maintenance manual training presentation_r.a

Pakistan Railways Rehabilitation Signalling Project

OCS950 Maintenance Training

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OCS950 – Maintenance Training Course

100174081 OCS950 Maintenance Manual Training Material Rev.A2


OCS950 � Basic Course

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OCS950 – Basic Course


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Features


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System Overview


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Concentrator


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Concentrator

PCM : Pulse Code Modulation

Fiber optic

RS232 RS232


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Concentrator


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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


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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


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Object Controller


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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.


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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.


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Object Controller


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Object Controller

COM: Communication and Modem Board

� COM3(Serial Connection)


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Object Controller


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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


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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.


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Object Controller


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Object Controller

Power Supply Units

� PSU 72

� PSU 330

� PSU 321


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Object Controller

PSU 72

� Input Voltage 220 Vac

� Output Voltage 24 Vdc

� Used for OC subracks and fan unit


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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


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Object Controller

PSU 321

� Input Voltage 3x380 Vac

� Output Voltage 3x380 Vac

� Used for MOT


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Object Controller


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Data Transmission


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Tools



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.


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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.


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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


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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.


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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.


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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


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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


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Back Plane Address Strapping Fields


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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


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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


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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


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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


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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


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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



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


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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.


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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



Connection Unit (Voltage Input)


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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)


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CCM-E

LMP

MOT1

SRC

Have

fuses

and

Terminals

For

Power



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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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� Power Cables

� Boards


� 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


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For PSU 330: Signal and Magnetic Key Locked Point


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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





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Connecting: 3x380 VAC to PSU321





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� Power Cables

� Boards


� 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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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


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� Power Cables

� Boards


� 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.


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3NSS008732-xxxx0 4x1.5 sq.mm.


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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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� Power Cables

� Boards


� 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


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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


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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


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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


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LMP: Inputs and Outputs


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LMP: Pin Designation


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Connection Unit

LMP: Connection

Connection Cable


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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


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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


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MOT1: Pin Designation


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Power to Drive Motor

Detection


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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


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SRC: Pin Designation


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SRC: Pin Designation

Power

Equipment(Relay)


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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


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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


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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


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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


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Fan Unit: Connection

3NSS003446-0020

DSUB9

Fan Unit and PSU72


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Dummy Panel

� Fulfil the space in OC and Subrack


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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


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Dummy Panel: for PSU Space

•3NSS003646-01 �� used with cassette (at least 1 PSU in the row)


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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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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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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



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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Signal Controller

Alarm 58: Invalid Order for Signal Aspect

Alarm when software has an error.

Contact Bombardier for solving.


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Signal Controller

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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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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Signal Controller

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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Signal Controller

Alarm 5E: Return Current out of Limits

Check and replace LMP board for this error.

218 100174081 OCS950 Maintenance Manual Training Material Rev.A

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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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Point Controller

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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Point Controller

Alarm 2D: MOT Board AC Power Supply Failure

•When the point machine power supply to the MOT board is lost.


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Point Controller

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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