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Hkkjr ljdkj &GOVERNMENT OF INDIA jsy ea=ky;& MINISTRY OF RAILWAYS

¼dk;kZy;hu iz;ksx gsrq½& (For official use only)

MkVk ykWxj ds usVodZ ls fuokjd vuqj{k.k ij gLriqfLrdk

A HANDBOOK ON

PREDICTIVE MAINTENANCE THROUGH NETWORK OF DATA LOGGERS

dSeVsd@,l@izkSt@2009&10@,p ch &Mh ,y-2-0 Qjojh 2011

CAMTECH/S/PROJ/2009-10/HB-DL.2.0 FEBRUARY 2011

Egkjktiqj] Xokfy;j & 474005 MAHARAJPUR, GWALIOR – 474 005

MkVk ykWxj ds usVodZ ls fuokjd vuqj{k.k ij gLriqfLrdk

A HANDBOOK ON

PREDICTIVE MAINTENANCE THROUGH NETWORK OF DATA LOGGERS

dSeVsd@,l@izkSt@2009&10@,p ch &Mh ,y-2-0 Qjojh 2011

CAMTECH/S/PROJ/2009-10/HB-DL.2.0 FEBRUARY 2011

izkDdFku

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dSeVsd] Xokfy;j ,l-lh-fla?ky

fnukad 31-3-2011 dk;Zdkjh funs’kd

FOREWORD

Data acquisition, transmission, its storage and handling has pervaded all spheres

of technology. It also assumes a role of significant proportion for train operations.

Notwithstanding the increased traffic intensity, Data logger diligently keeps track of each

signalling related activities involved during train operation. This logged on data serves as

useful guide for preventive maintenance of signalling gears. The present handbook

discusses at length as to how the signalling system can be made more effective, trouble

free, and reliable.

I am confident that this handbook in the hands of field staff will be especially

helpful not only in their day-to-day maintenance activities but also be useful to get the

feel of the new technology.

CAMTECH Gwalior S.C.SINGHAL Date: 31.03.2011 Executive Director

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dSeVsd] Xokfy;j txeksgu jke

fnukad % 30-3-2011 funs’kd ¼la-,oa nw-la-½

PREFACE

Railway Signalling system plays a vital role in the movement of trains. It is of utmost

importance that these signal gears are maintained properly to ensure their reliability and

availability.

Data loggers have been proved to be very effective in continuous monitoring of signalling

gears and ascertaining the actual cause of their failure. This helps in taking systematic and

correct approach in rectifying the faults especially of intermittent nature. Preventive maintenance

of signalling gears can be effectively carried out with a network of data loggers and the

signalling data of each station can be centralized.

Continuing its efforts in documentation and up-gradation of information on maintenance

practices, CAMTECH has prepared this handbook to help the maintenance personnel in

analyzing the signal failures in a better way and take remedial action.

We are sincerely thankful to Shri Alok Katiyar, Director/Signal/RDSO, M/s Efftronics Systems

Pvt. Ltd., M/s Crompton Greaves Ltd. and maintenance personnel of BSL division, C.Rly. who

helped us in preparing this handbook.

CAMTECH Gwalior JAGMOHAN RAM Date: 30.03.2011 Director (S&T)

CONTENTS

Chapter Description Page No. izkDdFku Foreword IV Hkwfedk Preface VI fo"k; lwph Contents VIII la'ksk/ku ifpZ;ka Correction Slip X fMLDySej Disclaimer XII

1. MkVk YkkWxlZ iz.kkyh Data Logger System 1.1 ifjp; Introduction 1 1.2 MkVk ykWxj Data Logger 1 1.3 MkVk YkkWxlZ dk usVodZ Network of Data Loggers 2 1.4 MkVk YkkWxlZ usVodZ iz.kkyh ds vuqHkkx Modules of data

logger Network system 2

1.5 ,DlsI’ku fjiksVZ Exception Reports 7 1.6 v vk eka l }kjk vuqeksfnr QeZs RDSO approved firms 8

2. MkVk YkkWxj usVodZ dk laLFkkiu Installation of Data Logger Network

2.1 MkVk YkkWxj midj.k ¼QhYM ;wfuV½ dk laLFkkiu Installation of Data Logger Equipment (Field Unit)

9

2.2 vkjVh;w dk laLFkkiu Installation of RTU 14 2.3 ,Q bZ ih dk laLFkkiu Installation of FEP 14 2.4 lh ,e ;w dk laLFkkiu Installation of CMU 15

3. MkVk YkkWxlZ midj.k ¼QhYM ;wfuV½ Data Logger Equipment (Field Unit)

3.1 ,QSDVªkWfuDl MkVk YkkWxlZ midj.k ¼QhYM ;wfuV½ Field Unit of Efftronics Data Logger System

16

3.2 ØkWEiVu xzhOl MkVk YkkWxlZ midj.k ¼QhYM ;wfuV½ Field Unit of Crompton Greaves Data Logger System

32

4. fjeksV VfeZuy ;wfuV ¼vkjVh;w½ Remote Terminal Unit

(RTU)

4.1 ,QSDVªkWfuDl fjeksV VfeZuy ;wfuV ¼vkjVh;w½ RTU of 36

Chapter Description Page No.Efftronics Data Logger System

5. ÝaV ,aM izkSlslj ¼,Qbih½ Front End Processor (FEP) 5.1 ,QSDVªkWfuDl MkVk YkkWxlZ iz.kkyh dk ,Qbih FEP of

Efftronics Data Logger System 39

5.2 ØkWEiVu xzhOl MkVk YkkWxlZ iz.kkyh dk ,Qbih FEP of Crompton Greaves Data Logger System

44

6. ¼lh,e;w½ Central Monitoring Unit (CMU) 6.1 ifjp; Introduction 45 6.2 ,QSDVªkWfuDl MkVk YkkWxlZ iz.kkyh dk lh,e;w CMU of

Efftronics Data Logger system 45

6.3 ØkWEiVu xzhOl MkVk YkkWxlZ iz.kkyh dk lh,e;w CMU of Crompton Greaves Data Logger system

63

7. nks"k ds rdZ Fault Logics 7.1 nks"k dh psrkouh gsrq rdZ Logics for fault alarm 71 7.2 vlkkekU; ?kVukØeks gsrq rdZ Logics for unusual

incidences 73

7.3 vlkkekU; Øe dh ifpku gsrq fuxjkuh Identification of Unusual Sequence to be monitored

74

8. D;k djsa o D;k u djsa Do’s & Don’ts 8.1 D;k djsa Do’s 75 8.2 D;k u djsa Don’ts 76

9. nks"k fuokj.k Troubleshooting 9.1 MkVk YkWkxj ds nks"k fuokj.k Troubleshooting of Data

logger 78

9.2 usVodZ ds nks"k fuokj.k Troubleshooting of Network 81

vuqyXud&A Annexure I

laf{kIr 'kCnkoyh Abbreviations 82

vuqyXud&AA

Annexure II lanHkZ References 84

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dSeVsd@,l@izkSt@2009&10@,p ch &Mh ,y-2-0 lh,l #XX fnukad--------

tgkWa “XX” lEcfU/kr la’kks/ku iphZ dh dze la[;k gS ¼01 ls izkjEHk gksdj vkxs dh vksj½

izdkf’kr la’kks/ku ifpZ;kWa

dz-la- izdk’ku dh rkjh[k la’kksf/kr Ik`"B la[;k rFkk en la[;k

fVIi.kh

ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows :

CAMTECH/S/PROJ/2009-10/HB-DL.2.0 C.S. # XX date ---------------- Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).

CORRECTION SLIPS ISSUED Sr. No. of

C.Slip Date of issue Page No. and Item no. modified Remarks

fMlDySej ;g Li"V fd;k tkrk gS fd bl gLriqfLrdk esa nh xbZ tkudkjh flxuy bftfu;fjax eSuqvy] jsYos cksMZ izdk’kuks rFkk v-v-eka-l- ds izdk’kuks ds fdlh Hkh fo|eku izcU/kksa dks foLFkkfir ugh djrh gSA ;g gLriqfLrdk oS|kfud ugha gS oju blesa fn;s gq;s funsZ’k dsoy ekxZn’kZu gsrq fn;s x;s gSaA ;fn fdlh facanw ij fojks/kkHkkl izrhr gksrk gS rc flxyu baftfu;fjax eSuqvy] jsYos cksMZ izdk’kuks rFkk v-v-ek-al- dh fu;ekoyh dk lanHkZ fy;k tk;s ;k tksuy jsYos ds orZeku funsZ’kksa dk ikyu fd;k tk;sA

It is clarified that the information given in this handbook does not supersede any existing provisions laid down in the Signal Engineering Manual, Railway Board and RDSO publications. This document is not statuary and instructions given are for the purpose of guidance only. If at any point contradiction is observed, then SEM, Railway Board/RDSO guidelines may be referred or prevalent Zonal Railways instructions may be followed.

gekjk mís’;

vuqj{k.k iz©|©fxdh vkSj dk;Ziz.kkyh dks mUu;u djuk rFkk mRikndrk vkSj jsYos dh ifjlEifRr ,oa tu’kfDr ds fu"iknu esa lq/kkj djuk ftlls vUrfoZ"k;ksa esa fo’oluh;rk] mi;ksfxrk vkSj n{krk izkIr

dh tk ldsA ;fn vki bl lUnHkZ esa dksbZ fopkj vkSj lq>ko nsuk pkgrs gksa rks d`i;k gesa bl irs ij fy[ksaA

lEidZ lw= : funs’kd (ladsr ,oa nwjlapkj) i=kpkj dk irk % Hkkjrh; jsy mPp vuqj{k.k izkS|ksfxdh dsUnz]

Ekgkjktiqj] Xokfy;j ¼e-iz-½ fiudksM 474005 VsyhQksu % 0751&2470185 QSDl % 0751&2470841 bZ&esy % [email protected]

OUR OBJECTIVE

To upgrade Maintenance Technologies and Methodologies and achieve improvement in Productivity and Performance of all Railway assets and manpower which inter‐alia would cover Reliability,

Availability and Utilisation.

If you have any suggestion & any specific comments, please write to us: Contact person : Director (Signal & Telecommunication) Postal Address : Centre for Advanced Maintenance Technology, Maharajpur, Gwalior (M.P.)

Pin Code – 474 005 Phone : 0751 ‐ 2470185 Fax : 0751 – 2470841

Email : [email protected]

CAMTECH/S/PROJ/2009-10/HB-DL.2.0

Predictive maintenance through network of data logger February 2011

1

v/;k; & 1 Chapter 1

MkVk ykWxj iz.kkyh

DATA LOGGER SYSTEM 1.1 ifjp; Introduction Signalling system plays an important role in the movement of trains over the vast Railway network. The signalling system is supposed to provide safer, accident-free operation and at the same time ensuring punctual and reliable management of train movement. There are some inherent short- comings in signalling system, which result into failures and reliability is affected badly. A few of these are described below: Normally the failures which are intermittent in nature are put right automatically hence their cause remains unknown to S&T staff. There are failures on account of insufficient information about the function i.e. about its operating characteristics and continuous past behavior. Periodical scheduled maintenance of gears is not effectively done due to heavy traffic and less available time for maintenance. Such gears fail intermittently and require preventive maintenance. The cause of many disputed type failures like wrong operation, late clearance of signal, late start by Driver etc is not established. Performance of signalling gears cannot be monitored continuously by Railway authorities at divisional HQ as they do not have proper record of the gears. There is no method available for maintenance staff attending failure to know the specific cause and operational history of gears. Due to signal failure the detention is considerably high. There is no time margin on S&T account. Failure means loss of punctuality on S&T account. To overcome these problems in existing signalling system and to upgrade the reliability of signalling system, continuous efforts are being made to modernize the signaling system and to provide a device which can log the events in a proper manner. Provision of data loggers is an effort in this direction. 1.1.1 MkVk ykWxj Data logger It is a microprocessor based equipment data acquisition system to log the changes in the status of Electrical Signalling System (relay contacts). Data logger acts like a “Black box”, which can scan, store and process the data for generating various user-friendly reports. It is also known as “Event logger.” On Indian railways data logger conforms to specification



2

No.IRS:S:99/2006.Data logger records the change in the status of digital and analog inputs of signalling system and has following features: Data loggers help in analyzing the failures such as intermittent, auto right in nature. Help in detecting the human failure/errors such as Driver passing signal at danger. Operational mistakes done by panel operators/ASMs of operating department. Help in preventive maintenance of signalling gears. Data loggers can be connected in the network which help in monitoring PI/RRI/EI remotely. Failure reports can be generated remotely with the help of data logger network. On-line and off-line track simulation is possible. Age of the equipment in terms of number of operation/operating time can be calculated. 1.3 MkVk ykWxj dk usVodZ Network of Data loggers Data logger in various stations can be interconnected in a network with the use of Main Telecom cable or Quad cable or Microwave or OFC (Optical Fiber Cable). Data is brought to the centralized system called Front End Processor (FEP) which is connected to the station data loggers through the modems. FEP in turn is connected to a PC placed in Control room/HQ office called Central Monitoring Unit (CMU). The CMU is having the Graphical User Interface (GUI) software to retrieve data from all networked data loggers. CMU collects the data from the FEP, stores it and processes for report generation and analysis. 1.4 MkVk ykWxj usVodZ iz.kkyh ds ekM~;wYl Modules of data logger network system The network of data logger system consists of the following modules: Data logger Remote Terminal Unit (RTU) Front End Processor (FEP) Central Monitoring Unit (CMU)



3

Fig.1.1: Block diagram for network of data loggers The brief description of above modules is as follows: 1.4.1 MkVk ykWxj Data logger The data logger monitors and records the change of status of digital inputs i.e. Relay and analog signals like DC and AC supply. It works on 24 V DC power supply. The equipment caters for minimum 512 digital inputs (in the form of potential free relay contacts) and 32 analog inputs, expandable upto 4096 digital and 96 analog inputs by expansion/cascading the similar equipment. It has the facility to interface with Remote Terminal Unit (RTU) and EI (Electronic Interlocking). Data logger is provided in station. 1.4.1.1 MkVk ykWxj midj.k ds eq[; #i Salient features of Data Logger equipment Chronologically monitors and records the status of various field functions like track circuits, points, signals, operator’s push buttons/switches (digital Inputs) and level of various analog signals like DC and AC supply voltages, Axle counter signals etc. in the following format:

Date Time Channel no Field function Status / Value

Capable of statistical analysis, predict the faults and generate failure reports. The user can define fault logics taking digital/analog inputs into consideration and generate reports for such faults. Capable of generating audio-visual alarm under defined conditions and deliver non-vital relay outputs on receipt of command from CMU. At least 8 non-vital relay outputs are to be provided which are in the form of potential free contacts capable of driving 24V 'Q' series relays. These outputs may be used for non-vital functions like radio patching of control circuits etc. The status of various functions shall be recorded in the following way: -

FEP

DL 1 DL 2 DL 3 DL n

CMUCommunication Link

RTU 1

Serial Interface

Modem

Comm. Link



4

fMftVy buiqV Digital Input Sr. No.

Functions Status configuration

(i) Points Normal or reverse (N or R), locked or unlocked

(ii) Signal ON or OFF (Y, YY, R, G, RI, A marker) (iii) Track Occupied/Free (iv) Level crossing Locked/Free (v) Crank handle Locked/Free (vi) Axle counter Occupied /free (vii) Route Locked /free (viii) Route sections Locked / free (ix) Push buttons Pressed/released (x) SM’s key In/Out (xi) Slots Given/ not given; Received / not received (xii) Insulation of Sig. Cable Good /bad (through ELDs) (xiii) Slots (Outgoing) Locked/ released (xiv) Slots (Incoming) Received /Absent (xv) Switch (2 position) Normal/ Reverse (xvi) General Relay Pickup / drop

,ukykWx buiqV Analog Input

Sr. No. Functions Status configuration (i) Axle counter Rx signal at the tag block Value (ii) AC power supply (230/ 110V) Value (iii) DC supply (12/24/48/60/110 etc.) Value (iv) Temperature Value

The purchaser can indicate any additional field information required to be recorded. For digital inputs, potential free contacts are used. Analog signals like 230 V AC, 110 V AC, 110 V DC, 60 V DC, 24 V DC, 12 V DC and Axle Counter RX voltages etc. are converted to suitable level for recording by a built in Signal Conditioning module. Configuration of analog channels shall be as under.

Channel Nominal Voltage DC or AC (RMS)

Voltage Range for no alarm (adjustable)

1 230 AC 207- 253 2 110 AC 99- 121 3 110 AC 99- 121 4 110 DC 99- 121 5 60 DC 55- 69 6 60 DC 55- 69 7 24 DC 22.5-28 8 24 DC 22.5-28

9-16 1.0 AC,5KHz --



5

For termination of external digital and analog inputs, WAGO/ Phoenix or similar make are used as per RDSO SPN/144. Suitable for working on non-electrified, AC electrified and DC electrified areas. Capable of working in conjunction with conventional relay interlocking, MACLS installations operated by lever frames/ slides and Electronic Interlocking systems. It has facility to log data received from external equipment like Electronic Interlocking (EI) through a serial port. Can be connected to a printer for obtaining a hard copy of the following

I. On line events as they are generated. II. Exception report.

III. Status of user specified inputs for user definable time period. Easily re-configurable to any changes required by user, whenever modifications are carried out in the yard. Display provided on the front panel to display current status / faults/ alarms along with time stamp. Faults/ alarms generated up to one week earlier can be displayed on the panel. At least two row display with minimum 16 character in each row is used. Real time clock of data logger shall be synchronized with the central monitoring unit for recording time at which the status of the particular information has changed. At least 6 ports are provided for communication with other data loggers, CMU, RTU, EI, IPS etc. Compatible to the following media:

(i). Main telecomm. Cable. (ii). Quad cable.

(iii). Analog channel of OFC, digital microwave or analog microwave. (iv). 64 kbps data channel on OFC or digital microwave.

Facility to log minimum 10 Lac events with First-In First-Out (FIFO) logic, so that latest data is available. No loss of data from the data logger memory in case of power supply failure. Self diagnostic feature, hence any fault in the system generates error message in the system panel and generate alarm in the CMU. Scanning interval for digital inputs shall be less than 20 milli second. Change in status of digital inputs shall only be recorded. Scanning of analog signals shall be less than 1 sec. Variation of more than 5% of the nominal value from the last recorded value shall be recorded. Accuracy of analog signal shall be better than 1% within 40% of nominal value. 1.4.2 fjeksV VfeZuy ;wfuV ¼vkjVh;w½ Remote terminal Unit (RTU) The RTU is interfaced with Data logger through serial link. It has modules normally identical to that used in data logger and caters for minimum 32 digital and 8 analog inputs. The RTU have its own processor and communication modules and have facility to store at least 1 lac events. The inputs of RTU can be taken as part of data logger system. It is possible to connect maximum of 4 RTUs. Alternatively, the RTU can exist with separate ID. There shall be no loss of data due to power failure. It is possible to connect RTU upto 3 Km from main data logger equipment.



6

1.4.3 QzaV ,UM izkslslj Front End Processor (FEP) FEP is provided to continuously retrieve data from station data loggers and send the same data to Central Monitoring Unit (CMU) for monitoring. It accepts command from CMU and transmits them to data loggers in network. FEP works on 24 V DC power supply. 1.4.4 lsaVªy ekuhVfjax ;qfuV Central Monitoring Unit (CMU) CMU receives data from data logger(s) provided at station(s) through FEP. It stores this data in respective database files. The software installed in CMU analyzes the data and generate alarm and reports. 1.4.4.1 lkW¶Vos;j lajpuk Software configuration CMU is having Graphical User Interface (GUI) based software to retrieve data from all networked data loggers (upto 32) at various stations. Approved type licensed software shall be used for analysis of data, prediction of faults etc. and written in a structured format so that purchaser can reconfigure it. The database management system i.e. MS SQL Server or Interbase is used which stores data in standard database files. 1.4.4.2 gkMZos;j lajpuk Hardware configuration CMU is a state of art PC (of reputed brand) based system working on commercial supply of 230 V AC 50 Hz. The minimum configuration shall be as under or as specified by RDSO:

(i). Pentium 4 or equivalent processor 3 GHz, 2.56 MB RAM, 2 X 20 GB HDD with disk mirroring, 1.44” FDD, SVGA Colour monitor (17”), Sound card with speaker, 56 kbps modem, keyboard, optical mouse, 10/100T LAN card, CD writer and Inkjet printer.

(ii). UPS with minimum 6 hours battery backup for CMU. (iii). Software tools.

1.4.4.3 Lkh,e;w dh vU; egRoiw.kZ fo’ks"krk;sa Other essential features of CMU Capable of analyzing the data and generate reports and audio visual alarms on defined conditions. It is possible to compress the data and take backup on floppy. Status of signaling gears can be displayed at any selected time in graphic form for any selected station yard. Simulation of train movement possible by retrieving stored data. Commands can be sent to various data loggers to activate audio, visual alarm or operate an electromagnetic relay. Data available can be shared by other PCs through LAN for the purpose of train charting/passenger information.



7

1.5. ,Dlsi’ku fjiksVZ Exception reports The Data logger equipment is capable of generating following exception reports: Battery Low voltage

Battery charger defective

Under wheel flashing of points

Signal lamp failure

Blanking of Signals

Route section not released after passage of train due to track circuit failure.

Point Failure – point detection not available after set time period.

Track circuit failure

Fuse Blown OFF

Timer not properly set for 120 Sec.

Sluggish relay operation

Signal cable low insulation

Route not set when operation is valid.

Push button stuck.

Signal over shoot.

Wrong operation

Axle Counter RX low level

Bobbing of track, point, signal, crank handle, Level crossing or Ground frame

repeater relay.

Point repeated operation

Non sequential shunting of tracks

The CMU is capable of generating following additional exception reports. Emergency cancellation of route

Panel failure due to power failure

Late start of a train (train operation)

Late operation of signals with respect to local trains (train operation)

Route failure online indication with analysis of the stage at which it had failed.

Non-signal movement (train operation)

Total on time of lamp (to assess working life of signal lamp)



8

Total number of operations of the relay (to assess life of relay)

Emergency Point operation

Emergency Route Release

Emergency Sub Route Release

Overlap release

Emergency Crank Handle release

Calling on operations

Slot operations

Historical replay of events in a yard in graphical manner.

Circuit progression. Railway shall provide logic for the same.

Any other exception report.

Exception condition is stored in the data logger chronologically and displayed one by one on the front panel through a toggle switch. 1.6 v-vk-eka-l- }kjk vuqeksfnr QeZsa RDSO approved firms At present there are two RDSO approved firms for supply and installation of Data Logger System on Indian Railways: M/s Efftronics Systems Pvt. Ltd., Vijayawada.(A.P.)

M/s Crompton Greaves Ltd., Pithampur, Dist. Dhar (M.P.)

In the following sections predictive maintenance through Data logger systems of the above firms using Data logger field equipment, RTU, FEP and CMU in the network is explained.



9

v/;k; & 2 Chapter 2

MkVk ykWxj iz.kkyh dk laLFkkiu INSTALLATION OF DATA LOGGER NETWORK

2.1 MkVk YkkWxj midj.k ¼QhYM ;qfuV½ dk laLFkkiu Installation of Data logger equipment (Field unit) The field unit of data logger system is installed at station. It consists of following modules: Input Module (Digital/Analog) Signal Conditioning module Processor module (CPU) Power Supply module Communication module Printer 80 Column Dot Matrix (Optional) Modem(s) Relay inputs (Digital inputs) and AC/DC Voltages (Analog inputs) are required to be connected to the system. 2.1.1 fMftVy buiqV Digital inputs For monitoring of Digital inputs potential free (spare) contacts of the following relays are required: Field inputs – All TPRs, NWKRs, RWKRs, ECRs, Crank handle relays, Siding Control relays, LC gate control relays etc. Control Panel inputs – All buttons/Knobs, SM’s Key relays. Internal Relays : British interlocking System (Metal to Carbon relays) – All HR, DR, HHR, WNR, WRR, ASR, UCR, RR, LR,UYR, TLSR, TRSR, TSR,JSLR,JR etc. Siemens Interlocking system (Metal to Metal relays) – Z1UR, Z1UR1, GZR, ZDUCR, ZU(R)R, ZU(N)PR, G(R)R, G(N)R, U(R)S, U(N)PS, UDKR, DUCR, U(R)LR, UYR1, UYR2, G(R)LR, GR1,GR2, GR3, GR4, OVZ2U(R)R, W(R/N)R, (R/N)WLR, Z1NWR,Z1RWR, Z1WR, WKR1,WKR2,WKR3 etc. 2.1.2 ,usykWx pSuy Analog channels Following AC or DC Voltages and currents are required for monitoring of Analog channels: 230 V AC (for power supplies in the power panel) . 110 V AC (for signal & track transformers) 110 V DC (for point operation) 60 V DC (for Siemens relays) 24 V DC (for Q-series relays) 24 V DC (for Block, Axle Counters) 12 V DC (for indication) 1 V AC 5 KHz (for Axle Counter channels) etc.



10

2.1.3 buiqV ekM~;wy Input module The input module consists of Analog and Digital input cards. 2.1.3.1 flxuy dfMa’kfuax ekM~;wy Signal Conditioning Module The Signal conditioning module consists of following (i) flxuy dfMa’kfuax VSx cksMZ Signal Conditioning Tag Board This Card is used to terminate field analog inputs to Data logger and have capacity of maximum 32 inputs termination in one card. Output of this card goes to SC card. (ii) flxuy dfMa’kfuax dkMZ Signal Conditioning Card The Signal Conditioning Card converts the input voltage like 230 V, 110 VAC/DC etc to a suitable level for recording. The output of this card goes to Analog Input Card. .

Fig.2.1: Analog inputs connection diagram of data logger

2.1.3.2 ,ukykWx buiqV LdSuj dkMZ Analog Input scanner card The Analog Scanner Unit (ASU) contains maximum 3 nos. of Analog input cards. Each input card can be connected with 8nos. of Analog inputs. Maximum 4nos. of ASUs can be connected to the system. The input module of data logger can be connected with a maximum 96 Analog inputs. Depending upon the capacity of each card, a number of Analog input cards can be provided. The analog input module receives 0 – 5 V DC input voltage through Signal Conditioning card. The Signal conditioning card converts the input voltage to a suitable level for recording by Analog Input card. All these analog inputs are scanned at a rate of less than 1 sec. The Analog Input Card converts this voltage to digital form and send to Processor card for further processing.

CPU card

230 V AC 110 V AC 110 V DC 60 V DC 24 V DC 24 V DC 12 V DC

V

V

V

V

Data Logger

Signal Conditioning Signal Conditioning Analog InputTag board card scanner cards



11

2.1.3.3 fMftVy buiqV VSx cksMZ Digital Input Tag Board Field Inputs from free (spare) relay contacts will have to be connected to this tag board which consists of 128 tags. Field inputs from this tag board are connected to DI card via 16 core FRC in bunch of 64 inputs. 2.1.3.4 fMftVy buiqV LdSuj dkMZ Digital Input scanner Card Each Digital Scanner Unit (DSU) consists of 8 nos. of Digital Input cards. Each input card can be connected with 64 inputs. Maximum 7 nos. of DSUs can be connected to the system. So, Digital input capacity of the system is 4096. All these digital inputs are scanned at rate of 16m.sec. The Digital Input Card receives the digital inputs like track circuits, points, signals, operator’s push buttons/switches etc. the digital inputs may be in the form of potential free contacts of relays. All the inputs are optically isolated. The data logger consists of minimum 512 digital inputs and expandable up to 4096 inputs.

Fig.2.2: Digital input connection diagram data logger 2.1.4 izkSlslj ekM~;wy Processor Module The Processor Module monitors the status of digital and analog inputs and records the change of status with time stamp. It works on 24 V DC power supply. This card supports the LCD interface, keyboard, real time clock and communication module. It has the facility to interface with other data logger, CMU, Remote Terminal Unit (RTU) and EI (Electronic Interlocking) through serial communication. It has also a parallel port for printer. It has support for interface with tele control card to pick up minimum 8 vital relays.

Digital input Digital input Tag board scanner cards

Processor module

Digital inputs (potential Free relay Contacts)

V

V

V

V

Data Logger

Flat Ribbon cable



12

2.1.5 ckg~; ukWu okbZVy fjys laidZ External non-vital relay contacts At least 8 Nos. of relay contacts are to be provided on the rear panel through tele control ports to extend alarms and to control the power equipment from remote or local locations through computer in case of any occurrence of failure. In data logger, 8-relays have been provided which can be controlled through commands from the CMU. Thus the outputs of these relays can be controlled through the data logger. There is a provision to connect external devices to these relay outputs. The devices should be connected to the relay controls as per the numbers provided on the adapter PCB. These relays can be controlled from the CMU software.

2.1.6 ikoj lIykbZ ekM~;wy Power Supply Module The power supply module is a DC- DC converter, which converts the input 24 V DC to different DC voltages with desired current capacity for different modules. This consists of protections like over voltage, over load and short circuit. It works on 24 V DC (+20%, -30%) which is provided by Railways. 2.1.7 ekWMel~ Modem(s) Data loggers are provided with either external or internal modems for interconnection with other data logger/FEP. The modem should be 4-wire leased line ANS/ORG (Answer/Originate) modem. For a network of data loggers, connect ANS modem to ORG modem of one adjacent station and connect ORG modem to ANS modem of other adjacent station.

Fig2.3: Modem connection diagram for data loggers of adjacent stations 2.1.8 MkVk ykWxj igpku Øekad Data logger Identification Number Every Data logger in a network should have a data logger identification number. That will be given through a combination of switches called DIP Switch. This DIP Switch is available on the CPU card of the data logger. Unique identification no. can be set for each station data logger by setting the switches in On (low) or Off (high) positions. 2.1.9 buiqV lajpuk dks O;ofLFkr djuk Setting the input configuration For setting the number of inputs configuration, another dipswitch is provided on the CPU card. In this dipswitch, out of 8 switches only the last three were used to configure the number of inputs.



13

2.1.10 usVodZ esa la;kstu dk izdkj Mode of connection in a network Data loggers can be networked in Uni-directional mode and Bi-directional mode. 2.1.10.1 ,d fn’kh; izdkj Uni-directional mode Each data logger will send data in only one direction to the FEP. This mode is not normally preferred. Fig2.4: Uni-directional mode 2.1.10.2 f}&fn’kh; izdkj Bi-directional mode Each end of network is connected to FEP and each data logger can transmit data in both directions. Bi-directional mode is advantageous. It enables the data transmission even in case of network failure Fig2.5: Bi-directional mode 2.1.11 lapkj Communication For communication with other data logger in a network, 4-wire leased line modem is used which can be connected to Main telecomm cable, Quad cable Analog channel of OFC or digital microwave or analog microwave.

DL (1)

DL (2) DL (3)

DL (n)

FEP

DL(4)

CMU

DL (1)

DL (2) DL (3)

DL (n)

FEP

DL(4)

CMU



14

2.2 vkjVh;w dk laLFkkiu Installation of RTU Installation of RTU is similar to that of data logger equipment in following stages. 1. Connecting 24 V DC Power supply to RTU. 2. Connecting the Digital Inputs (minimum 32) to the DI tag block, which in turn is connected to the respective connector on RTU through flat ribbon cable. 3. Connecting the Analog Inputs (minimum 8) to Signal Conditioning Card which in turn connected to analog input card. AC inputs are connected to AC to DC Converter and its output is connected to the respective connector on RTU. DC inputs are directly connected to RTU through flat ribbon cable. 4. Setting the RTU identification number. 5. Communication - Current loop communication is provided for the purpose of networking the RTU with Data loggers or other RTUs. 2.3 ,Q bZ ih dk laLFkkiu Installation of FEP Installation of FEP has two stages. Connecting 24 V Power supply to FEP. Establishment of Communication Between Data logger and FEP – Through network ports (through modems). Between FEP and CMU – Through PC Ports of FEP. RTU can be directly connected to FEP instead of connecting it to data logger through current loop port provided on FEP. 2.3.1 ckg~; eksMse External modems These are generally used at FEP side to connect the data loggers. These modems work on 4-wire line communication.

Fig2.6: External modem connections



15

2.4 lh ,e ;w dk laLFkkiu Installation of CMU The installation of CMU have following steps Connection of CMU to FEP through a CMU port provided it. The FEP and CMU can be connected through RS-232 port. Connecting Printer to CMU. Connecting the 230 V AC power supply to CMU (computer CPU and the monitor). Configuring the system for logging and showing the data by loading the CMU with approved type of software. New datalogger installation in CMU. Creation of new user and password.



16

v/;k; & 3 Chapter 3

MkVk ykWxj midj.k

DATA LOGGER EQUIPMENT 3.1 ,QSDVªkWfuDl MkVk ykWxj iz.kkyh dh QhYM ;qfuV Field unit of Efftronics Data logger system The field unit of data logger system manufactured by M/s Efftronics Systems Pvt. Ltd., Vijayavada consist of a Main Euro rack which is installed at the station relay room. The Main Euro Rack with various cards, Keyboard, LCD and LED displays is shown below in Fig. 3.1.1.

Fig. 3.1.1.: Data logger Main Euro RackData Logger equipment records the change in the status of two types of inputs. 1. Digital inputs 2. Analog inputs The procedure for getting various types of information or status through the data logger system is explained in the following paragraphs.

Digital scanning cards

Key board

LED block display (for digital input status display)

LCD display

Internal modem card (answering modem)

Provision for data retrieving into memory card

Internal modem card (originating modem)

LED indications for processor health status

7-segment LED display for time

Display card reset button

CPU card



17

3.1.1 fMftVy buiqV~l dh fLFkfr Status of Digital Inputs Digital inputs i.e. relay status can be obtained in two modes:

On-line mode Off-line mode

3.1.1.1 vkWu ykbZu izdkj Online mode: In On-line mode the current status of digital input signals can be found in any one of the following means

(i).Through LCD display (ii).Through LED indication

(iii).By taking the print from printer.

(i) ,ylhMh n`’; }kjk fMftVy buiqV dh fLFkfr ¼ vkWu ykbZu izdkj½ Digital Input Status through LCD display (On-line mode) On switching on the data logger a screen similar called ‘Default Display Menu’ appears. Where in 1st row, T stands for the total records sent from com port – 1 F stands for total fail records received by com port – 1 D stands for total pending packets to transmit from com port – 1 Similarly for com port – 2 in second row. Now Press ‘*’ key, the following menu called “Main Menu” will be displayed : Press key ‘1’ and the screen containing data logger options will appear Now press the key ‘3’ to select the ‘DGT’ (digital) option, following screen will appear on the LCD panel: By selecting the required category of digital input, the status of the corresponding signals will be displayed on the LCD. For Example: When key '3' is pressed, the screen similar to the one shown below will be displayed on LCD.

COM01 T:0128 F:0000 D:0128 COM02 T:0128 F:0000 D:0128

1. DATALOGGER 2.RELAY HUT 3. FLASH MEM 4. MEM CARD

1.TIME 2.PGE 3.DGT 4.ANG 5.FALT 6.PRN 7.TMP 8.PWD

1.ALL 2.TPR 3.PNT 4.ROUT 5.BTN 6.SLT 7.SIG 8.RLAY

Fig.3.1.3: Data logger main menu

Fig.3.1.2: Default Display Menu

Fig.3.1.4: Data logger options

Fig.3.1.5: Digital Inputs Menu



18

In the above screen, first row indicates the selected input number, date and time at which the signal status is changed. Second row indicates ‘Signal name’ and its status. The DGT (digital) options and their significance for viewing the digital input status are as given below: 1. ALL: Status of all digital inputs. 2. TPR (Track Proving Relay): Status of all the TPRs connected to the data logger. 3. PNT (Points): Status of all the POINTS relays connected to the data logger. 4. ROUT (Route Relays): Status of all ROUTE relays connected to the data logger. 5. BTN (Button): Status of all the BUTTON relays connected to the data logger. 6. SLT (Slots): Status of all the SLOT relays connected to the data logger. 7. SIG (Signals): Status of all the SIGNALS connected to the data logger. 8. RLAY (Relay): Status of all other inputs, which are configured as relays. For viewing the status of the previous relay press ‘0’ key. For viewing the status of next relay press the “#” key. (ii) ,ylhMh ladsrksa }kjk fMftVy buiqV dh fLFkfr ¼ vkWu ykbZu izdkj½ Digital Input Status through LED indications (On-line mode) Online status of digital inputs can be known with the help of LED indications on the LED Block display consisting of 512 (32X16) LEDs. Each LED in the block indicates the status of one digital input. LED glowing indicates the corresponding relay in pickup state and LED off indicates the particular relay in dropped condition. The LEDs in the block display are numbered serially from left to right corresponding to each digital input. For example the top most left corner LED indicates the status of first digital input, and the next to the right will indicate the status of the 2nd input, and so on. Similarly the first LED in the 2nd row indicates the 33rd input status and the last LED on the right most of the last row indicates the 512th input status. A block of 512 LEDs is called a PAGE. If the number of inputs are more than 512 then the status of remaining inputs can be viewed in the next pages. Maximum 8 pages can be provided to view the 4096 digital inputs status. To view the next page status In main menu, press key “1” for selecting the data logger options, a screen as shown in Fig. 2.4 will be displayed. Select the page option by pressing the key “2”, the following screen will appear on the screen.

0001 20-AUG09 17:10:00:000 RWKPR2 REVERSE

DGTL DSP PAGE NUMBER XX0 PRV # NXT 1-9 ENTRY * MAIN

Fig.3.1.6: Status of digital input signal corresponding to

points relay

Fig.3.1.7: Page options menu



19

PAGENUMBER XX represents present page no. To view previous page display – press 0 To view next page display – press # To view Default Display Menu – press * Alternatively, by entering the page number in the page number option user can directly go to the required page. Default display of page number will be ‘00’.The digital input configurations and the concerned page numbers are given in the table below:

Key Digital signal Page no 0 1 2 3 4 5 6 7

1-512 513-1024 1025-1536 1537-2048 2049-2560 2561-3072 3073-3584 3585-4096

00 01 02 03 04 05 06 07

After entering the page number, if it is a valid page number, then the following screen will appear on the LCD panel.

By pressing ‘#’ key the LED display will change accordingly to the status of digital inputs selected. If page number entered is invalid, the following screen will be displayed. i For Main Menu, press ‘*’ key.

For going back to the previous screen, press ‘#’ key. (iii) fizaVj }kjk fMftVy buiqV dh fLFkfr ¼ vkWu ykbZu izdkj½ Digital Input Status through Printer (On-line mode) User can get the online information of the change in digital inputs status by using the printer option. If the digital input status has changed, it shall be recorded or printed. If it is not changing then its status will not be printed. To get the printout in online mode follow the instructions below: In main menu, press key “1” for selecting the data logger options, the screen as shown in Fig.2.4 will appear on the LCD.

DGTL DSP PAGE NUMBER XX# ACCEPT * MAIN

INVALID PAGE NUMBER # BACK * MAIN

Fig.3.1.8: Valid page menu

Fig.3.1.9: Invalid page menu



20

For selecting PRINT option press the key ‘6’. Then LCD displays the following screen called

“PRINTER MENU”

Press ' 0 ' key to change it to the ONLINE mode, then the following screen will appear Now printer starts printing the latest changes in the status of Digital and Analog inputs provided printer is ready to print. 3.1.1.2 vkQ ykbZu izdkj Off line mode To get the status of digital inputs and analog voltages in off-line mode there is only one option and that is taking “printouts” (i) fizaVj n`’; }kjk fMftVy rFkk ,usykWx buiqV dh fLFkfr Digital and Analog Input Status through Printer In model DL99/06 user can even print a single input status or faults of one type (digital or analog). For this, all the events for printing are mainly divided into two categories. They are 1. Digital 2. Analog In Digital, it is again divided into two types : 1. Digital Input (Relays status) 2. Digital faults All the Digital Inputs are divided into 7 types (i)Tracks (ii).Points (iii).Routes (iv).Buttons (v).Slots (vi).Signals (vii).General Relays Thus, if the time interval entered for off line printing is valid, then the following screen will appear.

Press Key “1” for selecting digital, analog events and faults printing. Press Key “2” for selecting digital events printing.

Press Key “3” for selecting analog events printing. Press Key. ‘‘*’’for Main Menu Press Key”0” for going back to the previous screen

PRINTER IN OFF LINE MODE ONLINE (0) USER (1)

PRINTER MODE IS CHANGED…. PRINTER IN ONLINE MODE

1. ALL 2. DIG 3. ANA 9. PRNT 0. BACK *. MAIN

Fig.3.1.10: Printer menu

Fig.3.1.11: Screen showing printer on-

line

Fig.3.1.12: Offline printing options



21

For example, on pressing key “2” for printing the digital inputs, following screen appears. Press Key “1” for selecting both digital inputs status and faults printing. Press Key “2” for selecting digital inputs status printing. Press Key “3” for selecting digital faults printing. Press Key. ‘‘*’’for Main Menu Press Key”0” for going back to the previous screen Here, for example, on pressing key “2” for printing the digital inputs, the following screen appears. For selecting the other group input for printing, use key “#” or “0”. For example, if the user wants to print the status of a track input. Then the user has to follow the procedure given below. Press key “2” at the above screen. Now the display should be as below. Press Key “1” for selecting all TRACK inputs. Press Key “2” for selecting only selected TRACK inputs. If we Press key “2” for selecting few TRACK inputs, then the following screen appears. Here, in first row, signal name and its selectivity (i.e. whether it is already selected or not) will be displayed. Press Key “1” for selecting the input if the input is not selected earlier Or for deselecting if it is already selected. Keys “#” & “0” are for next and previous digital inputs viewing in this type. Press key “9” for end of selection of inputs for printing. Now the display on the screen will be as shown below. Press Key “1” for viewing the selected inputs for printing. Press Key “2” for printing the selected inputs. Press Key “3” for editing the selected inputs for printing. Press Key “*” to go to main menu

1. ALL 2. DIGIPS 3. DIGFLT 0. BACK *. MAIN

Fig.3.1.13: Digital inputs Offline

printing options

1. ALL 2. TPR 3. PNT #. NEXT 0. BACK *. MAIN

1. ALL 2. SOME 0. BACK *. MAIN

DIGITAL INPUT NAME -S 1. S/D #. NEXT 0. PREV 9. END *.MAIN

1. VIEW 2. PRINT3. EDIT *. MAIN

Fig.3.1.14: Offline digital inputs printing menu

Fig.3.1.15: Track input status

Fig.3.1.16: Selected Track input status

Fig.3.1.17: Menu after selection of inputs



22

For example on pressing key “2” for printing the selected inputs the following screen appears. Press Key “#” to STOP printing. Press Key “*” to go to main menu. Note: Make sure that the printer is ready to print while going for off line printing. If the printer is not ready then the fallowing message will be displayed on the screen. And after some time, main menu will be displayed. Same procedure has to be followed for printing the digital faults, analog channel voltages, and faults of analog channels. 3.1.2 pSVfjax buiqVl dks igpkuuk ¼ vkWu ykbZu izdkj½ To identify chattering inputs (On-line mode) If any input status changes more than or equal to 8 times in 4 seconds, then that input will be declared as ‘Chattering input’. By using corresponding option in data logger, user can find out the loose contacts and defective Relays. To view the chattering inputs (online), follow the given steps. Press ‘#’ key in the keyboard at default display menu, the following screen appears on the

LCD.

Press key ‘4’ to select the CTR (chattering) option. If any of the inputs are chattering then a screen similar to one below appears on the LCD.

0318 represents inputs number. A2-HHECR represents input name. If no inputs are chattering, LCD screen will show the following message.

PRINTING IS IN PROGRESS #. STOP *.MAIN

PRINTER IS NOT READY

Fig.3.1.18: Display while printing in progress

Fig.3.1.19: Display when printer not ready

NO CHATTERING INPUTS

DISPLAY OF CHATTERING INPUTS0318 A2-HHECR

1.PKTS 2.CONFIG 3.CD STAS4. CTR 5.ADB 6.DCS 7.MDMR

Fig.3.1.20.: Display on pressing # key

Fig.3.1.21.: Display of chattering inputs

status

Fig.3.1.22.: Display of no chattering

inputs status



23

3.1.3 ,usykWx pSuy Analog channels The analog voltage variations can be logged through data logger. If the variations in analog voltages are beyond the tolerance limits then its value will be recorded and will be updated in the concerned fields. User can get this information in two modes, Online Mode Off-line Mode Analog channels status can be known in two ways.

(i). Through LCD. (In On-line mode) (ii). By taking Printout.( In On-line & Off-line mode)

(i) ,ylhMh n`’; }kjk ,usykWx pSuy dh fLFkfr ¼vkWu ykbu izdkj½ Analog Channels Status through LCD (On-line mode) User can view the online status of the different analog channels by following the given procedure. At the data logger options screen (Fig.2.4) press key ‘4’ on the keyboard to select ANG (Analog) option; the following screen appears on the LCD. In the above screen, First row contains, channel number and the date and time at which the channel was scanned. Second row contains, the channel name and the actual voltage on the channel. Press ‘#’ key for knowing the voltage of next analog channel. If analog scanning cards are not connected properly or analog communication fails between CPU module and analog scanning module, then it will show following screen. Here “F” indicates that the corresponding channels are out of link (or not connected). Press ‘*’ key to go to “Default Display Menu”.

(ii) fizaVj }kjk ,usykWx pSuyksa dh fLFkfr ¼vkWu o vkWQ ykbu izdkj½ Analog Channels Status through Printout (On-line & Off-line mode) Follow the similar procedure mentioned in digital module to take the printout for online status and user selected time intervals.

001 ANG 24DEC06 11:10:00 230 V AC – 1 233.530V

001 ANG F 230 V AC – 1 XXXX

Fig.3.1.23: Display of analog channel status

Fig.3.1.24: Display of analog channel failure



24

3.4. MkVk ykxj ds vklikl ds rkieku dks tkapuk To know data logger surrounding temperature Data logger also logs the temperature surrounding it which can be seen on the LCD display of the Data logger. To view its status follow the procedure given below. At the data logger options screen (Fig.2.4) press ‘7’ on the keyboard to select TMP (Temperature) option; the following screen appears on the LCD. In the above screen, the value “30 C” is the surrounding temperature value logged by the data logger. By pressing the key ‘*’ the screen will return to the “Default Display Menu”. 3.1.5 nks"k Faults Fault is an abnormal condition. The data logger, based on the logic embedded in it, will identify this abnormal condition. The user in their requirements will give the logic behind the fault (Refer Annexure). Faults are of two types. 1. Digital Faults 2.Analog Faults

3.1.5.1 fMftVy nks"k Digital Faults When a digital fault occurs data logger will activate the buzzer. These faults can be viewed on LCD screen by using keypad. These faults can be viewed in two modes. Online Mode Off-line Mode

3.1.5.1.1 vkWu ykbZu eksM Online mode There are two ways to identify the latest faults in On-line mode

(i). Through LCD (ii). By taking printout.

(i) ,ylhMh n`’; }kjk fMftVy nks"kksa dh igpku ¼vkWu ykbZu izdkj½ Digital faults identification through LCD (On-line mode) When a fault occurs Data logger activates the buzzer and displays the corresponding message on LCD screen. For that user has to follow given procedure. At the data logger options screen (Fig.3.1.4) press ‘5’ on the keyboard to select FAULT (faults) option; the following screen appears on the LCD.

Press key ‘3’ to select the LATEST FAULT option. This option gives the latest faults occurred (if any). The following screen shows a sample fault.

1.DGTL FAULT 2.ANLG FAULT3.LATEST FAULT

001 24DEC06 18:18:17 1A TPR TRACK CIRCUIT FAILURE

EXT. TEMPARATURE: 30 C

Fig.3.1.25.: Display showing surrounding temperature

Fig.3.1.26.: Screen showing faults menu

Fig.3.1.27: Digital faults status



25

Here 001 represents the fault number that has occurred. “24DEC06” represents the date, month & year “18:18:17” represents the time of occurrence of fault. “1A TPR TRACK CIRCUIT FAILURE” represents the fault name

(ii) fizaVvkmV }kjk nks"kksa dh igpku ¼vkWUk ykbZu izdkj½ Faults identification through printout (on line mode) Follow the same procedure that explained in digital module to take the printout for online Digital faults. In the Printout the corresponding fault message will also print. By observing the related inputs status user can validate that fault.

3.1.5.1.2 vkWQ ykbZu eksM Off-line mode In this mode also two ways are available to get the information about the Digital faults in off-line mode i.e.

(i). Through LCD (ii) By taking Printout.

(i) fizaVvkmV }kjk nks"kksa dh igpku ¼vkWQ ykbZu izdkj½ Faults identification through LCD (Off-line mode) The data logger is able to store the status of 500 latest faults. To see the status of faults occurred in off line mode, follow the steps given below. Press the key ‘1’ to select the DGTL FAULT option in fault menu (Fig.2. ); if any fault has occurred previously, user can view its status on LCD. To view the status of next fault press “#” key. To view the status of previous fault press ‘0’ key. To view the status of last fault occurred press key ‘2’. To view the status of first fault occurred, press key ‘1’. If no digital faults have occurred then the following display will appear on the screen.

(ii) Faults identification through printout (Off-line mode) Follow the similar procedure to get printout of Digital faults in Offline Mode as explained in digital module.

3.1.5.2 ,usyksx nks"k Analog faults If any analog channel voltage is not within its maximum and minimum voltage range then Analog fault occurrs. When analog fault occurs, the buzzer is activated. User can get the Analog fault information in two modes. Online mode. Off-line mode.

NO FAULTS PRESENT Fig. 3.1.28.: Display when no Digital faults have

d



26

3.1.5.2.1 vkWu ykbZu izdkj Online mode User can identify the latest Analog faults in two ways.

(i). Through LCD (ii). By taking Print out

(i) ,ylhMh n`’; }kjk ,usykWx nks"kksa dh igpku ¼vkWu ykbZu izdkj½ Analog faults identification through LCD (On-line mode) Follow the similar procedure to get the online information about the Analog faults as explained in Digital faults.

(ii) fizaVvkmV }kjk ,usykWx nks"kksa dh igpku ¼vkWu ykbZu izdkj½ Analog faults identification through printout (On-line mode) Follow the similar procedure to take the printout for online Analog faults as explained for digital faults.

3.1.5.2.2 vkWWQ ykbZu izdkj Off-line mode In this mode there are two ways to get the Printout of analog faults.

(i). Through LCD (ii) By taking Printout.

(i) ,ylhMh n`’; }kjk ,usykWx nks"kksa dh igpku ¼vkWQ ykbZu izdkj½ Analog faults identification through LCD (Off-line mode) The data logger is able to store 500 faults. Follow the given procedure to view Analog faults on LCD screen. Press key ‘2’ to select the ANALOG FAULT option in “Faults Menu”. Now the user can view the analog faults occurred (if any). To view the status of next input press key “#” To view the status of previous input press key “0” To view the status of the latest analog fault occurred press key “2” To view the status of the first analog fault occurred press key “1”. An example screen is given below when the analog fault is occurred. Here 16 represents the fault number occurred 20DEC06 - represents the date, month, & year. 18:18:17 - represents the time (Hour, Minute, second) 110VAC - represents the channel name LOW - represents the status of fault occurring 0.2100V - represents the voltage value at which the fault is occurred.

016 20DEC06 18:18:17110V AC - 3 LOW 0.2100V

Fig.3.1.29.: Analog faults status occurred



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If no faults have occurred then the following screen will appear on LCD.

(ii) fizaVvkmV }kjk ,usykWx nks"kksa dh igpku ¼vkWQ ykbZu izdkj½ Analog faults identification through printout (Off-line mode) Follow the similar procedure to get the printout of Analog signals in OFFLINE mode as explained in digital faults. 3.1.6 vU; dk;Z Other functions Data Logger has following additional functions. 1. Time & Date setting 2. Change of password 3. Packet information. 4. Configuration details. 5. Digital cards health status information From the above, 1 & 2 are explained below. Functions 3,4 & 5 are not within the scope of this handbook hence if required then ‘Data Logger System Hardware User Manual’ of M/s Efftronics may be referred. 3.1.6.1 fnukad rFkk le; cnyus dh dk;Zfof/k Procedure for changing date & time Follow the given procedure to set the time and date of the data logger. At the data logger options screen (Fig.3.1.4) press ‘1’ on the keyboard to select TIME (Time) option; the following screen appears on the LCD.

By pressing any key to change the time the following screen will appear.

Now enter the password. By default the password is ‘123456’. If the entered password is incorrect then the following screen will be appeared on the LCD.

Press the key ‘*’ to return to the “Default Display Menu”. If user enters the correct password the screen as shown in Fig. will appear.

TIMESET DATE DD / MM / YYYY TIME HH : MM : SS

ENTER PASSWORD:- - - - - -

PASSWORD INCORRECTMAINMENU (*)

NO FAULTS PRESENT Fig.3.1.30.: Display when no Analog faults have occurred

Fig.3.1.31.: Option to set date & time

Fig.3.1.32.: Message to enter password

Fig.3.1.33.: Message when entered password is incorrect



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Now update the required date and time in the fields given in Fig. . To move the cursor between the fields press the key ‘#’. Now after updating the above fields, press the key ‘*’. Then the following screen will appear. Press the key ‘#’ for effecting the changes, press ‘ * ’ key for canceling the changes made in the above fields. When the ‘#’ key is pressed, the following screen will appear on the LCD. When the key ‘*’ is pressed instead of ‘#’, the following message will appear on the screen. Press ‘*’ key to return back to Default Display Menu.

3.1.6.2 MkVk ykWxj ikloMZ dks cnyuk To change data logger password This feature is provided to authorize the user to change the analog database and the time. ‘123456’ is the default password present in the system. To change the password, follow the given procedure. At the data logger options screen (Fig.3.1.4) press key ‘8’ on the keyboard to select PWD (Password) option; the following message appears on the LCD Now enter the old password if any or enter the default password ‘123456’. If the entered password is correct the following message will appear on the LCD display Now enter the required password, then it will ask again to enter the new password as which is as shown below. Then re-enter the new password for confirmation. If the re-entered password matches with the previously entered one then the following screen will appear.

SET TIME… YES (#) NO (*)

TIME UPDATED… MAINMENU (*)

TIME NOT UPDATED … MAINMENU (*)

ENTER OLD PASSWORD - - - - - -

ENTER NEW PASSWORD - - - - - -

RE ENTER NEW PASS WORD- - - - - -

Fig.3.1.34.: Display after date & time fields are updated

Fig.3.1.35.: Message when changes are effected

Fig.3.1.36.: Message when changes are cancelled

Fig.3.1.37.: Message on giving PWD option

Fig.3.1.38.: Message when entered password is correct

Fig.3.1.39.: Message for confirmation of new password



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If the re-entered password does not match with the previous one then the following screen will appear and the old password remains unchanged. 3.1.7 MkVk ykWxj esa MkVk cSdvi Data backup in data logger In Data logger, flash memory chip is used for data backup of more than 10 lac events. To see the status of the flash memory, follow the procedure given below. When the LCD is showing Default Display Menu, press “*” key to go to “Main Menu” as shown below. Now press key “3” for viewing the status of Flash Memory. The screen will be as shown below. For viewing the Health status of the Flash Memory, press key “1”, now the screen will be as shown below. (a) If the Flash Memory is Healthy, (b) If the Flash Memory is failed message will be displayed as shown below with Card failed Date and Time.

PASSWORD UPDATED

PASSWORD NOT UPDATED

1. DATALOGGER 2.RELAY HUT 3. FLASH MEM 4. MEM CARD

1. STATUS 2.CLUSTERS 3. MEM USED 4. FROM DATE

FLASH MEMORY IS HEALTHY

FLASH MEMORY FAILED

Fig.3.1.40.: Message when new password is correct

Fig.3.1.41.: Message when new password is incorrect

Fig.3.1.42.: Main menu

Fig.3.1.43.: Menu for flash memory status

Fig.3.1.44.: Message when flash memory is healthy

Fig.3.1.45.: Message when flash memory is failed



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(c) If the 68k Processor to 89LPC936 Controller Communication link is failed message will be displayed as shown below with link fail Date and Time. For viewing the date of the Oldest File and the Latest File stored in the Flash Memory, press key “4” at display shown in Fig.2.. Now the screen will be as shown below. 3.1.8 ¶yS’k eseksjh ls QkbZyksa dh izfr cukdj MkVk ykWxj dh ckg~; esaeksjh esa Hkstuk Copying the files from flash memory to external memory card in the data logger User can copy the Files from Flash Memory to External Memory Card in the data logger. To do that, External memory card is to be inserted into data logger and the procedure to be followed given below. When the LCD is in Default Display Menu, press “*” key to go to “Main Menu” as shown in Fig.3.1.42 Now press key “4” to copy the files into Memory Card . Now the screen will be as shown below. Now users has to enter from date and to date of the files to copy and press * to start copying. If the entered dates are not valid dates then the screen will be as shown below If the entered from date is greater than to date then the screen will be as shown below. If the entered dates are valid dates then the screen will be as shown below.

FLASH MEM COMM LINK FAIL

DATA AVAILABLE IN FLASH MEM FRM: DD/MM/YY TO: DD/MM/YY

Fig.3.1.46.: Message when communication link is failed

Fig.3.1.47: Date of oldest and latest file

COPY FLSH MEM TO MEM CARD FRM: DD/MM/YY TO: DD/MM/YY

INVALID DATE TIMESET (#) MAIN (*)

ENTERED DATES ARE VALID #. CONTINUE *. MAIN

ERROR FROM TIME > TO TIME TIMESET (#) MAIN (*)

Fig.3.1.48: Display while copying files into Memory card

Fig.3.1.49: Message when valid dates are not entered

Fig.3.1.50: Message when entered date is greater than to date

Fig.3.1.51: Message when entered dates are valid



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To continue press #, the message will be as under If the Memory Card is not present then it will be as shown below and users can press * to go to Main. If the Flash Memory is busy then it will be as shown below. If the data available in the Memory Card is not a valid data then it will be as shown below. If there is no enough space in the Memory Card 2 to copy the requested files, then it will be as shown below. When Files are being copied into the Memory Card 2, then it will be as shown below. When copying is finished, then it will be as shown below

MEM CARD VALIDATIONS IN PROGRESS

MEMORY CARD FAILED

FLASH MEMORY BUSY

MEM CRD VALIDATIONS FAILED #. FORMAT *. MAIN

NO ENOUGH SPACE IN MEM CARD #. DEL OLD FILE *. MAIN

FILE XXXX COPYING IN PROGRESS...........

COPYING FINISHED

Fig.3.1.52: Memory card validations in progress

Fig.3.1.53: Message when Memory card is not present

Fig.3.1.54: Message when Flash Memory is busy

Fig.3.1.55: Message when valid data not available in memory card

Fig.3.1.56: Message when space is not enough in memory

d

Fig.3.1.57: Files copying message

Fig.3.1.58: Files copying finished message



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3.1.9 MkVk ykWxj esa vkj Vh ;w MkVk dks ns[kuk To see RTU data in the data logger User can see the RTU inputs status, which are configured and connected to the data logger. To verify the inputs status of the RTU, fallow the procedure given below. When the LCD is in Default Display Menu, press “*” key to go to Main Menu as shown in Fig. Now press key “2” for viewing the status of inputs of RTU. Now the screen will be as shown below. For viewing the digital input status of the RTU, press key “1”, For viewing the analog channel voltage of the RTU, press key “2” . 3.2 ØkWEiVu xzhOl MkVk ykxj iz.kkyj dh QhYM ;qfuV Field Unit of Crompton Greaves Data logger system Fig 3.2.1: Field unit of Crompton Greaves Data logger system The field unit of data logger system manufactured by M/s Crompton Greaves. Ltd., which consists of Power Supply module, Digital and Analog input cards, Signal conditioning card, Keyboard and display module. In Keyboard and Display module user can view status of various inputs as described in Key board and Display module feature. This is connected to CPU via serial bus. The module has LCD type of 20 x 4, display unit with backlit and Keyboard of 4 x 3 matrixes, which consists of telephonic push button.

1. DIGITAL 2.ANALOG Fig.3.1.59: RTU input status menu



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3.2.1 dh cksMZ rFkk fMLIys ekWM~;wy dh fo’ks"krk;sa Key board and display module features Open the front door of DL and switch on the power supply module, which is placed on the top portion of the unit. Observe the display, which prompts to Home frame. This ensures the healthiness of system. For Main menu press #. The following screen is displayed: Select digits to go to sub-menu under each item, i.e. 3.2.1.1 lk¶Vos;j laLdj.k Software version From main menu press ‘0’ to display software version. Press ‘*’ to go back to Main menu. 3.2.1.2 fMftVy buiqV~l dh fLFkfr Digital Inputs status From main menu press ‘1’ to see the menu for Digital input. Display will show following frame. At the above screen Press ‘*’ to go back to Main menu. Press ‘1’ to know the status of Digital Input. The following screen is displayed: Enter desired input No. e.g. ‘No 0123’ and press # (OK). The following screen is displayed:

DATA LOGGER CROMPTON GREAVES LTD.

TIME: HH:MM:SS DATE: DD/MM/20YY

1 Dinp 2 Ainp 3 Exp 4 List 5 Time 6 Sp 7 Flts 8 Config 9 Ltst 0 sw ver

DIGITAL INPUTS 1 STATUS 2 EVENTS (Particular) 3 ALL EVENTS

Enter Input No here ----- *Cancel #OK

1.DI 0123 Status :Pick Up Date: 10/09/08 Time: 15:23:44:236

Fig. 3.2.2: Home Frame

Fig. 3.2.3: Main Menu

Fig. 3.2.4: Digital Inputs Menu

Fig. 3.2.5: Display on pressing option ‘1’of Digital inputs menu

Fig. 3.2.5: Digital Input Status



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Press ‘*’ to go back to Main menu. Press ‘2’ to view the status of particular digital input over selected period. On pressing ‘2’ a screen is displayed prompting to enter Digital Input No, From date & From time. Enter the values and press ‘Enter’. For example on entering the values for Digital Input No.0123, From date 10/09/08 and from time 15:23 the screen will look as given below: Press ‘#’ and the following screen is displayed. Enter the ‘To date’ and ‘To time’ values and press ‘Enter’. The following screen is displayed: Press ‘1’ to print the status and press ‘2’ to display. 3.2.1.3 ,usykWx buiqV~l dh fLFkfr Analog Inputs status Press 2 from main menu to view Analog Input status. Follow same procedure as described under para 3.2.1.2. Read Analog input (AI) where ever Digital input is printed. 3.2.1.3 ,DlsI’ku fjiksVZ Exception Report Press 3 from main menu to view Exception report. Follow same procedure as described in para 3.2.1.2. Read Exp in place of Digital input. Press ‘*’ to go back to Main menu. Press ‘*’ to go back to Main menu

EXCEPTION RPT 1 STATUS 2 EVENTS (Particular) 3 ALL EVENTS

Input No:0123 From date:10/09/08 From time:15:23 *Back #Enter

To date: To time: *Back #Enter

1. PRINT 2. DISPLAY

*Back #Enter

Fig. 3.2.6: Display on pressing option ‘2’of Digital inputs menu

Fig. 3.2.7: Display on entering From date & from time

Fig. 3.2.8: Particular events menu

Fig. 3.2.9: Exception report menu



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3.2.1.4 lajpuk dks lwphcí djuk Listing configuration From main menu press ‘4’ for viewing Digital Input List, Analog Inputs List and Exceptions List. Display will show following frame. Press ‘*’ to go back to Main menu. 3.2.1.5 le; o fnukad Time & Date From main menu press ‘5’ to set Time & Date. A message will prompt to enter password. Enter the valid password. Press ‘1’, the next screen will prompt to set the new Time & Date. Enter new Time& Date and press ‘#’. A message will prompt to confirm. After few seconds the new Time & Date will be updated and Home Frame is displayed. In Main menu, digit ‘6’ is spare. 3.2.1.6 nks"kska dh fLFkfr Faults status From main menu press ‘7’ to view or print Faults status over a selected period. Display will show following frame. Follow instructions to view/print the required status. Press ‘*’ to go back to Main menu. 3.2.1.7 lajpuk Configuration From main menu press ‘8’ to see Configuration. In configuration frame user can modify printer status, passwords and touch pad beep. A message will prompt to enter password. After entering the valid password, following menu is displayed: 1 Printer Config 2 Sound Enable 3 Change Password 4 Set AI Limit Press ‘1’ to know the Status of printer i.e. On-line or Off-line. Press ‘2’ to make sound On or Off . Press ‘3’ to change password. Press ‘4’ to set upper and lower limit of Analog input.

LIST 1 DIGITAL INPUTS 2 ANALOG INPUTS 3 EXCEPTION RPT

FAULTS 1 DIGITAL INPUTS 2 ANALOG INPUTS

Fig. 3.2.10: Exception report menu

Fig. 3.2.11: Faults status menu



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3.2.1.8 rktk ?kVukØe Latest events From main menu, press 9 to view the Latest Events. Following screen is displayed: Press ‘1’ to view the latest event of Digital Input. Following screen is displayed: On pressing required key following screen is displayed: Press ‘1’ for Print and press ‘2’ for display. Similarly print or display Latest Analog Inputs, All inputs and Exceptions.

Latest Event of: 1:DI 2:AI 3:All 4:Exp

1:All 2:TPR 3:PNT 4:ROUT 5:BTN 6:SLT 7:SIG 8:Others Select TYPE

1.PRINT 2.DISPLAY * Back # Enter

Fig. 3.2.12: Latest events menu

Fig. 3.2.13: Latest Digital Input options menu

Fig. 3.2.14: Print & Display menu for Latest Digital Inputs



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v/;k; 4 Chapter 4

fjeksV VfeZuy ;qfuV¼vkjVh;w½ REMOTE TERMINAL UNIT (RTU) 4.1 ,QsDVªkWfuDl MkVk ykWxj iz.kkyh dk vkjVh;w RTU of Efftronics Data logger system The RTU of dtata logger system manufactured by M/s Efftronics Systems Pvt.Ltd. consists of a Main Euro Rack as shown below.

Fig. 4.1: RTU Main Euro rack

Analog scanning card (with controller)

LED indications for power on and communication User interface

switches

Digital scanning card

CPU card

7-segment LED for time display

LED block indication for digital input status

LED indication for analog communication



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4.1.1 ;wtj baVjQsl vkfdZVsDpj User interface architecture RTU have a user interfacing unit which consists of a Key Board (with 3 keys. namely Mode key, Next key & Previous key), 7 Segment LED Display and a Block LED display. A total of 7 modes are defined for user interface module and these modes are mentioned below.

(i) eksM 0 ¼fMQkYV½ Mode 0 (Default) Default time display Current date display - (Message)

(ii) eksM 1 ¼lajpuk izdkj½ Mode 1 (Configuration Mode) Version display Relay Hut ID Monitors Version Number of Analog Inputs Number of Digital Inputs Check Sum Even - (Message) Check Sum Odd - (Message) Relay Hut On Calendar – (Message) Relay Hut On time - (Message)

(iii) eksM 2 ¼lapkj fLFkfr izdkj ½ Mode 2 (Communication Status Mode) Network Port1 Communication packets Transmit Packets - (Message) Fail Packets Pending Packets Duplication Packets

Network Port4 Communication packets Transmit Packets - (Message) Fail Packets Pending Packets Duplication Packets

Analog Port1 Communication packets Receive Packets - (Message) Fail Packets

Analog Port4 Communication packets Receive Packets - (Message) Fail Packets



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(iv) eksM 3 ¼,usykWx izdkj½ Mode 3 (Analog mode) Temperature - (Message) Analog channel status

(v) eksM 4 Mode 4 Chattering of Digital Inputs

(vi) eksM 5 Mode 5 Digital Card Health St

mkvk ykwxj ds usvodz ls fuokjd vuqj{k on... · mkvk ykwxj ds usvodz ls fuokjd vuqj{k.k ij...

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