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Pakistan Railways Rehabilitation Signalling Project
OCS950 Maintenance Training
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OCS950 – Maintenance Training Course
100174081 OCS950 Maintenance Manual Training Material Rev.A2
Pakistan Railways Rehabilitation Signalling Project
OCS950 � Basic Course
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A4
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A5
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A6
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A7
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Features
100174081 OCS950 Maintenance Manual Training Material Rev.A8
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Features
100174081 OCS950 Maintenance Manual Training Material Rev.A9
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A10
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System Overview
100174081 OCS950 Maintenance Manual Training Material Rev.A11
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System Overview
100174081 OCS950 Maintenance Manual Training Material Rev.A12
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System Overview
100174081 OCS950 Maintenance Manual Training Material Rev.A13
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System Overview
100174081 OCS950 Maintenance Manual Training Material Rev.A14
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System Overview
100174081 OCS950 Maintenance Manual Training Material Rev.A15
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System Overview
100174081 OCS950 Maintenance Manual Training Material Rev.A16
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A17
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A18
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A19
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A20
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Concentrator
PCM : Pulse Code Modulation
Fiber optic
RS232 RS232
100174081 OCS950 Maintenance Manual Training Material Rev.A21
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A22
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A23
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A24
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A25
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A26
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A27
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Concentrator
100174081 OCS950 Maintenance Manual Training Material Rev.A28
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A29
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Object Controller
Object Controller 1 to 4 in First Sub-rack
� Max 4 OC per sub-rack
� CCM-E board in first slot of each OC
� Control boards
� 1 CCU with 2 COM boards
� 1 OCT board
100174081 OCS950 Maintenance Manual Training Material Rev.A30
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Object Controller
Object Controller 5 to 8 in Second Sub-rack
� Max 4 OC per sub-rack
� CCM-E board in first slot of each OC
� Control boards
� 1 OCT board
100174081 OCS950 Maintenance Manual Training Material Rev.A31
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A32
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Object Controller
CCM-E: Controller and Contact Monitoring Enhanced Board
� 4 vital inputs for Track Circuit Status (Occupied, Free, Out of Control), Relay Detection (ML, Photo cell and so on), and Relay Interface between CBI and Non-CBI.
� Main board to put EEPROM for signal software, point software, and Transparent Input Output software.
� Always exist in the first slot of every OC position.
100174081 OCS950 Maintenance Manual Training Material Rev.A33
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Object Controller Front panel LED indicatorsCCM-E
LED Description Hints for fault tracing
“PWR”
Green
ON
Power on (5V) indication
OFF
Power missing
- Check corresponding 24V push-
button on the OCT board.
- Check the “PWR” LED on the OCT
board indicating 24V system voltage
from the power supply unit.
- Check fuses.
- Replace CCM-E board.
“RD”
Green
ON
Receive Data from CCU
OFF
No Receive Data from CCU
Check COM board status
“CPR”
Green
ON
Processor running
OFF
Processor halt
Check for OC error codes in
interlocking processor alarm log.
100174081 OCS950 Maintenance Manual Training Material Rev.A34
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A35
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A36
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A37
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A38
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A39
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A40
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A41
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Object Controller
COM: Communication and Modem Board
� COM3(Serial Connection)
100174081 OCS950 Maintenance Manual Training Material Rev.A42
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A43
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A44
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Object Controller
OCT: Power Supply Board � One per sub-rack
� Power the sub-rack with 24V
� Switches for disconnection of each OC
100174081 OCS950 Maintenance Manual Training Material Rev.A45
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Object Controller
LED Description Hints for fault tracing
“PWR”
Green
ON
Power on (24V) indication
OFF
Power missing
- Check fuses.
– Check the power supply
unit.
100174081 OCS950 Maintenance Manual Training Material Rev.A46
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A47
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A48
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A49
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A50
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Object Controller
Power Supply Units
� PSU 72
� PSU 330
� PSU 321
100174081 OCS950 Maintenance Manual Training Material Rev.A51
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Object Controller
PSU 72
� Input Voltage 220 Vac
� Output Voltage 24 Vdc
� Used for OC subracks and fan unit
100174081 OCS950 Maintenance Manual Training Material Rev.A52
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Object Controller
PSU 330
� Input Voltage 220 Vac
� Output Voltage 110 Vac and 24/50 Vdc
� Used for LMP and SRC
100174081 OCS950 Maintenance Manual Training Material Rev.A53
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Object Controller
PSU 321
� Input Voltage 3x380 Vac
� Output Voltage 3x380 Vac
� Used for MOT
100174081 OCS950 Maintenance Manual Training Material Rev.A54
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Object Controller
100174081 OCS950 Maintenance Manual Training Material Rev.A55
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A56
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Data Transmission
100174081 OCS950 Maintenance Manual Training Material Rev.A57
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OCS950 – Basic Course
100174081 OCS950 Maintenance Manual Training Material Rev.A58
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Tools
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Tools
100174081 OCS950 Maintenance Manual Training Material Rev.A60
Pakistan Railways Rehabilitation Signalling Project
OCS950 - Configuration of Subrack and Address Strapping (based on Pakistan Rehab project)
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Configuration of subrack and address strapping
� Tools for generate the address for OC and CCU and generate configuration file for board strapping.
100174081 OCS950 Maintenance Manual Training Material Rev.A62
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Why we address the system?
� A name indicates what we seek. An address indicates where it is.
� Addressing indicates the logical location of the object.
� If wrongly coded, the object controller will not start.
100174081 OCS950 Maintenance Manual Training Material Rev.A63
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Addressing in the System
� The object controller addresses are built on the following data
– Interlocking area
– Communication loop
– Concentrator unit (CCU)
– Object controller
100174081 OCS950 Maintenance Manual Training Material Rev.A64
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How addressing work ?
� First address will generate from Config subrack and board strapping file.
� ILS team will map address with the wayside object.
� Now the interlocking know that where each address is.
� When CIS want to communicate with wayside they send the telegram which contain address and order.
� To identify which part of telegram stand for the OCgentab file is required.
100174081 OCS950 Maintenance Manual Training Material Rev.A65
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Where each address comes from ?
� A1 = 0X AB
� A=Loop no. then transform to Hex
� B={IL no (0-7) x 2} Hex
� A2 = 0X AB
� A=CCU no. (0,1,2,…) then transform to Hex
� B = {(OC no.(1-8)x2 )-1} then transform to Hex
� IND : Individualization
Note : IND is not directly use for addressing but it’ll tell us about
configuration of each combination
of board for example CCME-SRC
� CRC
CRS is abbreviation for Cyclical Redundancy Check and the CRC-program is used
to calculate and verify checksums for our config subrack we use CRC8
Note : The calculation for A1 and A2 is for the same understanding between the team only it can change depend on designer or type of IPU.
100174081 OCS950 Maintenance Manual Training Material Rev.A66
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CCU Address
CCU COM1 A CCU COM1 B
X 8 X
X 7 X
X 6 X
X 5 X
X 4 X
X 3 X
X 2 X
X 1 X
SW33 SW34
Loop No.
Range 1-13Cable
data
CCU address
Rang 0-14 Not
used
100174081 OCS950 Maintenance Manual Training Material Rev.A67
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Object Controller Address Field
A1 IND
X 8 X
X 7 XX 6 X
X 5 XX 4 X
X 3 X
X 2 X
X 1 X
SW9 SW11
A2 CRC
X 8 X
X 7 X
X 6 X
X 5 X
X 4 X
X 3 X
X 2 X
X 1 X
SW10 SW12
Loop No.
Range 1-13
CCU address
Range 0-14
Type of
object
OC No.
Range 0-7
CRC
Interlocking area
Range 0-6
Always 0
Always 1
100174081 OCS950 Maintenance Manual Training Material Rev.A68
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Back Plane Address Strapping Fields
100174081 OCS950 Maintenance Manual Training Material Rev.A69
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A1
ON
12
34
56
78
ON
12
34
56
78
ON
12
34
56
78
ON
12
34
56
78
IND
A2 CRC
MSB
LSB
MSB
LSB
A1 = 32 (Hex)
A2 = 01 (Hex)
IND = 38 (Hex)
CRC = C4 (Hex)
Back plane DIP Switches
0 1 0 1
0 1 0 1
100174081 OCS950 Maintenance Manual Training Material Rev.A70
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Board and Position Strap
� To avoid shifting positions of connectors in between boards in same sub-rack
� If wrongly coded or placed the object controller will not start
100174081 OCS950 Maintenance Manual Training Material Rev.A71
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� The position and board straps will protect the OC from going into operation if the wrong boards are used in the wrong position.
� The position and board straps used for all boards except COM and OCT.
OCS950 - Configuration of Subrack and Address Strapping
100174081 OCS950 Maintenance Manual Training Material Rev.A72
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12
6543
A6A5A4POSF5
POSF3POSF4
12
6543
NR1
POSF1POSF0
NR0POSF2
ONOFF
C
ONN
EC
TO
R
P1SW1
SW2
Board Straps(Address)
Position Straps
Board Straps(Number)
Position Straps
OCS950 - Configuration of Subrack and Address Strapping
100174081 OCS950 Maintenance Manual Training Material Rev.A73
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Board Strap
12
6543
A6A5A4POSF5
POSF3POSF4
12
6543
NR1
POSF1POSF0
NR0POSF2
ONOFF
C
O
NN
E
C
T
O
R
P1SW1
SW2
•The board straps are used to make a distinction between boards of the same type within the same OC.
A4-A6 will depend on the type of board.
Protect wrongly place for the
same type of board in the OC in
case that more than 1 same type board is used in 1 OC
100174081 OCS950 Maintenance Manual Training Material Rev.A74
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LED indication
LED 1 LED 2 LED 3 Description
Off Off Off CCM-E board is powerless.
On - - CCM-E board is powered.
On On Off The CCM-E board receives data from the CCU. But, the CPU is not triggering one of the RTWs. The board is either performing a start up or is not working correctly.
On On On The SW is executing.
LED1 LED2 LED3
P2
P4
Frontpanel
Connectors
P2 and P4
Three LEDs
indicating thestatus
100174081 OCS950 Maintenance Manual Training Material Rev.A75
Pakistan Railways Rehabilitation Signalling Project
OCS950 - Object Controller Cabinet
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� Cabinet Layout and Components
� Power Distributions
� Power Supply Units
� Power Cables
� Boards
� Communication Controller Unit (CCU)
� Coding Pin
Outline
100174081 OCS950 Maintenance Manual Training Material Rev.A77
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Indoor OBC
3NSS004544-11
HxWxD: 2260x1400x600mm
4 OCS950 sub-racks 16 OC
4 Compact PSUs
Base 3NSS005039-02 HxWxD:100x1400x600mm
Cabinet
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Subrack
•Subrack 3NSS001503-01: Indoor use only
•The sub-rack should preferably be ordered completely assembled with OC boards and dummy panels and with address strapping coded in the back plane.
100174081 OCS950 Maintenance Manual Training Material Rev.A79
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Power from PSUs to Connection Units
20% Spare needed for each unit
1 function per 1 Unit
Use with Power Cable
Connection Unit (Voltage Input)
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8x5 5 Voltage Levels
6x2 2 Voltage Levels
3x2 2 Voltage Levels
Connection Unit (Voltage Input)
100174081 OCS950 Maintenance Manual Training Material Rev.A82
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Power from Voltage Input to Board (Except CCM-E)
Feed power to Board
Outputs from Boards
Use with Connection Cable (for inputs and outputs)
Connection Unit (Terminal Block)
100174081 OCS950 Maintenance Manual Training Material Rev.A83
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CCM-E
LMP
MOT1
SRC
Have
fuses
and
Terminals
For
Power
Connection Unit (Terminal Block)
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Connection Unit (Terminal Block)
Connection Unit Voltage Input (3x2)
From PSU
Connection Unit Voltage Input Connecting with Connection Unit
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Connection Cable
Connection between board and Connection Unit
Power (except CCM-E)
Inputs from equipment to board via Cable Rack Cabinet
Outputs from board to equipment via Cale Rack Cabinet
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Connection Cable
CCM-E
LMP
MOT1
SRC
Have
Inputs
for Power
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� Cabinet Layout and Components
� Power Distributions
� Power Supply Units
� Power Cables
� Boards
� Communication Controller Unit (CCU)
� Coding Pin
Outline
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•Receive power from Power Supply Panel (through Circuit Breaker)
•Feed power to PSU
•Main components � Fuse, Protective Earth Terminal, Disconnection Terminal
Power Distribution Terminal
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For PSU 72: Subrack and Fan Unit
100174081 OCS950 Maintenance Manual Training Material Rev.A90
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For PSU 72: Subrack and Fan Unit
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For PSU 330: Signal and Magnetic Key Locked Point
100174081 OCS950 Maintenance Manual Training Material Rev.A92
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For PSU 330: Signal and Magnetic Key Locked Point
100174081 OCS950 Maintenance Manual Training Material Rev.A93
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For PSU 321: Electrical Point Machine
100174081 OCS950 Maintenance Manual Training Material Rev.A94
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For PSU 321: Electrical Point Machine
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Connecting: 220 VAC to PSU 72 ���� BX220 / NX220
Power Supply Panel Power Dist Terminal PSU72
Cables beyond OBC and Circuit Breakers � CRSC
OBC � Power Cables
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Connecting: 220 VAC to PSU330 ���� BX220 / NX220
Power Supply Panel Power Dist Terminal PSU330
Cables beyond OBC and Circuit Breakers � CRSC
OBC � Power Cables
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Connecting: 3x380 VAC to PSU321
Power Supply Panel Power Dist Terminal PSU321
Cables beyond OBC and Circuit Breakers � CRSC
OBC � Power Cables
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� Cabinet Layout and Components
� Power Distributions
� Power Supply Units
� Power Cables
� Boards
� Communication Controller Unit (CCU)
� Coding Pin
Outline
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.•Receive power from Power
Distribution Terminals
•Feed Power to Subracks and Power Connection Unit
Voltage Inputs
•PSU72, PSU330 and PSU321
Power Supply Unit
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PDCPower
Distribution
Terminal
PSU
Connection Unit
Voltage Input
Subrack
Fan Unit
Board
Power Feeding Arrangement
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PSU72
•Input 220VAC
•Output 24VDC
•to Subracks and Fan Unit
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Pin Designation: in Application Document
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Pin Designation: in OBC
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PSU321
•Input 3x380VAC
•Output 3x380VAC
•Electrical Point Machine
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Pin Designation: in Application Document
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Pin Designation: in OBC
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PSU330
•Input 220VAC
•Output 110VAC for Signal
•Output 28 VAC for Night
Mode Signal
•Output 50VDC for External
Logic (SRC for Magnetic
Key Locked Point, Axel
Counter, Level Crossing
100174081 OCS950 Maintenance Manual Training Material Rev.A108
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Pin Designation: in Application Document
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Pin Designation: in OBC
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� Cabinet Layout and Components
� Power Distributions
� Power Supply Units
� Power Cables
� Boards
� Communication Controller Unit (CCU)
� Coding Pin
Outline
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Length (mm.)Cable TypeNumber and Size of Cores
Power Cables
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3NSS005965-xxxx 2x2.5 sq.mm.
3NSS005202-xxxx0 3x1.5 sq.mm.
100174081 OCS950 Maintenance Manual Training Material Rev.A113
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3NSS005966-xxxx 3x2.5 sq.mm.
3NSS008732-xxxx0 4x1.5 sq.mm.
100174081 OCS950 Maintenance Manual Training Material Rev.A114
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3NSS005745-xxxx
DSUB15 Female - Male
OCT and PSU72
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3NSS003446-xxxx
DSUB9 Female - Male
Fan Unit and PSU72
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3NSS005967-xxxx 5x2.5 sq.mm.
100174081 OCS950 Maintenance Manual Training Material Rev.A117
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3NSS005201-xxxx 2x1.5 sq.mm.
100174081 OCS950 Maintenance Manual Training Material Rev.A118
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� Cabinet Layout and Components
� Power Distributions
� Power Supply Units
� Power Cables
� Boards
� Communication Controller Unit (CCU)
� Coding Pin
Outline
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CCM-E: Contact Monitoring-Extended Board
4 Inputs
For detection (relay contact status)
Ex. Track Circuit, Alarm, Magnetic Key Locked Point Detection
EEPROM: burn according to boards in the same OC as CCM-E
100174081 OCS950 Maintenance Manual Training Material Rev.A120
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CCM-E: Pin Designation
Numbers of connected pins are defined according to order of channels of inputs.
CCO = Contact Code Output
CCI = Contact Code Input
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CCM-E: Controller and Contact Monitoring Enhanced Board
100174081 OCS950 Maintenance Manual Training Material Rev.A122
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.•Single Connection of Contact Monitoring
•4 Inputs: 3 Used 1 Spared (Unused)
•Interface: CRSC
CCM-E: Circuit: Track Circuit Detection
Connection UnitConnection Cable
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Connection Unit
Connection Cable
CCM-E: Connection
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CCM-E: Circuit: Level Crossing
100174081 OCS950 Maintenance Manual Training Material Rev.A125
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LMP: Lamp Board
•Controls Signal
•6 Outputs = 4 Proceeds 2 Stops
•Maximum 2 LMPs in 1 OC
•IND Specified by Type of Signal Control
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LMP: Inputs and Outputs
Proceed lamp no 1
Proceed lamp no 2
Proceed lamp no 3
Proceed lamp no 4
Stop lamp no 1
Stop lamp no 2
110/230 V*
110/230 V*
28/56 V*
0 V
1
2
3
4
1 Mandatory fuse*2
3 4 Optional fuse*
MAINS_SUPPLY_PROCEED
MAINS_SUPPLY_STOP
MAINS_RETURN_NIGHT
MAINS_RETURN_DAY
LMP board
Proceed1
Proceed1_return
Proceed2
Proceed2_return
Proceed3
Proceed3_return
Proceed4
Proceed4_return
Stop1
Stop1_return
Stop2
Stop2_return
x
x
x
x
x
x
* Application specific
100174081 OCS950 Maintenance Manual Training Material Rev.A127
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LMP: Inputs and Outputs
100174081 OCS950 Maintenance Manual Training Material Rev.A128
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LMP: Pin Designation
100174081 OCS950 Maintenance Manual Training Material Rev.A129
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Connection Unit
LMP: Connection
Connection Cable
100174081 OCS950 Maintenance Manual Training Material Rev.A130
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LMP: IND
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MOT1: Motor Control Board Type 1
� Controls AC point machine, both one phase and three phase
� Maximum two MOT1 in one OC
� In voltage 80-400 VAC
� Out voltage 80-400 VAC
• IND Specified by Type of Point Control
100174081 OCS950 Maintenance Manual Training Material Rev.A132
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MOT1
� Use CMO (CCO, CCI) and CMD (CMD) for Contact Monitoring
� 2 Channels are CMO (CCO1 and CCO2)
� 2 Channels are CMD (CMD1 and CMD2)
Power to Drive Motor
Detection
Use CMD because of Normal
and Reverse Position
CCO2, CCI2 must be internally
looped according to the software requirement
100174081 OCS950 Maintenance Manual Training Material Rev.A133
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MOT1: Pin Designation
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MOT1: Pin Designation
Power to Drive Motor
Detection
100174081 OCS950 Maintenance Manual Training Material Rev.A135
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MOT1: Pin Designation
Power to Board
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Connection Unit
MOT1: Connection
Connection Cable
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MOT1: IND
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SRC: Safety Relay Controller Board
� Controls wayside equipment such as Magnetic Key Locked Point, Level Crossing, Axle Counter, typically relays
� Maximum three SRC in one OC
� Input/Output voltage 12-60VDC
� 4 Vital Outputs
100174081 OCS950 Maintenance Manual Training Material Rev.A139
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SRC: Pin Designation
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SRC: Pin Designation
Power
Equipment(Relay)
100174081 OCS950 Maintenance Manual Training Material Rev.A141
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SRC: Connection
Connection Unit
Connection Cable
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SRC: IND
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OCT: Power Supply boards (Octopus)
� To be the power transfer of +24 V
to the back plane and the
I/O-boards and the CCU-unit from
the power supply unit and to
control the current to each OC.
� To have the +24 V power supply
switches for each OC (position)
for the on/off control.
� To be the interconnection point
between two sub-racks for the
CCU-OC transmission links
having one mutual CCU.
� Part of CCU
� The OCT board is a mandatory
board for every sub-rack.
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OCT: Pin Designation
� P2 ���� Power from PSU� 24 VDC from PSU to Subrack
100174081 OCS950 Maintenance Manual Training Material Rev.A145
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OCT: Pin Designation and Connection
� P4 ���� Communication
between Subrack 1 and
Subrack 2 (same CCU)
� 3NSS002775-xxxx
� 37 female poles only for
OCT Communication
with next Subrack
100174081 OCS950 Maintenance Manual Training Material Rev.A146
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COM-3: Communication and Modem Board
� Communication between OC (via OC Cabinet) and Interlocking System (via IPUC)
� Can be the communication between 2 OC Cabinets (same Communicating Loop)
� Part of CCU
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COM-3: Pin Designation
� P6 ���� DB9 ���� Outside Cabinet
� P4 ���� DB25 ���� Inside Cabiinet
To Next CCU in the same Cabinet
From CCU in another cabinet / from IPU in IPUC
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COM-3: Connection
� 3NSS003442-0120� 9 Poles � IPU and CCU
IPUC IPUC
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COM-3: Connection
� 3NSS003831-0020� 25 Poles � CCU and CCU in the
same Cabinet
IPUC IPUC
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COM-3: Connection
� 3NSS003442-0085� 9 Poles � CCU and CCU in
another cabinet
IPUC OBC
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Fan Unit
� 24VDC from PSU72
� 6 Fans
• The fan unit should be placed in-between sub-racks, providing the fan unit to use both suck and blow air technique.
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Fan Unit: Position
100174081 OCS950 Maintenance Manual Training Material Rev.A153
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Fan Unit: Pin Designation and Circuit
Male 9 pin D-sub
connector forpower supply
Female 9 pin D-
sub connector foralarm
Pin 1 Normally closed
Pin 5 CommonPin 9 Normally open
Fan 1
Fan 2
Fan 3
-X2
321
-X3
321
-X4
321
-X5
321
-X6
321
-X7
321
-X1
3
2
1
-X8
2
1Temp.sensor
Relay
-X9
21
-X12
+
-
1
5
9
8
4
7
3
Pin
-P1
-P4
Fan 4
Fan 5
Fan 6
SC
SC
-Fan unit
100174081 OCS950 Maintenance Manual Training Material Rev.A154
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Fan Unit: Connection
3NSS003446-0020
DSUB9
Fan Unit and PSU72
100174081 OCS950 Maintenance Manual Training Material Rev.A155
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Dummy Panel
� Fulfil the space in OC and Subrack
100174081 OCS950 Maintenance Manual Training Material Rev.A156
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Dummy Panel: for Board Space
•6 available sizes
•Defined in Configuration of Subrack and Address Strapping but not in OC Distribution List
100174081 OCS950 Maintenance Manual Training Material Rev.A157
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Dummy Panel: for PSU Space
•3NSS003646-01 ���� used with cassette (at least 1 PSU in the row)
100174081 OCS950 Maintenance Manual Training Material Rev.A158
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•3NSS004967-01 ���� entire row +H5 (replaces cassette if there are not PSU in the row)
Dummy Panel: for PSU Space
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•3NSS008898-01 ���� between subrack +H5 and +H7
Dummy Panel: for Position +H6
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Board Size
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Board Position in Subrack
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Board Position in Subrack
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Board Position in Subrack
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Board Position in Subrack
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� Cabinet Layout and Components
� Power Distributions
� Power Supply Units
� Power Cables
� Boards
� Communication Controller Unit (CCU)
� Coding Pin
Outline
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CCU: Communication Controller Unit
� 2 COM-3 + 1 OCT
� 1 CCU handles 2 Subracks (8 OCs)
� Communication between OC (OC Cabinet) and CIS (IPU) and between 2 OC Cabinets (same communicating loop)
� Loop number, IPU number, Interlocking Area number are defined in Loop Communication Diagram
� 1 IPU per 1 Station except BQM (2 IPUs)
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Loop Communication Diagram
� 1 IPU can be used up to 12 loops (8 for this project)
� Loop 3 and 4 for communication for IPU Loop
� Loop 1, 2, 5-8 for communication between OC Loop
� IPU950 R3
Standby
1 ... ... 15
1 ... ... 8
Interlocking
System
Concentrator
Loop
Loop Port
Concentrator
Controller
Link
Object
Controller
Object
Cable
Wayside
Object
Central
Interlocking
System
Object
Controller
System
1 ... ... (n)
Main
Central Computer
...1 ... (n)
From Paki Rehab OC Distribution List Training Material by Wichit Inuthai
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Loop Communication Diagram
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OC Cabinet and IPU Cabinet
NWS OBC_DN1 Sheet 51 NWS IPUC Sheet 6
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OC Cabinet and IPU Cabinet
NWS OBC_DN1
NWS IPUC
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Loop Communication Diagram and IPU Cabinet
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� Cabinet Layout and Components
� Power Distributions
� Power Supply Units
� Power Cables
� Boards
� Communication Controller Unit (CCU)
� Coding Pin
Outline
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Coding Pin
Prevents the mismatching between Connection Unit and Connection Cable
Defines in OBC drawing, assigned according to the position of Connection Unit in OC Cabinet
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Coding Pin
Break fingers and
insert to Connection
Unit
Insert to Connection
Unit female plug number as assigned
100174081 OCS950 Maintenance Manual Training Material Rev.A175
Pakistan Railways Rehabilitation Signalling Project
OCS950 � Maintenance Manual
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OCS950 – Maintenance Manual
Prerequisites
Persons who need to perform the maintenance shall have the knowledge of OCS950 and able to read and understand the OC Cabinet drawing before performing the work.
The following prerequisites shall be considered during maintenance and fault-finding:
�All OCS950 components should be handled in accordance with the guideline for Electrostatic Discharge for handling electronic equipment,
�Good workmanship is required.
�Maintenance and fault finding should be performed by personnel with proper education and training.
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OCS950 – Maintenance Manual
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OCS950 – Maintenance Manual
Electrical Isolation
High voltages are distributed in object cables and interconnection cables.
All the necessary safety precautions required to handle electrical appliances
shall be taken. This includes the following:
•Isolate appropriate supply voltages before
•removing front connector
•replacing boards in the sub-rack
•replacing fuses
•accessing terminals
•Remove the front connector before a board is to be replaced.
•Ensure that cables are handled carefully to avoid accidental damage.
•Ensure that proper earthing of the equipment is maintained
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OCS950 – Maintenance Manual
Electrical Isolation
The site specific drawings should be referred to if isolation is required at this
level. Generally isolation should be performed at the lowest practical level
based on the need to keep trains running.
Reference must be made to the appropriate wiring diagrams and product
application manuals.
The methods to isolate supply voltages are detailed below:
•Switching off the OC Logic 24 V DC circuit breaker on the front of the
“System Power” PSU 72 to remove power to all object controllers in a sub-
rack.
•Selective breaking of the 24 V DC supply to one of the four object
controllers in a sub-rack is accomplished via the POS1 to POS4 24 V push
buttons on the OCT board, see Figure in next slide.
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OCS950 – Maintenance Manual
Electrical Isolation
OC1 OC2 OC3 OC4 CCU
OC sub-rack OCT
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OCS950 – Maintenance Manual
Electrical Isolation
The methods to isolate supply voltages (cont.):
•Observe that only the 24 V DC supply is broken and not the supplies that
may be required for the objects connected to the object controller in
question. This supply also removes the coded signal from the 4 “CMO”
inputs on the CCM-E board.
•Selective breaking of the supply voltage for signal lamps, point machines
and relays is accomplished by removal of the individual circuit protection
devices for each board i.e. LMP, MOT, COM-3 or SRC. The circuit protection
devices, i.e. fuses, are placed in the cable connection units for each board.
•Isolation of the supply voltage for signals and point controllers can be
achieved by using one of the installed isolation switches.
•Isolation of the 24 V DC to the fan unit is achieved by switching off the
relevant circuit breaker on the front of the PSU72.
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OCS950 – Maintenance Manual
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OCS950 – Maintenance Manual
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OCS950 – Maintenance Manual
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OCS950 – Maintenance Manual
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OCS950 – Maintenance Manual
Preventive Maintenance
No periodic adjustments are necessary to sustain continuous system
operation.
Some simple preventive maintenance, such as inspection and cleaning
activities, should be done to maintain high availability, ensure long
component life, and simplify corrective maintenance. If the maintenance
is done periodically, it may help to prevent system malfunction.
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OCS950 – Maintenance Manual
Preventive Maintenance:Interval – 12 months
Check Locks, Doors and Covers
• Unlock, open, close, and lock all doors.
• Check that all doors close properly and seal against incoming
dust.
• Check that all door seals are OK.
Tighten Board, Unit, Plug and Socket Screws
• Tighten all screws securing the electronic boards in the racks.
• Tighten all screws holding the contacts on the front of the
electronic boards.
• If a screw is missing, replace it with a new screw.
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OCS950 – Maintenance Manual
Preventive Maintenance:Interval – 12 months
Check for Outside Damages on Indoor Cabinets
• Check the exterior of the cabinet for damages.
• Check the doors, especially that they connect to the seal
properly when closed, and that they do not let any dust in.
• Paint scratches on the surface to prevent rust.
• Remove rust and re-paint the cabinet stand.
• Damaged doors must be replaced.
• Damaged lock covers or locks must be replaced.
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OCS950 – Maintenance Manual
Preventive Maintenance:Interval – 12 months
Check COM-3 Board Redundancy
• Reset the active COM-3 board and check that the standby COM-3
board takes control and stays in control of the OC.
• Check with the dispatcher that there is no loop split and that there is
still central control of the OC.
• Repeat the test above for the now active COM-3 board.
• If this test fails, one of the COM-3 boards is probably broken.
Notify the dispatcher before performing the test or replacing the COM-3 boards.
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OCS950 – Maintenance Manual
Preventive Maintenance:Interval – 12 months
Vacuum Clean Cabinet
• Use plain nozzle to vacuum the cabinet floor and any surface
that can assemble dust.
• Use nozzle with long brushes to further clean the surfaces
above and to also vacuum all other visible surfaces and parts.
• Excessive dust inside the cabinet indicates that door seals
might have to be replaced or that seals of incoming cables are
insufficient.
Clean Cabinet Exterior, Indoor Cabinets
• Brush off dust from the cabinet roof.
Check Seal of Incoming Cables
• Inspect the grommets for incoming cables to make sure that
dust, water or insects cannot enter.
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OCS950 – Maintenance Manual
Preventive Maintenance:Interval – 3 months
Check Fan Unit Alarm Indication
• Check the LEDs on the optical display on the front.
Green The fan is OK.
Red Fan failure.
• There may be an acoustic alarm if the red LED is lit. It can
be turned off via a reset button on the front panel.
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OCS950 – Maintenance Manual
Corrective Maintenance
The OCS is designed to minimize the frequency of corrective
maintenance and to provide a high degree of system
reliability and availability.
Corrective maintenance involves performing fault isolation to a
failed system component, replacing the system component,
and checking out the system for correct operation.
Additional diagnostics to aid in fault isolation is available in the
form of LED indicators that reveal the operating status of
relevant boards.
Exchanging components such as EEPROMs is considered as
reinstallation and not maintenance.
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of Boards
If a board is found to be defective, it must be replaced by a
spare board.
Board replacement from spares requires that the hardware
used to configure an object controller for a specific
wayside object remains intact.
Therefore, if the CCM-E board is replaced, the contents of
the EEPROM on the spare must be identical to those
on the failed board (i.e. microprocessor instructions for
CCM-E.
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of Boards (For both OC boards and COM-3 boards)
• Turn off the power to the OC.
• Replace the board.
• Check serial number and revision state of the board to
be changed.
• Check that the object controller board is properly
fastened.
• Check that the board connectors are in the correct
position and properly fastened.
• Check that the board connectors are free from defects.
• Check that the board connectors are labelled correctly.
• Start the OC and check that it is running and in control.
• If a COM-3 board is replaced, check that the replaced
board is online. If the replaced board is not online,
push the reset button on the other COM-3 board.
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OCS950 – Maintenance Manual
Corrective Maintenance
Test after Replacement
•Turn on the power to the concerned object controller position using
the corresponding button on the OCT board.
Test of Signal Object Controller
•A replacement test shall be performed either by the interlocking or
Win OC-test version 2.0. The test procedure must cover the
following inspections:
•Signal aspects: Stop, Proceed (All combinations of the signal).
•Contact detection: Check all used functions according to circuit
diagrams.
•To perform the above test it is necessary to use the existing object
or an object simulator.
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OCS950 – Maintenance Manual
Corrective Maintenance
Test of Point Object Controller
•A replacement test shall be performed either by the interlocking or Win OC
Test version 2.0. The test procedure must cover the following inspections:
•Point in control in both directions and out of control.
•Contact detection: Check all used functions, according to circuit diagrams.
•If local mode exists, check the above-mentioned inspections in local mode.
•To perform the above test it is necessary to use the existing object or an
object simulator.
Test of Other Object Controller
•Start the OC and check that it is running and in control. A replacement test
shall be performed either by the interlocking or Win OC-test version 2.0.
The test procedure must cover the following inspections:
•Check that all used functions are tested, according to circuit diagrams.
•To perform the above test it is necessary to use the existing object or an
object simulator.
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of Fan Unit
• Isolate the 24 V DC supply using the appropriate
isolation switch on PSU72.
• Disconnect the d-type connectors from the front of the
unit and unscrew the TORX fittings holding the unit in
the 19” frame.
• Remove the whole unit.
• Insert the replacement fan unit into the same location
and secure with the TORX fittings.
• Reconnect the d-type connectors and switch the
24 V DC supply back on.
• Check if the system is OK.
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of Cables: System Cable Replacement
• System cable replacement is considered to be unlikely since
these cables are contained entirely within the housing.
• Since the interface modules are provided with front connectors,
all cable connections can be reached from the front of the sub-
rack. A cable shelf is provided below each sub-rack to support
the cables.
• To prevent any hazards resulting from the misplacement of
interface modules or front connectors, the front connectors are
provided with electrical coding to match the configuration on the
OC sub-rack back-plane.
• The front connector DIP switch settings are shown on the
Configuration of Sub-rack and Address Strapping of each of 23
stations in the project.
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of Cables: System Cable Replacement
The front connectors are only uniquely coded within a sub-rack and
not across sub-racks. When connectors from different sub-racks are
swapped over, then if the swapped connectors are for identical output
board types (i.e. SRC, LMP or MOT) in the same position (i.e.
position 1, 2, 3 or 4) within the sub-racks, the object controller will
drive the wrong signal, point or relay.
If the front connectors were removed from adjacent sub-racks
simultaneously it is important to verify the functions of the wayside
objects concerned. Check that the correct wayside object is controlled
from the corresponding object controller.
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of Sub-Rack
A sub-rack breakdown is considered to be unlikely. The
replacement of a sub-rack will affect a number of
signals, points or relay interfaces. The impact on
railway operation may be significant, especially if a
second sub-rack is connected to the same CCU (via a
cable between the OCT boards on each sub-rack).
• Isolate the sub-rack, including all 24 V DC, and other
power supplies Disconnect all front connectors and let
the cables remain in the tracks in the cable shelf Do
not remove the lid.
• Remove all boards, observing ESD precautions and
storing the boards in anti-static bags and preferably the
correct cardboard boxes whilst replacing the sub-rack.
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of Sub-Rack (cont)
A Replace the sub-rack by a spare one.
• Adjust all backplane DIP switches i.e. A1, A2, IND, and
CRC according to the site specific Configuration of
Sub-rack and Address Strapping in the new sub-rack.
This step can be done before the new rack is inserted,
if preferred. Verify that the switch settings match the
old sub-rack for extra confidence by using the IND Tool
in the start-up kit.
• Check again in a methodical manner that the DIP
switches are set correct.
• Insert all the boards, and attach all the front connectors
EXCEPT for the loop communications cables on the
front of the COM-3 boards.
• Seal the sub-rack
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of Sub-Rack: test after replacement
The new sub-rack, including OC boards, shall be verified
with the following check list:
• Restore all the 24 V DC and other power supplies as
required.
• Restart all the object controllers and ensure that the
CPR lamps on the CCM-E boards are lit and steady
• For object controllers, check the following:
• CCM-E boards: all three LEDs are lit.
• For all CCUs, check the following:
• COM-3 boards: appropriate LEDs are lit.
• OCT board: LED is lit.
• Verify all object controller addresses with Win OC-test.
• After the replacement the sub-rack must be protected
by a seal again
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OCS950 – Maintenance Manual
Corrective Maintenance
Replacement of PSU
• Isolate the faulty PSU from the mains. All power
supplies have a mains power switch either on the unit or on the associated cassette.
• Remove the faulty PSU. Note that some PSUs may
weigh up to 30 kg.
• Remove the protective cover from the faulty PSU.
Inspect and make notes of how the input voltage
selection devices are set.
• Copy the setting of the input voltage selectors to the
spare PSU.
• Install the spare PSU. Be sure to tighten all screws
securing the PSU to the metal frame.
• Restore the mains power.
• Ensure that all PSU output voltages are available.
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OCS950 – Maintenance Manual
Corrective Maintenance
Sealing instructions
Sealing of double connector
• Disconnect the double connector.
• Clean the area around the dip switch area to remove
grease etc.
• Apply the seal label.
• Connect the double connector.
• Fasten the double connector with the screws.
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OCS950 – Maintenance Manual
Corrective Maintenance
Sealing instructions
Sealing of sub-rack
All sub-racks shall be protected by a seal when they are
mounted in a rack. This is an extra precaution, because
the addresses of the spare sub-rack must be exactly
identical to the replaced sub-rack. These addresses are
placed inside of the backplane of the sub-rack.
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OCS950 – Maintenance Manual
Corrective Maintenance
Sealing instructions
Sealing of sub-rack: Tie Strap
• Sign the label area of the tie strap with date and
signature.
• Make a small bend of the tip of the tie strap.
• Pull the tie strap through in a suitable hole in the sub-
rack on the left hand side and through a hole in the bar.
• Connect the tie strap and pull gently.
• Cut the over length of the tie strap.
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OCS950 – Maintenance Manual
Corrective Maintenance
Sealing instructions
Sealing of sub-rack: Seal Label
• The seal shall be glued on both the sub-rack and the
standing bar. The location is on the right-hand side of
the sub-rack on the upper part.
• Sign the label area of the seal with date and signature.
• Clean the area where the seal is to be applied (to
remove grease etc.).
• Apply the seal label.
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OCS950 – Maintenance Manual
Fault Finding on EBI Lock Systems
The most likely starting point for a fault finding is an alarm
reported on the Maintenance Terminal. This should pinpoint the
address of the affected object controller.
CCU Alarms / Error CodesCCU faults will generate a number of alarm codes. Information
regarding hardware status as well as external conditions
affecting wayside objects may be retrieved. A list of alarms and
the associated actions can be found in the Alarm Code List.
Object ControllerOC faults will generate a number of alarm codes. Information
regarding status of OC hardware as well as wayside objects
may be retrieved.
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OCS950 – Maintenance Manual
Fault Finding on EBI Lock Systems
Signal Controller
Alarm 50: Open Circuit / Lamp Failure and Aspect-
Degradation
- Lamp Failure- LMP board fault- Cable break- Fuse failure
Lamp circuit failure is detected by measuring current as for any other type of interlocking.
Aspect degradation is therefore beneficial in terms of reducing delays, because LED signal only return to stop when absolutely necessary.
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Fault Finding on EBI Lock Systems
Signal Controller
Alarm 5C: LMP Output Low Current Limits
The OCS determines failure of a lamp or its circuit by current measurement as for other types of interlocking. The used current limits are programmed into the PROM software and cannot be adjusted.
The low current limits determine the threshold for alarm generation and aspect degradation.
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Signal Controller
Alarm 52: Short Circuit/Over-current Failures on LMP
Board Output Circuits
If there is a circuit failure such as a damaged cable resulting in an over-current, the object controller will detect this excess current by measurement and degrade the signal in the same way as for lamp failures.
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Fault Finding on EBI Lock Systems
Signal Controller
Alarm 56: Lamp 110/120 VAC Voltage Level Error and
Fuse Pulling
If the voltage is absent, an alarm is generated and the safety relays drop internal to the LMP board.
the voltage detector is attached to the STOP circuit in the LMP board.
If the PROCEED fuse blows, the alarm is not produced.
Open circuit alarms will be produced if a PROCEED output is being driven when the PROCEED fuse is pulled.
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Fault Finding on EBI Lock Systems
Signal Controller
Alarm 58: Invalid Order for Signal Aspect
Alarm when software has an error.
Contact Bombardier for solving.
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Fault Finding on EBI Lock Systems
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Alarm 5B: Frequency Error
This alarm will occur if the power supply frequency drifts out of tolerance.
This is expected to be a very rare event for a grid supplied system.
However fuse pulling or total power supply failures can produce this alarm spuriously and it should be ignored in these cases, especially if Voltage Level error alarms are also seen.
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Fault Finding on EBI Lock Systems
Signal Controller
Alarm 59: Current Through a Lamp that Should be Off
• One possible failure mode of the SSRs used for LMP board outputs is a short circuit failure on the output. • When the SSR fails, supply voltage will be applied to the output and light any lamp connected.• LMP detects failure by current measurement circuit determining that a current above a certain threshold is flowing. • The controller software detects that there is “current through a lamp that should be off”. • An alarm is generated and drops the safety relay to put the signal back to its most restrictive aspect.
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Alarm 5D: Signal Controller Earth Faults
• The earth fault is tested for every 5 minutes and an alarm is generated if an earth fault is detected. •In addition to issuing an alarm, restrictive status ‘dark signal’ can be configured as a market specific parameter.•An earth fault in one of the cables will expand to all object controllers connected to the same winding in the power supply
unit.
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Fault Finding on EBI Lock Systems
Signal Controller
Alarm 5E: Return Current out of Limits
Check and replace LMP board for this error.
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OCS950 – Maintenance Manual
Fault Finding on EBI Lock Systems
Point Controller
Alarm 20: Point Movement Failure (Start Error )
• When any point machine does not leave the initial position within a defined time after a point operation is initiated. The point operation is also stopped.
Alarm 21 (22): Point Movement Failure (Point machines
connected to 1st (2nd) MOT board are in undefined position)
•If the point fails to reach the ordered position or the position detection is lost due to some failure the point controller will send status “Out of correspondence” to the CIU and generate alarm for diagnostic purpose.
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Point Controller
Alarm 24: Motor Current Out of Limits (Run Current Out)
•The total load current to point machines supplied by a MOT board exceeds 15 A for more than 1,700 ms. This will occur if a fault in the point machine or object cable causes excessive load current that does not blow the fuse within the 800 ms time. Point operation is stopped.
•A short circuit is detected in the solid state relays (SSRs) during hardware integrity tests before point operation is started. The point controller halts.Replace the MOT board
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Alarm 25: Motor Current Out of Limits (Stop Current Out)
•A short circuit is detected in the solid state relays (SSRs) during hardware integrity tests when point operation is completed. The point controller halts.
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Alarm 2D: MOT Board AC Power Supply Failure
•When the point machine power supply to the MOT board is lost.
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Alarm 2F: Earth Fault
•When a fault is detected internally in the earth fault detector on MOT.
•The possibility to determine that the alarm is caused by an external earth fault or an internal fault:
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Q & A
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Thank You
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