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1. lt Click for Contents NI DISCLAIMER It is clarified that the information given in this handbook does not supersede any existing provisions laid down in Signal Engineering Manual Railway Board and RDSO publications This document is not statutory and instructions given in it are for the purpose of guidance only If at any point contradiction is observed then Signal Engineering Manual Railway Board RDSO guidelines or Zonal Railway instructions may be followed lt Click for Contents NI CAMTECH S PROJ 2013 14 HB EI MIS 1 0 1 Chapter An Introduction to ELECTRONIC INTERLOCKING SYSTEM 1 1 Electronic Interlocking System Electronic Interlocking EI system is a microprocessor based interlocking equipment to read the yard and panel inputs process them in a fail safe manner as per selection table and generate required output This system is the alternative to the conventional Relay Interlocking system PI amp RRI On Indian Railways the Electronic Interlocking system shall comply with the RDSO specification No RDSO SPN 192 2005 Draft 1 2 Advantages over conventional relay interlocking No relays are required for interlocking function Only interface relays are required Space requirement 1s reduced substantially Reduction in power consumption Reduction in wiring interconnections and no of fuses More reliability and safety due to less relays and accessories suitable for AC electrified area No air condi
2. HINA GOVERNMENT OF INDIA Yel H3ITeRI MINISTRY OF RAILWAYS TIT 8g For official use only ELECTRONIC INTERLOCKING MAINTENANCE INSTRUCTIONS SERIES I MICROLOK II ELECTRONIC ai i 2 Tha J mp CAMTECH S PROJ 2013 14 HB El 1 0 FEBRUARY 2014 aca wT Nw we lt lt a STU lt lt Transforming Railways xCELLENCE IN MAINTENANCE Indian Railways Centre for Advanced Maintenance Technology MAHARAJPUR GWALIOR 474 005 Click for Contents FOREWORD Railway signalling has come a long way from un interlocked mechanical and electro mechanical interlocking With the advent of electronics and computers there have been revolutionary changes in the field of railway signalling Electronic Interlocking system has several advantages over Electro Mechanical or Conventional Panel Interlocking such as reduced space requirements self diagnostic features safety and reliability etc Electronic Interlocking installations of different approved manufacturers have been commissioned on a number of stations on Indian Railways and are going to increase in future CAMTECH has prepared this handbook on the subject to get the Signal personnel acquainted with the system am confident that this handbook apart from updating the knowledge will help the field staff in maintenance and troubleshooting of the system CAMTECH Gwalior A R TUPE Date 28 02 2014 Executive Director
3. 0 22 b System Event log The system event log records upto 5000 of the most recent critical errors warnings and events Any system critical error or warning will be logged in the system log Events are used to relay miscellaneous system information and may be limited by use of the configuration c System Error log The system error log is limited to critical errors Since the older events may be lost in the system event logger the system error log contains a list of the last 50 time stamped critical system errors d Merged Events log The merged events log enables us to view errors warnings and events as in the User data System Event System Error log and Dynamic variable changes merged onto the same time axis This log also provides graphic displays of parameters and events as specified in the user data log 2 3 System adjustment Setup These buttons enable us to modify parameters of the Microlok II which are as under a Set Time of Day Clock This function displays the date and time settings for both the Microlok II system CPU and the laptop computer and sets the Microlok II on board clock b Software upload This tool is used for uploading a custom designed application software program from the laptop PC to the Microlok If CPU This tool interacts with Windows based files therefore one should be familiar with application software and Windows file navigation to use this feature c Reset Microlok Il This tool
4. CAMTECH Gwalior D K M YADAV Date 28 02 2014 Jt Director S amp T Click for Contents NI Chapter Description Foreword Preface Contents Correction Slip Disclaimer An Introduction to Electronic Interlocking System Introduction Advantages over conventional relay interlocking Frequently used terms in El system system composition Working System Architecture El systems of different available configuration RDSO approved firms Scope MICROLOK II Electronic Interlocking System Introduction MLK Il Hardware MLK II Software Configuration of MLK II Microlok Il modes of operation Microlok II Development System 5 10 installation Microlok Il Maintenance Tool Program Viewing the logged information Powering up the Microlok II system oystem Maintenance Preventive Maintenance Corrective Maintenance Precautions Do s amp Don ts References and Service information Abbreviations Click for Contents NI Page No IV XII COCONNND ISSUE OF CORRECTION SLIPS The correction slips to be issued in future for this handbook will be numbered as follows CAMTECH S PROJ 2010 11 HB EI MIS 1 0 C S XX date Where XX is the serial number of the concerned correction slip starting from 01 onwards CORRECTION SLIPS ISSUED Date of issue Page No and Remarks ltem no modified
5. OFF o The CPU upper 4 character display repeatedly scrolls the phrase US amp S MICROLOK II and the executive version information e The CPU lower 4 character display scrolls the pre programmed application name e The power supply board VCOR LED illuminated E If all the above indications are present perform the System test and configutration procedures as per instruction manual Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 26 2 10 System Maintenance 2 10 1 Weekly Maintenance a Measuring Voltages Performed by Signal Maintainer Date Observation Signature Cardfile Supply T O Supply AtIPS At AtIPS At E SMS II Rack II Rack NENNEN b Fuse Checking Performed by Signal Maintainer Date Fuse Checking Converter Observation Signature Cum isolator fuses Switching Panel Circuit Fuse MLK Relay MLK Rack Rack Rack Backup Schedules Performed by Signal Engineer The User Data Log Event Log and Error Log backups are to be taken in Hard Disk as well as Floppy Disk for remote storage S No Backup Date User Log Event Log Error Log Observation Signature Backup o PN 1 12 03 08 Done Done 2 10 2 Monthly Maintenance a System Changeover Performed by Signal Engineer Sr No Date System Observation Signature B Ba BoA 10 01 08 During
6. click on the Save icon button in the toolbar of User Data Log window Mini active window Save as appears Y Vv Y NN NN NN NN Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 24 Vv NN WV Double click on the Weekly Maintenance folder in the Maintenance PC drive Sub folders User Data Log System Event Log amp System Error Log appear Double click on the User Data Log folder Rename the default file name User Data Example File name CAMTECH Click the Save button Note If the CPU Board is removed from Cardfile the User Data Log may be lost Ensure User Data Log backup is taken from CPU Board before removing the CPU Board from Cardfile Starting amp Ending time should be in correct format otherwise User Data Log downloading would not start Syntax for the Date Time string Month 1 or 2 digits Date 1 or 2 digits Year 2 digits Hour 1 or 2 digits AM or PM optional 2 8 2 Viewing the System Event Log For downloading the System Event log the following steps are to be followed gt Click on the System Event Log icon in the Maintenance Tools main menu gt System Event Log window appears in which event log is downloaded gt On completion of Event Log download click on the Save icon button in the toolbar of System Event Log window gt Mi
7. CAMTECH ERROR 30JULOY Click on the Save button VVV WV Note If the CPU board is removed from Cardfile the System Error Log may be lost Ensure System Error Log Backup is taken from CPU board before removing the CPU Board from Cardfile 2 8 4 Viewing the Merged Event Log gt To view Merged Event Log click on the Merged Event Log button on the Maintenance Tools main menu After some time when the loading of System Event Log and User Data Log in the Merged Event Log the Merged Event Log window appears gt To return to the Maintenance Tools main menu from the Merged Event Log display click on the Back button on the tool bar 2 9 Powering up the Microlok Il system Before applying power to the system for first time the entire hardware installation should be verified for correctness as per relevant instruction manual Once the verification 1s completed satisfactorily apply 12 V DC battery power to the Mocrolok II cardfile E Verify that the 5 V ON LED on the cardfile power supply board is illuminated If everything has been connected and configured properly the Microlok II CPU will begin to run a series of self tests and initialization routines After successful completion of above procedure CPU board will assume the on line mode of operation and the following cardfile indications should be present e The CPU board ON LINE LED ON e The CPU board VPP ON LED OFF e The CPU RESEST LED
8. Changeover SGE block instrument must be in condition Ensure Synchronization Microlok II clock time with Maintenance PC time after changeover Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents NI 5 2013 14 15 1 0 21 b Measuring Earth Resistance Value Performed by Signal Engineer tion 3 SR Pit Pit Pit Pit Pit Pit 1 2 4 5 6 7 8 1 10 01 08 0 3 0 8 0 5 0 7 0 4 0 6 0 8 0 2 Ohm Ohm Ohm Ohm Ohm Ohm Ohm Ohm Note Earth Resistance value should be less than 1 Ohm 2 10 4 Annual Maintenance Performed by Signal Engineer Replace the Lithium Battery Check the Converter cum Isolator Remove the VCOR relay from the installation and inspect it Perform the inspection activities mentioned under Preventive Maintenance 2 10 5 Five Years Maintenance Performed by Signal Engineer B Inspect Surge Protection Devices SPDs m Replace if found deteriorated 2 10 6 System failure Register 5 Interlocking Equipment or Down Time Component Descript Date Time failed ion 1 System 14 01 08 11 10 14 01 08 11 14 04 CPU RAM CPU 14 01 08 He dmm aces 2 11 Preventive Maintenance The following checks should be performed at least on an annual basis Clean the outside of the cardfile enclosure using a soft clean cloth Inspect the cardfile enclosure for dents and scratches and inter
9. ECRs in case of signal WKR in case of points and TPR in case of Track B Since the inputs are dealing with the detection of 1 outdoor gears they normally configured with double oS cutting arrangement ES un Indications m I 2 2 INI IN8 Green LEDs Monitor state of 4 5 vital inputs 1 through 8 When lit indicates respective input is turned on IN9 IN16 Green LEDs Monitor state of vital inputs 9 through 16 When lit indicatesrespective input is turned on F ig 2 6 F ront view of Vital Input Board Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents CAMTECH S PROJ 2013 I4 HB EI MIS I 0 14 2 2 7 Vital Cut Off Relay Each cardfile will have one Vital Cut off relay VCOR to ensure the healthiness of the system VCOR has 6 F B dependent contacts each rated for 3 Amps The VCOR contacts are used to control the power to all card file vital outputs The VCOR is controlled by the CPU board When the system is healthy the coil receives voltage from PS PCB on the power supply board On failure of a safety critical diagnostic the DC supply to the VCOR is removed thereby opening the contacts that provide battery power to the vital output boards Fig 2 7 Vital Cut Off Relay VCOR 2 2 7 Plugging of PCBs Each PCB is having 96 pin connector on the lower half of the rear portion There are corresponding 96 pin female connectors 1 to 20 in the cardfile
10. In this mode application logic 1s not processed and also all control functions are inactive Electronic Interlocking Maintenance instructions series I February 2014 ue for Contents CAMTECH S PROJ 2013 14 HB EI MIS 1 0 19 2 5 4 Reset mode The primary purpose of the RESET mode is to reset the relay and the Microlok II system software when the occurrence of a CPS trip RESET LED on the CPU board front panel ON when reset push button is pressed OFF when the button 1s released i To enter the Reset mode from CPU front panel Press and release the RESET push button on the CPU board front panel E Quickly operate any one of the four front panel toggle switches Hold the switch in the toggled position Release the toggle switch that was operated in step 2 after the CPU board 4 character displays shows RES MENU ii access this function E Toggle the MENU UP DOWN switch to the DOWN position Toggle the MENU L R switch to the Right position Toggle the MENU L R switch to the Right position with CLR CPS shown on the CPU board displays Toggle the Action ACCEPT REJECT switch to the ACCEPT position This action resets the CPU software amp VCOR relay and returns the CPU to the on line mode 2 6 MICROLOK II Development System 5 10 installation The MICROLOK II Development System 5 10 is installed in the Maintenance PC by loading a CD containing the Development System installation soft
11. lt Click for Contents NI PREFACE Railway Signalling system plays a vital role in the movement of trains Electronic Interlocking an advanced signalling system used worldwide has been introduced on Indian Railways At present the working installations of this system on Indian Railways are of different approved manufacturers Although Electronic Interlocking system is supposed to give flawless performance failure of this due to its safe shut down feature or any other reason may paralyze train movements For ensuring the efficiency and reliability of the system the staff installing or maintaining this should have fair knowledge about its components and working Continuing its efforts in documentation and up gradation of information on maintenance practices CAMTECH has prepared this handbook The topics have been covered to the point and concise not going into details of circuitry The purpose is to impart knowledge to Signal personnel about different manufacturers systems which will help them in installation maintenance and troubleshooting of the same oince technological up gradation and learning is a continuous process you may feel the need for some addition modification in this handbook If so please feel free to write us We shall highly appreciate your contribution We are sincerely thankful to Shri P S Bhattacharyya Dy C S T E Con VSKP E Co Rly maintenance personnel and approved firms who helped us in preparing this handbook
12. ay coil under the control of the CPU board As long as CPU detect no internal external system faults it sends a 250 Hz check signal to PS PCB which in turn holds the VCOR relay in pick up condition Failure of a diagnostic check results in removal of check signal thereby de energisation of VCOR This results in removal of power to all vital system output Power input to the system B Voltage range 9 5 to 16 5 V DC B Min Voltage 12 V DC B System Start Up Voltage 11 5 V DC Indications Fig Label Device Purpose Ref 1 5V ON LED green When lit indicates 5V 1 power to other cardfile 2 PCBs If not lit refer to Figure LED green When lit indicates conditional power on to VCOR relay CPU diagnostics normal If not lit refer CLEAR FUNCTION details in Figure Fig 2 3 Front view of Power Supply Board Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents CAMTECH S PROJ 2013 14 HB EI MIS 1 0 12 2 2 4 Non Vital O Board E The Non Vital I O board is designed to receive non vital inputs controls and generate non vital outputs indications Each PCB provides 32 inputs and 32 outputs through its rear 96 pin connector E Available in 12 V and 24 V DC applications Non vital inputs Panel push buttons and keys Non vital outputs Panel indication LEDs counters and buzzers LEDs are available on the fr
13. be referred UM 6800B Micolok II Installation UM 6800E Micolok II Troubleshooting and Recovery For Error Codes Service Manual 6800C Appendix A may be referred For service information contact M s Ansaldo STS Transportation Systems India Pvt Ltd 35 SLV Complex AVS Compound 80 feet Road 4 Block Koramangala Bangalore 560 034 Tele 080 25525737 66949200 FAX 080 25525732 2 15 Abbreviations ABS Automatic Block Section AC Alternating Current AF Audio Frequency CCIP Control Cum Indication Panel CD Compact Disc CIU Central Interlocking Unit CLR Clear CPS Conditional Power Supply CPU Central Processing Unit CSI Coded System Interface CTC Centralized Traffic Control DC Direct Current DR Green aspect Controlling Relay ECR Lamp Proving Relay EPROM Erasable Programmable Read Only Memory EEPROM Electrically Erasable Programmable Read Only Memory EI Electronic Interlocking EMU Electrical Multiple Unit GN Signal Button HR Yellow aspect Controlling relay IBS Intermediate Block Signalling IC Integrated Circuit I O Input Output Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 32 LED L R LED L R MB MLK I NWKR OC OFC PC PCB PI PS RAM RDSO RI RO ROM RRI RWKR SPD TMR TPR UN UPS US amp S VCOR VDU VGA WKR WNR WRR WNR WRR Electronic Interlocking Maintenance inst
14. ble to use conductive card frames or racks However bags and wraps are preferred iv Transport The equipment or modules must not be transported in close proximity to magnets e g AWS magnets v Handling Lithium Batteries Following precautions should always be observed while handling Lithium Batteries Packaging Package all modules with batteries in a non conductive anti static bag An electrically conductive bag may short the battery terminals causing premature discharge of the battery Damage The lithium batteries contain very highly corrosive electrolyte If a battery 15 damaged E Ensure unnecessary personnel do not enter the affected area Ventilate the immediate area Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 30 E Avoid contact with any liquid or internal components by wearing the appropriate safety equipment E Thoroughly wash the affected area with clean water and allow it to dry Return the module that may have been in contact with the electrolyte to the firm for inspection duly packaged with an appropriate safety warning Disposal Dispose of the battery according to the local regulations Don t e Short the terminals together e Attempt to recharge e Crush e Disassemble e ncinerate or heat above 100 deg 212 Deg F e Attempt to solder the cell vi Do s and Don ts Do s B To avoid possibl
15. by processor s system may be provided with facility of automatic changeover E In case of Warm standby the system starts functioning with a time delay of approximately 120 secs of failure of main system without affecting train operation and safety In case of hot standby system train operation should not be affected The fault which affected the main processor system should not affect the hot standby processor system Two out of two hardware architecture with identical hardware and identical or diverse software E In addition warm standby hot standby processor s system using 2 out of 2 hardware and software architecture may be provided with facility of automatic changeover Two out of three hardware architecture with identical hardware and identical or diverse software El systems of different available configuration Single hardware with software redundancy 1 Single processor without any standby 11 Single processor with standby Two Els connected in parallel Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 8 1 7 2 Dual hardware with hardware redundancy 2 out of 2 system 1 Dual hardware without standby 11 Dual hardware with warm standby 111 Dual hardware with hot standby iv Dual hardware with object controllers 1 7 3 Triple modular redundancy Hardware redundant 2 out of system TMR w
16. d m Clack Serial i Message E i For Help press Ft Fig 2 13 Maintenance Tools main menu 2 7 1 Run time Monitor This group of tools enables us to view the current status of operating Microlok II equipment and related systems The following buttons are provided under this group a System information E It enables us to view system events By clicking this button a display appears which shows the current version no of the Executive software and an abbreviated snap Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents CAMTECH S PROJ 2013 14 HB EI MIS 1 0 21 shot of the most recent system events Where appropriate the display defines the action taken in response to an event The system information display lists the time and date when the following types of events last occurred e System resets e System errors e Unit configuration e Cleaning of the system log clear e Clearing of the user data log clear e Time changes e Clearing of additional power supply CPS trips Since some of these events do not occur frequently the displayed data also includes the year in which the associated event occurred b Board information It displays the status information about input output interface PCBs of a Microlok or serial link It displays the current status of each enabled PCB in the Microlok II cardfile Each board type is dynamically updated c Fre
17. e damage to the diagnostic computer when connected to the Electronic Interlocking equipment if the power supply of the diagnostic computer is connected to an AC power source isolate the power source from earth ground by way of a 3 prong to 2 prong adapter Before powering up the Electronic Interlocking equipment ensure that there is no train entering into the section in both Up and Down Direction Observe all Electrostatic discharge precautions while handling any Printed Circuit Board or board component B For repair or replacement if any return the equipment to the firm Don ts Do not use Radio equipment within the immediate vicinity of Electronic Interlocking system as Radio transmissions can affect electronic equipment B Do not make circuit alterations or repairs to the Electronic Interlocking system B Do not install or remove any printed circuit board with battery power applied to the system B Do not attempt to repair any Electronic Interlocking system printed circuit board or peripheral device in the field Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 31 2 14 References amp service information RDSO specification No RDSO SPN 192 2005 Draft UM 6800A Micolok II Functional description UM 6800C Micolok II Startup amp Maintenance For installation and troubleshooting of Mocrolok II System following Manuals may
18. e normally working software for taking over at the time of failure Warm standby In this arrangement only one system is in power on mode while the other is in power off mode There is no communication between the two systems Once powered on system is failed the other system will be powered on after a time delay Hot standby In this system the Main and standby systems are powered on Both the systems take inputs process it communicate with each other and finally give one output If any one of the two systems shuts down there is no interruption in the output The load is automatically taken over by the other equipment without any time delay 1 4 System composition The EI System mainly comprises of two sections Hardware and Software 1 4 1 Hardware The basic hardware structure of EI consists of the following 1 CPU Chassis B Read Relay interface Card Processor Card B Relay Output Card 2 Control Cum Indication Panel Operator s panel 3 Panel Processor 4 Maintenance Terminal 5 Object Controller 1 to 4 above constitutes Central Interlocking Unit CIU Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 3 1 4 1 1 Relay interface Card This card acts as an input interface to the system from the input relays The input to the system comes from various fields relays like track circuits point status relays signal lamp pro
19. e run variable display This tool lists the current values for selected variables and bits as well as a real time list of changes The free run display presents the status information in a text mode d Dynamic Bit Variable display This tool provides the same information as that provided by Free run variable display but in a different way The Dynamic bit Variable display represents the indications graphically in strip chart view of bit and variable changes 2 7 2 Historical data These buttons lead to views which display data which an operating Microlok II has collected and stored The Microlok II system logs and reports information in three classifications e Critical errors e Warnings e Events This section contains the following four tools that enable the user to review the logged system information in several ways Note In the Maintenance PC Weekly Maintenance folder to be maintained in which User Data Log Event Log amp Error Log backup to be done on weekly basis a User data log The user data log records only those events that the user specifies It displays changes of selected bit and numeric variables as requested by the application or configuration This log is capable of recording upto 90 000 of the most recent specified Boolean changes or at least 64 000 Boolean and or numeric changes Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1
20. enables the user to reset the Microlok IJ CPU from the laptop computer The reset function is used mainly to clear system faults and return the system to normal operation d System configuration This tool provides options for checking and modifying the configuration of the Microlok II system hardware and software Three types of options are provided within this tool e System configuration options enable the user to modify the general system parameters and the user parameters and to assign specific parameters to the user data log e Board configuration options enables the user to enable disable and configure the individual Microlok II system PCBs e Link configuration optionsenable the user to configure the Microlok II system communication links Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 23 2 7 4 Other tools These buttons lead to views which allow special diagnostic functions to be performed These are as under a Systems Memory Dump Allows system personnel to provide specialized debugging assistance The system memory dump tool enables system developers and maintainers to perform debugging operations when a customer encounters a software problem b Program Settings The Program Settings dialog is used to modify the way in which the system stores and displays data These options can also change the general appearance of the scre
21. ens c Serial message monitor This tool enables the user to monitor serial message traffic on a selected active serial link d Save Comma Delimited download This tool lets the user download the user data log in a comma delimited format This file can be viewed in Microsoft Excel The file can be saved via the diagnostic port link or directly from the PCMCIA card in the card reader on the individual PC e Application download This tool lets the user download the application image from the EEPROM on the Microlok II unit As a default the file 1s stored with a filename mlp extension so that it can be easily uploaded to the system if necessary 2 8 X Viewing the logged information Procedure for viewing the logged information is given in the following paragraphs 2 8 1 Viewing the User Data Log For downloading the viewer data log the following steps are to be followed Click on the User Data Log icon in the Maintenance Tools main menu Mini active window Select Start End Time for Download appears Select N Download Starting at Enter MM DD Y Y HH AM or PM Example 07 30 09 08AM Select N Download Ending at Enter MM DD Y Y HH AM or PM Example 07 30 09 09AM Click on the Get Log button in the Select Start End Time for Download dialog box User Data Log window appears in which user data is downloaded 1 from the specified start time On completion of User Data download i e upto the specified end time
22. ics VPP ON Yellow LED When lit indicates FLASH 5 or 12V programming voltage enabled via board jumper RESET Green LED When lit indicates that the system is in reset mode RESET Momentary When pressed resets the pushbutton CPU Also used to place the CPU in the reset mode MENU L R 3 position Used to search main return to program menu items center shown on displays toggle switch MENU UP 3 position Used to select main DOWN return to program menu items center shown on displays toggle switch ADJUST UP 3 position Used to cycle through DOWN return to configuration values to be center selected with ACTION toggle switch switch ACTION 3 position Executes cancels ACCEPT return configuration value REJECT tocenter selected with ADJUST toggle switch switch RS 232 DTE DB9 RS 232 Used for connection to Fig 2 2 CPU PCB Diagnostic Connector Maintenance PC for Link DTE System monitoring Connector diagnosis Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents CAMTECH S PROJ 2013 14 HB EI MIS I1 0 11 2 2 3 Power Supply Board The power supply board performs the following functions Converts the external supply voltage 9 8V to 16 2V DC to regulated 12V and 5 needed for the operation of the cardfile circuitry Provides an isolated source voltage for external contact sensing Supplies energisation voltage to the VCOR rel
23. instructions series I February 2014 lt Click for Contents CAMTECH S PROJ 2013 14 HB EI MIS 1 0 17 2 2 12 EEPROM PCB EEPROM PCB which is provided on rear side of the CPU connector to configure various serial communication ports see fig 2 10 Keying plugs are provided in the cardfile to ensure coding to each type of cards oS TARAL ud ROTG 1 of sl 1 WS 0 Car 1 Add ess se Tee PTE Jumper settings EEPROM PCB Fig 2 10 Rear view of Cardfile Address Select PCBs 2 3 MLK II Software Microlok II software components mainly consist of the Executive Software and the Application Software Executive Software is actually the Microlok operating system software while the application software is specific user written software 2 3 1 Executive Software The US amp S developed Executive Software Operating system is standard for all Microlok II systems It is responsible for overall vital monitoring and control of the system 2 3 2 Application Software The vital application program software is developed using US amp S developed maintenance tools program which is also used to input Executive software version upgrades In addition to this site specific configuration data is stored in the Card file mounted EEPROM and can be loaded using the CPU board front panel toggle switches and LED displays This data can also be loaded using the Maintenance tools program on a laptop PC which is connected to
24. ith relay interface 11 TMR with object controllers 1 8 RDSO Approved Firms At present the following firms are approved by RDSO for design supply and installation of Electronic Interlocking Systems on Indian Railways B M s Ansaldo STS Transportation Systems Pvt Ltd 35 SLV Complex AVS Compound 80 feet Road 4 Block Koramangala Bangalore 560 034 B M s Invensys Rail Systems India Pvt Ltd 112 amp 114 Raheja Chambers No 12 Museum Road Bangalore 560 001 B M s GE Transportation Systems AIFACS Building 1 Rafi Marg New Delhi 110 001 B M s Medha Servo Devices Pvt Ltd P 4 5 IDA Nacharam Hyderabad 500076 1 9 Scope This handbook covers MICROLOK II Electronic Interlocking system of M s Ansaldo to help the user in maintaining the system without going into circuitry details Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 9 Chapter 11 MICROLOK ELECTRONIC INTERLOCKING SYSTEM 2 1 Introduction Microlok II is a microprocessor based electronic interlocking system developed by M s US amp S P Ltd It is a Single Processor system with diverse dual software with extensive safety checks 2 2 MLK Il Hardware MLK II hardware consists of the following components 2 2 1 Card File B Slot No 1 to 15 amp 20 accommodate Non Vital Input Output or Vital Input or Vital Output boards Slot No 20 is used to acc
25. m Software The Executive Software is programmed in system EPROMs This Software defines what the system can do and how the various parts of the system operate together It includes all start up and operational safety tests including checking the Executive software itself that are the parts of the processor for continual assurance of safety operation Executive software pertains to Principles of Interlocking Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 SM s CONTROL PANEL Room a pee ELECTRONIC INTERLOCKING SYSTEM Relay Racks Relay Room FIELD GEARS Fig 1 2 Block diagram of EI System 1 4 2 2 Application Software The application software is programmed in Data EPROMS It contains the logic that defines how the inputs and outputs for a particular station are related It pertains to Table of Control of yard This shall be station specific The Executive Software and Application Software are programmed into Read Only Memories ROMs by the manufacturer Both the ROMs shall be separated and isolated from each other comparative study 1s shown in the following table Executive software Application software Common to all Els for Yard specific Different for different same manufacturer station 2 Factory installed Can be in
26. motherboard for plugging the different cards 1 e Vital Input Vital Output Non vital Input Output CPU and PS PCBs All the PCBs can communicate with one another through motherboard M TO LE 13 14 15 Fig 2 8 View of motherboard of a cardfile with some PCBs plugged in Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents CAMTECH S PROJ 2013 I4 HB EI MIS I 0 15 2 2 9 Keying plugs B Each PCB requires 6 Nos of keying plug adjacent to the 96 pin connector according to type of the board and corresponding female connectors on the motherboard slots B The purpose of the keying plug is to avoid insertion of wrong type of board in card file slot and it is similar to the code pin of a relay T 2 H Keying plug 5 ay 6 7 E JE m Keying plug JE sockets Female connectors tad wd Lm r i EM it sith AN Fig 2 9 Keying plugs on PCB and corresponding female connectors on motherboard 2 2 10 Connector Assembly Connector assemblies are used to connect MLK II cards with relays relay contacts and panel with the help of pre wired cables E Each connector assembly consists of connector receptacle i e cover guide pair to fix the connector on the card file and crimp contacts The 48 pin connector assembly is used for Vital input and Output boards The 96 pin connector assembly is used for Non Vital I O boards 48 pin connector assembly i
27. nal damage Ensure that the all cardfile modules are properly mounted and securely fastened Remove all printed circuit boards from the cardfile Inspect the cardfile back plane for loose or damaged connectors Also thoroughly inspect each printed circuit board for physical damage discoloured or damaged components and wiring insulation cracked or broken component leads and copper traces Questionable circuit boards should be replaced from the spares inventory B If necessary vacuum clean the interior of the cardfile without disturbing any wiring Use a non metallic insulated vacuum head Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents NI CAMTECH S PROJ 2013 14 HB EI MIS 1 0 28 B Re install the circuit boards into the cardfile Tighten the board retaining screws finger tight B Check all power input and signal supply leads for frayed or discoloured insulation and loose connections Also check all lightning arrestor voltage suppressor devices for any signs of physical degradation Visually examine all wire and cable harnesses for proper bundling and slack B Remove the VCOR relay from the installation and inspect it 87 Caution When handling any MICROLOK II circuit board or board component observe all Electrostatic Discharge ESD Precautions Improper handling of boards or components may result in damage to static sensitive circuitry Do not install or remove any MICROLOK II
28. ni active window Save as appears gt Double click on the Weekly Maintenance folder in the Maintenance PC drive gt Sub folders User Data Log System Event Log amp System Error Log appear gt Double click on the System Event Log folder gt Rename the default file Events Example File name CAMTECH_EVENT_ 30JULOO gt Click on the Save button Note If the CPU Board is removed from Card file the System Event Log may be lost Ensure that Event Log backup is taken from CPU board before removing the CPU board from Card file 2 8 3 Viewing the System Error Log For downloading the System Event log the following steps are to be followed gt gt gt gt Click on the System Error Log icon in the Maintenance Tools main menu System Error Log window appears in which event log is downloaded On completion of Event Log download click on the Save icon button in the toolbar of System Error Log window Mini active window Save as appears Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 25 Double click on the Weekly Maintenance folder in the Maintenance PC drive Sub folders User Data Log System Event Log amp System Error Log appear Double click on the System Error Log folder Rename the default file name Events Example File name
29. ogram available in EPROMs and finally gives output if the conditions are favourable The output voltage generated by the CPU Card is connected to Relay Output Cards 1 4 1 3 Relay Output Card RO card receives the output of CPU Card as input and gives output voltage to pick up relevant output relays through a tag block Before connecting output voltage to output relays safety checks are done internally Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 4 1 4 1 4 Control Cum Indication Panel Operator s panel CCIP is provided with push buttons control switches for individual operation of points clearing of signals releasing of crank handle interlocking ground lever frame gate controls cancellation of routes and other functions including block signalling auto signal IB signal adjacent yard layout to facilitate indication or operation cum indication as per requirement A control terminal with VDU in lieu of or in addition to conventional CCIP is provided as per requirement It consists of e A latest PC colour VDU monitor with minimum size of 17 43 cm as specified by purchaser e A Key board and Mouse Suitable interface to continuously display the current position status of various field equipment and track circuits It is possible to display the complete yard layout including the section on the monitor It also ha
30. ommodate Coded System Interface Card or CSI Card for CTC B Slot No 16 amp 17 accommodate Power Supply Board B Slot 18 amp 19 accommodate CPU board Vital input Vital output non vital I O cards Fig 2 1 Schematic diagram of MLK II Cardfile 2 2 2 CPU Board The CPU board is controlled by Motorola 68332 microprocessor and stores the Executive and Application software It contains the central controlling logic and diagnostic monitoring for the Microlok II system and provides five serial data ports to communicate with peripheral devices B Ports and 2 RS 485 type for communication with other MLK systems B Port 3 RS 423 232 types for communication with non vital control system such as operator s PC VDU Panel CTC Genesys Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents NI CAMTECH S PROJ 2013 14 HB EI MIS 1 0 10 B Port 4 RS 232 type for communication with non vital control system such as VDU panel CTC Genesys Indication Panel B Port 5 Debug port RS 232 type for communication with Maintenance PC for debugging Indications and buttons are available on front side of the CPU card as shown in Fig 2 2 Fig Label Device Purpose Emm 1 2 None 4 character On site configuration alphanumeric programming menus displays and options status application software ON LINE Green LED When lit indicates normal system operation successful diagnost
31. ont panel to show the status of non vital input output Indications Ref INPUTS 1 32 Green LEDs Monitors states of non vital inputs 1 32 When LED is lit respective input is on OUTPUTS Yellow LEDs Monitors states of SWITCHED non vital outputs 1 TO N12 1 32 32 When LED is lit 2 respective output is Fig 2 4 Front view of Non Vital I O Board 2 2 5 Vital Output Board B Each Vital Output PCB is having 16 independent 24 V outputs B Each output is assigned to the final relay which is driving the outdoor signalling gears such as HR DR in case of signal amp WNR WRR in case of points B Since the output boards are driving outdoor gears they are continuously monitored by the CPU and any abnormal voltage present in the output will lead to system reset shutdown to ensure safety Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents CAMTECH S PROJ 2013 14 HB EI MIS I1 0 13 Indications Fig Label Device Purpose Ref OUT1 OUT8 Monitor state of vital outputs 1 through 8 1 When lit indicates respective output is turned on OUT9 OUT16 Monitor state of vital outputs 9 through 16 2 When lit indicates respective output is turned on Fig 2 5 F j Board 2 2 6 Vital Input Board ig 2 5 Front view of Vital Output Boar B Vital Output PCB is having 16 inputs B Each vital input is assigned to the detection of outdoor gear status such as
32. printed circuit board with battery power applied to the cardfile Damage to the circuit board or the cardfile backplane may result 2 12 Corrective maintenance Corrective maintenance on the MICROLOK II system is limited to the correction of basic wiring and hardware problems and the replacement of modular system components If a component has been determined faulty return it to M s Ansaldo for repair or replacement STS Transportation Systems Pvt Ltd 8 Warning Do not attempt to repair any MICROLOK II system Printed Circuit Board or peripheral device in the field This equipment must be returned to M s Ansaldo for repair or replacement Any attempt to repair the MICROLOK II system may jeopardize the safety related functions of the system 2 13 Precautions do s amp don ts i Electrostatic Discharge Precautions When working on the Electronic Interlocking System contact with the system printed circuit boards cannot be avoided Hence following guidelines to be observed E Always stand on an approved conductive floor mat when touching or handling printed circuit boards E Always wear a strap grounding device The wrist strap should have a 1 0 megohm current limiting resistor Connect the wrist strap grounding connector to suitable ground connection Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents NI CAMTECH S PROJ 2013 14 HB EI MIS 1 0 29 Periodically check each wris
33. ructions series I Light Emitting Diode Left Right Light Emitting Diode Left Right Mega Byte MICROLOK Normal Point Indication Relay Object Controller Optical Fibre Cable Personal Computer Printed Circuit Board Panel Interlocking Power Supply Random Access Memory Research Design amp Standards Organization Relay Input Relay Output Read Only Memory Route Relay Interlocking Reverse Point Indication Relay Surge Protection Device Triple Modular Redundancy Track Proving Relay Route Button Un interrupted Power Supply Union Switch amp Signal Vital Cut Off Relay Visual Display Unit Video Graphic Adapter Point Indication Relay Normal Point Control relay Reverse Point Control Relay Normal Point Control relay Reverse Point Control Relay EEE February 2014 lt Click for Contents Et
34. s facility for displaying a portion of the yard or section in an enlarged mode if required The control terminal works with 230 V 10 50 Hz AC power supply for which a UPS of adequate capacity is provided The system have suitable interface like RS 232 or any other approved type to receive and process the information for displaying the status of field equipment on the control terminal l Processor with U T i memory chips U EPROMS T B and RAM L mero A C DLL R E eed D R K S D S tj Output Inputs 50 Core Processor relays cables cards HR DR WNR WRR CHKLR Field inputs ECRs TPRs NWKRs RWKRs etc etc Panel inputs GN UN EWN etc Read back inputs HRs DRs WNHs WPRs etc Fig 1 1 Interconnection diagram of Input Output amp CPU cards in EI System 1 4 1 5 Panel processor A microprocessor based electronic device used as interface between control indication panel and the EI system This is also called as non vital processor or panel processor Electronic Interlocking Maintenance instructions series I February 2014 ue for Contents CAMTECH S PROJ 2013 14 HB EI MIS 1 0 5 1 4 1 6 Maintenance Terminal Data logger Maintainer s terminal Maintenance Terminal consists of a standard PC with printer It performs the following operations e Display of the current status of points signals controls etc of the yard e Storage of minimum one month data or 10 00 000 e
35. s used for CPU and PS PCB E These connector assemblies are on top half potion on the back side of the PCB A corresponding female connector is provided in the motherboard according to the type of card 1 e vital non vital CPU or PS PCB 2 2 11 Address Select PCB In order to allow communications between the CPU board and the other boards 1 the cardfile each board must have its bus address configured in the hardware Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents CAMTECH S PROJ 2013 14 HB EI MIS 1 0 16 B The address select PCB is used to address particular slot of the card file Each address select PCB consists of 6 Nos of two position O amp 1 jumpers B These jumper settings are unique and shall match with the definition of cards in application program B 45 pin address select PCB is used for vital input and output boards and 96 pin address PCB is used for non vital boards B It is installed on the rear end of connector assembly B The jumper settings must exactly match the values set in the application program to ensure normal system operation and it does not depend on the order of the boards that happen to appear in the card file 96 pin Connector L8 pin Connector 1 B1 Fig 2 11 a Rear view of Narrow 96 pin connector for Non Vital I O PCBs b Rear view of Wide 48 pin connector for all other PCBs Electronic Interlocking Maintenance
36. stalled at engineers site by signal 3 Performs all operations Performs operations as per table of control of specific station Executive Software modify application software as and when It is not possible to modify Application engineers have the facility to required At the time of yard alteration work Data EPROMs are to be replaced with new Data EPROMs programmed with software pertaining to revised table of control as per altered yard data Compiler software is used for yard alteration Electronic Interlocking Maintenance instructions series I ue for Contents February 2014 CAMTECH S PROJ 2013 14 HB EI MIS 1 0 7 1 5 Working Input cards give information to the CPU card via system bus When any request is given by the panel operator e g Signal and Route buttons pressed for taking OFF a signal through operating panel the information Panel inputs along with field inputs is processed at the Processor Card The output of the Processor Card is taken on Relay Output Relay Drive RO Card only when the conditions are safe The output of RO Card is connected to the terminals of another tag block The output voltages from the other side of the tag block pick up the relevant Output Relays 1 6 System Architecture One of the following architecture may be employed in the system 1 6 1 Single hardware architecture with diverse software s 1 6 2 1 6 3 1 7 1 7 1 E In addition hot warm stand
37. t strap for continuity using an approved tester Continuity readings must be between 500 ohms and 10 megohms Discard any wrist strap that does not meet this criterion Always handle printed circuit boards by the edges Do not touch board components Keep the work area clean and free of debris Avoid using non conductive materials such as Styrofoam cups plastic ashtrays cellophane wrappers or plastic covered binders in the vicinity of the cards and modules Once removed from the cardfile rack immediately place printed circuit boards into an anti static conductive shielded bag Wrap the bag in conductive foam to protect the circuit board during transport and shipment Modules fitted with batteries may require special packaging Avoid wearing clothing made of synthetic fabric when handling modules Cotton overalls are preferred ii Packing plug in modules and cards shall be packaged in anti static packaging to prevent damage to Electro Static Sensitive Devices ESSD from electro static discharge When so packed the modules may be stored and transported without further precaution iii Storage For storage of Modules and cards following precautions shall be taken Must not be in close proximity to magnets e g Automatic Warning System AWS magnets Must be protected from damage due to electrostatic discharge Must be protected from the environment including physical handling damage If many modules are involved it is permissi
38. the CPU board front panel serial port Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents CAMTECH S PROJ 2013 14 HB EI MIS 1 0 18 2 4 2 5 2 5 1 2 5 2 2 5 3 Configuration of MLK II The configuration of single MLK II with VDU Maintenance PC is shown in the Fig no 2 12 To Adjacent Station Adjacent Station Fig 2 12 Configuration of MLK II Microlok 11 modes of operation The Microlok II CPU board has the following four basic modes of operation On line mode It is the normal mode of CPU operation This can be confirmed by observing the two 4 character displays and the LED indicators at top of the CPU board front panel In On line mode The phrase MICROLOK II scrolls across the upper display The application program name scrolls across the lower display and The ON LINE LED on the CPU board front panel illuminates CPS down mode The CPU assumes the CPS Conditional Power Supply down mode whenever the processor detects the failure of an internal diagnostic check The system is in CPS down mode can be confirmed by VCOR LED on the power supply front panel is OFF when the power supply board drops the VCOR relay Configuration mode The system assumes the CONFIGURATION mode whenever a Maintenance PC is connected to the Microlok CPU board diagnostic port and the configuration section of the Microlok II Maintenance Tools program is accessed
39. tioning is required Self diagnostic features Any failure in the system is located and enunciated Faulty module can be immediately replaced by spare module hence the down time of installation 1s reduced Less prone to short cut method total system goes to shut down if even if wrong feed comes across m The conventional block and intermediate Block system circuit can be incorporated in the EI system circuitry m Alteration due to yard remodelling does not require any wiring change only data of the CPU card is required to be changed Hence yard remodelling does not require large scale alterations and can be carried out in negligible time 1 e less manpower 1 3 Terms used in El system CPU Central Processing Unit Microprocessor or Microcontroller RAM Random Access Memory Used for vital data processing and logs EPROM Erasable Programmable Read Only Memory Used for storing Executive and Application software Electronic Interlocking Maintenance instructions series I February 2014 Click for Contents NI CAMTECH S PROJ 2013 14 HB EI MIS 1 0 2 EEPROM Electrically Erasable Programmable Read Only Memory Used for storing Executive and Application software IC Integrated Circuit Hardware redundancy Availability of additional hardware identical to the normally working hardware for taking over at the time of failure Software redundancy Availability of additional software identical to th
40. vents e Display of recorded events and e Data transfer to floppy CD flash memory or any other storage media e Transfer of recorded events to external data logger E Result of the failure of any card module in the system is clearly indicated E Control operation of yard functions is not possible from the maintenance terminal E In case of any module card becoming faulty this fact is displayed on MT with diagnostic facility to identify faulty module card 1 4 1 7 Object Controller E Object Controller is a processor based system having similar architecture as of CIU It works as a slave unit of Central Interlocking Unit CIU through duplicated serial communication and placed within 15 Km radius from CIU The OC drives the field gears Points Signals amp Relays and take feedback Inputs from various field gears OC is normally placed in field locations The medium of communication between CIU and OC is OFC provided on a ring basis In case of communication failure between CIU and OC all the outputs are brought to safe state whenever two consecutive telegrams are not received in stipulated time period Occurrence of any error in any OC or hardware fault leading to unsafe condition immediately withdraws all output commands and removes the source supply to outputs 1 4 2 Software The software of the system has two layers e Executive Software or System Software e Application Software 1 4 2 1 Executive Software or Syste
41. ving relays button inputs from the operator s panel and read back of output relays Total no of inputs depends on yard layout The inputs to the RI Cards consist of e Field inputs ECRs TPRs NWKR RWKR etc e Panel inputs GNs Signal buttons UNs Route buttons etc e Read back inputs HRs DRs WNR WRR etc All the inputs are terminated on tag blocks which in turn are connected to input cards These cards read the conditions of inputs and pass the information to EI system Provision has been kept for testing of malfunctioning of the system in reading the status of the relays Opto couplers are provided to isolate field optically from the system in input cards 1 4 1 2 Processor Card This card is also called as CPU card of the system It 1s provided with microprocessor chip consisting of RAM ROM EPROM EEPROM memory ICs EEPROMs or EPROMs are programmed with software required for executing the system commands There are two types of EPROMs e System EPROMs e Yard data EPROMs Executive software is loaded in the system EPROMs System EPROMs are universal Yard data EPROMs are loaded with Application software These are yard specific The function of this card is to execute the commands given by the user Station Master Panel Operator on processing of relevant push buttons on the operating panel The Processor card senses the operation of the panel through input cards It processes the input as per the pr
42. ware and following simple instructions 27 Microlok Il Maintenance Tools Program Maintenance personnel and application engineers can perform a wide range of Microlok II system maintenance configuration and diagnostic functions using the tools provided in this Maintenance tools program Following tasks can be performed with this program B Viewing the current status of the Microlok II equipment and related systems B Reviewing stored system event and error data B Reconfiguring and resetting the system when necessary The Maintenance Tools program provides these tools as selections on the Microlok II Maintenance Tools main menu as shown in Fig Electronic Interlocking Maintenance instructions series I February 2014 lt Click for Contents Et CAMTECH S PROJ 2013 14 HB EI MIS 1 0 20 The main menu displays the selection buttons that activate the primary functions of the program E These selection buttons are grouped into four categories E Run time Monitor Historical Data System adjustment Setup Other Tools The functions of various tools are explained in the following paragraphs The Maintenance PC is linked to the Microlok II installation CPU board through an RS 232 serial connection Y MICROLOK II Maintenance Tools Program OYO c2 S02 at Select me of the toos belma a p MELEE TT j Monitor 5 CY Ld Vaidle p 5 pslam Ero Bet Time

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