In signaling we use two different types of sources i.e. DC & AC supply DC-supply All the interlocking circuits are powered with DC supply. Every DC circuits are provided with individual chargers and Batteries During power failures DC circuits are continuously powered with individual battery bank backup
All the line side signals are fed through AC supply During AC supply failure all the line side signals will become blank. No solution is available to avoid blank signals in the present signaling arrangement. As a rule if signals become blank treated as defective signals. Which implies non- interlocking of signaling system. Though the interlocking is well intact. During blank signals due to AC supply failures in the face of an approaching train can create panic among the crews to control the high speed trains
CONVENTIONAL POWER SUPPLY ARRANGEMENT OF RAILWAY SIGNALLING 230V AC 230V AC 230V AC BATTERY BATTERY BATTERY CHARGER 110V SP CHARGER SP CHARGER 12V SP 24V110V BATTERY 24V BATTERY 12V BATTERY BANK BANK BANK 230V AC 230V AC 110V DC CVT CVT INV. INV. SIGNALS 110V AC 110V AC 110V AC 110V AC SIGNALS TRACK CIRCUITS
To avoid these contingencies- Un – interrupted power supply is required. By this principle integrated power supply system was developed i.e. complete power solutions from one system to all signaling circuits for a station
• Single battery bank is used • 110V (55 nos of cells)/200 AH in RE ,300 AH in NON - RE • To replace defective cells in the battery bank additional1 05 Nos of cells are kept as spare cells. • To charge the batteries SMPS based switch mode rectifiers are used in parallel redundancy.2 • To feed DC- supply to various circuits different ranges of DC-DC converters are used.3 • All the signals are powered by AC supply derived from inverters with hot standby.4 • All the field track circuits supply taken from main source through CVT.
Pre-request items before planning for IPS at stations1. Ensure the availability of stable grid supply minimum voltage of 200V-AC.2. In RE-AREA ensure that 70sq.mm cable is available between 10kVA AT transformer to CLS panel to keep minimum voltage drop on cable (Ref: TI/PSI/Project/CLS/01 dt. 04.01.2002)3. Measure the load currents of various DC & AC circuits.4. Pre-commissioning check list for IPS should be followed .
IPS Specifications – Revision History and Improvements SpecificationSl. No Features Added /Modified Advantages N0 1 Amendment – 1 Introduction of SMPS based IPS (Ver.1) Achieved protection of IPS from Introduction of LPD & SPD protections at heavy lightning & surges during 2 Amendment - 2 the I/P stage of IPS. raining season & improves the system reliability. 3 Amendment - 3 New clause has been added to provide 1) Better heat dissipation . 2) ventilation for individual modules. Reliability improvement. 4 Amendment - 4 * IPS cabinet dimensions have been standardized. * Ear thing guidelines are formalized. * Can avoid ear thing related issues and improves overall system reliability * Pre-commissioning check list for Proper installation & commissioning installation & commissioning of IPS has can be ensured. been added. * Over load & Over voltage protections, have Improves module and load reliability been added for IPS system. as well. 5 Amendment - 5 *Class-’C’ protection is added in Data & Improves data & signaling loads Signaling lines. reliability and power interruption to the load is avoided. *Guidelines given for Installation of LPD & Proper LPD & SPD co-ordination can SPD Devices. be achieved, 9
Typical Block Diagram of IPS as per RDSO / SPN / 165 / 2004 150- 275V AC TYPICAL BLOCK SCHEMATIC OF IPS AS PER RDSO/SPN/165/2004 AVR TRACK CIRCUIT UP 230/110V,500VA 230V AC BUS 1.0 KVALPD PANEL 230/110V,500VA TRACK CIRCUIT DNCLASSINCOMING -B&C BY PASS CVT TX 110V AC 230V AC AVR FUSE 1000VA 500VA TRACK 230V AC BUS 230V AC BUS CKT. SUPPLY STEP DOWN TRANSFORMERS C C 7 SMR CVT 1.5 KVA 7 TX 110V AC 110V/20A 1500VA230/110V,500VA SMR (FRBC) INVERTER 500VA SIGNAL UP C SIGNAL UP 110V/20A 110 V DC BUS 5 SMR 1.5 KVA INV 1 230/110V,500VASTATIC SWITCH 1500VA C 110V/20A FUSE FUSE TX 110V AC 110V/20A SMR 500VA SIGNAL 1.5 KVA DN INV 2 230/110V,500VA FUSE SMR 1500VA 230V AC BUS C 110V/20A 110V/20A SIGNAL DN 6 230/110V,500VA 110V/20A SMR 110V/20A 110 V BATTERY ASM INDICATION PANEL COLD STANDBY COLD STAND BY LVDS FUSE 110 V DC BUS FUSE REMOTE ASM 110V DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC PANEL DC-DC DC-DC DC-DC C1 TO POINT CONV CONV CONV CONV CONV CONV CONV CONV CONV CONV CONV CONV CONV CONV CONV Battery 1 1 MACHINE Set 110V/300AH 24-32V / LA LM 5A-1No 24-32V/ 5A-2Nos 12-28V/ 5A-2Nos 12-28V/ 5A-2Nos 12-28V/ 5A-2Nos 24-32V/ 5A-4Nos BUS 110 V DC RELAY INT. 24-32V/ 5A-2Nos AXLE COUNTER PANEL IND. BLOCK LOCAL. Datalogger RELAY INT. RELAYEXT-1. (COLD STANDBY) DC-DC DC-DC DC- DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC DC-DC CONV DC-DC CONV DC-DC DC DC-DC CONV CONV DC-DC CONV DC-DC CONV DC-DC CONV DC-DC CONV DC-DC CONV DC-DC CONV DC-DC CONV DC-DC CONV DC-DC CONV DC-DC DC-DC DC-DC FUSE CONV CONV CONV CONV CONV CONV CONV CONV CONV CONV CONV (20A) CONV CONV CONV CONV CONV CONV RELAY INTERNAL RELAY EXTERNAL PANEL INDICATION BLOCK LINE (UP) BLOCK LINE (DN) BLOCK LINE SICK CELL 24-32V/5A X 2 24-32V/5A X 2 & HKT 12-40V/1A X 2 12-40V/1A X 2 (BLOCK LOCAL) CHARGER 3-6V/12-28V/5A X 2 0.1A-2Nos 3-6V/ 0.1A-2Nos 24-32/ 5A-2Nos 24-32V/ 5A- 24-32/5A TO POINT 2-12V 12-40V/ 1A-2Nos 12-40V/ 1A-2Nos BLOCK TELE UP. BLOCK TELE DN. 2-12V/ 5A-2Nos 12-40V/1A X North BPAC 2 2Nos 02 Nos MACHINE BLOCK LINE UP. BLOCK LINE DN. FOR SPARE CELLS BPAC south Relay Ext-2
RDSO APPROVED FIRMS ARE M/S AMARA RAJA POWER SYSTEM STATCON POWER CONTROL SYSTEM HBL NIFE POWER SYSTEM
IPS comes with three panels namely1. FRBC or SMR panel Five rectifier modules Rated modules 110V-20A, 2.7kW output of the panel is connected to battery bank and other panels2. DC distribution panel It can accommodate Max. of 39 converters it consists of different rating of DC-DC converters3. AC distribution panel Combinations of inverters, step-down transformers and CVT
Layout of 3 Panels, Class ‘B’ Protection Box & ASM Box ALL FAIL SIGNALSI/P SUPPLY FROM PANEL Class ‘B’ ASM Protection BOXAUTOC/O SMR PANEL DC PANEL AC PANEL Battery LOADS
System should be installed with sufficient space at rear and front side minimum of one meter. Keep the cabinets side by side with a spacing about one foot between them Grout the cabinet to floor Draw the 10sq.mm copper wires from IPS panels to power panel. Earthing of IPS
Earthing of IPS panel The Earthing Value should be less than 2 Ω as measured by megger. If the Megger is not available at site, then we should measure the N- E Voltage of Mains Supply on class B protection Box. It should be less than 5V. SMR PANEL DC PANEL AC PANEL MCD50-B MCD125- FUSE VDE B NPE 32A/63A X1 X2 X3 X4 L N N L FROM TO IPS MAINS CUSTOMER EARTH TYPICAL PROTECTION SCHEME SHOWING LIGHTNING & SURGE PROTECTION AT INPUT OF POWER SUPPLY
DC-DC converters, signal transformer voltages should be adjusted to required voltages. According to load current, number of DC-DC converters should be selected as N+1 redundancy. It means if any one converter fails our circuit should not go to failure mode.
DC CIRCUITS POSITIVE : RED , NEGATIVE :BLACK AC CIRCUITS PHASE : BLUE , NEUTRAL :YELLOW EARTH :GREY/GREEN
FIXED AT ASM OFFICE. INDICATES HEALTHY OF COMPLETE IPS SYSTEM. AFTER COMMISSIONING OF IPS. LETTER TO BE SERVED TO ASM ,REGARDING SMP WORKING TILL CORRECTION IS MADE IN SWR. IN PANEL BLOCK TELE PHONE SUPPLY FOR CONVERTERS ARE AVAILABLE.
Start generator: 50% DOD or Approx. 109V Emergency start generator: 60% DOD or Approx 107V System shut down: 70% DOD or Approx 105V Call S&T staff: Failure of FRBC, Converters, Inverters, CVT’s & Transformers. PF contacts are available for DATA LOGGERS.
SMR Maintenance SMRs are fully alarmed and operate in an active loop sharing arrangement. However , some regular checks can be an early warning of problems waiting to happen. Current sharing (Applicable , when number of modules is more then one number) Under normal conditions the currents contributed by every rectifier should be within +/-2 Amps of each other. It is possible however, for internal loop parameters to change to such an extent that a unit does not share to the extent that it should.
S No CHECK POINT ACTION REQUIRED FREQUENCY1. Converter O/P Check if the O/P voltages are set as Once in 15 voltage per requirement. If not, correct them days2. Paralleling of Switch OFF main Converter and Once in a Converters observe if the stand-by is taking the month load.3. Paralleling of Switch OFF Stand-by Converter and Once in a Converters observe if the main is taking the month load.4. Converter Check if all the converters are Once in 3 Mechanical inserted properly months Alignment5. Converter Cleaning Remove one by one and clean the Once in 3 converter using a soft cloth . Gently months blow some air from top or Bottom to remove the dust inside.
SNo Check Point Action Required Frequency1. O/P voltages of Check if the O/P voltages are set Once in 15 Inverters, CVTs as per requirement. If not , check days Step- Down for fuses Transformers contactors. as per requirement2. Inverter O/P current Check if the DPM is showing the Once in 15 signal current as per original days settings.3. Auto changeover Check for this changeover Once in a between Inverters and operation as described in month Bypass CVT instruction manual4. Connector Mechanical Check if all the connectors of Once in a Alignment various sub systems are month inserted properly5. Sub System Cleaning Remove one by one and clean Once in 3 them using a soft cloth . Gently months blow some air to remove the dust inside.
Low Maintenance Battery IRS 88/93 Cleaning of all cells around top cover and terminals periodically. Applying petroleum jelly over the terminals. Periodically recording of all cell voltages and their specific gravity. Periodically checking of electrolytic level of cells. Periodically recording of all cell voltages with Battery Charger switched OFF. Boosting of Sick cell using Sick cell Charger. Replacement of non-reparable cell in a bank by fresh charged cell. Cleanliness Apart from these instructions regular cleaning of IPS and battery room should be done. Cleaning of dust collected inside the IPS panels (SMPS, DCDP & ACDP) should be done with the help of blower once in a month.
EFFECT OF DUST ON WORKING OF IPSSince IPS uses double side PTH PCB’s having high component density and compact module construction It needs clean environment around it. It is true for any modern electronic equipment. • The floor should be pucca with mosaic/tiles or with PVC flooring. • There should be windows with glass doors so that they can be closed. • Doors and windows should have gaskets. • There should be provision for exhaust fan and dampers on outside. • The windows should preferably have wire mesh or Netlon type jali.
Measure the voltage of each individual cell while the battery is at REST. Variation of 0.05V between cells and variation of 20 points in the specific gravity indicates imbalance in the bank. Battery bank needs equalizing charge. In IPS equalizing charging can be done by operating manual start EQ in CSU.
HOUSED IN SMR PANEL LVDS TRIP; 98 V TERMINALS SHOULD BE SHORTED DURING THE CONTACTOR RELAY FAILURE
SLNO PROBLEMS ACTION TAKEN1 CLS PANEL MCB TRIPPING SMR CURRENT LIMITED TO MAX 10A2 LVDS OPEN LVDS SHOULD BE IN AUTO3 BLOCK TELEPHONE HEAVY DISCONNECTED BLOCK HUMMING TELEPHONE CONVERTER4 D2 SIGNAL BLANK,AND HOME AC SUPPLY FEEDING TO SIGNAL FOR LOOP LINE NOT SIGNALS WERE EXTENDED OBEYED ON IPS SUPPLY BACKUP TO D2’s AND HOME SIGNAL ROUTE INDICATORS.
ELECTRONIC SWITCH MAY BE AVAILABLE PARALLEL WITH LVDS TO MAKE USE IN EMERGENT CONDITIONS. UNIFIED CAPACITY OF CONVERTERS 12V – 32V/5 AMP HIGHER CAPACITY TRANSFORMER ,CVT REMOTE DIALINIG FEATURE MADE COMPULSERY. SUFFICIENT LENGTH OF CABLE TO BE MADE AVAILABLE BETWEEN SMR TO BATTERIES. Cable entry hole to be provided on top of modules. Extra converter slot made available in dcdp for circuit expansion.