BIPR2 will pick up After 1 minute of over lap, BIPR1 will drop The cycle repeats for every 15 minutes * it is to ensure that the Health monitoring are not struck at faults ( like Siemsns EI interlocking )

28. PARTS OF UFSBI 2 nd Upper I/P Connector (I/P -9 to I/P 16 Complementary) On WAGO Board 1 st Upper I/P Connector (I/P -1 to I/P 8 Complementary) On MB 1st Lower I/P Connector (O/P -1 to O/P 8, BIPR1 & BIPR2 Complementary) On MB 1st Lower I/P Connector (O/P -1 to O/P 8, BIPR1 & BIPR2 Complementary) On WAGO Board 1 st Upper I/P Connector (I/P -1 to I/P 8 Complementary) On WAGO Board 2 nd Lower I/P Connector (O/P -9 to O/P 16 Complementary) On WAGO Board 2 nd Lower I/P Connector (O/P -9 to O/P 16 Complementary) On MB 2 nd Upper I/P Connector (I/P -9 to I/P 16 Complementary) On MB O/P 1 to O/P 8 Relay Drive O/P 9 to O/P 16 Relay Drive MB to MODEM Data Connector MB 6 Pin Power Connector BIPR1 & BIPR2 Relay Drive on MB BIPR1 & BIPR2 Relay Drive on WAGO Board WAGO BOARD TO MOTHERBOARD INTERCONNECTIVITY

29. MODEM OF UFSBI MODEM FRONT VIEW MODEM BACK VIEW Steady Red. To Indicate the MODEM Power ON Condition Steady Red to Indicate The Carrier Detect Flashing Red. To Indicate the MODEM receives Data Flashing Red. To Indicate the MODEM Sends Data Steady Red when Modem Put in LOOP position Loop / Normal Switch To Test the Modem Data Connector from Mother Board to Modem MODEM ON/OFF Switch PWR IN Line Connector from MODEM to OFC or QUAD Cable ANS / ORG Switch To Select the Modem mode Modem is provided to convert the data as per RS232 to Voice Frequency. The Fig above shows the front and back view of the Modem. Modem works on 4 wire, Asynchronous, 2400 bps mode. Maximum permitted loss between to modem is 30db.

30. Link status The systems exchange telegrams One telegram – 16 bytes of data it contains Start bit Packet of 8 bit Stop bit No parity 16 bit of relay status Inverse of same Address of Transmitter Inverse of address Mode of Operation Inverse of mode

31. Link status if no telegram is received with in a time span of 900 ms .. Then it is treated as link failure Auto change over arrangement : External module to connect dual channels The Transmission will be sent on both the channels Both the channels receive is monitored for seemless change over

32. ALARM PANEL OF UFSBI UFSBI ALARM PANEL FRONT VIEW UFSBI ALARM PANEL BACK VIEW

33. Potential free indications System fail Redundant DC-DC converter failure Single CPU failure

34. DISPOSITION CHART SL) BIPR1 QN1 (8F/8B) TIMER (120EJ) TGTXR QN1 (8F/8B) SHKR QN1 (8F/8B) TGTR QL1 (11F/4B) ASGNCR QNA1 (8F/8B) HSGNCR QNA1 (8F/8B) TCFR QL1 (11F/4B) FR1 QN1 (8F/8B) BIPR2 QN1 (8F/8B) LFR 4R-3-24 (3 CO) TCFXR QN1 (8F/8B) TCFCR QN1 (8F/8B) TGTYR QN1 (8F/8B) ASGNCPR QN1 (8F/8B) TGTZR QN1 (8F/8B) BLR QN1 (8F/8B) FR2 QN1 (8F/8B) CAR QN1 (8F/8B) BTSR QN1 (8F/8B) TAR2 QN1 (8F/8B) TAR1 QNA1 (8F/8B) HSBTPR QNA1 (8F/8B) HSATPR QNA1 (8F/8B) TGTPR QN1 (8F/8B) AZTR QNA1 (8F/8B)   CNR QN1 (8F/8B) TGTNR QN1 (8F/8B) ASCR QN1 (8F/8B) 12O JPR QN1 (8F/8B) BPNR QN1 (8F/8B) TCFZR QN1 (8F/8B)      

35. DISPOSITION CHART (DL) BIPR1 QN1 (8F/8B) TIMER (120EJ) TGTXR QN1 (8F/8B) TGTR QL1 (11F/4B) ASGNCR QNA1 (8F/8B) HSGNCR QNA1 (8F/8B) TCFR QL1 (11F/4B) FR1 QN1 (8F/8B) BIPR2 QN1 (8F/8B) LFR 4R-3-24 (3 CO) TCFXR QN1 (8F/8B) TCFCR QN1 (8F/8B) TGTYR QN1 (8F/8B) ASGNCPR QN1 (8F/8B) TGTZR QN1 (8F/8B) BLR QN1 (8F/8B) FR2 QN1 (8F/8B) CAR QN1 (8F/8B) BTSR QN1 (8F/8B) TAR2 QN1 (8F/8B) TAR1 QNA1 (8F/8B) HSBTPR QNA1 (8F/8B) HSATPR QNA1 (8F/8B) [D]AZTR QNA1 (8F/8B)   CNR QN1 (8F/8B) TGTNR QN1 (8F/8B) ASCR QN1 (8F/8B) 12O JPR QN1 (8F/8B) BPNR QN1 (8F/8B)   [R]AZTR QNA1 (8F/8B)    

36.   SL. NO.   RELAY TYPE AND NORMAL STATUS   DESCRIPTION   1. TGTR (SL & DL) QL1, 11F.4B DROP Train Going To Relay. Operates to pick up on receipt of LINE CLEAR at train sending station. Normalizes, when station in advance sets to Line closed after train arrival or cancellation of LINE CLEAR. 2. TCFR (SL & DL) QL1, 11F.4B DROP Train Coming From Relay. Operates to pick up on receipt of LINE CLEAR enquiry from train sending station. Normalizes after complete train arrival or cancellation of LINE CLEAR.       3. ASCR (SL & DL)   QN1, 8F.8B DROP Advance Starter Signal Control Relay Picks up, when LINE CLEAR is available and necessary controls are reversed by SM. Drops in any of the under-mentioned cases: a) Entry of train in Block Section. b) Withdrawal of any SM control.

37.     4. TGTXR (SL & DL) QN1,8F.8B DROP Train Going To code Relay. Picks up at train sending station pressing of buttons for LINE CLEAR enquiry. Drops when train sending station releases buttons for LINE CLEAR enquiry or picking up of TGTR which ever is earlier.     5. TCFXR (SL & DL) QN1, 8F.8B DROP TRAIN COMING FROM code Receive Relay. Picks up on receipt of LINE CLEAR enquiry from train sending station. Drops when station in rear releases buttons for LINE CLEAR enquiry or TGTR pick up which ever is earlier.     6. TGTYR (SL & DL) QN1, 8F.8B DROP Train Going To code Receive Relay. Picks up on receipt of LINE CLEAR at train sending stationDrops in any of the under-mentioned cases: a) Entry of train in Block Section. b) Cancellation of Line Clear.

38.   7. 120 JPR (SL & DL) QN1, 8F.8B DROP Timer mature repeater Relay. Picks up on maturity of Timer for cancellation. Drops when block status set to Line Closed.   8. BPNR (SL & DL) QN1, 8F.8B DROP Bell Push button Relay. Picks up on pressing of BELL push button with SM’s Key IN, else drops.   9. TGTNR (SL & DL) QN1, 8F.8B DROP Train Going To button Relay. Picks up on pressing of TRAIN GOING TO push button else drops.

39.   SL. NO.   RELAY TYPE AND NORMAL STATUS   DESCRIPTION   10. CNR (SL & DL) QN1 , 8F.8B DROP Cancel button Relay. Picks up on pressing of CANCEL push button else drops.   11. FR1 (SL & DL) QN1 , 8F.8B DROP Flash controller Relay No. 1. Toggles when Cancellation commenced or any other abnormal condition occur.   12 . FR2 (SL & DL) QN1 , 8F.8B DROP Flash controller Relay No. 2. Toggles when Cancellation commenced or any other abnormal condition occur.  

40.   13. TAR1 (SL & DL) QNA1, 8F.8B DROP Train Arrival First Relay. Picks up when control on Reception Signal is Reverse and HS AT occupied by train and HS BT clear. Drops when AT clear with a delay.   14. TAR2 (SL & DL) QN1, 8F.8B DROP Train Arrival Second Relay. Picks up when control on Reception Signal is Reverse and HS AT is clear and HS BT occupied by train. Drops when block status set to Line Closed.   15. CAR (SL & DL) QN1, 8F.8B DROP Cancel relay. Picks up at Train receiving station on initiation of cancellation, provided all controls pertaining to Advance Starter and Reception Signal/Signals and signals controlled by them are at Normal at both the stations. Drops when cancellation matures and system goes to Line Closed condition.

41.     16. BTSR (SL & DL) QN1, 8F.8B PICK UP Block Track Stick Relay. Picks up when Block status is LINE CLOSED and Block track is clear. Drops in any of the under-mentioned cases: a) Entry of train in Block Section. b) Cancellation of Line Clear.     17. AZTR (SL )   QNA1, 8F.8B PICK UP Block Section track Relay of dispatch line. Drops in the under mentioned cases: Entry of train in block section, or Axle Counter failure     18. TGTZR (SL & DL) QN1, 8F.8B PICK UP Advance starter signal normal checking repeater Relay. Picks up to repeat Line Closed condition at train receiving station after arrival of train or after a Line Clear cancellation has been initiated, else drops.

42.   SL. NO.   RELAY TYPE AND NORMAL STATUS   DESCRIPTION   19. 120 EJ (SL & DL) Electronic Time delay unit (Fail Safe) Timer unit for cancellation time of 120 seconds.     20. HS ATPR (SL & DL) QNA1, 8F.8B PICK UP First track for direction proving repeater Relay. Picks up when HSAT track circuit is vacant else drops.   21. HS BTPR (SL & DL) QNA1, 8F.8B PICK UP Second track for direction proving repeater Relay. Picks up when HS BT track circuit is vacant else drops.  

43.   22. AS GNCR (SL & DL) QNA1, 8F.8B PICK UP Advance Starter Signal Normal Checking Relay. Picks up when Advance Starter Signal and all its controls are at Normal, else drops.   23. HS GNCR (SL & DL) QNA1, 8F.8B PICK UP Reception Signal Normal Checking Relay Picks up when Reception signal/signals and all its controls are at Normal, else drops.   24. TCFCR (SL & DL) QN1, 8F.8B PICK UP Train Coming From Cancellation Relay. Picks up at receiving station when CANCEL CO OP button is pressed at sending station else drops.

44.   25. TCFZR (SL ) QN1, 8F.8B PICK UP Train Coming From Normal Proving Relay. Picks up at receiving station when TCFR drops, else drops   26. TGTPR (SL ) QN1, 8F.8B PICK UP Train Going To Normal Proving Relay. Picks up at train sending station when TGTR drops, else drops   27. SHKR (SL ) QN1, 8F.8B PICK UP Shunt Key Indicating Relay Picks up when EKT is “IN” & Shunt Release Key is “OUT”, else drops

45.   28. AS GNCPR (SL & DL) QN1, 8F.8B PICK UP Advance Starter Signal Normal checking (for other station) Relay Picks up when Advance Starter Signal and all its controls are Normal at the other station, else drops.   29. BIPR1 (SL & DL) QN1, 8F.8B TOGGLE UFSBI health checks Relay.     30. BIPR2 (SL & DL) QN1, 8F.8B TOGGLE UFSBI health checks Relay.     31. BLR(SL & DL) QN1, 8F.8B DROP Bell Relay Picks Up When Other Station Presses the Bell Button

46.   SL. NO.   RELAY TYPE AND NORMAL STATUS   DESCRIPTION   17. [D]AZTR ( DL) QNA1, 8F.8B PICK UP Block Section track Relay of dispatch line. Drops in the under mentioned cases: Entry of train in block section, or Axle Counter failure   . [R]AZTR ( DL) QNA1, 8F.8B PICK UP Block Section track Relay Of Receive line. Drops in the under mentioned cases: Entry of train in block section, or Axle Counter failure TOTAL RELAY REQUIREMENT FOR SL (1 PAIR):- QN1 – 44, QNA1 – 12, QL1 – 4, TIMER – 2

47. ADDRESSING The UFSBI equipments are provided with Jumpers for addressing The system will work only when the source and destination addresses are matched 8 PIN jumper is provided each one for Transmitter and Receiver. Total of 256 no of addressing is possible At Station A A t Station B Address of Transmitter Address of Receiver Address of Receiver Address of Transmitter

48. Installation Prerequisites Sl. No. Description Specified Value / nos. 1   Environment Spacious, Clean, Dry, Well ventilated room preferably with a fan/ exhaust fan. 2   Battery 24 V / 120 AH 3   Battery Charger i) Good Quality low ripple battery charger (Axle Counter type) as per IRS: S-86/2000 or IPS module as per RDSO/SPN/165/2004 Nominal Voltage – 24 V/10A (-10% to +20%) at The Output voltage at following 2 conditions must be within 21.6V to 28.8V: Charger ON & UFSBI ON Charger OFF (for 15 min) & UFSBI ON   ii) Separate Power Supply provided for each of BPAC, SSDAC & Block Telephone. 4   Earthing Value of Earth resistance: < 2  5   Communication Channel   4 wire Voice Channel on OFC (2400 bps , asynchronous) S/N ratio: At least 20 dB Max. TX Signal: -7 dBm to -5 dBm Min. RX Level: -12 dBm to -14dBm  

49. 6   Communication Cable Jelly filled Quad Cable as per specn : IRS: TC 30-05. Out of the 6 Quad or 4 Quad One Full Quad is to be assigned for UFSBI. Do not make Four different wires of different Quads for making a Quad to run the system. Length of quad cable : The cable insulation (must be better than10 M  /Km when tested with 500V Megger ): Loop resistance (should be less than 55  /Km): Signal loss (should be less than 30 dB at 2.5 KHz): The armour of the cable must be properly earthed. The cable shall be terminated properly. 7   External Terminals (Centre Link Open type )   All inputs from the Field and the Relay room shall be terminated with proper identification in a separate location to connect to the UFSBI terminals   8   V/F Tapping Transformer Characteristics impedance 470Ω in cable side and 600Ω on UFSBI side. If the communication link between two UFSBI is QUAD cable then only it is required. 9   Relays Following number of relays required for each pair QN1 – 44 , QNA1 – 12, QL1 – 4, TIMER – 2 10   Signalling Cable (0.9 mm dia) From SM Panel at SM Room to UFSBI cubicle placed at relay room – 60 core

50. GENERAL FAILURES OF UFSBI Relay Complementary Failure Relay force Pick Up. Relay Fail to Pick Up. Communication Link Failure. Cards or DC-DC converter Failure

51. Complementary Failure Error 10 Error 11 W2 WAGO BOARD M1 W10 M3 M3 W11 W3 I N P U T Check if error code is shown in all 3 CPU’s or at least in 2 CPU’s. a. Due to contact failure of Relays. b. Due Terminal loose fitted. c. Due to Flat Cable Cut. If Error code is shown in only one CPU. a. Change corresponding I/P card . M1

52. Complementary Failure Codes For Various Relays are given below Failure Code Relay Name Corresponding WAGO No. 10 IN1 W2, W10 11 IN2 W3,W11 12 IN3 W4, W12 13 IN4 W5, W13 14 IN5 W6, W14 15 IN6 W7, W15 16 IN7 W8, W16 17 IN8 (STRAPPED) W9, W17 18 OUT1 W18, W26 19 OUT2 W19, W27 1A OUT3 W20, W28 1b OUT4 W21, W29 1C OUT5 W22, W30 1d OUT6 W23, W31

53. Failure Code Relay Name Corresponding WAGO No. 1E OUT7 W24, W32 1 OUT8 (STRAPPED) W25, W33 20 IN9 (STRAPPED) W64, W72 21 IN10 (STRAPPED) W65, W73 22 IN11 (STRAPPED) W66, W74 23 IN12 (STRAPPED) W67, W75 24 IN13 (STRAPPED) W68, W76 25 IN14 (STRAPPED) W69, W77 26 IN15 (STRAPPED) W70, W78 27 IN16 (STRAPPED) W71, W79 28 OUT 9 (STRAPPED) W80, W88 29 OUT10 (STRAPPED) W81, W89 2A OUT11 (STRAPPED) W82, W90 2b OUT12 (STRAPPED) W83, W91

54. First check the condition of relay i.e Pick Up or Drop. Check the voltage with as per contact no. and corresponding Wago terminal with respect to W1 terminal. If voltage is present Check the corresponding Flat Cable. Failure Code Relay Name Corresponding WAGO No. 2C OUT13 (STRAPPED) W84, W92 2d OUT14 (STRAPPED) W85, W93 2E OUT15 (STRAPPED) W86, W94 2 OUT16 (STRAPPED) W87, W95 30 BIPR1 W34, W36 31 BIPR2 W35, W37

55. Relay Forced/ Fail To Pick UP OUT P U T Error 80 Error 81 W47 W48 W50 W49 M2 M4 1. Check O/P indication comes in O/P card or not. a. If Indication does not come change the O/P Card. b. If Indication comes in O/P card but then also System shows fail to pickup code then Check Corresponding Connectors, Terminals and Relay Coil. WAGO BOARD

56. Fail to Pick Up Error Codes For Various Relays are given below Failure Code Relay Name CONT. NO. TO BE CHECKED Corresponding WAGO No. 80 OUT1 R1, R2 W47, W48 81 OUT2 R1, R2 W49,W50 82 OUT3 R1, R2 W51, W52 83 OUT4 R1, R2 W53, W54 84 OUT5 R1, R2 W55, W56 85 OUT6 R1, R2 W57, W58 86 OUT7 R1, R2 W59, W60 87 OUT8 R1, R2 W61, W62 88 OUT 9 R1, R2 W102, W103 89 OUT10 R1, R2 W104, W105 8A OUT11 R1, R2 W106, W107 8b OUT12 R1, R2 W108, W109 8C OUT13 R1, R2 W110,W 111 8d OUT14 R1, R2 W112, W113

57. Failure Code Relay Name CONT. NO. TO BE CHECKED Corresponding WAGO No. 8E OUT15 R1, R2 W114, W115 8 OUT16 R1, R2 W116, W117 Please note that O/P 8 to O/P 16 are kept as spare for BPAC. So Fail pick up code for O/P-8 to O/P 15 will not come in the UFSBI CPU’s when used for BPAC.

58. Communication Link Failure For This failure the Error cod e would be “33” / “34” 1 . First check the +12V & -12V power supply from DC-DC converter is present or not. 2. Then Check all the physical connection from Modem To OFC Primary Mux /Quad Cable . 3. Put the Loop/ Normal Switch which is placed in the back MODEM to the Loop position and check if all the CPU’s are showing “06” or not. a. If all the CPU’s are showing “06” then the digital part of Modem and CC card of UFSBI is OK. Check the communication link for this failure. To Check this communication line first check the Modem TX power which has to be in the range of -7dB to - 12dB . Then check the receive power at other end. The Loss should not be more than 30dB in the line. b. If the system does not show “06” change the CC Card first and see the result . If this does not solve the problem change the corresponding Modem.

59. Cards or DC-DC Converter Failure CARD FAILURE : For any Hard failure i.e. components/ IC’s failure in Cards the corresponding codes will be shown in the CPU cards. Power OFF the system then Power On the system again. If it does not solve the problem change the corresponding card. The main reason of this hard type of failure are Improper Battery Charger, Battery Charger without Battery bank, Improper earthing, Direct Lightning. So before inserting a new card ensure these are proper. This system is 2/3 Active Redundant system so if any one CPU card fails the system can continue to work without any hindrance in block working operation but Single CPU failure alarm will come to the SM room so that maintainer can attend the system and rectify the fault, as a preventive measure. DC-DC CONVERTER FAILURE: DC-DC converter used in UFSBI is Dual redundant hot standby type. So any of the module fails system can work as each module is capable of taking full load of UFSBI on it’s rated voltage. Like CPU, redundant DC-DC converter failure indication is also extended to the SM’s room.

60. The Following Cards has to be replaced during the following error codes showing in all the 3 CPU’s . If these errors are shown in only one CPU change the corresponding CPU card. Please note that before changing any of the card perform at least TWO power On reset to ensure that card is permanently damaged not a temporary hang. For Detailed failure Code Refer Failure Code List attached with the Manual. Error Code Card To be replaced 01, 02, 05, 07, 08, 0A, 3A, 73, 7A, 7B, A0, A1, A2,A3,A4, A5,A6,A7,A8, B5,B6, B7,B8,B9, BA, BD, C1, C6, C9, CA, E1, E2, E8,E9, EB, EC, ED, FA, FB, FD CCC 93 O/P 1 then O/P 2 95, AA O/P 1 96, AB O/P 2

61. Protection against Lightening surges on both power and communication line A combination of Class C & D SPD for Power Line and Class D SPD for Data Line from OBO Betterman

62. Maintenance of the Instrument MAINTENANCE SCHEDULE FOR BLOCK PANEL WITH AXLE COUNTER USING UFSBI & SSDAC Sr. No. Description ESM JE/SE SSE 1 Check the Display in all 3 CPU's. It must display flashing O (ZERO) O (ZERO) indicates that the system is healthy & functioning properly. F M Q 2 Check the working voltage of UFSBI unit. It should not be below 21.6 V & above 28.8 V DC. (ALTHOUGH IT CAN WORK FROM 19.2V TO 31.2V) F M Q 3 Check the various output of DC-DC converter and record all the output supply voltage & output lavel should be as fallows : - ( i ) 5V [+/- 3%] ( ii) +12V [+/- 2%] (iii) -12V [+/- 2%] (iv) 24V [+/- 5%] F M Q 4 Check the working current. A healthy UFSBI should not draw more than 1.8 amp DC. F M Q

63. 5 Check the communication channel (OFC) loss with Telecom staff & it should not be more than 30 db between two modems of UFSBI. - HY Y 6 Check the link parameters with Telecom staff ( i ) For trans = -05 to -10 db (After removing cable side connection) (ii) For Receive = -12 to -22 db - HY Y 7 Check the surge arrester module working properly with zero voltage drop. F M Q 8 Check the block interface working OK indication ( BI.OK.IND ) on reset box. This indication is normally on indication (green ). It is glows when block interface is in working condition & BIPR1 & BIPR2 are in picked up condition. (NOT REQUIRED as "00" display of CPU's are already checked.) F M Q 9 Check the link fail indication on reset box. This indication (yellow) will normally flicker continuously meaning modem receiving data from remote station modem. Link failure is indicated by steady yellow F M Q 10 Check proper functioning of all push buttons , indications, buzzers,counter & keys provided on ASM block pannel . F M Q 11 Check that all the connectors & PCBs in the 6U rack are inserted properly. F M Q 12 Check that all UFSBI relay contacts are clean and free from pitting. F M Q 13 Check that all fuses provided are of proper capacity F M Q 14 Check that ripple voltages are not more than the specified voltage which are as follows :- i ) 5 V DC not more than 40 mv ii ) +12 V DC not more than 30 mv iii) -12 V DC not more than 30 mv F M Q

64. MAINTENANCE SCHEDULE FOR BLOCK PANEL WITH AXLE COUNTER USING UFSBI & SSDAC   i ) If Single CPU fail indication appears on UFSBI alarm panel then check all 3 CPUs cards.If any one is not working, replace defective CPU         ii) If redundant DC-DC convertor fail indication appears on UFSBI alarm Panel then check the DC-DC convertor.       16 iii) If System failure indication ( audio & visual ) appears on UFSBI alarm panel it would be ON till the UFSBI functioning normally ( till BIPR1& BIPR2 picks up ) then rest the system . if not resetted then checked error codes shown on the CPU & the LED on the out put cards & the control & communication card & take the recommended actions by manufacturer       17 Check that all the relay in UFSBI relay rack are properly plugged and holding clips are intact. F M Q 18 Check that all cable terminations are tight and properly connected. F M Q 19 Measure the earth resistance & it should be less than 2 ohm HY HY Y 20 Check the earthing wire & its connectivity for tightness F Q HY 21 Check address jumper of both mother cards of connected UFSBI unit for their correspondence unit. - HY y

65. 22 Check all the parameters of communication link along with telecom staff. - HY Y 23 Check that proper gasketting is provided in the UFSBI cubicle to prevent the ingress of water dust, insects / pests etc. F M Q 24 Check the SM's key is effective. F M Q 25 Check that all the counters on ASM block panel are working properly . F M Q 26 Check that all buzzers on ASM block panel are functioning properly. F M Q 27 Check the Block telephone and its cord for proper functioning F M Q 28 Check that terminations of wires are with a unique number for easy identification. - - Y 29 Wiring of relay rack is properly dressed and laced. - - Y

66. RECOMENDED METER: FLUKE 289 WITH TRUE RMS mV and dB measurement ALTERNATIVE METER: FLUKE 115 WITH TRUE RMS mV measurement 30 Check that the timer is working and a time delay of 120 Sec for cancellation of line clear is achieved. - Hy Y 31 Ensure that ASM alarm panel indications are extended to ESM's duty room & to the Data loggers . - - Y 32 Ensure that all potential free contact of UFSBI ( power supply monitor , single CPU failure detection & single System failure detection ) are wired in Datalooger and extended to ESM's duty room. - - Y

67. Improvements for Reliability Enhancement of UFSBI Automatic Modem / Media Changeover for working UFSBI redundant media ( viz. OFC Voice Ch. / Quad Cable or Radio / OFC Voice Ch. )

68. Front View Rear View Automatic Media Changeover arrangement for UFSBI The functional advantages of the Automatic Media Changeover Seamless changeover the primary and the secondary media Very low latency media switchover (<1 ms), thereby ensuring no link failure of UFSBI. between Continuous monitoring of both working / non-working media providing potential free contact for recording media performance over networked data logger. I n-system network performance / failure logger Note: The same media changeover unit may be used for other devices like digital axle-counter provided the communication packet format (like size, speed, number of Start /Stop bit etc. are provided