Operational Instructions & Maintenance Manual

for

SMPS Based Integrated Power Supply

(IPS)

for

Railway Signaling Application

SPECIFICATION NO : RDSO / SPN / 165 / 2004

Power Systems (P) Ltd.

Renigunta – Cuddapah Road
Karakambadi – 517 520
TIRUPATI (A.P.)
Tel : (0877) 2285561 ( 5 Lines )
Fax : (0877) 2285599 / 2285600

1
 CONTENTS OF SMPS - I PS MANUAL
SECTION - A
A.1. GENERAL DESCRIPTION
A.2. UNPACKING
A.3. INSTALLATION & COMMISSIONING
A.3.1. INSTALLATION
A.3.2. COMMISSIONING

SECTION - B
B.1. OVERALL FUNCTIONING OF SMPS PANEL.
B.2. SWITCH MODE RECTIFIER

B.2.1. GENERAL DESCRIPTION

B.2.2. WHAT IS CSU?
B.2.3. TECHNICAL SPECIFICATION ON SMRs
B.2.4. RECTIFIER MODULE
B.2.5. CSU MODULE
B.2.6. USER INTERFACE BOARD (MUIB)
B.2.7. OPERATING THE CSU
B.2.8. CSU SCREEN
B.2.9. CSU ALARMS
B.2.10. MAINTENANCE
B.2.11. SYSTEM SET POINTS

SECTION-C
C3.0. OVERALL FUNCTIONING OF DCDP PANEL

C.3.1. GENERAL DESCRIPTION

C.3.2. DC-DC CONVETER SPECIFICATION
C.3.3. TROUBLE SHOOTING
C.3.4. MAINTENANCE CHECK POINTS FOR DC-DC
CONVERTERS

SECTION-D
D.1.0. OVERALL FUNCTIONING OF ACDP
D.2.0. INVERTER
D.2.1. GENERAL DESCRIPTION
D.2.2. TECHNICAL SPECIFICATION
D.2.3. SYSTEM DESCRIPTION
D.2.4. OPERATING INSTRUCTIONS
D.2.5. MAINTENANCE & TROUBLE SHOOTING
D.3.0. BYPASS CVT REGULATORS
D.4.0. STEP DOWN TRANSFORMERS
D.5.0. TROUBLE SHOOTING ON ACDP
D.6.0. MAINTENANCE CHECK POINTS FOR ACDP.

2
 SECTION –E
ASM INDICATION PANEL

SECTION-F

ANNEXURES

SYSTEM BILL OF MATERIALS

SCHEMATIC DIAGRAMS

DIMENTIONAL DRAWINGS

DOs AND DON’Ts FOR IPS SYSTEM

FEED BACK FORMAT

GUARANTEED TERMS & CONDITIONS

COMMISSIONING CHECK LIST

NOTE
Read this Manual carefully before attempting to
Install, Commission, Maintain or troubleshoot this
Integrated Power Supply.

3
 Section - A

A.1 GENERAL DESCRIPTION

SMPS based INTEGRATED POWER SUPPLY SYSTEM (IPS), as the name

indicates, is designed and developed with a view to provide complete power

solutions from one system to all signaling circuits at a typical 4 or 6 line way

side station in Indian Railways, meeting the requirements of RDSO

specification RDSO / SPN / 165 / 2004.

It basically consists of,

i. SMPS Panel, comprising of

- Light Weight, Hot swappable Switch Mode Rectifiers (SMRs)

- Microprocessor based Control and Supervisory Unit (CSU) for above SMRs

ii. DC Distribution Panel (DCDP), comprising of

- DC-DC Converters for various applications

iii. AC Distribution Panel (ACDP), comprising of

- Step Down Transformers

- Bypass CVT Regulators
- Pulse Width Modulated Inverters
- CVT Regulators for Track & Signal where required.

iv. Remote Panel to be mounted in ASM room for indicating the status of
various sub systems and DC-DC Converters, comprising of

- 03 – 06V/0.1A Block Tele (Up & Dn) converters are accommodated in status
monitoring panel.

The above are supplied in three or four cabinets depending on the specific

station requirement. IPS caters to both AC and DC power requirements without

any interruption to various equipment in a Railway Signaling Station. The single

line functional block diagram of the system is enclosed for reference.

4
 A.2 Unpacking
To avoid transit damages, the sub- modules like SMRs, DC-DC Converters and
Inverters are packed separately in thermocol / cartoon boxes and in turn in
Wooden Crates. User is suggested to preserve these thermocol / cartoon
boxes, as they would be useful for sending the modules for the purpose of
servicing.

Follow the below mentioned steps for unpacking the IPS.

• Remove the wooden packing and discard it.

• Observe SMPS Panel, DC Distribution Panel and AC Distribution Panel for
any damages during transportation and Check the received material as per
packing list. In case of any damage or discrepancy, bring it to the notice of
AMARA RAJA in any of its works, Regional or Branch offices within seven
days of receipt.
Registered Office
Manufacturing Facilities & Central Distribution Center
Karakambadi–517 520, TIRUPATI, Andhra Pradesh, India.
Tel : 0877-22855 61 to 65 Fax : 0877-2285599 / 2285600
Email : [email protected]
Corporate Operations Office
Central Marketing Office–Customer Support Center
5th Floor, Riaz Garden, No.12, Kodambakkam High Road, Nungambakkam,
CHENNAI-600 032, India, Tel : 044-821 3270, 821 3275
Fax: 044-828 4821
Other Marketing Offices: Bangalore :
No.19/D, Mysore Deviation Road,
Hyderabad : Near Minarva Mills, Bangalore-560 023,
Suit 203, 2nd Floor Tel : 080-3102140 / 3102141 Fax: 080-3102142
6-3-550, L.B. Bhawan, Somajiguda,
Hyderabad.Tel.:+91-40-23328868, Fax :23328868 Kolkata :
263/2, Rajarphat Road, Dashadrone Check post
Ahmedabad: R.Gopalpur (P.O), Kolkata-700 059
Survey No 341, Tel : 033-25730655 / 677, Fax:033- 5730656
Behind EKTA Hotel Sarkaj,
Bavia road sarkaj, Ahmedabad-382210.
T el: 079-658-8932,33, Fax No: 6588938 Cochin :
CC43/51A, Ameer Complex, Ayyappankavu, East Road,
Delhi : Kochi–682 018, Tel: 0484-2398289, 2398290
B – 93A , Panchasheel Vihar , Fax : 2398291
New Delhi – 117 Coimbatore :
Tel : 011-29541892-96, Fax.No: 29541044 LCT Complex,1986, Trichy Road
Singanallur, Tel : (0422) 2320614,2320218
Mumbai :
69-P, Nirlon Compound Chandigarph :
Western Express Highway, Goregaon (East), Behind Mayur Restaruant,PRABHAT (VI),
Mumbai-400 063, Tel : 022-26850556/57 Zirakpur,
Fax: 26850537 Chandigarh,Tel : 0172-652495 / 566 / 865
Fax : 652518
Chennai : Pune :
Buckingham Terrace Survey No New 163 ,
No.61, Mc Nicholas Road, Behind MSEW,
Chetput, Chennai – 600 031, Phursingi Village ,
Tel : 044 – 2661 5695 / 5697 Taluka Haveli. Pune - 412308
Fax: 044 – 2661 5794 Tel : 020 – 6363693,94. Fax : 6363643.

5
 A.3 Installation & Commissioning
The system should be installed with sufficient space at rear and front for easy Maintenance and
servicing. The location selected for placing the system should be away from dropping or falling
substances as well as heat generating equipment.

SAFETY NOTICE: Before applying power to the system, please ensure that the body of each
rack is properly connected to earth through proper size cables & lugs.

WARNING:
• Initial battery connection & load connection shall be done without the system energised. When
the system is under operation, adequate precautions have to be taken while installing &
removing sub modules, since high voltages (Approx. 400V) are available in side of the panel.
• Do not install the equipment near heat-generated equipment. Avoid locations subjected to
corrosive fumes or extremes of dirt & moisture.
• To avoid voltage drop and fire hazards, cables of specified rating and type as shown in
interconnection drawing only shall be used for input, output and interconnections.

A.3.1 Installation Procedure

• Keep the cabinets side by side leaving a gap of about 1foot in between. Grout
the cabinets to floor using the holes provided in U-Channels.
• Cable Entry holes are provided at bottom.
• Keep the entire front panel Switches in DC-DC Converters, Step down
Transformers, CVTs, and MCBs of SMRs in OFF position. Remove Battery Input
Fuse and Point Operation Fuse.
• Make the input, output and interconnections, except the loads connected to DC-
DC Converters, and step down transformers as per the installation diagram.
Punch type cable glands are provided to run the cables safely into the cabinets.
Refer the interconnection drawings for connectivity details.
• Insert the Rectifier Modules (SMRs) in their respective slots in SMPS panel.
Follow the procedure mentioned in SMR Section.
• Insert the DC-DC converters in their respective slots in DCDP. Keep the Voltage
adjustment potentiometer fully anti clock wise so as to keep the output voltage
minimum. This potentiometer is located at the left side on the Front panel. Follow
the procedure mentioned in DC-DC Converter Section.
• Insert the Inverters in their respective slots in ACDP and insert the input and
output connectors in respective female connectors and fix the inverters with
screws. Follow the procedure mentioned in Inverter Section.
• Place the Battery temperature-sensing probe on Batteries and connect the
other end of the probe Connector X17 to MUIB (PC3) in SMPS panel.
• Mount the ASM indication Panel in ASM chamber at appropriate place.
Connect the Multi core Cable, one end to ASM indication panel first and then
to SMPS panel.
• Connect Generator Output supply to SMPS panel at TB – 3( with 1Sqmm
cable).
• Separate earth pit is to be provided for IPS as per RDSO guide lines.

6
Lightening protection:
This IPS system has been provided with Class B and Class C type two stage protection.
Class B Protection (LPD): This protects the IPS against Lightening. This system is designed in a
separate module of wall mountable type, which is to be provided at the power-input point in the
IPS room. These devices are of encapsulated type and have self-arc quenching facility.
Class C Protection (SPD): These devices are also provided in the LPD Module of wall mountable
type. Potential free contacts are provided for failure monitoring of the devices.
Potential free contacts are provided for health monitoring of SPD and the same can be wired to
ASM room/where ever required to monitor the healthiness of SPDs.

LPD and SPDs used are inductor less co-ordinators for better protection.
Earthing guide lines for installation of Lightning protection devices of IPS system:
Electrical connection:
• Connecting wires to the surge protection devices should always be kept as short as
possible from mains (In this case the I/P to the IPS is taking from LPD module), to prevent
voltage rising on the wiring impedance.
• Protected and unprotected conductors should not be laid parallel and close together. They
must be spaced apart or separated by shielding in such a way as to minimize the transfer
of voltage surges from unprotected conductors to protected conductors.
• Same conductor cross-sections must be used for the wires to the surge arrestors(class-C)
as for the Input AC cable and neutral.
• Paralleling and looping of protected and unprotected wires should be avoided.
Earth Connection:

The cable size of the earth wire here is 0.5Xcross-section copper of the mains wire, with an upper
limit of 25mm² copper. But a lower limit of 10mm² copper is required.

No earth shall be connected to the system. The system earth shall be connected to Class – B
protection module and Class – B module only shall be connected to earth.

Care must be taken so that the distance between earth pit connection and IPS is always higher
than that of the distance between earth pit connection and Class – B module.

Inspection and maintenance:

Surge arrestors of Class-C containing varistors have an indicator, which shows weather the
device is faulty. The indicators of these should be checked, especially after a period of thunder
storms. If the Indicator changes from green to red, the device must be replaced, since it no longer
gives protection.
Lightning arrestors of Class-B aging phenomena may occur in rare cases, adversely affecting the
protective function of the devices, because of frequent over loading/lightning. It is therefore
advisable to check the arrestors every two to four years, and after direct lightening strikes.

7
 Example-I
Example-II
Lightening
Lightening
Protector System
Protector System

Correct Two Earthing points

are Incorrect

Example-III Separate routing and

combining of all earths
at one point is Correct

Class B
LA

PE

AC DB/
DCDB
Battery
SMRs

Input

8
A.3.2 Commissioning
• Ensure that the Mains voltage is within the specified limits of 150V to 275V
AC. Connect the mains to the system. In case of dropping of the input voltage
beyond its limits on loading, the cable sizes and at transforms trappings to be
checked and adjusted to keep the voltage with in limits.

• Connect the Battery with proper polarity and insert the Battery Fuse. CSU will
come ON and all the Input LEDs in DC-DC Converters will glow. Press Batt.
Push button in CSU; Battery Voltage will be displayed.

• Switch ON DC-DC Converters one by one and adjust the voltages as

required. Refer to adjustment procedure in DC-DC Converters section. Digital
Voltmeter with Patch Cards on DCDP front panel may be used for measuring
the each DC-DC converter output voltage.

• Connect the relays and equipment loads one by one to DC – DC Converters.

• Throw the Input ON/OFF switch in TRACK CVT to ON position.

‘OUTPUT ON’ LED will glow. Keep the Voltage selector switch in TRACK
CVT position and monitor the output voltage of this CVT in Digital Voltmeter
provided on front panel. This will be around 230V AC.

• Throw the Input ON/OFF switch in TRACK UP Step down Transformer to ON

position. ‘OUTPUT ON’ LED will glow. Keep the Voltage selector switch in
TRACK UP position and monitor the output voltage of this step down
Transformer in Digital Voltmeter provided on the front panel. This will be
around 110V AC. Switch OFF this unit and select appropriate voltage tapping
in the transformer, accessible from backside.

• Repeat the above step for TRACK DOWN step down transformer.

• Repeat the above three steps for checking Signal CVT and Signal Step down
Transformers.

• Switch OFF the CVTs and Step down Transformers.

• Press reset push button in the inverter and switch ON Inverter –1 by throwing
the MCB into ON position and then press start button gently, after a short
delay of around 10 seconds, the inverter will come ON. Output ON LED will
glow. Keep the Voltage selector switch in Inverter-1 position and monitor the
output voltage of this Inverter-I in digital voltmeter provided on the front panel.
This will be around 230V AC.

• Switch OFF inverter-1 and repeat the above step for Inverter-2.

• Keep both the inverters and both the CVTs in ON condition. In this condition,
Inverter-1 will supply to the load and inverter-2 will be in hot standby mode.

9
 • Switch OFF Inverter-1 at this moment. Inverter –2 should take over the load.

• Switch OFF Inverter-2 also. Now signal Bypass CVT will take the load.

• Switch ON both the inverters one by one. Inverter-1 will take the load and
Inverter –2 will be in Hot Standby mode. Bypass signal CVT will go into
Standby mode.

• Throw the MCBs of SMRs to ON position one by one. LEDs in Current Bar
Graph will glow depending upon the current being supplied to load. Observe
the parameters like Float Voltage, Boost (Equalize) Voltage, SMR currents
etc. in CSU. Change the parameters, if required, depending upon the site
conditions as per the procedures given in SMR section of this Manual.

• Make ASM Panel connections to DCDP as per the Interconnection diagram

enclosed. Discharge the battery by Switching OFF the SMRs and check for
various indications at different voltage.

Note: Protect the inverters from output over lapping give minimum 30 sec between
operations / while testing transfers.

PROCEDURE FOR ADJUSTMENT OF INPUT POWER LIMIT (MUIB-3)

1. Switch off mains and allow the battery to discharge for half an hour.

2. Turn VR2 in fully counter clockwise direction in PC-2. (This is to limit the I/P current to the
possible low level).

3. Switch on mains (i.e SMRs to switch on mains only), the SMRs may not deliver full output
and operates in current limit.

4. By connecting a Multi meter at the I/P mains of the system, Turn VR2 in Clock wise
direction (PC-2) slowly to open the current limit and may observe fall in I/Pac Voltage due
to loading on mains. Continue to turn VR2 in clockwise direction (PC-2) till the I/P AC falls
below approximately 180Vac and lock the pot.

To limit the GENERATOR POWER TO THE IPS:

5. Start Genset and allow the IPS to work on Generator.

6. Adjust VR1 if the Genset is having any limitation in catering to IPS. This is only possible
when the system is working on Genset.

7. Load the SMRs to take an I/P current that the DG can supply.

8. Adjust VR1 slowly and see that there is a fall in O/P voltage and lock the pot with nail
enamel.

10
 Section – B

SMPS Panel

- Overall Functioning of SMPS Panel.

- Switch Mode Rectifiers

11
B.1 Overall Functioning of SMPS Panel.
Refer to functional single line block diagram of SMPS Panel enclosed.

Static switch (SCR UV/OV) is mounted in the SMPS panel. It protects the IPS system from AC
under voltage or over voltage. The operating voltage of the static switch is 150 + 5V To 275 + 5V.
It automatically cut-off the AC input supply goes out of above limit. It reconnects the AC supply to
system automatically with a time delay of 10 - 15 seconds after getting the voltage of 165 + 5V to
265 + 5V band.

The AC Incoming Mains Supply of 150-275V AC is fed to SMPS Panel at TB-1from Class B (LPD)
protection. This voltage is further fed to SMRs through a Galvanic Isolation board . The AC input
is wired to MMIB -3 (Mains Monitoring Interface Board) to monitor the input voltage, frequency
and current continuously. MMIB - 3 provides these signals to CSU, where analog signals are
processed and will displayed on the LCD display. Provision is also provided in this board to limit
the Input current wherever the input line is having poor regulation and cannot supply required I/P
current to the system (Refer board adjustment procedure in commissioning procedure). Outputs of
all SMRs are paralleled and fed to DC-DC Converters, point operation through a Fuse (FU-2) and
inverters. Battery is connected to SMRs through a fuse (FU-1) and a low voltage disconnect
contactor (CON 1).

CSU (Control and Supervisory Unit) is a microprocessor-based unit that controls and monitors
various parameters with regard to SMRs, Battery and AC Mains.

MUIB (Main User Interface Board - PC 3) is a PCB that acts as a junction connecting various
points / components like Battery low voltage disconnect contactor, Temperature sensor, Fan
Power Supply, SMR fail potential free contacts and CSU through a flat cable.

Incoming mains is connected to PC 4 to monitor the “Mains Fail” Indication when the AC Input
power is not available.

DC power supply is fed to PC 4 to power the PCB and to monitor the reverse polarity of the
battery I/P. When the battery is connected in reverse direction, the LED provided at the battery I/P
TB will glow.

Low Voltage disconnect contactor (CON 1) is provided in Battery path side. When the Battery
voltage reaches end cell voltage, the MUIB de-energizes the battery Input contactor (CON1) and
isolates the battery from load. It will be connected automatically when the charger comes ON and
DC voltage builds up.

Fuse Trip Board (PC 6) is connected across the Battery Input Fuse (FU 2). When the Battery
Input Fuse (FU 2) blows, the plunger in the fuse trip pops out there by operating the micro switch.
The potential free contact of this switch is linked to MUIB to indicate battery disconnection on
CSU.

Potential free contacts Board (PC 5) is connected with the battery bus as said above to provide
potential free contacts for DCDP Fault / call S&T staff / SMR Fail. These potential free contacts
can be used to link IPS with external Data logger and to extend the same to ASM Panel.

12
AC Socket: One AC Socket of 5 Amps is provided for the purpose of connecting any instrument
during servicing or maintenance.

Door Lamp: One lamp is provided in the cubicle through a push button. This arrangement is
made in such a way that it glows only when the door is in open condition.

B.2 SWITCH MODE RECTIFIERS (SMRs)

B.2.1 GENERAL DESCRIPTION
This modular system has been designed specifically to power 110V S&T equipment requiring
accurate temperature compensated float and boost (equalization) voltages, low output noise and
EMI levels and currents up to the 20A (per module) region.
A typical IPS system comprises of three (or) four SMRs, a monitoring and control sub-system,
called Control & Supervisory Unit (CSU), Main User Interface Board (MUIB), Mains monitoring
Interface Board (MMIB – 3) and AC input circuit breakers.
The rectifier is designed to slide and plug into a magazine and this can be monitored and
controlled by CSU.
The system is configured as shown below.
AC Supply

AC input
circuit To Modem or
breaker CSU PC

MUI Remote
(Potential-free
contacts)

DC
SMRs Inverter
Magazin
LVDS DC-DC
Converter

Tbatt
Battery

Figure 1. System with basic Monitoring and Control Functions

The rectifier is housed in the magazine and the DC output is connected to the Inverter, DC-DC
converter and to the battery bank. Low Voltage Disconnect Switch (LVDS) is included in series
with the batteries in order to prevent over-discharging the battery bank in the event of an
unusually long AC power outage.

13
The monitoring and control signals, such as battery current, temperature, battery status, LVDS
control and status, system voltage are connected to the monitoring and control module (CSU) via
an interface card (MUIB). This module is in turn connected to the CSU via a 34-way ribbon cable.
A 4-wire cable, which carries the digital communications signals that allow control and monitoring
of the rectifier, connects the CSU.

B.2.2 CSU.

A CSU (Control and Supervisory Unit) is a microprocessor-based module to control and monitor
various parameters of SMRs, Battery and Load either at the site or from a remote station.

Principal Features of CSU

Used in conjunction with the CSU and optional WINCSU windows based control and supervisory
software, the principal features of the unit are as follows:
• Local and remote (via modem) monitoring of any alarm condition of each of the rectifiers

• Local and remote (via modem) monitoring of the output current of each rectifier

• Enables setting of parameters of all the rectifiers using the CSU front panel or an optional
remote PC running WINCSU software;

• Enables monitoring of DC Load current and voltage.

The following functions are standard:

• Temperature compensation of the battery Float and Equalization voltage using a
temperature sensor

• Programmable battery charging Current limits (3 limits)

• Automatic Equalization of the battery with selectable start (choose voltage / current level or
discharge Ampere-hours) and end (choose time duration or Equalization current) parameters

• Active current sharing

The following functions are optional:

• Automatic dialing – the monitoring and control software has automatic dialing features whereby
a remote PC is dialed via a optional modern in the event of an alarm condition occurring.

• RS-232 port connection to computer or modem.

14
 B.2.3. TECHNICAL SPECIFICATION ON SMRs
SMR RACK POWER SUPPLY with 110V/20A MODULE SPECIFICATIONS
A. 110V/20A MODULE SPECIFICATION

Input
Voltage 150 to 275V single phase Remote
Controls
Active .Neutral Earth Equalise Equalise Mode is initiated
Mode
220+25%-32%Vac by signal from the CSU.

Frequency 45 to 65 Hz Rectifier inhibit Rectifier module can be

Current 18.5A rms max at 150V ac. inhibited by a signal from a
13A rms at 220V ac. remote computer
transmitted via the CSU.
Power Factor >0.99 at full load Environment
Efficiency >90% typical from 50 to Cooling Fan cooling. Two temperature
100% Output at nominal controlled fans are provided on the
input voltage.
rear side of each SMR module to
suck the hot air out of the module.
Protection HRC fuses at input of SMR
Power Circuit is turned off if Temperature Operating range :
AC Voltage Humidity 0°C to 50°C
> 280V ac or <145V ac. 0% to 95%
non-condensing.
Surge Tested to ANSI C 62
Protection 41- 1991. Cat. Mechanical
B3 high system exposure. (Module)
Combination wave Noise <45 dBA (A Weighted)
6KV / 500A test. Dimensions Height 132.5mm
Width 482mm
Voltage 1500Vac input to chassis for Depth 380mm
Withstand 1 minute (2200Vac 100% Mass 9.5kg
Test
Testing on production Connections
units). A multi-purpose Male
Module connector is mounted
EMI CISPR22 Class B VDE0871 Input, Output & on the back of the rectifier module.
Class A DOT.Spec.G/EMI- Communica-
01/01APR 91 tions A female matching Connector is
wired at rack.
Inrush <8A peak at nom. Mains
Current

15
Soft Start 3 secs min o/p current Parameter Menu driven through CSU
Time ramp-up
Programming Display and push button
Output Monitoring
Voltage Float Adjustable 110V to Current Monitored on CSU display.
129V Accuracy ± 1% of full load
Equalise Adjustable 124V to
135V
Current Limit Adjustable 4 to 23A Bar-graph display on module
Conversion 90KHz.
Freq. Line ± 0.1%
Voltage System voltage displayed on CSUs
Static Load ± 0.5% display. Accuracy
Regulation Alarm ± 0.5% at full load.
SMR normal, SMR alarm and SMR
shutdown.
indicated on Front panel
of each module Other alarms and
status Displayed
Dynamic ± 1% of final voltage for on CSU.
Regulation 10% to 90% to 10% step
load Change.

± 1% for ± 25% step change

in AC Input voltage

Output Noise <2mV rms psopho metric.

Weighting. 100mV peak to
peak.
Load Sharing Better than ± 5% active
current sharing at full load.

Protection Fuse at output of SMR

Over voltage Only faulty unit shuts down
Over current Can sustain short circuit of
Output terminals indefinitely

Over Gradual reduction of current

temperature limit
If heat sink temperature
exceeds Pre-set limit

16
SYSTEM EXTERNAL CONNECTIONS
AC Supply

AC INPUT
CSU To PC or
BREAKER
Voltage
Modem free
(optional)
Contact(for Alarms)
(optional)
MUIB Battery
temperature
sensor
( i l)
SMRs
Magazine Inverters

DC – DC
Converters
LVDS

Battery
Bank Batteries

Earth

INSERTING A MODULE IN TO THE MAGAZINE

• Remove the Phil pan head screw fixed to the rack at the place of module needs to
insert.

• Hold the unit by the handle provided with one hand and holding it in the correct
orientation by placing the other hand the unit, place the unit carefully on the guide rails
provided and gently slide it into the rack.

• Press the unit into the rack until it is flush with the rack and then by keep holding the
module put and tighten the screw.

17
B.2.4 RECTIFIER MODULES
The CSU is used for the purpose of setting rectifier operating parameters and showing system
voltage and current, while a bar graph on each module displays output current supplied by each
module.

LED INDICATORS ON THE RECTIFIER FRONT PANEL

There are three LEDs on the front panel of each rectifier module to indicate the operating status
of the individual module. They are as follows:

LED Name LED Colour What it indicates

1 ON Green Rectifier functioning normally, Mains
Available.

2 Alarm Amber (flashing) Alarm condition

2 Alarm Amber (not flashing) Unit is in Equalisation mode
3 Shutdown Red (with amber LED flashing) Unit is switched off or failed
3 Shutdown Red (amber LED not on or flashing) Micro in SMR has failed

If necessary, further information about the particular rectifier alarm condition if exists, can be
found by referring to the CSU.
OUTPUT CURRENT BAR GRAPH
A 10 LED bar-graph display is included in the front panel of the rectifier module to indicate the
output DC current. Each element of the bar graph represents one tenth of the rated capacity of
the rectifier.
ADDING AND REMOVING RECTIFIERS FROM THE MAGAZINE.
The rectifiers are designed to be “hot pluggable” in that they can be plugged into and out of a
“live” rack connector.

A relay in the output circuit ensures that the rectifier output is connected to the output DC bus
only when the difference in voltage between the output bus and the rectifier output is less than a
predetermined value. An inrush limiting circuit in the AC input circuit, which utilises a relay and
an inrush current limiting resistor limits the disturbance to the AC source to an acceptable level
when a unit is plugged in with AC voltage present on the AC bus.

TO REMOVE A RECTIFIER FROM THE RACK:

Although the WAGO make connectors are designed to be “hot pluggable” it is advisable to first
switch off power to the unit by means of the circuit breaker in the AC distribution panel before
unplugging the unit.
Each rectifier is fixed with Phil pan head screws. After removing the screws, remove the module
with the handle provided on the module front panel.
Warning!! Take care when removing the rectifier as it may be uncomfortably hot to hold
especially if the ambient temperature is high and the unit has been operating at maximum load.

18
INSERTING A RECTIFIER INTO THE MAGAZINE WHILE IN OPERATION
Although the connectors in the unit are designed for “hot pluggability” it is advisable to turn off
the AC power to the input connector by means of the related circuit breaker in the AC
distribution panel before plugging in the unit.
Remove the Phil pan head screw fixed to the rack at the place of module needs to insert.

Hold the unit by the handle provided with one hand and holding it in the correct orientation by
placing the other hand the unit, place the unit carefully on the 2 guide rails provided and gently
slide it into the rack.

Press the unit into the rack until it is flush with the rack and then by keep holding the module put
and tighten the screw.

Connect the respective female connector to the module and ensure that it is firmly seated with
the module connector.

Connect the 6 Way communication cable from module to the respective connector on
communication Interface board.

Switch on the AC circuit breaker. The rectifier will start automatically and connect itself to the DC
bus and gets interface with the system at appropriate time.

CHANGING OPERATING PARAMETERS

There are two ways in which the operating parameters of the rectifiers can be changed:

1. By means of the CSU front panel SMR menu; press SMR menu button and scroll through the
menu using the INC or DEC buttons. Once the appropriate parameter is displayed, press
Enter key which will make the parameter value flash on and off ; the value can now be
incremented or decremented using the INC or DEC buttons until the desired value is
obtained; press Enter again and the new value is executed.

2. By means of a laptop PC connected to the CSU. This is the most convenient method of
making changes to any parameter.(* This is an optional feature)
It should be noted that it is not possible to change parameters on individual rectifiers. Any
parameter change will be implemented in all the rectifiers connected to the CSU.

SECURITY FEATURE
A security function can be activated such that it is impossible to change any operating
parameters unless the security function is first disabled. If an attempt is made to change an
operating parameter a message “Panel disabled” will appear on the screen.
This function is intended to prevent any personnel not familiar with the equipment from
unintentionally changing operating parameters.

To temporarily disable the security function, press all three INC, DEC and ENTER buttons
simultaneously and hold pressed for three seconds. The security function is automatically
enabled again if no button is pressed during a period of approximately two minutes.

19
B.2.5 CSU MODULE
ALPHANUMERIC LCD DISPLAY
A single line 16 characters alphanumeric backlit display with large 9mm high characters
normally display output voltage and current as well as the system status Float (FL) or Equalise
(EQ). This is the default or “home” screen.

10A 123.6V FL “ HOME SCREEN”

Whenever there is no push-button activity for more than 40 seconds, the display always
reverts to this home screen.

FRONT PANEL PUSH BUTTONS

There are push buttons associated with the LCD screen for the purpose of entering different
Menus and for scrolling through the menus.
The layout of the push buttons is shown below:

SMR BATT ALARM

SYSTEM OK
10A 122.0V FL ALARM

INC DEC ENTER SMR SHUTDOWN

Apart from the CSU or “Home” menu, which includes mostly system oriented parameters, there are three
other menus which can be accessed by momentarily pressing the relevant push buttons.
a) SMR menu, which includes the rectifier related programmed parameters as well as the
output current and heat-sink temperature for each rectifier;

b) Battery menu in which all the parameters pertaining to the batteries are found;

c) Alarm log which stores all the individual alarm information together with date and time
starting with the most recent alarm. A total of 99 alarms are stored in memory

ENTERING AND MOVING THROUGH DIFFERENT MENUS

To scroll through the CSU menu from top to bottom, just press the INC button. The screens,
which will appear, are shown in section 2.8/2.9.

20
If the DEC button is pressed, the screen at the bottom of the menu will appear first and will be
followed by the other screens in reverse order. This can be useful when it is desired to access a
screen near the bottom of the menu.

To enter the other menus, momentarily press the relevant button SMR, BATT or ALARM LOG.
The associated menu contents are shown in sections 2.8.

If at any time it is necessary to return to the CSU or “home” menu, just press the current menu
button once. E.g. if the present menu being scrolled is BATT, just press BATT button again and
the screen will return to the default “home” screen.

The INC and DEC keys are also used to increase or decrease parameter values when the
parameters are programmable.
In this case, press ENTER first. The parameter value will begin flashing on and off. Press INC to
increase the value or DEC to decrease the value until the desired value is obtained. Then press
ENTER again to actually enter the value into memory.

STATUS INDICATING LEDS (CSU)

In addition to the alphanumeric display there are also three LEDs to indicate system status as
follows:
SYSTEM OK Green
ALARM Amber
SMR
Red
SHUTDOWN

When all three LEDs are off, the unit is off and there are a number of possible reasons for this:
• DC is not present
• Internal failure of CSU

The amber LED indicates any alarm condition, either system or rectifier related.
The red LED indicates that one or more of the rectifiers in the system is shut down.

B.2.6 USER INTERFACE BOARD – MUIB

The connections between the CSU and the external transducers and other inputs are made on
connectors provided on an interface card MUIB (Main User Interface Board) which in turn is
connected to the CSU via a 34-way ribbon cable.

A block diagram showing the location and labeling of the connectors on the MUIB is enclosed.
Detailed information about the pin-outs for various MUIB connectors is given in table-1.
This information is necessary when making the various external connections to the current and
temperature transducers, LVDS, DC bus etc.

RELAY CONTACT OUTPUTS

Relay contact for remote annunciation for group alarm is provided in the MUIB.

21
B.2.7 OPERATING THE CSU
A detailed description of the contents of the various menus is given below.

Summary of CSU front panel controls

There are four Menus that can be viewed using the INC or DEC buttons:
a) The default or “Home” menu which contains general system information;
b) SMR menu - contains all the parameters pertinent to the rectifiers;
c) Battery menu - contains all the parameters regarding the batteries;
d) Alarms log - which is a chronological record of the last 100 alarms.

Moving from one menu to another

If no button has been pressed for two minutes, the display will revert back to the Home screen.
This shows the output voltage and current.
To move from any menu to any other menu, press the corresponding button. E.g. to move to the
Battery Menu from any other menu, momentarily press the BATT button.

To move to the Home menu from any other menu, press the button of the current menu. E.g. if
in the SMR menu, press SMR button to return to the Home menu.

Scrolling through the Menus:

To scroll through any menu from the first screen to the last, press the INC button;
To scroll to the last (bottom) screen first, then upwards through the menu to the first screen,
press the DEC button.

Incrementing and decrementing programmable parameters

To change a programmable parameter press ENTER; the value will flash on and off. To increase
the number, press INC; to decrease the number press DEC. When the desired number is on the
screen, press ENTER again.

To change parameters when the security function is activated

If an attempt is made to alter any parameter when the security function is activated, the display
will show the message “Panel Locked”.

To change a parameter, simultaneously press all three INC, DEC and ENTER buttons for three
seconds. Then proceed to change the parameter in the normal way.

When scrolling through the Alarms log

To observe the date and time of a given alarm, do not press any button for at least two seconds
and the date and time will flash on for two seconds and then the alarm name will be displayed
for two seconds. The display will alternate between the two screens in this manner until a button
is pressed.

22
CSU DISPLAY MESSAGES
The screens, which are displayed if the INC button is pressed when the default or “home” screen
is displayed, are shown below.
As can be seen, some screens merely display a monitored operating parameter, such as load
current, while other screens display programmable operating parameters, such as rectifier
current limit, which can be altered if so desired.
The screens have been arranged so that, when scrolling using the INC button, all the monitoring
screens are displayed first followed by the programmable parameter screens, since it is unusual
to access these except during commissioning.
By scrolling with the DEC button, the reverse is true - the programmable parameter screens are
accessed first, starting with the one at the bottom of the menu.
In either case, if the buttons are not touched for forty seconds, the display reverts to the “home”
screen.

WHEN AN ALARM CONDITION EXISTS

If one or more alarm conditions exist at any time the following message will alternate with the
“home” screen for 2 seconds every six seconds in addition to warning LED indicators:

3 Press ENT
In this case, the message indicates that there are three alarms present and they can be
observed by pressing the ENTER button.

When the ENTER button is pressed the most recent alarm name, such as the one shown below
will appear on the display.
Ambient Temp. Hi
If the ENTER button is not pressed again for ten seconds, the display will revert to the “home”
screen and the sequence begins again.

To view the remaining alarms, use INC and DEC buttons. ENTER returns to the home screen.

Pressing the ENTER button a fourth time will return the display to the “home” screen.
The time and date of any given alarm can be obtained by entering the ALARM LOG menu - see
later section.

B.2.8 CSU SCREENS

As stated earlier, the INC button can be pressed to scroll through the CSU menu.
The following screens will appear in sequence.

CSU “Home” screen; indicates system is in

float mode
10A 123.6V FL
“C” indicates that battery temperature
compensation function is active
10A 123.6V FLC
The screens below display programmable parameters within the CSU menu.

23
To change a parameter, press INC button until the desired parameter is found, then press
ENTER. The parameter value will flash on and off. Press INC to increase the value or DEC to
decrease the value until the desired value is on the screen.
Press ENTER to enter the value into memory.
Ambient temperature alarm level :
Amb Tmp Alrm 45 C
Float voltage High level :
Volts High 128.4V
Float voltage Low level :
Volts Low 105.6V
System output load current there :
should, “Sys O-Load” Alarm will appear
when output load current is higher than Sys O-Load 21A
this level
Security on or off. When security :
function is activated attempts to alter
any programmable value will result in
the display showing “Panel Locked”. To
Security On
temporarily unlock the system press all Panel Locked
three INC, DEC and ENTER buttons
simultaneously for three seconds. The Security Off
system reverts back to the locked state
if no button is pressed for longer than 2
minutes.
Test function. When this function is :
activated, all LEDs on the rectifiers and
CSU begin flashing on and off. The
display alternates between showing the Test On
software version and a screen with all
pixels on.
Number of SMRs in the system. This :
number must be entered otherwise the
display will show that some SMRs are No. Of SMRs 1
not responding.
No. of external boards such as mains :
monitoring board can be interfaced to
the SMR for various applications where Interface MUIB
in this case MUIB is the one which is
interfaced to the SMR.
No. of batteries to be connected to the :
battery terminals is an option between
independent and common battery
banks. No. of Batt 1.
(Set No. of batteries as – 1, irrespective of
No. of Batteries connected.
DC transducer full scale rating. E.g. if a :
Hall transducer has 100A/4V rating, FS Batt I - 100A
enter 100 in the screen.
CSU Access code address; this can be :
a number up to 7 digits long. CSU# 1252636

24
 Clock set; used to set the date and time :
of the CSU clock. Note DD/MM/YY 24 25/12/1999 21:58
hour clock
Modem enable; this can be toggled :
between ON and OFF. Modem ON
The screens below will only be :
displayed if the modem is enabled (ON) Modem OFF
Audio Alarm is a choice among OFF, t- :
out and ON . No audible Alarm will be
observed if this option is set to OFF.
Audio Alarm OFF
And the same can be enabled by setting Audio Alarm t-Out
it to ON. In between , by setting to t-out
option, the audible alarm will cut off Audio Alarm ON
automatically after 3 minutes .
:
To measure and view the 1∅ AC I/P
parameters This menu is to be activated
Expan 1 [ENTER]
by pressing ENT. AC Volt Hi 260V
The parameters can be adjusted as per
requirement.
AC Volt Low 200V
Frequency low 45Hz
Frequency Hi 55Hz.
These two parameters are not applicable.
Do not adjust this menu. Expan 2 [ENTER]

B.2.9 CSU ALARMS

A list of all the possible alarms, which can be annunciated, is shown in the following table.
R = red LED on A = amber LED flashing

Alarm Name Comments LED

SMR Alarm Combination of one or more SMR alarms A
SMR Alarm-Urgent One or more SMRs have shut down A+R
SMR HVSD SMR shut down due to output over voltage A+R
UNIT OFF SMR is off A+R
No Response A particular SMR is not responding to the CSU A
Power Limit SMR is in Power Limit A
SMR I Limit SMR in current limit A
Volts High Voltage measured by SMR too high A
Volts Low Voltage measured by SMR too low A
EEPROM Fail EEPROM failed (CSU or SMR) A
No Demand Control loop in SMR not in normal state A
H/S Temp High SMR heat sink temperature too high A
DDC Controller SMR DC/DC converter fault A+R
Temp Sensor Fail Temp sensor in SMR faulty - S/C or O/C A+R
Reference Fail Voltage reference in SMR microprocessor cct faulty A+R
HVDC not OK DC/DC converter (boost) voltage in SMR not OK A+R
High Volts SD Shut-down of SMR due to output volts too high A+R

25
 AC Fail None of SMRs are responding (AC fail assumed) A+R
Temp Sensor Fail Temp sensor in MUIB not plugged in A
Battery Switch One or more battery switches open A
LVDS Open Low Voltage Disconnect switch open A
Sys Volts High System output volts too high A
Sys Volts Low System output volts too low A
Battery Disch Batteries are discharging A
SMR Comms Fail One or more of SMRs are not responding A
AC Volt Fault AC voltage lower or higher than preset value A+R
Batt Temp High Battery temperature higher than preset limit A
Batt I-Limit Battery charging current is being limited to preset value A
Equalise System is in equalise mode A*
* not flashing

SMR MENU AND DISPLAY MESSAGES

All information relating to the individual rectifiers is found in the menu activated by pressing the
SMR button on the CSU front panel.

When an SMR is not connected or not

switched on or is faulty, the screen
indicates that the rectifier is not SMR 1 No Response
responding.

Warning : It is important to declare the correct number of rectifiers in the rack using
the CSU (home) menu.

:
SMR1 Current: When a rectifier is on
line and operating normally, its output SMR 1 10A
current is displayed.
:
When the ENTER button is pressed
momentarily, the Version and heat-sink
temperature are displayed together
with the SMR number. Press ENTER SMR1 G1141dh 68C
again to return to the SMR “home”
screen.

To return to the CSU menu at any time, press SMR button. To return to the SMR menu, press
the SMR button again.

The rest of the SMR menu consists of screens, which show the operating parameters of the
SMRs.

26
 Float Voltage value. This parameter is
globally (and indirectly) set in the BATT
:
menu so cannot be changed in this
screen. It is set automatically to a value SMR Float 123.8V
equal to the sum of the Sys Float and
Sys Drop values set in the BATT menu;
As with the Float Voltage value, the
Equalisation Voltage parameter is
globally (and indirectly) set in the BATT : SMR Equal 126.5V
menu so cannot be changed in this
screen. It is set automatically to a value
equal to the sum of the Sys Equal and
Sys Drop values set in the BATT menu;

The remaining screens show the SMR related operating parameters which can be changed by
pressing ENTER.

When this is done, the number flashes on and off and can then be incremented or decremented
by pressing the INC or DEC buttons respectively. When the correct value is obtained, press
ENTER to enter the number into memory.

Please note that any parameter change will apply to all the SMRs.
SMR high voltage alarm level; :
SMR V High 128.6V
SMR low voltage alarm level; :
SMR V Low 105.6V
SMR DC High Volts Shutdown :
(HVSD);
SMR HVSD 137.0V
SMR Current Limit; :
SMR I Limit 21A
Fault Reset; by pressing ENTER when :
this screen is displayed, any latched
alarm, such as HVSD, is reset and the SMR Fault Reset
unit will restart unless it is damaged or
faulty.
Short circuit, will be displayed if there is :
any short circuit arrived at the
O/P(When LVDS open & Battery is Bus short ckt.
healthy).

BATTERY PARAMETERS MENU

All information pertaining to the batteries is accessed by momentarily pressing the Batt button
on the front panel.

To return to the CSU “home” menu at any time, momentarily press the Batt button.

27
As for the other menus, in general a programmable parameter can be incremented or
decremented by use of the INC and DEC buttons respectively. If this is attempted when a
monitored parameter is being displayed (i.e. not a programmable operating parameter), then the
message “Not Adjustable” will be displayed.
The following screens will appear in turn when the INC button is pressed:

Total Battery Current; :

Batt 1 13A
Battery Temperature; If a sensor is
fitted, the battery temperature is shown
in degrees Celsius.(Since there is
provision for only one sensor, the sensor Batt Temp 35C
should be located in the hottest spot of
the two batteries.) If the temperature
: Temp Sensor N/A
sensor is not connected, the message
reads as shown (sensor not attached); Temp Sensor Fail
When Bat Temp Sensor condition alarm
is selected, this screen will show:
Battery over temperature alarm level. :
This is a programmable level and can be
Batt T Alarm 60°C
adjusted in the normal way by the INC,
DEC and ENTER buttons.
Estimated Battery 1 state of Charge; this :
screen shows the estimated charge in QEst Batt 1 500AH
the battery at any given time.
Ampere-hour rating of batteries; the rated :
A/H number for the batteries must be
entered in this screen. (Set total AH Batt Rated 500AH
capacity)
Battery Temperature Compensation :
Coefficient in mV per Deg C per Cell is
entered in this screen. The allowable BTC mV/C/C 3.0
range is 0.1 to 5mV/C/Cell. If the value
is decremented below 0.1, the display BTC 3.0mV/C/C
will show Off.
BTC Nominal setting is a base :
temperature for all temp. Compensation
calculations. Output voltage will be
corrected to the temperature with this BTC Nominal 27°C
setting as a reference. This is normally
set at 27°C .

Please Note:
a) If there are no temperature sensors connected or if BTC is set to 0 the compensation function
is disabled. In this instance, the status message in the CSU home screen is FL or EQ instead
of FLC or EQC.

28
 Number of cells for the Battery :
connected must be entered in the screen
enter 24 for 110V Battery; 12 for 24V Number cells 55
Battery
Maximum Voltage per cell must be :
entered in this screen. This screen can
be observed when the battery Max 2.30V / c = 126.5V
temperature compensation coefficient
function is enabled.
Minimum Voltage per cell must be :
entered in this screen. This screen can
be observed when the battery Min 2.10V / c = 115.5V
temperature compensation coefficient
function is enabled .
Battery Charging Current Limit applicable :
for voltages below Vdd. This parameter
sets the maximum current which flows
into the batteries when the voltage BILim Vb<Vdd 12A
across the two batteries is less than Vdd,
the deep discharge voltage. Vdd is
programmed in the next screen.
Battery deep discharge voltage - Vdd. :
Vdd Level 105.0V
Battery Charging Current Limit applicable :
when the battery voltage is between Vdd
and the float voltage Vfl. This limit is
normally higher than the one for a deeply BILim Vb<Vfl 12A
discharged battery.
System Float Voltage; this sets the :
system output voltage at the output Sys Float 123.75V
busbar terminals.
Battery Charging Current Limit for battery :
voltages greater than the float voltage.
This applies when the batteries are being BILim Vb>Vfl 12A
equalised.
Equalisation Voltage. This sets the :
maximum voltage reached during Sys Equal 126.5V
equalisation of the batteries.
System Voltage Drop. This parameter is :
used to set the maximum voltage that the
individual rectifiers can output over and Sys Drop 0.6V
above the programmed System Float
voltage.

The System Voltage Drop parameter is calculated by summing the resistive voltage drop in
each rectifier (due to output connector, output relay and passive current sharing output “slope”)

29
and the increased voltage required for temperature compensation, if this function is activated.
For example, if the temperature compensation coefficient is set to (negative) 3.0mV/ oC/cell,
then the maximum increase in float voltage will occur if the temperature is 17 oC or below. In
this instance, the compensation will be +0.72V since the compensation range is 10 to 50oC
with the reference (no compensation) temperature being 27 oC. (27-17=10 oC multiplied by 24
cells and 3mV = 720mV).

Add 0.6V for resistive voltage drop at full load and a Sys Drop value rounded up to 1.4V would
be programmed into the system.
Battery discharging alarm level. This :
level is set to a value to which the
battery voltage falls to during a
discharge. It is used to issue an alarm B Disch Al 110.0V
indicating that the batteries are
discharging.
Equalization initialized by voltage level :
V reached during battery discharge. V Start Eq On
Equalisation is initialized when the :
battery voltage falls to this level. V Eq Trig 113.0V
Equalization not initialized by voltage :
level. V Start Eq Off
Equalisation is initialized based on :
charge supplied to the load by the Q Start Eq On
batteries (measured in Ampere-Hours).
Equalisation is initialized when the :
charge out of the batteries is greater Q Start Eq Off
than the level set in this screen.
Equalisation can be terminated after the :
time set in this screen. If termination is
to be only based on the A/H discharge Qdis Trig 20AH
method, set this number to its highest
value (48 Hr).
Equalisation initialized by current level I :
reached during Battery discharge. I Start Eq ON
Equalisation is not initialized by Current :
level . I Start Eq Off
Equalisation is initialized when the :
Battery current falls to the level I Eq Trig 6A
Equalisation is not initialized by the :
discharge A/H method. EQ End (OFF) 0A
Equalisation is ended based on the :
level of battery charging current set in Equal Dur 20Hr
this screen.
If Equalisation is to end independently :
of charging current, reduce the value of
current in this screen to less than 5% of EQ End 4A
the A/H rating of the batteries
(programmed in earlier screen) and the

30
number will then be replaced by OFF as
shown.
If no equalisation occurs due to battery :
discharges for a period longer than the
time set in this screen, an equalisation Eqal Per 12Wk
cycle will be initiated automatically.
Equalisation can be ended manually by :
pressing ENTER when this screen
appears. This screen is only obtained if
the system is in Equalisation mode. Manual Stop EQ
When ENTER is pressed, the system
reverts to Float mode and the window
changes to that shown, ready for a
manual equalisation start. This screen is
Man Start EQ
only obtained if the system is in Float
mode.
A Low Voltage Disconnect contactor :
(LVDS) is often integrated into the
system to disconnect the batteries from
the load in the event that the AC power LVDS Trip 98.0V
outage is too long causing the batteries
to discharge beyond a safe level. The
voltage level at which the LVDS opens
LVDS Auto
is set in this screen.
When this screen is as shown, the :
LVDS contactor opens automatically
when the voltage drops to the trip level
set in the previous screen.
When the AC power is restored and the
system output voltage rises after the
rectifiers start up, the LVDS contactor LVDS Closed
will close automatically. To close the
contactor irrespective of Battery voltage,
press ENT, press INC to scroll to LVDS
closed and press ENT.

To operate the contactor manually, :

press ENTER and the Auto will flash on
and off. Press INC to scroll to closed,
followed by Open followed by Auto LVDS Open
again. Press ENTER at the desired
state – e.g. Open to open the contactor.
Battery Discharge Test (BDT) :
parameters are not applicable, and set BDT Off
to ‘Off ‘ .

ALARMS LOG
A record of the most recent alarms is kept in the CSU memory and can be viewed by
momentarily pressing the Alarms Log pushbutton.

31
The screen shows the number corresponding to where the particular alarm is in relation to the
most recent alarm which is number one. It then shows the alarm name as shown below.

1 AC Fault
In the example shown, the frequency of the AC source is either too high or too low.
If the INC button is pressed within two seconds, the second alarm will be shown. If pressed
again the third alarm appears etc.
If on the other hand the button is not pressed for two seconds a second screen will appear which
shows the alarm sequence number followed by the date and time at which the alarm occurred.

1 01/02/1999
It is thus possible to quickly scroll through the alarm log to identify the most recent alarms that
have occurred and then if the time and date of a particular alarm is required, it is only a matter of
scrolling to that alarm, waiting two seconds and the date and time information will appear.
If at any time it is desired to clear the alarms log, press ENTER whilst in the Alarms Log menu
and the following screen will appear:

DEC to Clear Log

Press the DEC button as requested and the log will be cleared and the following screen will
confirm it.

No Alarms

32
 MUIB Connection Diagram

34-way ribbon
cable to CSU

X1
X17 X39

X23 X50 X64 X65

Conn # Conn Label Class Comments

X1 CSU Anal/Dig 34-way ribbon cable to CSU
X17 BAT. TEMP. Analog Temp. Transducer
BAT. SW.
X23 Digital Aux contact from fuse trip board of Batt. Fuse
(CB TRIP/AUX)
X39 BATTERY Analog Battery current transducer
X50 POWER I/PB Analog System voltage sensing and DC power input for CSU
X 64 LVDS Aux. Digital Aux contact from LVDS contactor
X65 LVDS Coil Digital Drive for contactor or similar

33
 Table 1 MUIB Connectors wiring information

Conn Pin Signal Name Conn Pin Signal Name

X1 CSU 1-34 See CSU Schematic 4 Input
X2-ALARM 15 N/O relay contact 5 GND
14 N/C relay contact X50 POWER I/P 1 Bat +ve terminal
13 Common 2 Bus +ve terminal
X17BATTEMP. 1 No connection 3 No connection
2 Sensor –ve 4 Battery -ve terminal
3 Sensor +ve 5 Bus -ve terminal
X39BATTERY 1 -15V X64 LVDS Aux. 1-2 LVDS auxiliary contact
1
2 +15V X65 LVDS Coil 1-3 Coil driving voltage
3 No connection 2 No connection
X23 BAT SW. 1-2 Contact closure required between pins 1 and 2

34
B.2.10 Maintenance
In this section some general routine maintenance procedures are described which should be
carried out to ensure that the equipment performs to the high reliability standards that it has
been designed to.

WARNINGS AND PRECAUTIONS

Since the unit utilizes high voltages and large storage capacitors, it is imperative to take great
care when working on the unit.
In particular, only qualified personnel should be allowed to service the units.
In addition, the following precaution should be observed:

Make sure the relevant isolating CB is off (open) before attempting

to remove any unit from the rack;
Do not remove the cover with power on;
Allow two minutes to elapse after switch off before removing the
cover to make sure high voltage capacitors are fully discharged

SMR MAINTENANCE
Since the SMRs are fully alarmed and operate in an active loop current sharing arrangement,
there should be no need for regular checks or adjustments of operating parameters.
However, some regular checks can be an early warning of problems waiting to happen.

CURRENT SHARING (Applicable, when number of modules is more then one

number)
Under normal conditions the currents contributed by every rectifier should be within +/-2 amps
of each other. It is possible however, for internal loop parameters to change to such an extent
that a unit does not share to the extent that it should.
If the lack of sharing is extreme then either a CURRENT LIMIT or NO LOAD alarm will be active
and the operator should then refer to the next Section.
If, however, the current sharing is not so extreme as to generate an alarm, a regular check of the
current sharing among the rectifiers can lead to early detection of any units which may be
developing a fault.
In general, if only one or two units are “drifting”, the most probable explanation is a “drifting”
component in the FPB2 front panel control card of the SMRs involved.
If, on the other hand, many of the SMRs are not sharing satisfactorily, then the most likely
problem area is in the CSU.

INTEGRITY OF ELECTRICAL CONNECTIONS

It is good practice to check all accessible electrical connections at regular intervals to ensure
that no "hot spots" develop over time due to loose connections.
An infra-red "hot spot" detector is very useful for this function.
Alternatively, mechanical connections can be checked manually for tightness.

35
FAULT FINDING AND REPLACEMENT PROCEDURES
This section describes in some detail the possible causes for alarms that may occur from time to
time and the procedures that should be followed to clear the alarms and more importantly,
redress the problem or cause of the alarm.
It is assumed here that the most that a field maintenance person will do is change a complete
assembly. It is normally impractical to attempt to repair a particular PCA without test equipment,
which is normally only available in the manufacturer's service laboratory.
The recommendation is that the supplied spare complete sub-assemblies be kept on site. This
includes a complete SMR, a CSU unit, and a MUIB sub-assembly.
The faultfinding procedures are presented below.

SYSTEM FAULT FINDING PROCEDURES

The following table outlines suggested procedures to be followed if it is assumed that no PCA
swapping will be attempted. It is assumed instead that only front panel adjustments and unit
replacement will be performed.

Alarm Condition Possible Cause Action Suggested

UNIT OFF No AC power to SMR Check AC supply to SMR; if
necessary reset CB supplying SMR

SMR faulty Replace SMR

Equalise Mode Automatic cycle in progress due No action required

to recent AC power failure

Automatic Periodic Equalise Check on CSU if system is in AUTO

cycle in progress or MAIN mode -If in AUTO mode,
display will show remaining Equalise
time. Check log for previous cycle
date. If cycle too early, replace CSU

Manual initiation of Equalise Check Operator log; in BATT menu,

cycle scroll to “Manual Stop EQ” screen
and press ENTER to terminate cycle
if necessary

SMR Alarm – All SMRs off due to AC power If possible restore AC power
Urgent failure

1 or more SMRs off due to Check Individual SMRs for obvious

faults; problem; replace SMRs if necessary

All SMRs off due to incorrect Replace CSU

Inhibit signal from CSU

One or more SMRs in Current Check Current Limit settings and

Limit adjust if necessary; or batteries being
recharged

36
Alarm Condition Possible Cause Action Suggested
SMR Warning Any of the above or non critical Check SMRs
problem with one or more
SMRs

Any of the above or No Load If unit is not sharing correctly, replace

alarm SMR

Any of the above or unit is in Check Equalise/Float Mode and

Equalise mode change if in incorrect state; change
SMR if CSU is not requesting
Equalise mode

AC Fail Total AC power failure or AC Check AC supply and confirm

voltage not within operating condition; If AC is OK replace SMR
limits units if only two show alarm condition

Communications link failure Check 4-way communications cable

between CSU and all SMRs

Battery Switch Any one of 3 battery switches is Close if appropriate

open

Bad connection to MUIB Repair connection

Batt Temp High Battery sensors is reporting Check battery temperatures and if
temperature higher than pre-set necessary increase ventilation and
level cooling

Set point is too low Check Batt Temp High threshold

level and re-adjust if necessary

Temperature sensor is faulty Replace sensor

Connection to MUIB faulty Repair connection

Volts High SMR fault SMR Fault Chart

One SMR in Equalise Mode Switch SMR back to Float mode

Float level set too high on CSU Check and adjust if necessary

CSU fault Replace CSU

Volts Low AC power has failed; system on Restore AC power if possible

battery power

Alarm threshold level set too Check set point and adjust if
high necessary

All SMRs are off due to CSU Check reason for signal; if necessary
37
Alarm Condition Possible Cause Action Suggested
Inhibit signal replace CSU

Battery charging current limit Check battery currents. If one of

LED on due to faulty battery them shows figure higher than Batt
current signal - this will depress Chg Curr Lim set point, check
float voltage corresponding current transducer;
check connections to transducer;
check MUIB connections

Battery Temperature Check battery temperature readings

Compensation too high due to in Batt menu; Check and if necessary
faulty battery temperature replace faulty sensor; check
monitoring connection to MUIB

Battery Temperature Replace MUIB

Compensation too high due to
faulty MUIB

SMR HVSD Output voltage too high due to Replace faulty SMR
SMR fault

HVSD threshold level on SMRs Check and re-adjust threshold level

set too low

CSU fault Replace CSU

SMRs not sharing Faulty CSU voltage and current Replace CSU
load current control loop IODEM signal

Float or Equalise level on SMRs Check and re-adjust Float or

not set sufficiently high Equalise level

Float or Equalise level on CSU Check and re-adjust Float or

set too high Equalise level on CSU

No Response SMR not responding to CSU Check and if necessary replace

comms cable at back of magazine
faulty

Faulty DSCC card in SMR Replace SMR

Power Limit Unit not current sharing (if only Replace SMR
one showing power limit)

Load current too high (if more Reduce load

than one unit showing alarm)

Reduce battery charging current limit

if it is too high

38
Alarm Condition Possible Cause Action Suggested
No Load Load circuit breakers have Reset circuit breakers
tripped and there is no load

If only one unit showing alarm, Check and replace comms line
comms line to SMR faulty

Faulty SMR Replace SMR

Current Limit Batteries being recharged if No action required

more than one unit showing
alarm

If only one unit shows alarm, Replace SMR

internal control loop faulty

No Demand Internal control loop faulty Replace SMR

EEPROM Fail Faulty EEPROM or DSCC Replace SMR

DDC Controller Fault in DC/DC converter Replace SMR

H/S Temp High SMR Heat sink temperature too Check that air intake by the fans into
high. SMR is not blocked and the fan is
healthy.

Ambient temperature is too high Try to reduce ambient temperature

DSCC card is faulty Replace SMR

Temp Sensor Fail Temperature sensor is faulty Replace SMR or temperature sensor
in SMR

Reference Fail Reference voltage source in Replace SMR

DSCC is faulty or DSCC is
faulty

HVDC not OK Faulty boost controller; Replace SMR

Inrush limiting fuse or resistor Replace SMR

O/C

High Volts SD Feedback voltage circuit faulty Replace SMR

Temp Sensor N/A Temperature Sensor in CSU Plug in temperature sensor if

not attached or faulty required; Replace temperature
sensor

Faulty MUIB connection(s) Replace MUIB

Faulty CSU card Replace CSU

39
Alarm Condition Possible Cause Action Suggested
LVDS Open Battery discharged to the limit Check AC voltage and reset if
voltage level due to no AC possible
power

Battery voltage OK, and CSU Replace CSU

faulty

Battery voltage OK, and CSU Replace CSU

faulty

LVDS threshold level set too Reset level in BATT menu

high

Sys Volts High Volts High threshold in CSU set Reset level to correct value
too low

Temperature compensation Set correct temperature

coefficient set too high compensation coefficient

Faulty MUIB or CSU Replace CSU

Sys Volts Low Volts Low threshold in CSU set Reset level to correct value
too high

Temperature compensation Set correct temperature

coefficient set too high compensation coefficient

Faulty MUIB or CSU Replace CSU or MUIB

Battery Disch Output voltage low due to Check AC voltage and restore if
SMRs off possible;

Float level set too low Set float level to correct value

Battery Disch level set too high Set correct Battery Disch level

Faulty control loop in CSU Replace CSU

SMR Comms Fail Comms cable faulty Replace cable

Faulty MUIB or CSU Replace CSU or MUIB

AC Volt Fault AC voltage out of tolerance Check AC voltages and fix if possible

Batt I-Limit Battery charging current is No action necessary

being limited to preset value

Battery current limit set too low Set correct limit

Battery current sensor faulty replace sensor

40
Alarm Condition Possible Cause Action Suggested
Faulty MUIB or CSU Replace CSU or MUIB
Batt Dis 1 Fail Battery 1 is faulty Check battery and repair/replace if
necessary
(For all Batteries) Battery 1 current sensor is Check and replace sensor if
faulty necessary
Faulty MUIB or CSU Replace CSU or MUIB

CSU FAULT FINDING AND REPAIR PROCEDURES

In addition to performing a supervisory function by monitoring output voltage and current and the
various system alarms, the CSU also performs a voltage control function in order to achieve
battery charging current control, battery temperature compensation, battery equalisation and
active current sharing.
To control current to the lowest battery voltage, the CSU has the ability to suppress the SMR
output voltage to a value lower than the minimum battery voltage.
It therefore follows that it is possible for a CSU fault to occur which can suppress the SMR
voltage to that low level and thus cause a battery discharge despite the precautions that have
been taken to ensure that this does not happen.

In such a situation disconnecting the 4-way cable, which connects the SMRs to the CSU,
will remove the voltage suppressing PWM control signal and thus avoid the batteries
discharging. Without the CSU connected, the SMRs will revert to their pre-set Float
voltage and passive current sharing.
The CSU can then be changed to resolve the problem.
There are virtually no electronic components on the MUIB except for the Remote alarm relay,
and some fuse links, but there are many connectors. It is worth checking for poor connections
when a CSU system problem is being investigated.

Replacing CSU:
To replace an CSU the following procedure should be followed:
1. Unplug the 34-way cable first (removes all power) and then the other cables. The SMRs will
now be working in passive current sharing mode and current sharing may not be as good as
previously. The output voltage will also rise to the value pre-set in the SMRs.
2. Remove the knurled screws holding the front panel in the DSA rack and hold away from the
DSA.
3. Gently pull the CSU unit forward, and hold it in a horizontal position until the back is just clear
of the rack.
4. Bring the replacement CSU to its position in the rack .
5. Plug in all the cables making sure that the 34-way cable is connected last; Gently push
unit into rack and secure the escutcheon with screws supplied;
6. Check operating parameters by following procedures in Section 6.

41
NOTE :

In ‘CSU’ one can able to set different parameter as required based on the configuration. All
settable parameters are set at factory before dispatch as listed in the set points / System test
report. Few parameters may be adjusted based on

- No. of module connected

- No. of Batteries connected.

List of set points / parameters are listed as shown below, for easy reference along with settable
range.

CAUTION

Only Qualified personnel who aware all systems parameters and through with

this manual are allowed to change the parameters, as & when required.

42
 B.2.11 SYSTEM SET POINTS
Sl.No Description Settable range Set points
CSU (OR) Home menu 30 ºC – 90 ºC (Not applicable)
01. Amb. Temperature alarm
02. Volts High alarm 120 – 160V 136.5 V
03. Volts Low alarm 95V – 125.0V 105.0 V
04. System Overload Depending upon the 104%
No. of modules
connected
05. No of SMRS 1-15 Must be no of working
modules
06. Interface MUIB/ MUIB – 2 MUIB
07. Num batt. 1,2/ Ind, 2/ com 1 (Irrespective of
number of batteries
Connected)
08. FS Batt I 100A
09. Modem OFF /ON OFF
10. Audio Alarm ON/T-out / OFF t-Out
11. Expan 1 None / AC1-ph AC1-ph
12. Expan 2 None / AC 3-ph None
SMR MENU
01. SMR V Hi 120 – 160V 136.5V
02. SMR V Low 95 – 125.0V 105.0 V
03. SMR HVSD 120 – 158.5V 137.5V
04. SMR I Limit 4A – 24A 21A
BATTERY MENU
01. Batt. T. Alarm 30 deg. C – 90 deg.C 50 deg.C
02. Batt. Rated Depending upon the number of batteries
connected.
Each battery rated 120AH. 1 Batt. –
120AH/200AH/300AH/As Applicable.

03. BTC ON,0.1mV/C/C– 3.0 mV / C/C

6mV/C/C
04. Number cells 53-96 cells 55 cells
05. Max. 2.30V /C = 126.5V DO NOT ADJUST
Min. 2.10V /C = 115.5V DO NOT ADJUST

43
 Sl.
Description Settable range Set points
No
06. Batt. I lim Vb <Vdd 12A-40A The max. limit (40A)
BI lim Vb < VFL depends upon the
BI lim Vb > VFL battery rated capacity
for 1X120AH-12A
07. Vdd level 92-110V 100.0V
08. Sys float 110.0-130.0V 123.8V
09. Sys Eq. 120.0 – 135.0V 126.5V
10. Sys Drop 0 – 1V(In steps 0.1V) This volt is adjusted in
such a way that the
load sharing for all
modules should be
equal.
11. B. Dis Alarm 100-120V 108.0V
12. V start – Eq * ON/OFF OFF
13. V Eq- Trig 100-115V 105V
14. Q start – Eq ON/OFF OFF
15. Q Dis Trig 5AH - 5AH
16. I start Eq ON/OFF ON
17. I Eq. Trig Depending upon the 5% of rated
battery rated capacity
5% of battery AH- Float Connected Battery AH
– Boost capacity.
18. Eq. End Depending upon the Boost to Float current
battery rated capacity set in the screen
3% of battery AH- 1X120AH Batt. – 4A
Boost– Float
19. Equal Dur 3Hr. 48Hr. Not applicable
20. Equal Per 1wk – 52wk 52 Wk
21. Manual start Eq.(when in Float -- May select EQ mode
mode)
22. Manual stop Eq.(when in EQ -- May stop EQ mode
mode)
23. LVDS trip 92V – 110V 100.0V
24. LVDS Closed/Open/ Auto Auto
25. Sensor Alarm ON/OFF ON
26. BDT per OFF/ 1 day – 365 days ---
27. BDT Time 00.00 to 23.00 ---
28. BDT dur 3Hr.to 2Hr.in steps & ---
5min
29. BDT current OFF/1A ---
30. BDT End V NA ---
31. BDT End Q NA ---

NOTE:-
1. One can select “EQUALISE” mode either by Vstart-Eq(or)Istart Eq, selecting respective
menu in ON.
2. Refer the procedure for input power limit given under section A.3.2.

44
 Section – C

DCDP

- Overall functioning of DCDP.

- DC – DC Converter.

45
C.3.0 Overall functioning of DCDP
Refer to single line functional block diagram of DCDP enclosed.

The 110VDC Power supply taken from the SMPS panel is fed to DC-DC converters pertaining to
RL.INT, RL.EXT, AXLE COUNTER, BLOCK LINE, BLOCK TELE UP&DN, PANEL INDICATION
& HKT etc,. The Input and ground for the Converters are wired on to female 3way Molex
connectors and the Output and the fault sensing cable is on to female 2way Molex connectors. A
minimum of two converters is paralleled for each application so that in case of failure of one
converter, the other shall takeover immediately without any delay.

C.3.1. General Description

These DC-DC Converters are designed to convert the 110 V DC supply that is available from
Battery to various levels using high Frequency technique for powering interlocking relays etc.
The output is fully isolated from input and protected from over loads and short circuits.
All the DC – DC converters are of natural cooling. However where higher rating converters are
required will have built in fans. Two fans are provided in the top of the cabinet to exhaust the hot
air.

Principle of Operation
Refer to single line functional block diagram of DC-DC Converters enclosed. The positive of the
supply voltage is first filtered and given to the primary winding of the high frequency transformer.
The other end of the transformer is connected to the MOSFET, which is switched at a high
frequency in the order of above 60 KHZ. The output of the high frequency transformer is
rectified using diodes and filtered using a LC filter to reduce the ripple. This filtered output is fed
to an optically isolated control circuit which will in turn control the width of the firing pulse given
to the gate of the MOSFET there by keeping the output voltage constant.

Redundancy: Keeping in view the safety and importance of the Signaling operations, each DC-
DC converter is provided with a standby such that there is no discontinuity in power supply to
stick relays. Depending upon the importance and requirement, number of modules can be
paralleled for each application.
Modular Construction: To provide ease in maintenance, these converters are designed for
modular construction. The weight of the converter is kept very low (less than 2 Kg) and can be
inserted and removed in the rack. The I/P and O/P connections are wired to 3 way and 2 way
female molex connectors. Once the converter is inserted into rack, the wago connectors shall
be firmly plugged into the male wago connectors provided at the backside of the converter.
46
ON / OFF Switch : This switch is provided to keep the converter either in ON or in OFF
position. Converter goes OFF in upward position while comes ON in Downward position

Output Current Sharing: These converters are designed to function in active sharing mode
there by sharing the load current equally. This feature prevents one converter getting over
loaded and improves the life of the converters, as the semiconductor devices shall operate at
low currents.

Output Voltage Adjustments: All Converter voltages are factory set. However, the user can
adjust Converter voltages as per requirement. Each DC-DC Converter is provided with a 24-turn
potentiometer on left side of the front panel. Turning clockwise will increase the voltage, while
the output voltage reduces in anti-clockwise direction. This adjustment requires a small pre-set
driver (pot adjuster). Follow the below mentioned steps for adjusting the voltages.

Initial Adjustment Procedure during Commissioning:

• One no. of 3Way and Two no. of 2Way connector Card extenders are supplied along
with the system for connecting the Input supply and Output of the converter to the rack.
• Remove Converter from magazine and by holding the converter in hand connect the
converter into card extender to its respective I/P Connector.
• Before switching ON the converter, turn the voltage potentiometer anti-clockwise fully.
• Two test points are provided in each converter to monitor the output voltage. Connect
these test points to Digital Voltmeter (provided on front –top panel) using patch cards,
supplied by Amara Raja or to a digital multimeter (DMM)
• Switch ON the Converter by throwing the input switch to ON position. Digital Meter will
show the minimum voltage of that respective converter.srt the potentiometer to the
required value.
• Switch OFF this converter, remove card extenders & patch cards and insert the
Converter in its place.
• Follow the above steps for rest of the converters.

47
 Adjustment Procedure during system working (without disturbing loads)
• Connect the converter to the rack with both I/P & O/P card extenders.
• Connect the test points to Digital Voltmeter (provided on front –top panel) using patch
cards.
• Adjust the potentiometer to get the desired output.
• Check all the converters voltages pertaining to individual applications will be equal.

Front Panel Indications:

1. Input ON: indicates the availability of input power.
2. Output OK: indicates the availability of output power
3. Converter Fail: indicates the failure of converter
DC-DC Converter Fault : Each DC-DC converter is designed to extend a fault signal whenever
there is a fault. Fault signals of all the converters are combined and are given to PC Board (PC 1
) and in turn to PC-5 in SMPS panel. A relay in this board picks up when ever a fault persists in
any of the converter. A Potential Free contact of this relay is extended to ASM panel for
showing “Call S & T Staff” indication. Another Potential Free contact is terminated as
customer connection for data logger connection.

Output Diode Protection : Each Converter is provided with a blocking diode at the output to
prevent the working converter from getting affected by a paralleled faulty converter

Output Over Voltage Protection : When ever over voltage condition persists due to
any fault in the converter, the converter shall be switched off instantaneously so as to allow the
other converters in parallel to cater to the load.

Output Current Limit : The output current is continuously monitored and whenever it
exceeds the set limit , the output voltage shall droop such that the current is maintained
constant . The output current limit set point can be adjusted using the potentiometer ( VR 2)
after opening the DCDC converter cover.

Output Short Circuit Protection All the DC –DC converters are provided with output short
circuit protection . During this condition , the output current is limited to less than its maximum
rated current there by protecting the module. On removal of the short, the converter will restore
the output to the set level. Converter Fail indication blinks during this condition.

48
C.3.2 DC-DC Converter Specification

Type-1 Type-2 Type-3 Type-4 Type-5

Parameter
24-32V/5A 12-28V/5A 12-40V/1A 3-6 V/0.1A 2-12V/5A
Relay int, Relay
ext, Axle Panel Ind&HKT, Block Line UP, Block Tele UP, Spare cell
Application
counter,Data Block Local Block Line DN Block Tele DN charging
logger ,SSI
I/P Voltage 98-138 V DC 98-138 V DC 98-138 V DC 98-138 V DC 98-138 V DC

O/P Voltage
24-32 V / 5 A 12-28V/5A 60-100V/1A 3-6 V / 0.1 A 2-12V/5A
& Current

+/- 1% of set +/- 1% of set +/- 1% of set +/- 1% of set

O/P Voltage +/- 0.3 Volts
Regulation Value Value Value Value

O/P I Limit 5.5 +/- 0.5A 5.5 +/- 0.5 1.5 +/- 0.5 A 0.2 A 5.5 +/- 0.5 A
I/P ON
Amber LED Amber LED Amber LED Amber LED Amber LED
Indication
O/P OK
Green LED Green LED Green LED Green LED Green LED
Indication
Converter
Red LED Red LED Red LED Red LED Red LED
Fail indication
O/P Short ckt Provided Provided Provided Provided Provided
O/P Over 110% of Max 110% of Max 110% of Max 110% of Max 110% of Max
Voltage O/P Voltage O/P Voltage O/P Voltage O/P Voltage O/P Voltage
4 mm Banana 4 mm Banana 4 mm Banana 4 mm Banana 4 mm Banana
O/P Voltage Sockets Sockets Sockets Sockets Sockets
Test Points Red – +Ve Red – +Ve Red – +Ve Red – +Ve Red – +Ve
Black – -Ve Black – -Ve Black – -Ve Black – -Ve Black – -Ve
Irreversible 1 Irreversible 1 Irreversible 1 Irreversible 1 Irreversible 1
O/P
Part Connector- Part Connector- Part Connector- Part Connector- Part Connector-
Connection
Molex Make Molex Make Molex Make Molex Make Molex Make
O/P Current -
+/- 0.5 Amps +/- 0.5 Amps +/- 0.5 Amps
Active @ <0.5 V @ <0.5 V Not provided Not Provided @ <0.5 V
Sharing Difference Difference Difference

230mm (H) 230mm (H) 230mm (H) 230mm (H) 230mm (H)
Size in mm 89mm (W) 89mm (W) 89mm (W) 89mm (W) 89mm (W)
250mm(D) 250mm(D) 250mm(D) 250mm(D) 250mm(D)
Weight > 2.0 Kg > 2.0 Kg > 2.0 Kg > 2.0 Kg > 2.0 Kg

Cooling Natural Natural Natural Natural Natural

Convection Convection Convection Convection Convection

49
Removing the Converter from Sub- Rack:
• Switch off the converter by keeping the switch in off position
• Lift the handle gently and pull the converter out.
Inserting the Converter into Sub–Rack:
• Keep the input switch in OFF position.
• Hold the handle firmly and insert the converter into the respective slot.
• Connect the Input and Out put connectors of the respective converter.
Block Tele Converters: The Block Telephone connectors are directly connected to Battery,
while all other converters are connected through Battery Under Voltage contactor. This facility
will enable the ASM to communicate even if the total system is down due to Battery Low
Voltage. Further these converters are designed to work from 90 V DC while the under voltage
cut off point is 98 V DC.

C.3.3 Trouble Shooting ON DC-DC Converters.

SL No Symptom Possible Cause Action Suggested
I/P ON LED glowing. O/P OK LED not
Output OK LED is Get it changed by
1.0 glowing. But voltage is available at Test
defective. the manufacturer
Points.
Over Voltage Replace the faulty
2.0 Converter Fail LED blinks
Condition Converter.
Converter Fail , I/P ON , O/P OK LEDs
Conv. Fail LED is Get it changed by
3.0 glowing continuously. But voltage at test
defective. manufacturer
points is available.
Disconnect the load
Converter Fail , I/P ON , O/P OK LEDs
and check if the
glowing continuously in Main and Stand- Converter output is
4.0 voltage is restored.
by converters. Voltage at test points is short circuited.
If so , check for the
less than 3 V.
short in load.
Improper plugging of Insert the
5.0 No LED glows on the front panel
connectors connectors firmly
Failure of I/P, O/P
Converter Fail or Converter is in Restart Get it changed by
6.0 surge suppression
mode the manufacturer
circuit

50
C.3.4 Maintenance Check Points for DC-DC Converters

Caution: It is advised check these points once in month and only when there is in no
train movement .
SL No Check Point Action Required Frequency
Converter O/P Check if the O/P voltages are set as
1.0 Once in 15 days
voltage per requirement. If not, correct them.
Switch OFF main Converter and
Paralleling of
2.0 observe if the stand-by is taking the Once in a month
Converters
load.
Switch OFF Stand-by Converter
Paralleling of
3.0 and observe if the main is taking the Once in a month
Converters
load.
Converter Mechanical Check if all the converters are
4.0 Once in 3 months
Alignment inserted properly .
Remove one by one and clean the
converter using a soft cloth . Gently
5.0 Converter Cleaning Once in 3 months
blow some air from top or Bottom to
remove the dust inside.

51
Section – D

ACDP

- Inverter

- Bypass CVT

- Step Down Transformers

52
D.1.0 Overall Functioning of ACDP
Refer to single line functional Block diagram of ACDP enclosed.

The incoming Mains of 150-275V is fed to both the CVTs pertaining to signals and Track circuits.
Track CVT is always kept in ON condition while signal CVT is made ON only when there is no
inverters output. It is also ensured to cut off the AC input of signal CVT to avoid no load losses
of CVT, when output is not available from any of the inverters.

SMRs / Battery voltage is fed to inverters through respective input MCBs. Normally these MCBs
of inverter –1 & 2 need to be kept in ON condition so as to keep the inverter-2 in hot standby
condition. Cold standby is provided in the system so as to facilitate this cold standby inverter
connectivity to work as any of the inverter – 1 or 2. The cold standby inverter module is provided
(located at the middle position) to bring into operation whenever any one of the inverter fails to
supply, by plugging - in the respective connectors without changing the cold standby inverter
module from its position. All the connectors of the inverters are irreversible.

(Refer procedure for making the cold standby inverter module operation in the next page).
Auto Changeover Operation:

RL – 4 & RL – 5 and DC Contractor are provided in ACDP, which are used for Auto Changeover
operation. During power failure and battery discharging, the CSU in the SMPS panel senses
under voltage condition at 105VDC and activates the RL - 1, and cuts the Inverter O/P feeding to
signal transformers. The same will be extended to PFC Board provided in SMPS panel and in
turn system shut down through status monitoring panel in ASM’s room.
In normal condition Inverter – 1, Inverter – 2, Signal & Track CVTs and transformers are kept
in ON condition and cold standby in off

When Inverter –1 fails, the load will be supplied by the Inverter-2. Cold standby inverter can
be put into operation to work as inverter – 1.

If both Inverter-1 and Inverter-2 fails/trips at a time, because of DC under voltage and signal
CVT input will be switched on there by the load will be supplied by Signal CVT.

In this condition, by putting the cold standby inverter in to operation or if any inverter is
switched ON, then the load will be transferred to respective inverter with preset time delay of
0.5 seconds.

When any one or both of the Inverters are healthy and any one is catering to load, the I/P
supply to the signal CVT is cut by the power relays provided at I/P of the CVT, to avoid input
losses.
The common output of Inverter-1 or Inverter-2 or bypass CVT is fed to signal transformer to
reduce the voltage to 110V AC. Taps are provided at 100V, 110V, 120 and 130V for selecting
the output voltage depending up site condition.

53
The track circuit step down transformers are connected at the output of Track bypass CVT to
ensure constant 110V AC to Track feed chargers. Here too, taps are provided at 100,
110,120,130 for selecting the required voltage depending upon site condition.

Procedure for making Cold standby Inverter operational

1. In case of any fault occurs in either of the inverters, switch off the DC input breaker of the
faulty inverter module and disconnect the Connector –7, P1, P2 & P3 from the rear side
of the faulty inverter module. (The connectors provided are irreversible).

2. Ensure DC input breaker should be in OFF position before connecting the connectors.

3. Connect the corresponding connectors, which are removed from the faulty inverter
module to the cold standby inverter module.

4. Switch ON the cold standby inverter as described in the inverter operating instructions.

PF Contacts:
In each step down transformers and CVTs, a relay is used to provide potential free contact in
case of fuse failure. The same extended is to ASM panel as “Call S&T Staff” indication.

System Shutdown:
During power failure and battery discharging, CSU in the SMPS senses under voltage condition
at 105VDC and RL – 1 will operates at SMPS panel, and cuts the Inverter O/P feeding to signal
transformers. The same will be extended to PFC Board provided in SMPS panel and in turn
system shut down indication to status monitoring panel in ASM’s room.
Inverter – 1 & 2 Fail:
When the Inverter Input voltage is available and there is no voltage at the output of the Inverters
a PF contact is extended and terminated on to a TB as given in Schematic drawing and the
same shall be interfaced with SMPS panel as per schematic drawing, for external data logger
connection and another is for ASM Panel for “Call S&T Staff” Indication.

Output Voltage Measurements:

A digital voltmeter is provided on Front Panel with a set of test points to monitor the output
voltage of CVTs, inverters and step down transformers. One digital ammeter is connected at the
output of signal transformer to monitor the signal current on 230V AC side.

Door Lamp:
One lamp is provided in the cubicle through a push button. This arrangement is made in such a
way that it glows only when the door is in open condition.

54
D.2.0 INVERTER :
D.2.1 GENERAL DESCRIPTION:
Sine wave weighted high frequency Pulse Width Modulation (HF-PWM) technique is used for
conversion of DC power supply to AC output (Pure Sine Wave). The PWM wave is composed of
a series of pulses of variable width these pulses are very narrower at the beginning of the half
cycle and become progressively narrower towards the end of the next half cycle. As a result of
which the generated waveform made up of pulses shall have a sine wave envelope. The
duration of the pulses decides the instantaneous amplitude of the modulating sine signal with the
result that the average value of the output at any given time approximates to a sine wave, the
higher order harmonics are eliminated with the use of PWM techniques and thereby reduces
losses in the filter and improves overall efficiency. The efficiency of this type of system is about
85%. The PWM technique also improves the transient response and the reliability of the system.
Equipment MTBF is very high with zero down time.

D.2.2 TECHNICAL SPECIFICATION OF INVERTER

1) INPUT VOLTAGE : 98V – 138V DC
2) OUTPUT
a. VOLTAGE : 230V AC (SINGLE PHASE)
b. REGULATION : 230V ± 2%
c. FREQUENCY : 50Hz 0.5Hz
d. WAVEFORM : SINEWAVE
e. DISTORTION : < 8%
f. POWER FACTOR : 0.85 LAGGING TO UNITY
g. INVERTER EFFICIENCY : BETTER THAN 85% FROM 50-100% LOAD
FOR THE ENTIRE INPUT RANGE.
103% CONTINUOUS , 125% for 4 hours,
h. OVER LOAD CAPABILITY :
200% FOR 300ms
i. COOLING : FORCED COOLING .
3) PROTECTIONS
a. INPUT : MCB
b. OUTPUT : OUTPUT OVER VOLTAGE
OUTPUT UNDER VOLTAGE
OUTPUT OVERLOAD
OUTPUT SHORT CIRCUIT
4) INDICATIONS :
Indicates the presence of DC supply at input of
A) INPUT ON :
the Inverter.
Indicates that the output of the inverter is ready
B) OUTPUT ON :
to connect the load.
C) INVERTER FAIL : Indicates that the Inverter is tripped.
D) INVERTER “ON LOAD” : Indicates that the Inverter is loaded.
E) FAN FAIL INDICATION : Indicates when the fan fails.
5) GENERAL
A) OPERATING TEMPERATURE : 0°C to 55°C
B) RELATIVE HUMIDITY : 0-95%

55
D.2.3 SYSTEM DESCRIPTION :

Refer to Single line Functional Block Diagram of Inverter enclosed.

1) POWER CIRCUIT :

The point marked + ve and – ve is the DC Input to the unit. LED on the front panel will
given the indication of DC ON.

The DC supply is given to the bridge network consisting of Power IGBTS Q1-Q4 and the
Inverter Transformer T1. Driver section of Integrated Inverter Card – PMB –
12000025,Rev.0 gives the gate drive to the IGBTS Q1, Q2, Q3, and Q4 in accordance with
the signals coming from the Inverter.

The control waveform on card is achieved by comparing a sine waveform of a variable

amplitude Peak to Peak -8V of particular frequency 50Hz, with a triangular wave of fixed
amplitude Peak to Peak-8V with a much higher frequency 6.4KHz. The comparator gives
out a pulse when the sinusoidal voltage is greater than the triangular voltage and thus
trains of pulses of varied width are generated and these are coupled to the switching
elements.

The mean output voltage is controlled according to a sine function. This is a achieved by
repeated switching “ON” and “OFF” of a particular switching element (POWER IGBTs)
before the control is passed to the other element. The switching of the pulses, which is a
sinusoidal function of the angular position of the pulses in three cycle, is changed in a
closed loop to counter the change at the output of the INVERTER.

Thus the drive and control power is derived from regulated DC power supply. The output of
INVERTER Bridge is connected to the double wound Transformer, T1. Capacitor, C1
connected across the secondary of the output transformer removes unwanted higher
harmonics from the INVERTER output to obtain a low distortion sine waveform.

The higher order harmonics are eliminated with the usage of High Frequency Pulse Width
Modulation technique (HF PWM).

The current Transformer CT-1 is used to sense the current at the output of the INVERTER.
The signal of the same is pre-processed in the PMB – 12000025, Rev.0. This signal is fed
to the Integrated Inverter control card to control the O/P current.

D.2.4. OPERATING INSTRUCTIONS :

The sequence of the procedure to operate the Inverter system is listed here under :
1. INITIAL CHECK :
Ensure that all the installation procedures and Metering, Controls, Indications as specified,
is followed and the Battery of rated Voltage (V) or DC O/P of Rectifier charger is connected
to the DC I/P terminals of the Inverter with proper polarity. Check all the switches.

56
2. TO START THE INVERTER :

i) Switch ON the DC I/P ON/ OFF circuit breaker.. The ‘INPUT ON’ LED will glow.
ii) Press the Reset push button to remove any spurious indications.
iii) Press the Start push button, ‘OUTPUT ON’ LED will glow. Check the output voltage
with a DMM.
iv) Connect the load at the output of the system.

v) The Inverter trips under following fault conditions :

a) DC U / O Voltage
b) AC Over Load / Short Circuit
c) AC U/O Voltage

However, if so happens the ‘INVERTER FAIL’ LED will show. After attending the fault,
RESET the system & start the inverter.

3. TO STOP THE INVERTER:

To switch off the Inverter, press the STOP push button.

IMPORTANT

Before switching ON or switching OFF the Inverter, switch off all the loads at
the Output.

D.2.5 MAINTENANCE & TROUBLE SHOOTING

This system is conservatively designed. It is completely static with all advanced digital circuits.
This system will provide trouble free service with minimum maintenance. However a regular
periodic maintenance program should be followed. Table given below provides the schedule of
maintenance procedure in details.

WARNING
High voltage is used in the operation of the system. Hence extreme care
should be taken when performing maintenance task or trouble shooting this
system. To prevent accidental electric shock.

57
A. TABLE OF PERIODIC INSPECTION AND MAINTENANCE
TABLE – I

INSPECTION
ITEMS PROCEDURE
PERIOD
1. Ventilation and Check that intake and exhaust air
Daily
Openings openings are not obstructed.
Remove dust and foreign particles within
the Chassis using compressed air or
2. Cabinet Assemblies Weekly
blower. Check mounting bolts and
terminals looseness. Tighten them.
Inspect transformers for evidence of over
heating, damaged insulation or loose
mounting screws. Correct any
malfunctioning before operating the unit.
3. Cabinet 3 Months Tighten any loose screws or nuts. Clean
electrical contacts with a cloth dampened
in with carbon tetra-chloride. Do not use
cleaning solvents on electrical contacts.
Replace if found defective.
3 Months Check all LEDs
Check all controls for operability. Replace
6 Months if any damage or malfunctioning is
observed.
Check the cable for input and output
power and internal wiring to components.
12 Months
Check for cracks or broken insulation.
Replace as indicated.
4. Controls & Indications Inspect the general conditions of PCB.
Check the components for evidence of
12 Months
over heating cracks or peeling. Repair or
replace board if necessary.
Inspect Diodes, Silicon Controlled
Rectifiers (SCRs) & MOSFETS and their
12 Months heat dissipaters for loose mounting or
defective electrical connections. Tighten
screws and nuts.
Inspect PCB, sockets for loose electrical
12 Months connections. Tighten the mounting screws
and replace defective sockets, if any.
5. Internal components Inspect the electric wiring for broken solder
connections, evidence of peeled insulation
12 Months
and general deterioration. Repair or
replace damaged wiring.

CAUTION
FUSE FUSE REPLACEMENT MUST BE MADE ONLY WITH
REPLACEMENT FUSES RATED APPROPRIATELY.

58
B. TROUBLE SHOOTING CHART

In case there is any fault in the system, it is preferable that the unit is tested step by step. It is
further desirable that the basic principle of operation of each section is clear in mind before
trouble shooting. However, brief guidelines are provided through the following chart for
expediting the fault tracing.
SR
SYSTEM FAULT PROBABLE CAUSE REMEDY
NO.
a) Skin effects due to prolong a) Replace fuse.
use.
b) Short circuit or excessive b) Check Inverter O/P for
overload on Inverter. excessive over loading &
1. DC Fuse fail.
reduce the load to the limit or
Check Inverter Power
Transistors for short circuit &
replace defective Transistors.
DC UNDER a) DC Input Cable is less than a) Replace the cable. Use the
Voltage comes rated capacity. cable of proper rating.
immediately after b) Loose contact at input side. b) Tighten all connections.
2.
Inverter is
switched ON &
Inverter trips
a) Break in DC supply either a) Replace fuse & check
due to blown fuse or wiring as may be necessary.
disconnected wire.
3. Inverter not ON.
b) Power Supply Transistors c) Replace them.
faulty.
c) Control card defective. d) Replace control card.
4. Inverter output a) Feedback loop broken. a) Check Feedback X’mer or
high break in wiring of X’mer or
voltage adjust Potentiometer.
b) Inverter card not functioning b) Replace control card.
properly.
c) False indication due to c) Check the set right O/V
defective O/V sensing circuit. sensing circuit.
5. Inverter trips a) Over Load trip setting not a) Set the overload tripping by
before loaded fully. proper. means of adjusting pot on the
Inverter card. Check power
requirement of the load.
Switch on the load one by one
after the output reaches
220V.
6. Unit not working a) Output Fuse is blown. a) Replace the fuse.
neither on Inverter
nor on Mains.

59
D.3.0 Bypass CVT Regulator
The Bypass CVT Regulator is connected to the AC Input power through a rotary switch.
The primary winding of the ferrosonant Transformer is connected through a Fuse .The
secondary of Transformer in conjunction with the Resonating capacitors produces a clean
and stabilized 230V sine wave. This Transformer has an inherent feature of output current
limiting.

Bypass CVT Regulators Specification

Parameter Type-1 Type-2

Application Signal Bypass CVT Track Circuit Bypass CVT
Rating 1.5KVA 1KVA
AC Input
160-270VAC 160-270VAC
a) Voltage
(Nominal : 230V AC) (Nominal : 230V AC)
b) Phase Single Single
c) Frequency 50 ± 2.5 Hz 50 ± 2.5 Hz
AC Output
a) Voltage (Taps) 0, 220, 230 and 240V AC 0, 220, 230 and 240V AC
b) Frequency 50 ± 1Hz 50 ± 1Hz
c) Regulation ± 1% ± 1%
d) Current 4.5A 4.5A
e) Output Distortion < 8% < 8%
Protections a) Short circuit at output a) Short circuit at output
b) Input Fuse b) Input Fuse
Indications Input ON Input ON
Output ON Output ON
Output Fail Output Fail
Controls Input ON/OFF Switch Input ON/OFF Switch
Through irreversible Wago
Termination Through irreversible Wago Connectors
Connectors
Natural Air Cooling
Cooling Natural Air Cooling Convection
Convection

60
D.4.0 STEP DOWN TRANSFORMERS
The supply from AC Bus ( either from inverter or from Bypass CVT ) is fed to each
Transformer through an AC Input ON/OFF switch. A LED lamp is connected at the input
of each switch to indicate the availability of power to that respective transformer. A fuse
is provided at the input of each transformer. As shown in the drawing Necessary tapings
(100,110,120,130V) are provided at the secondary of each transformer.
SIG UP/ DN Transformers :
Parameter Type–1 Type–2 Type–3 Type–4
Application Signal UP(1&2) Signal DN(1&2) Track circuit UP Track circuit DN
Rating 0.5KVA 0.5KVA 0.5KVA 0.5KVA
AC Input Voltage 230V AC 230V AC 230V AC 230V AC
Output Voltage 100, 110,120 100, 110,120 and 100, 110,120 and 100, 110,120 and
(Taps) and 130V AC 130V AC 130V AC 130V AC
MCB at AC MCB at AC MCB at AC MCB at AC
Protection
Input Input Input Input
Indications Input ON Input ON Input ON Input ON
Output ON Output ON Output ON Output ON
TX Fail TX. Fail TX. Fail TX. Fail
Input ON/OFF Input ON/OFF Input ON/OFF Input ON/OFF
Controls
switch switch switch switch
Through Through
Through Through
irreversible irreversible Molex
Termination irreversible Molex irreversible Molex
Molex Connectors
Connectors Connectors
Connectors
Natural Air Natural Air Cooling Natural Air Natural Air
Cooling Cooling Convection Cooling Cooling
Convection Convection Convection

D.5.0 Trouble Shooting on ACDP

SL No Symptom Possible Cause Action to be taken
Inverter I/P ON LED is glowing. O/P LED is Check the connections
1.0 O/P OK LED is not glowing . But defective. and change the LED.
voltmeter shows the O/P voltage.
Inv-1 Fail Indication glowing. Inv-2 Faulty Inverter –1 Send it for repair.
2.0
is taking the load.
Inv-1 is faulty . But Inv-2 is not Contacts of Relay – Change Relay 4/5
3.0 taking the load though O/P LED is 4/5 may not be
glowing. proper.
Though both inverters are in Defective Contactor Check if the coil is
working condition , only inverter-2 ( Relay -4 ) or getting + 24V DC to
4.0 is taking the load. PC - 1 Relay - 4. If yes ,
Change the Relay. If
not replace the PC – 1
Though both inverters are in Either Con-1 or Change the defective
5.0 working condition , only bypass Con-2 or both are contactor.
CVT is taking the load. defective.

61
 Though all subsystems are in Check for any lose
working condition in ACDP , Defective selector connection
6.0
Voltmeter is not showing some of switch Or
the values Change the switch.
Check if the frequency
The O/P of CVTs sometimes show This is due to low is less than 48 Hz. If
7.0
220 V or less instead of 230 V . grid frequency so inform local supply
board.
Batteries of Track
Circuits may be in
Start the generator.
deep discharged
Battery is in charged condition , condition as their
Or
8.0 but some of the Track Circuits are chargers are
not functioning properly. connected to Track
Replace defective
CVT which is
track batteries.
directly connected
to input mains
The relay
When any fuse is removed in any connected across
Change the defective
9.0 sub-system , Call S&T staff LED in the output of
relay board.
ASM panel is not glowing. respective sub-
system is defective.

D.6.0 Maintenance Check Points for ACDP

Caution : It is advised check these points once in month and only when there is in no
train movement .
SL No Check Point Action Required Frequency
O/P voltages of Check if the O/P voltages are set
1.0 Inverters, CVTs , Step- as per requirement. If not , check Once in 15 days
Down Transformers for fuses , contactors.
Check if the DPM is showing the
2.0 Inverter O/P current. signal current as per original Once in 15 days
settings.
Auto changeover Check for this changeover
3.0 between Inverters and operation as described in ‘Overall Once in a month
Bypass CVT functional description of ACDP’.
Check if all the connectors of
Connector Mechanical
4.0 various sub systems are inserted Once in a months
Alignment
properly .
Remove one by one and clean
them using a soft cloth . Gently
5.0 Sub System Cleaning Once in 3 months
blow some air to remove the dust
inside.

62
Section –E
ASM INDICATION PANEL
To ensure continuous power supply to signals and relay circuits, one Indication panel is supplied
with the IPS system which should be mounted in ASM room. The following indications are
provided to enable ASM to prompt signaling staff as and when there is a fault condition. This
panel will also help ASM to switch ON Generator only when it is required. Block Tele Converters
are also accommodated in Status monitoring panel.

Start Generator : This indication glows when the battery is discharged to 50% (approx. 109V,
fix 300AH). Audio alarm is also provided for this condition. Once the generator is started the
indication goes off, as the battery voltage increases. Audio alarm can be acknowledged by
pressing Reset Push Button.

Emergency Start Generator : This LED glows when the battery is discharged to 60% (approx.
107V). This is a second indication and alarm to ASM to start the generator. The audio alarm can
be reset using Reset Push Button.

System Shut Down : This indication glows when the Battery is discharged to 70%
(approx.105V). The audio alarm will continue to operate until the generator is started.

Call S&T Staff : This LED glows when any of the sub modules like SMRs , DC-DC Converters,
CVT and step down transformer fail. ASMs may be advised to bring it to the notice of S&T staff
whenever this LED glows.

Voltage Monitoring bar Graph : 10 LED bar graph is provided to show the voltage level in
steps of 2V from 102V and above. 6 LEDs are of Green Colour, 2 of Amber and 2 of Red
Colour . Green indicates safe operation zone, Amber indicates alert zone

Block Tele Converters: The Block Telephone connectors are directly connected to Battery,
while all other converters are connected through Battery under voltage contactor. This facility will
enable the ASM to communicate even if the total system is down due to battery low voltage.
Further these converters are designed to work from 90V DC while the under voltage cut off point
is 98V DC.

Stop Generator : Set of NO contact in MMIB3 (PC2) is being used for sensing the generator
availability so as to sense the stop generator indication in status monitoring panel which is in
series with NC contact of the Equalize charge (Boost charge) sensing relay in MUIB i.e. Relay –
5. When the system is switched to equalize mode Relay –5 in MUIB gets energized and for float
the relay gets de energized, as a result the NC contact makes the connection. Simultaneously
the relay in PC2 energized when the system starts working on the genset and the NO contact
becomes NC and the indication will glow in the ASM panel.

63
Potential Free Contacts:

All potential free contacts are derived in PC-4 and are interfaced through PC-5.

Mains Fail: The AC I/P supply is fed to PC-4 and this board will monitor the same. The mains
fail is being sensed to PC-5, where data logger and ASM panel is interfaced.

50% DOD: Whenever the battery voltage goes below 50% DOD level, an Indication is generated
in ASM Panel, as start Generator and a potential free contact (NO) is extended and terminated
on PC-5 in SMPS panel for connecting to ASM Panel.

SMR Fail: When SMR output voltage goes beyond the set parameter (HVSD: High Voltage Shut
Down), and for any fault in any of the SMRs, a relay PC 4 is energized through MUIB. A PF
Contact of this relay is extended on PC-5 for external data logger connection and another is
extended for ASM panel for “Call S & T Staff” indication.

DC-DC Converter Fault: Each DC-DC converter is designed to extend a fault signal whenever
there is a fault. Fault signals of all the converters are combined and are given to Pin No. 2 in
CN-4 PC Board (PC 5). Relay in this board picks up whenever a fault persists in any of the
converter. A potential free contact of the relay is extended on PC 5 for external data logger
connection and another extended on to the same PC 5 to ASM panel for “Call S & T Staff”
indication.
Call S & T Staff: Each DC-DC Converters / SMRs / Step down Transformers / CVT & Inverters
is designed to extend a Fault signal, whenever there is a Fault. Fault signals of all the DC-DC
converters / Chargers / Step down Transformers / CVT & Inverters are given to a PC Board (PC
4). The respective relays in this board picks up. A potential free contact is extended on PC 5 for
external Data logger connection and another is extended on PC 5 for ASM Panel as “Call S&T
Staff”.

System Shutdown: A Battery voltage is being monitored by the CSU in SMPS panel and
energies RL-1 which is mounted in PC-3 when ever the battery voltage falls below pre set
value(105V). This will in turn energies the Re PC 1 in ACDP and disconnects the O/P of the
Inverters when ever the battery voltage falls below pre set value. A connection, which senses
“System Shut Down”, is terminated on Pin No.3 of CN 4 in PC 5 in SMPS Panel for connecting
to ASM Panel.
Inverter – 1 & 2 Fail: When the Inverter Input voltage is available and there is no voltage at the
output of the Inverters, a PF contact is extended and terminated on PC 5 for external data logger
connection and another is extended and terminated on PC 5 to ASM Panel for “Call S&T Staff”
Indication.

64
 Section – F

Annexures

SYSTEM BILLOF MATERIALS

SCHEMATIC DIAGRAMS

DIMENTIONAL DRAWINGS

Dos AND Don’ts FOR IPS SYSTEM

FEED BACK FORMAT

GUARANTEED TERMS & CONDITIONS

INSTRUCTIONS TO BE FOLLOWED DURING OPERATION &

65
 MAINTENANCE FOR IPS

DOs

1. Keep the AC Input MCBs of at least 2 SMRs always ON.

2. Keep the Inverter Input MCBs always ON.

3. In case of emergency or any problem, switch OFF all the MCBs.

4. Remove control cable connector accessible from backside, before pulling out
inverters/ step Down Transformers / Bypass CVTS

5. Whenever any module is removed and inserted again , ensure that it is properly
inserted and fixed on to the rack.

6. Whenever any PCB is Replaced, connect the wires as per schematic drawing only.
Else a severe damage to PCBs may occur.

7. Keep the AC Input switches always ON in Step Down Transformers.

8. In case of emergency or any problem, switch OFF all the switches.

9. Keep the DC Input switches always ON in Converters

10. Keep the AC Input switches always ON in Bypass CVT Regulator.

11. Check the healthiness of SPD periodically and whenever you feel surge is occurred.

66
 DON’ Ts
1. Do not connect the Battery Bank to the IPS without removing the battery fuse.
2. Do not remove the Inverter input / output connectors with Inverter Input MCB ON.
3. Do not disturb the potentiometers used in PCBs. They have to be adjusted at
factor only.
4. Do not restart the system without knowing the basic cause.
5. Do not use wire fuses.
6. Do not install the equipment in a poor ventilated site.

WARNING

Removal of battery fuse during Mains fail condition shall trip

converters and inverters there by interrupting the traffic.

WARNING:
Do not switch OFF both Main & Stand by converters at
any time. This will disturb power to signal relays.

WARNING : Initial battery connection & load connection shall be done without
energising the system. When the system is under operation, adequate precautions have
to be taken while installing & removing sub modules , since high voltages (Approx. 400V)
are available on rear side of the panel.

• Do not install the equipment near heat generated equipment. Avoid locations
subjected to corrosive fumes or extremes of dirt & moisture.

• To avoid voltage drop and fire hazards, cables of specified rating as shown in
installation drawing only shall be used for input, output and interconnection.

67
 FEEDBACK FORMAT
(Kindly fill up this proforma for your valuable comments / suggestions which will lead to
improve upon the quality of the product as well as to take remedial action if required).

From :

1. Type of the Unit :

2. Serial No. of the Unit :
3. Year of Manufacturer :
4. Specification No. :
6. Date of Dispatch :
7. Date of receipt of the unit :
8. Whether unit was received in good :
Condition? Or any damage is noticed?
9. All the accessories / spares as per the :
packing slip found OK or NOT?
10. Any difficulty at the time of installation :
please mention.
11. Any suggestion to modify the unit for :
easy installation.
12. Performance test OK/NOTOK, :
if not OK please furnish the details
13. Any suggestion to modify the unit for :
better performance
14. Remarks :
15. Contact person at H.O : Manager (Service), M/S Amara Raja
complex,
Karkambadi, Ph: (08574) 85561-65

Note : If necessary please use separate sheet.

Signature: Stamp:

68
 GUARANTEED TERMS & CONDITIONS
AMARA RAJA POWER SYSTEMS (P) LTD. (ARPSL) guarantees to the original user of the
Rectifier Chargers, Inverters which are manufactured by ARPSL, are free from all
manufacturing defects both in the material and workmanship. Any claims against such defects
should be made within 24 months from the date of dispatch whichever. The user shall
promptly report any alleged defects to ARPSL and permit examination by its staff. If ARPSL
finds the items to be defective as a result of material or workmanship, ARPSL may repair/
replace same without charge provided the following conditions are satisfied.

1. The Installation Registration Card is filled and sent to ARPSL.

2. The claim under the guarantee shall be made within a period of seven (7) days from the
date of detection of the defect.

3. The items are handled, stored and installed in accordance with ARPSL published
instructions furnished with the systems.

4. The systems are operated, used and maintained in accordance with ARPSL published
instructions furnished with the systems.

5. The user shall inform ARPSL of any change in location within one week.

LIMITATIONS OF GUARANTEE
All terms of guarantee will be null and void and not binding on ARPSL if any additions /
repairs / replacement / modification is carried out by the user or his representative. Physical
damage claims made from places other than delivery point are not covered.

The above guarantee is provided by ARPSL to enduser. ARPSL disclaims all implied
warranties of merchantability and fitness. In no event shall ARPSL be liable for the
consequential or incidental losses/ damages.

For replacement, repairs and rectification – the items should be returned to our factory
covering Insurance and freight prepaid along with the Transporter Copy of Invoice and other
relevant statutory documents.

Under no circumstances, shall user return items to ARPSL factory without ARPSL prior
authorisation.

Date : for AMARA RAJA POWER SYSTEMS (P) LTD.

69
 Pre-Commissioning Checklist

of

SMPS based IPS

REFERENCE: SPECIFICATION NO. RDSO/SPN/165

SIG0101 (Revision 1)

Number of pages 12

RESEARCH, DESIGNS & STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

MANAK NAGAR

LUCKNOW - 226011
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

DOCUMENT DATA SHEET

Designation

SIG 0101 (Revision 1)

Title of Document

Pre-Commissioning Checklist of SMPS based

IPS

Authors: See Document Control Sheet

Name: Vipul Goel

Designation: Joint Director / Signal

Approved By

Name: Shri G.D.Bhatia

Designation: Sr.Executive Director /Signal, RDSO

Abstract

This document defines the guidelines for Pre-Commissioning Checklist of

SMPS based IPS.

2
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

Document control Sheet

Designation Organization Function Level

Joint RDSO Member Prepare

Director/Signal

Sr.ED /Signal RDSO - Approval

3
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

PRE-COMMISSIONING CHECKLIST FOR SMPS BASED IPS SYSTEM

1. STATION DETAILS

Zonal Railway Number of main signals

Division Number of shunt signals
Station Name Number of point machines
IPS Make Number of Axle Counters
RE/Non RE Number of Track Circuits
No. of lines / Roads Type of Track Circuit
(AFTC/DC)
Power availability Number/Type of Indoor
hours / day relays
DG set rating Number/Type of outdoor
relays
Type / capacity of Interlocking ( RRI/SSI)
battery (LM/VRLA)

2. PRE-COMMISSIONING REQUIREMENTS

S.N ITEM Specified Measured Remark

. Value/provision Value / (OK/Not
Observation OK)
A Ambience of IPS Room

A1 Availability of working 1 m (min.) from sides and

space for maintenance. rear. 2 m (min.) in front of
the IPS
A2 Provision of flooring to Pucca floor/ Ceramic tiles
ensure proper cleaning.
A3 Provision of forced Fresh Air fans with
ventilation dampers
A4 Arrangement for (i) Tight closing of doors &
protection against dust. windows; use gaskets if
necessary.

(ii) Washable dust filters on

windows.

(iii) Provision of double

door or entry through
adjoining room to reduce
dust ingress
A5 Provision of Ventilators As per RE Drg. No.
RE/Civil/S-129-2001
(Annexure-I).

Signature of Manufacturer's Representative Signature of Railway Supervisor

4
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S.N ITEM Specified Value/provision Measured Remark

. Value / (OK/Not
Observation OK)
B Batteries

B1 Installation of secondary Installed in separate room /

cell as per para 16.6 of apparatus case.
SEM Pt. Acid proof flooring and tiles
Exhaust fan
Initial charging as per instruction
of battery manufacturer
Use of battery grade sulphuric
acid conforming to IS: 266.
Use of distilled or de-mineralised
water conforming to IS: 1069
B2 Storage period of VRLA Less than 03 months (If the
batteries for IPS battery is being stored for more
than 3 months, freshening
charge should be given once in
3 months as given below. The
charging current should be 10%
to 20% (max.) of rated capacity:-

Float Charge @ 2.25V/cell for

24 hours
Boost Charge - @ 2.30V/cell for
15 hours)
B3 Measured capacity of Rated AH
battery after capacity test
on batteries.
B4 Feeder cable from battery
to charger
120AH 10 sq.mm copper
200AH 16 sq.mm copper
300AH 25 sq.mm copper
B5 Availability of Spare cell in 05 Nos.
charged condition at site
C Commercial/AT Supply

C1 Availability of commercial More than 6 hours in 24 hours

supply (Ref: RB letter No. with least fluctuations
2002/SIG/SGF/3 dt.
24.6.03). (Note: Nominal incoming AC supply
shall be 230V, 50Hz single phase
AC. The specified AC voltage range
for IPS is 150V-270V.)

Signature of Manufacturer's Representative Signature of Railway Supervisor

5
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S.N ITEM Specified Value/provision Measured Remark

. Value / (OK/Not
Observation OK)
C2 Voltage drop in input feeder Less than 30 volts
at full load.
C3 Provision of sources of RE Area
power supply as per para Power supply drawn from AT
16.2 of SEM Pt. II. Up/Dn/ Commercial
supply/Genset with auto/
manual changeover facility in
the control panel.

On double/multiple line
sections, at least one AT is
available to ensure power
supply in the event of power
block.

On single line sections where

power supply is drown from a
single AT, a DG set of suitable
capacity has been provided

In big yards, a DG set of

adequate capacity in addition
to supply from AT's and local
source

Non RE Area
Power supply drawn from
commercial feeder. In addition
two standby diesel generators
have been provided
C4 Size of input feeder cable
as per TI Directorate's note
no. TI/PSI/Project/CLS/01
dt. 04.01.02.(Annexure II)
from Auxiliary Transformer
(AT ) / Distribution
transformer to IPS room for
5 KVA AT 2X25 sq.mm Al
10KVA AT 2x70 sq.mm Al
50KVA AT 2x300 sq.mm Al

Signature of Manufacturer's Representative Signature of Railway Supervisor

6
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S.N ITEM Specified Value/provision Measured Remark

. Value / (OK/Not
Observation OK)
C5 Sanctioned Commercial
feeder load (KVA)=S
General Electrical Lighting
load (KVA)=L
Balance available for
Signalling Load(KVA) = S-L

4 Line Non-RE 7.4 KVA

4 Line RE 6.25 KVA
6 Line Non-RE 8.1 KVA
6 Line RE 7.0 KVA
C6 MCB/ Changeover switch 63 Amp of Merlin Gerlin
(Telemecanique) / Siemens,
(Ref: RB letter No. Schneider or ABB.
2004/SIG/SGF/3 dt.
25.3.2004.
D DG Set supply
D1 Provision of adequate
capacity DG set (without
AFTC)
4 Line Non-RE 10 KVA
4 Line RE/6 Line RE 10 KVA
6 Line Non-RE 12.5/15 KVA

with AFTC in yard At least 25 KVA

D2 Checking of DG set at
5KW dummy load:
Waveform Sinusoidal
Voltage Regulation within 3%
Frequency 50Hz ± 5% from no load to full
load
D3 Proper termination of Good workmanship
earth and neutral.
E Earthing
E1 Earth resistance of Less than 2 Ohm (without
earthing arrangement. adding water prior to
measurement)
Preferably maintenance free
earth.
E2 Extension of earth to Provided
equipotential bus bar.

Signature of Manufacturer's Representative Signature of Railway Supervisor

7
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S.N ITEM Specified Value/provision Measured Remark

. Value / (OK/Not
Observation OK)
E3 Connection of individual with individual copper insulated
equipment to cable of size
equipotential bus bar:
- IPS racks 4 Sq.mm
- DG sets 4 Sq.mm
-Surge protection devices 16 Sq.mm
F Lightning & Surge Protection
F1 Provision of lightning & One set
surge arrestors (As per
Cl. 3.12 of
RDSO/SPN/165/2004 Ver
2)
G. Instruction Manual
G1 Instruction Manual Two sets
consisting of Layout drgs.,
Circuit/ System diagram,
PCB Layout etc. (Ref: Cl.
7.1 of
RDSO/SPN/165/2004 Ver
2)
H Training
H1 Imparting on job training 3 days
to SE/SSE/JE and ESM

3. IPS LOAD DETAILS

N= Number of modules provided in hot standby

S.N ITEM Specified Measured Remark

. Value/provision Value / (OK/Not OK)
Observation OK Not
OK
1. Signalling Equipment load 80% of the DG Set
(KVA) capacity provided at
station
2. Relay internal 24-32V/5A 5 *(N-2) Amp
3. Relay external 24-32V/5A 5 *(N-1) Amp
4. Axle counter 24-32V/5A 5 *(N-1) Amp
5. Block local 12-28V/5A 5 *(N-1) Amp
6. Panel Indication12-28V/5A 5 *(N-1) Amp
7. HKT/magneto 12-28V/1A 1 *(N-1) Amp
8. Block UP 12-40V/1A 1 *(N-1) Amp
9. Block DN 12-40V/1A 1 *(N-1) Amp

Signature of Manufacturer's Representative Signature of Railway Supervisor

8
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S.N ITEM Specified Measured Remark

. Value/provision Value / (OK/Not OK)
Observation OK Not
OK
10. Block Tele UP 3-6V/0.1A 0.1*(N-1) Amp
11. Block Tele DN 3-6V/0.1A 0.1*(N-1) Amp
12. Data logger 24-32V/5A 5 *(N-1) Amp
13. SSI 24-32V/5A 5 *(N-2) Amp
14. Load on each Signal Tx UP 500 VA
15. Load on each Signal Tx DN 500 VA
16. Load on Inverter
4 Line 1.5 KVA
6 Line 2.0 KVA
17. Load on Signalling AVR
4 Line 1.5 KVA
6 Line 2.0 KVA
18. Load on Track Tx
UP 500VA
DN 500VA
19. Load on Track AVR
4 Line 1.0 KVA
6 Line 1.5 KVA
20. High voltage disconnect 275 V
21. Low voltage disconnect 160V
22. Battery capacity 300/200AH
23. Battery charging current 30/20A =Y
24. Total Current drawn from 20* (N-2) Amp=X
FRBC at 110 V after one hour
of discharge.
25. Current drawn from FRBC at X-Y
110 V when battery is in float
condition
26. Input feeder current at full
load 32 Amp
4 Line Non-RE 27.2 Amp
4 Line RE 35 Amp
6 Line Non-RE 30.2 Amp
6 Line RE
27. Input feeder voltage at full 160 Volts (Minimum)
load
28. Functioning of dynamic Operational
current control
29. Supply fuse 63 A

Signature of Manufacturer's Representative Signature of Railway Supervisor

9
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

S.N ITEM Specified Measured Remark

. Value/provision Value / (OK/Not OK)
Observation OK Not
OK
30. Working of Status Monitoring
Panel (Para 4.10 of spec.)
DOD 50% RED & Audio alarm
60% RED & Audio alarm
70% RED & Audio alarm till
DG is started

GREEN & Audio alarm

Stop DG Set
31. Call S&T due to failure of any RED & Audio alarm
module
32. Changeover inv. 1 to 2 and Inverter failure
vice versa
33. Changeover inv. to CVT and Both inverter fail
vice versa
34 DC-DC Converter for spare 02 Nos.
cells 2-12V, 5Amp
35 Temperature compensation Provided for VRLA
battery

4. Performance Monitoring of IPS

S.N ITEM Specified Observation Remark

. Provision
1 Monthly calculation of MTBF / As per Annexure-III
MTTR and sending it to Zonal
Railways for onward
transmission to RDSO.

Signature of IPS Manufacturer's Representative Signature of Railway Supervisor

Name Name
Designation Designation
Date Date

**********************

10
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

Annexure-II

Telephone : 2451200 Extn. 42394 Government of India - Ministry of Railways

Tele Fax : 91-0522-2452332 Research Designs & Standards Organisation
E-mail : [email protected] LUCKNOW - 226011

No.TI/PSI/PROJECT/CLS/01 Dated 04.01.2002

The Chief Electrical Engineer

i) Central Railway, Mumbai CST-400 001.

ii) Western Railway, Churchgate, Mumbai-400 020.
iii) Eastern Railway, Fairlie Place, Kolkata-700 001.
iv) South Eastern Railway, Garden Reach, Kolkata-700 043.
v) Northern Railway, Baroda House, New Delhi-110 001.
vi) Southern Railway, Park Town, Chennai-600 003.
vii) South Central Railway, Rail Nilayam, Secunderabad-500 371.
viii) CORE, Nawab Yusuf Road, Civil Lines, Allahabad-211 001.

Sub: The cable sizes between Auxiliary Transformer and Distribution Panel.

The existing cable between auxiliary transformer and distribution panel is of 2x25 Sq.mm
Aluminium cable for 5 KVA and 10KVA auxiliary transformers. The problem of excessive voltage
drop and failure of fuse / tripping of MCB in distribution panel especially during low OHE voltage
have been reported by the Signal Directorate. The cable size has been accordingly reviewed
considering the voltage drop as well as energy loss in the cable.
Presently, 10KV ATs are being provided at the end of platforms at the stations for
signalling loads. 5KVA ATs are being provided at IBH stations and level crossing gates. The
signalling load for ¾ line station in double line section on 10KV AT is about 8.5KVA. The
signalling load at IBH and level crossing gate is about 2.0KVA. 50KVA ATs are presently planned
for Mumbai area under DC-AC conversion where the requirement of load is higher. The
estimated max. signalling load on 50KVA AT is about 40KVA. These 50KVA ATs may be used in
future in other areas depending on the requirement of load.
Due to provision of voltage stabilizer, the signalling load is normally of constant VA type
i.e. if the voltage decreases the current will increase correspondingly. The input voltage range of
the voltage stabilizer is 160-270V. Considering this the optimum cable sizes for different types of
ATs are worked out and are given as follows:

AT type Cable sizes

5KVA 2 x 25 Sq.mm Aluminium
10KVA 2 x 70 Sq.mm Aluminium
50KVA 2 x 300 Sq.mm Aluminium

The above cable sizes of 1100V, PVC insulated, PVC sheathed, Al-conductor, Armoured
Power cable as per IS: 1554-Part-I are to be provided for the respective type of ATs. The cable
lugs and connectors are to be suitably provided. The taps of ATs should be judiciously kept so
that the available voltage is maintained in the range of 160-270 V, which is the input voltage
range of signalling voltage stabilizer.
(B.P.Singh)
for Director General/TI

11
 Format No. SIG 0101, Ver. 1 Pre-Commissioning Checklist for SMPS Based IPS RDSO/SPN/165/2004

Annexure-III

Suggested Format of field MTBF to be submitted by Zonal Railways

Make Total working hours Total number of failures MTBF

IPS SMR** Inv.** DC-DC IPS* SMR Inv DC-DC IPS SMR Inv. DC-
Conv** Conv DC
Conv
AMR
BSMC
HBL
Statco
n

*IPS failures shall be those failures which have affected the final performance of signalling
system i.e failures affecting signals, complete shut down, failure of complete function.

** Total working hours of SMR = ∑ number of SMR provided x working hours of IPS system

Total working hours of Inverter = ∑ number of Inverters provided x working hours of IPS
system

Total working hours of DC-DC Conv = ∑ number of DC-DC Conv. Provided x working
hours of IPS system

Total working hours

MTBF = Number of failures of sub system

Format of field MTTR to be submitted by Zonal Railways

Total duration of
Make Total number of failures MTTR (hours)
failures (hours)

AMR
BSMC
HBL
Statcon

12
 IPS for PI Station in RE Area with SMPS Charger
SDO/IPS/SMPS/PI/RE/002
Customer : Jasumall & Company, Kolkata
Spec Ref : RDSO/SPN/165/2004 with Amd-4
P.O No : JC/ECR/DNR/L.C.Gate/005, Dated 16/11/2005
ARP DWG NO : 0648-05
Qty : 6 Nos Sale Order No: PKOLS/000066/05-06
Rev. No. : 0
Station :
Dated : 30/11/2005

Step down Transformer

230/110V, 500VA 1
AVR
Signal (Up)
1.5KVA
230/110V, 500VA 2
110V , 20A X 4 Nos
SMR Inverter
230/110V, 500VA 1
AC Input SMR 1.5 KVA
110VDC Signal (Dn)
SMR 1.5 KVA
230VAC 230V AC 230/110V, 500VA 2
SMR Cold Standby

Cold Standby
AVR 230/110V, 500VA Track Ckt ( Up )

1.0 KVA
230/110V, 500VA Track Ckt ( Dn )

Step down Transformer

110V.200 AH
VRLA Battery Bank ASM Ind Panel

DC-DC Converters
24-32V, 5.0A Qty: 4 Nos
12-40V, 1.0A Qty: 2 Nos

Relay Int Block Line ( Up )

Cold Standby

24-32V, 5.0A Qty: 2 Nos 12-40V, 1.0A Qty: 2 Nos

Relay Ext Block Line ( Dn )

24-32V, 5.0A Qty: 2 Nos 3-6V, 0.1A Qty: 2 Nos

Axle
Counter Block Tele (Up)

12-28V, 5.0A Qty: 2 Nos 3-6V, 0.1A Qty: 2 Nos

Panel Indication Block Tele (Dn)

12-28V, 5.0A Qty: 2 Nos 2-12V, 5.0A Qty: 2 Nos

Block Local Spare cell

24-32V, 5.0A Qty: 2 Nos

12-28V, 1.0A Qty: 2 Nos
HKT & Magneto Data Logger

24-32V, 5.0A Qty: 4 Nos

SSI

Fuse, 20A Point operation

Prpd KISHORE

Chkd AMARA RAJA

POWER SYSTEMS (PVT) LTD.
Appd
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No : ENG-SFS-08/REV 0
Sale Order No PKOLS/000066/05-06 Line No 1 Configuration No 1 Customer Name Jasumall & Company Rev No 1.00
Item Code IPSM-165-REA-B Variant Code A057 Description IPS-SMPS-RDSO-165:SM5,1N2,CV2,TR6,DC27 Jobno 05-0648 Qty 6 UOM NOS
Sl.No Rev Circuit Designation Input Item Code Description Variant Variant Description Qty / System UOM Sub Remarks
1 1 ACDP IPS-ACD-001-B IPS-AC Distribution Panel B278 1.5KI2A1,1KA1,0.5KX6 1.000 NOS yes
2 1 ASM Panel IPS-ASM-000-B IPS-ASM PANEL for 2004 RDSO Spec A010 ARPSL 1.000 NOS yes
3 1 DCDP IPS-DCD-027-B DCDP-27 DC-DC CONVERTERS B514 DCDP-27 DC-DC CONV 1.000 NOS yes
4 1 I & C Cables IPS-ICD-003-A 3 CAB INTERCONNECT CABLE DETAILS A010 SMPS+DCDP+ACDP 1.000 NOS yes
5 1 LPD & SPD Box IPS-LPD-000-B IPS-LPD&SPD Module for 2004 RDSO spec A010 ARPSL 1.000 NOS yes
6 1 SMPS Panel IPS-SMR-005-B IPS-5 SMR MODULE SMPS PANEL B014 4Mod+1Cld 1.000 NOS yes
7 1 Spares IPS-SPA-001-B IPS SPARES A010 ARPSL 1.000 NOS yes

BOM Status Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:50:10 Prepared By Checked By Approved By Page No 1 Of 1
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-ACD-001-B Variant B278 Description IPS-AC Distribution Panel-1.5KI2A1,1KA1,0.5KX6 Qty 1 UOM NOS Rev 4
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 0 1.0KVA CVT MOD IPS-CVT-010-B IPS-1.0 KVA CVT Regulator Module A010 ARPSL 1.000 NOS yes
2 0 1.5KVA CVT MOD IPS-CVT-015-B IPS-1.5 KVA CVT Regulator Module A010 ARPSL 1.000 NOS yes
3 0 500VA SDT IPS-SDT-005-B IPS-500VA STEP DOWN XFR Module A010 ARPSL 6.000 NOS yes
4 2 C1 40403116221V Capacitor-Electrolytic-220mfd-160V-85deg I018 INCAP-IH2C22124TJ 1.000 NOS
5 2 CON 1 47940125010 Contactor-10A-110VDC coil-4c/o L001 L&TMM00-SS92824-1OOO 1.000 NOS
6 0 CT 1 (2 Turns) 47622031050 Current Transformer-Round Type-50/5A K006 Kappa 1.000 NOS
7 0 DL 1 42500000231V DOORLAMP-15W-230V AC W011 WIPRO 1.000 NOS
8 0 DL 1 (Holder) 42500000236V BULB HOLDER A008 Anchor 1.000 NOS
9 0 FAN 1-2 44500000014 Fan-240VAC-20W-120x120x38mm S048 Sunon-DP201A 2123HST 2.000 NOS
10 0 FU 1 47504320100V Glass Fuse-fast-1A-250VAC-32MM P011 PROTECTRON 1.000 NOS
11 0 FUB 1 47512000026V Fuse holder-glass-10A E014 ELCOM-PFH-51 1.000 NOS
12 0 Inverter 1.5KVA AEINCM00015 Inverter Control Mod Panel-1.5-2.0KVA A041 AREPL 3.000 NOS yes
13 0 L1 43200002757 Common mode choke A010 ARP-AT-2757 1.000 NOS yes
14 0 LED 1 40477112001V LED-RED-ROUND-5mm S009 Sanken-C4-R13 1.000 NOS
15 0 LED HOLDER 42500000378V Led Holder-5mm-P8032-15-16 P011 PROTECTRON 1.000 NOS
16 3 M1 47620831050 AC voltmeter-0-500V- ± 0.3%- ± 2digit N014 NIPPEN 1.000 NOS
17 3 M2 47620231002 AC ammeter-0-25A/5A- ± 0.5%- ± 2digit N014 NIPPEN 1.000 NOS
18 0 MOV 1-12 40413322000V MOV-320V-20mm E006 ELPRO-320/20 12.000 NOS
19 0 MS Parts 49031990105 IPS-ACDP Main encl-RDSO spec 2004 std H025 1.5KI2,AVR2,1.5KSDT6 1.000 NOS yes
20 0 P 1 (INV - 2 Nos) 41100000246 Conn-Female with cage clamp-4W W005 Wago-231-104/026-000 2.000 NOS
21 0 P 1 (SDT-6 Nos) 41100000310 Connector-molex-4W-F-13.5A-50-84-1040 M014 50-84-1040 6.000 NOS
22 4 P 1 (T 1 - 3 ) 41100000245 Conn-Female with cage clamp-6W W005 Wago-231-106/026-000 3.000 NOS
23 0 P 2 (INV - 2 Nos) 41100000305 Conn wago Cage+fixing-F-3W W005 Wago-231-103/026-000 2.000 NOS
24 0 P 2 (SDT-6Nos) 41100000308 Connector-molex-3W-F-13.5A-50-84-1030 M014 50-84-1030 6.000 NOS
25 0 P 3 (CVT-2 Nos & 41100000316 CONNECTOR-MOLEX-2W- M014 MOLEX-50-84-1020 8.000 NOS
BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G
Report Run Date & Time 30/12/2005 14:51:18 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 3
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-ACD-001-B Variant B278 Description IPS-AC Distribution Panel-1.5KI2A1,1KA1,0.5KX6 Qty 1 UOM NOS Rev 4
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks
SDT-6Nos) F-13.5A-50-84-1020
26 0 P 3 (INV - 2 Nos) 41100000111V Connector-molex-dil-ST-F-4W M014 39-01-2040 2.000 NOS
27 0 P1 (CVT - 2nos) 41100000244 Conn-Female with cage clamp-5W W005 Wago-231-105/026-000 2.000 NOS
28 0 P2 (CVT-2Nos) 41100000247 Conn-Female with cage clamp-2W W005 Wago-231-102/026-000 2.000 NOS
29 0 PB 1 47311000200V PB-door lamp-NC-(Refrig switch) A008 Anchor 1.000 NOS
30 2 PC 1-2 ARE02021006 Delay generating Bd-IPS A041 AREPL-P02021006 2.000 NOS yes
31 2 R1 40483350242V Resistor-24R-5W-5%-wire wound D004 D004 1.000 NOS
32 2 R2 40483370153V Resistor-150R-10W-5%-wire wound STD STD Vendor 1.000 NOS
33 0 RL 1-2 40474323400V Relay-110VDC-3C/O-PC solde-110D-pcb-3c/o P008 3C/O PCB 110 D 2.000 NOS
34 0 RL 3 40474323200V Relay-24VDC-3C/O-PC solder-big P008 PLA-3 C/O PCB 24 D 1.000 NOS
35 2 RL 4 - 5 40474622333 Relay-33A-24V DC- 3C/O- Panel mount O001 OEN-33D-24-330 2.000 NOS
36 0 SW 1 40070234203 Rotary switch-16A-3P-4W-ACDC S003 SG121C-B03-61090 1.000 NOS
37 4 T 1-3 43200002813 Inverter mainTransformer-1.5KVA A010 ARP-AT-2813 3.000 NOS yes
38 0 TB (INT) 41003006010V Terminal strip-PCB-barier-2row-10A-6W E005 ELECT-TB-130-6W 2.000 NOS
39 0 TB 1-2 41005002060V Terminal block-power-60A-2W E008 Essen-TPB-60/2 2.000 NOS
40 0 TB 11 41003010010V Terminal strip-PCB-barier-2row-10A-10W E005 ELECT-TB130-10W 1.000 NOS
41 0 TB 12 41003005010V Terminal strip-PCB-barier-2row-10A-5W E005 ELECT-TB-130-5W 1.000 NOS
42 0 TB 13-14 41003002010V TS-PCB-2row-10A-2W With Mounting hole E005 ELECT-TB-130-2W 2.000 NOS
43 0 TB 3-10 41005002030V Terminal block-power-30A-2W E008 Essen-TPB-30/2 8.000 NOS
44 0 Terminals (CVT/SDT) 41100000315 Power Connector-Female -terminal-42024 M014 MOLEX-.02-08-1002 58.000 NOS
45 0 Terminals (P 3 - Inv) 41100000126V Connector-power-crimp terminal-F-5556 M014 Molex-5556 4.000 NOS
46 0 TP 1 (Cable-Red) 44110010015V Cable-PVC-1C-multi strand-1.5sqmm-red C001 CAPI 2.000 MTRS
47 0 TP 1 (Socket-Red) 41010101000V Test socket-pm-bs5-red E014 ELCOM 1.000 NOS
48 0 TP 1(Plugs-Red) 41015100000V Banana plug-4mm-red-ME9 E014 ELCOM 2.000 NOS
49 0 TP 2 (Cable-Black) 44110040015V Cable-PVC-1C-multi strand-1.5sqmm-black C001 CAPI 2.000 MTRS

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:51:21 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 2 Of 3
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-ACD-001-B Variant B278 Description IPS-AC Distribution Panel-1.5KI2A1,1KA1,0.5KX6 Qty 1 UOM NOS Rev 4
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

50 0 TP 2 (Plugs-Black) 41015400000V Banana plug-4mm-black-ME9 E014 ELCOM 2.000 NOS

51 2 TP 2 (Sockets-Black) 41010401000V Test socket-pm-bs5-black E014 ELCOM 1.000 NOS

Use components of other vendors which are mentioned in Annexure approved from RDSO other than specified in BOM.

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:51:22 Prepared By Checked By Approved By BOM Ref Doc No
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Page No 3 Of 3
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-SDT-005-B Variant A010 Description IPS-500VA STEP DOWN XFR Module-ARPSL Qty 1 UOM NOS Rev 8
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 8 CB 1 40071109100 MCB-10A-1P-AC S049 Schneider-1C10-10KA 1.000 NOS

2 7 MS PARTS 49031990100 Step Dn Xfr Fixing Bracket (0.5-1.5KVA) H025 Torroid type 1.000 NOS yes
3 0 P1 41100000311 Connector-molex-4W-M-13.5A-50-84-2040 M014 50-84-2040 1.000 NOS
4 0 P2 41100000309 Connector-molex-3W-M-13.5A-50-84-2030 M014 50-84-2030 1.000 NOS
5 0 P3 41100000317 CONNECTOR-MOLEX-2W- M014 MOLEX-50-84-2020 1.000 NOS
M-13.5A-50-84-2020
6 7 PC 1 ARE12010212 PCB-12VDC Relay with 230V/110VAC Supply A041 AREPL-P12010212 1.000 NOS yes
7 6 SW 1 40070211103 Rotary switch-16A-1P-ON/OFF-ACDC S003 Sal-SG121C-B03-61191 1.000 NOS
8 7 T1 43199000040 500VA Step down Xfr-Toroidal type B048 Benaka Elect 1.000 NOS
9 7 TB 1 41003004020V Terminal strip-PCB-barier-20A-4W E008 ESSEN-20A/4W 1.000 NOS
10 7 Terminals (P1-3) 41100000314 Power Connector-Male terminal-42023 M014 MOLEX-.02-08-2004 7.000 NOS
11 0 TP 1 41010101000V Test socket-pm-bs5-red E014 ELCOM 1.000 NOS
12 7 TP 2 41010401000V Test socket-pm-bs5-black E014 ELCOM 1.000 NOS

Use components of other vendors which are mentioned in Annexure approved from RDSO other than specified in BOM.

BOM Status : Authorized KISHORE KUMAR.T.N KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:52:08 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 1
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-CVT-010-B Variant A010 Description IPS-1.0 KVA CVT Regulator Module-ARPSL Qty 1 UOM NOS Rev 7
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 0 C1 40731000100V capacitor-polyster-1mfd-1000V E013 1µF/±20%1000VDC/KT12 1.000 NOS

2 6 C2 40740600360V Capacitor-AC oil-36mfd-600V D010 Dhandapani 1.000 NOS
3 6 C2 40740600480V Capacitor-AC Oil-48mfd-600VAC-Bolted Typ D010 Dhandapani 1.000 NOS
4 4 Capacitor Mounting 44799000051 2 capacitor mount block-55mm W003 westren india electr 2.000 NOS
Blocks
5 5 FU 1 47503074032 HRC fuse-slow-32A-415VAC-clip on G001 GEC-NS32 1.000 NOS
6 5 FUB 1 47512000016V Fuse base-32A-415/500V AC G001 GEC-NSH32 1.000 NOS
7 5 MS PART 49030990128 FUSE BASE FIXING CLAMP(NS 32, IPS) H025 HEPL 1.000 NOS yes
8 7 MS PARTS 49031990119 CVT fixing bracket(0.5-2.0KVA)-vertical M075 MPPL1 1.000 NOS yes
9 5 P1 41100000048V Connr-wago-cage +fixing-M-5W-231-605/019 W005 Wago-231-605/0 1.000 NOS
10 5 P2 41100000046V Connector-wago-cage with fixing-M-2W W005 Wago-231-602/019-000 1.000 NOS
11 0 P3 41100000317 CONNECTOR-MOLEX-2W- M014 MOLEX-50-84-2020 1.000 NOS
M-13.5A-50-84-2020
12 5 P 3 (Terminals) 41100000315 Power Connector-Female -terminal-42024 M014 MOLEX-.02-08-1002 2.000 NOS
13 5 PC1 ARE12010212 PCB-12VDC Relay with 230V/110VAC Supply A041 AREPL-P12010212 1.000 NOS yes
14 0 SW 1 40070211103 Rotary switch-16A-1P-ON/OFF-ACDC S003 Sal-SG121C-B03-61191 1.000 NOS
15 2 T1 43200003491 1KVA Regulator CVT A010 ARP-AT-3491 1.000 NOS yes
16 0 TP1 41010101000V Test socket-pm-bs5-red E014 ELCOM 1.000 NOS
17 5 TP2 41010401000V Test socket-pm-bs5-black E014 ELCOM 1.000 NOS

Use components of other vendors which are mentioned in Annexure approved from RDSO other than specified in BOM

BOM Status : Authorized KISHORE KUMAR.T.N KRISHNAMURTHY NAIDU.G KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:53:32 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 1
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-CVT-015-B Variant A010 Description IPS-1.5 KVA CVT Regulator Module-ARPSL Qty 1 UOM NOS Rev 6
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 0 C1 40731000100V capacitor-polyster-1mfd-1000V E013 1µF/±20%1000VDC/KT12 1.000 NOS

2 5 C2 40740600360V Capacitor-AC oil-36mfd-600V D010 Dhandapani 2.000 NOS
3 5 C2 40740600480V Capacitor-AC Oil-48mfd-600VAC-Bolted Typ D010 Dhandapani 1.000 NOS
4 3 Capacitor Mounting 44799000051 2 capacitor mount block-55mm W003 westren india electr 2.000 NOS
Blocks
5 4 FU 1 47503074032 HRC fuse-slow-32A-415VAC-clip on G001 GEC-NS32 1.000 NOS
6 4 FUB 1 47512000016V Fuse base-32A-415/500V AC G001 GEC-NSH32 1.000 NOS
7 4 MS PART 49030990128 FUSE BASE FIXING CLAMP(NS 32, IPS) H025 HEPL 1.000 NOS yes
8 6 MS PARTS 49031990119 CVT fixing bracket(0.5-2.0KVA)-vertical M075 MPPL1 1.000 NOS yes
9 4 P 3 (Terminals) 41100000314 Power Connector-Male terminal-42023 M014 MOLEX-.02-08-2004 2.000 NOS
10 4 P1 41100000048V Connr-wago-cage +fixing-M-5W-231-605/019 W005 Wago-231-605/0 1.000 NOS
11 4 P2 41100000046V Connector-wago-cage with fixing-M-2W W005 Wago-231-602/019-000 1.000 NOS
12 0 P3 41100000317 CONNECTOR-MOLEX-2W- M014 MOLEX-50-84-2020 1.000 NOS
M-13.5A-50-84-2020
13 4 PC 1 ARE12010212 PCB-12VDC Relay with 230V/110VAC Supply A041 AREPL-P12010212 1.000 NOS yes
14 0 SW 1 40070211103 Rotary switch-16A-1P-ON/OFF-ACDC S003 Sal-SG121C-B03-61191 1.000 NOS
15 2 T1 43200003482 1.5KVA Regulator CVT A010 ARP-AT-3482 1.000 NOS yes
16 0 TP 1 41010101000V Test socket-pm-bs5-red E014 ELCOM 1.000 NOS
17 4 TP 2 41010401000V Test socket-pm-bs5-black E014 ELCOM 1.000 NOS

Use components of other vendors which are mentioned in Annexure approved from RDSO other than specified in BOM.

BOM Status : Authorized KISHORE KUMAR.T.N KRISHNAMURTHY NAIDU.G KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:54:28 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 1
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-ASM-000-B Variant A010 Description IPS-ASM PANEL for 2004 RDSO Spec-ARPSL Qty 1 UOM NOS Rev 2
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 0 C1 40403116221V Capacitor-Electrolytic-220mfd-160V-85deg K002 K002 1.000 NOS

2 0 D1 40462101003V Diode-GP-1A-1000V-SOD-81-1N4007 P007 1N4007 1.000 NOS
3 0 LED 1 40477112003V LED-GREEN-ROUND-5mm S009 Sanken-C4R21 1.000 NOS
4 0 LED Holder 42500000378V Led Holder-5mm-P8032-15-16 P011 PROTECTRON 1.000 NOS
5 0 MS Parts 49031990102 Cab-ASM Panel with Converters H025 Mangal 1.000 NOS yes
6 1 PC 1 ARE12001017 PCB-ASM PANEL A041 AREPL-P12001017 1.000 NOS yes
7 2 PC 2 - 5 ARE12001196 PMB-03-06/0.1A DC-DC A041 AREPL-P12001196 4.000 NOS yes
CONV WITH TINY Sw
8 0 R1 40483371003V Resistor-10K-10W-5%-wire wound P005 PEC-PIA-10K-10W-5% 1.000 NOS
9 0 TB 1 41003008010V TS-PCB-2row-10A-8W With Mounting Hole E005 ELECT-TB-130-8W 1.000 NOS
10 0 TB 2 41003006010V Terminal strip-PCB-barier-2row-10A-6W E005 ELECT-TB-130-6W 1.000 NOS
11 0 TB 3-5 41003002010V TS-PCB-2row-10A-2W With Mounting hole E005 ELECT-TB-130-2W 3.000 NOS

Use components of other vendor which are mentioned in Annexure approved from RDSO other than specified in BOM

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P NARAYANA REDDY.P

Report Run Date & Time 30/12/2005 14:55:22 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 1
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-DCD-027-B Variant B514 Description DCDP-27 DC-DC CONVERTERS-DCDP-27 DC-DC C Qty 1 UOM NOS Rev 1
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 1 CONV 11-15/21-24/ DC024032050 24-32V/5A DC-DC CONVERTER A041 AREPL 15.000 NOS yes
45-46/51-54
2 1 CONV 25-26/31-32 DC012028050 12-28V/5A DC-DC CONVERTER A041 AREPL 4.000 NOS yes
3 1 CONV 33-34 DC012028010 12-28V/1A DC-DC CONVERTER A041 AREPL 2.000 NOS yes
4 1 CONV 35-36/41-42 DC012040010 12-40V/1A DC-DC CONVERTER A041 AREPL 4.000 NOS yes
5 1 CONV 43-44 DC002012050 02-12V/5A DC-DC CONVERTER A041 AREPL 2.000 NOS yes
6 1 D1 40462101003V Diode-GP-1A-1000V-SOD-81-1N4007 P007 1N4007 1.000 NOS
7 1 DL 1 42500000231V DOORLAMP-15W-230V AC W011 WIPRO 1.000 NOS
8 1 DL 1(Holder) 42500000236V BULB HOLDER A008 Anchor 1.000 NOS
9 1 FAN 1-2 44500000014 Fan-240VAC-20W-120x120x38mm S048 Sunon-DP201A 2123HST 2.000 NOS
10 1 FU 1 47504320100V Glass Fuse-fast-1A-250VAC-32MM P011 PROTECTRON 1.000 NOS
11 1 FUB 1 47512000026V Fuse holder-glass-10A E014 ELCOM-PFH-51 1.000 NOS
12 1 LED 1 40477112001V LED-RED-ROUND-5mm S009 Sanken-C4-R13 1.000 NOS
13 1 LED HOLDER 42500000378V Led Holder-5mm-P8032-15-16 P011 PROTECTRON 1.000 NOS
14 1 M1 47620931020 DC voltmeter-0-200V- ± 0.1%- ±1digit N014 NIPPEN 1.000 NOS
15 1 MS Parts 49031990104 IPS-DCDP Main encl-RDSO spec 2004 H025 Mangal 1.000 NOS yes
16 1 P1 41100000308 Connector-molex-3W-F-13.5A-50-84-1030 M014 50-84-1030 26.000 NOS
17 1 P2 41100000316 CONNECTOR-MOLEX-2W- M014 MOLEX-50-84-1020 26.000 NOS
F-13.5A-50-84-1020
18 1 P3 41100000058V Conn.-molex-sil-ST-F-2W-5557-39-01-2020 M014 MOLEX 26.000 NOS
19 1 PB 1 47311000200V PB-door lamp-NC-(Refrig switch) A008 Anchor 1.000 NOS
20 1 PC 1 ARE02002012 PCB-PLA-RL-130V DC-2C/O CONT A041 AREPL-P02002012 1.000 NOS yes
21 1 R1 40483371003V Resistor-10K-10W-5%-wire wound P005 PEC-PIA-10K-10W-5% 1.000 NOS
22 1 TB 1 41003003010V Terminal strip-PCB-barier-2row-10A-3W E005 ELECT-TB-130-3W 1.000 NOS
23 1 TB 2 41003005010V Terminal strip-PCB-barier-2row-10A-5W E005 ELECT-TB-130-5W 1.000 NOS

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:56:15 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 2
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-DCD-027-B Variant B514 Description DCDP-27 DC-DC CONVERTERS-DCDP-27 DC-DC C Qty 1 UOM NOS Rev 1
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

24 1 TB 3-4 41005002060V Terminal block-power-60A-2W E008 Essen-TPB-60/2 2.000 NOS

25 1 TB 5/7-9/11-13/ 41005002030V Terminal block-power-30A-2W E008 Essen-TPB-30/2 11.000 NOS
15-17/19
26 1 TB 6/10/14/18/20 41003010020 Terminal strip-PCB-barier-20A-10W E005 ELECT-TB135-10W 5.000 NOS
27 1 Terminals(P1-2) 41100000314 Power Connector-Male terminal-42023 M014 MOLEX-.02-08-2004 130.000 NOS
28 1 Terminals(P3) 41100000126V Connector-power-crimp terminal-F-5556 M014 Molex-5556 52.000 NOS
29 1 TP 1 (Banana 41015100000V Banana plug-4mm-red-ME9 E014 ELCOM 2.000 NOS
Plug-Red)
30 1 TP 1(Cable-Red) 44110010015V Cable-PVC-1C-multi strand-1.5sqmm-red C001 CAPI 2.000 MTRS
31 1 TP 1(Socket-Red) 41010101000V Test socket-pm-bs5-red E014 ELCOM 1.000 NOS
32 1 TP 2 (Socket-Black) 41010401000V Test socket-pm-bs5-black E014 ELCOM 1.000 NOS
33 1 TP 2(Banana 41015400000V Banana plug-4mm-black-ME9 E014 ELCOM 2.000 NOS
Plug-Black)
34 1 TP 2(Cable-Black) 44110040015V Cable-PVC-1C-multi strand-1.5sqmm-black C001 CAPI 2.000 MTRS

Use components of other vendors which are mentioned in Annexure approved from RDSO other than specified in BOM.

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:56:17 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 2 Of 2
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-ICD-003-A Variant A010 Description 3 CAB INTERCONNECT CABLE DETAILS-SMPS+D Qty 1 UOM NOS Rev 0
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 0 Cable 44110040005V Cable-PVC-1C-multi strand-0.5sqmm-black C001 CAPI 96.000 MTRS

2 0 Cable 44110040025V Cable-PVC-1C-multi strand-2.5sqmm-black C001 CAPI 16.000 MTRS
3 0 Cable 44110040040V Cable-PVC-1C-multi strand-4sqmm-black C001 CAPI 16.000 MTRS
4 0 Cable 44110040060V Cable-PVC-1C-multi strand-6sqmm-black C001 CAPI 16.000 MTRS
5 0 Cable 44110040100V Cable-PVC-1C-multi strand-10sqmm-black C001 CAPI 16.000 MTRS
6 0 Cable 44110040160V Cable-PVC-1C-multi strand-16sqmm-black C001 CAPI 16.000 MTRS
7 0 Cable 44122040005V Cable-PVC-6C-cu-rou.she.-UnAr.-0.5sqmm C001 CAPI 30.000 MTRS
8 0 Cable Ties 44701000000V Cable Tie-75mm N002 Novoflex 200.000 NOS
9 0 Cable Ties 44701000002V Cable Tie-150mm N002 NOVOFLEX 200.000 NOS
10 0 Cable Ties 44701000003V Cable Tie-200mm N002 NOVOFLEX 100.000 NOS
11 0 Lug 44310810160V LUG-round-copper-16sqmm-8mmHD C026 Chetana 5.000 NOS
12 0 Lug 44320310015V LUG-fork-copper-1.5sqmm-3mmW C026 Chetana 36.000 NOS
13 0 Lug 44320310025V LUG-fork-copper-2.5sqmm-3mmW C026 CHETANA 5.000 NOS
14 0 Lug 44320310046V LUG-fork-copper-4.6sqmm-3mmW C026 Chetana 5.000 NOS
15 0 Lug 44320310060 LUG-fork-copper-6sqmm-3mmW C026 Chetana 5.000 NOS
16 0 Lug 44320310100 LUG-fork-copper-10sqmm-3mmW C026 Chetana 5.000 NOS
17 0 Paper Sticker Sheet 42500000056V PAPER STICKERS COMP 25*10 S014 Shipra Pkgs(P) Ltd. 1.000 NOS

1.Other than CAPI vendor specified in BOM We can use LAPP ,FINOLEX ,DELTAN & ECKO Vendors for cables since these Vendors are approved by RDSO.
2.We can use any colour cable other than black colour mentioned in BOM only if the same is not available .

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:57:25 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 1
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-LPD-000-B Variant A010 Description IPS-LPD&SPD Module for 2004 RDSO spec-ARPSL Qty 1 UOM NOS Rev 0
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 0 FU 1 47503014063 HRC fuse-slow-63A-415V/550VAC-offset tag G001 GEC-TSS63 1.000 NOS

2 0 FUB 1 47512000013V Fuse base-63A-415/500 VAC G001 GEC-SM63H 1.000 NOS
3 0 LPD 1 40413990018 LPD-L-N-10/350Micr sec-50KA W/O Inductor O006 OBO-MCD 50-B 1.000 NOS
4 0 LPD 2 40413990019 LPD-N-E-10/350Micr sec-125KA W/O Induct O006 OBO-MCD 125-B/NPE 1.000 NOS
5 0 MS PARTS 49030990504 LPD/SPD MODULE H025 HEPL 1.000 NOS yes
6 0 SPD 1 40413990020 SPD-L-N-8/20Micr sec-40KA W/O Induct O006 OBO-V 20-C/1-FS-320 1.000 NOS
7 0 TB 1/2 41005002060V Terminal block-power-60A-2W E008 Essen-TPB-60/2 2.000 NOS
8 0 TB 3 41003003010V Terminal strip-PCB-barier-2row-10A-3W E005 ELECT-TB-130-3W 1.000 NOS

Use components of other vendors which are mentioned in Annexure from RDSO other than specified in BOM

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:58:20 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 1
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-SMR-005-B Variant B014 Description IPS-5 SMR MODULE SMPS PANEL-4Mod+1Cld Qty 1 UOM NOS Rev 3
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 0 10 Core Flat Cable COMS-6000-000 10 Core Flat cable with connector A010 ARP 3.000 NOS yes
2 0 ARCSU (G1141dh) MCSU-110-000-A CSU-110V A999 CSU for IPS 1.000 NOS yes
3 0 Batt. Temp. Sensor TEMP-6001-000 Temp.Sensor with 25mtr cable A010 ARP 1.000 NOS yes
4 0 C1 40401225105 Capacitor-Polyster-1mfd-250V-flat type U005 U3-250-105K 1.000 NOS
5 0 CON 1 47930245016 Contactor-16A-110VDC coil-3P-2NO+2NC A009 AY-PAK-18U01-110VDC 1.000 NOS
6 0 CON 1 BB BUSB-6002-000 Contactor Shorting link A010 ARP 1.000 NOS yes
7 0 CONN 1-4 41100000318 Connector-molex-6W-F-11A-50-84-1060 M014 MOLEX-50-84-1060 4.000 NOS
8 0 CONN 13-14 41100000246 Conn-Female with cage clamp-4W W005 Wago-231-104/026-000 2.000 NOS
9 0 CONN 15-16 41100000247 Conn-Female with cage clamp-2W W005 Wago-231-102/026-000 2.000 NOS
10 0 CONN 5-8 41100000310 Connector-molex-4W-F-13.5A-50-84-1040 M014 50-84-1040 4.000 NOS
11 0 CONN 9-12 41100000058V Conn.-molex-sil-ST-F-2W-5557-39-01-2020 M014 MOLEX 4.000 NOS
12 0 CSU - MUIB Cable COMS-6003-000 34 Core Flat cable with connector A010 ARP 1.000 NOS yes
13 0 CSU - SMR Add Bd 50100000009 Comms Cable Addres PCB to CSU A010 ARP 1.000 NOS yes
14 0 CT 1-2 47612190001V Hall effect current sensor-100A/4V K023 KEC 2.000 NOS
15 0 CT COMM CABLE 42500000172V CT Communication Cable M014 M014 2.000 NOS
16 0 DL 1 42500000231V DOORLAMP-15W-230V AC W011 WIPRO 1.000 NOS
17 0 DL 1(HOLDER) 42500000236V BULB HOLDER A008 Anchor 1.000 NOS
18 0 FU 1 47503014050 HRC fuse-slow-50A-415/550V AC-offset tag G001 GEC-TSS50 1.000 NOS
19 0 FU 2 47503074020 HRC fuse-slow-20A-415VAC-clip on G001 GEC-NS20 1.000 NOS
20 0 FUB 1 47512000013V Fuse base-63A-415/500 VAC G001 GEC-SM63H 1.000 NOS
21 0 FUB 2 47512000016V Fuse base-32A-415/500V AC G001 GEC-NSH32 1.000 NOS
22 0 FUSE TRIPS 47599990000V Fuse Trip indicator G001 GEC-TI300 1.000 NOS
23 0 L1 43200003486 AC input common mode choke for IPS A010 ARP-AT-3486 1.000 NOS yes
24 0 LED 1 40477112004V LED-AMBER-ROUND-5mm S009 SANKEN 1.000 NOS
25 0 LED 2-3 40477112001V LED-RED-ROUND-5mm S009 Sanken-C4-R13 2.000 NOS
BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G
Report Run Date & Time 30/12/2005 14:59:40 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 2
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-SMR-005-B Variant B014 Description IPS-5 SMR MODULE SMPS PANEL-4Mod+1Cld Qty 1 UOM NOS Rev 3
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

26 0 LED HOLDERS 42500000378V Led Holder-5mm-P8032-15-16 P011 PROTECTRON 3.000 NOS

27 0 MOV 1-3 40413322000V MOV-320V-20mm E006 ELPRO-320/20 3.000 NOS
28 0 MS PARTS 49031990103 IPS-SMR Main encl-RDSO spec 2004 H025 Mangal 1.000 NOS yes
29 0 PB 1 47311000200V PB-door lamp-NC-(Refrig switch) A008 Anchor 1.000 NOS
30 2 PC 1 ARE12003051 PCB-SMR Address card for IPS A041 AREPL-P12003051 1.000 NOS yes
31 2 PC 2 ARE12001069 PCB-MMIB3 (IPS)-Input current limiting A041 AREPL-P12001069 1.000 NOS yes
32 0 PC 3 ARE12002207 PCB-110V MUIB1 with N/C logic A041 AREPL-P12002207 1.000 NOS yes
33 2 PC 4 ARE12000093 PCB-Potential free contacts bd. A041 AREPL-P12000093 1.000 NOS yes
34 2 PC 5 ARE12000101 PCB-PFC interface bd. A041 AREPL-P12000101 1.000 NOS yes
35 2 PC 6 ARE02008303 PCB-FUSE TRIP-SPSS A041 AREPL-P02008303 1.000 NOS yes
36 0 PC 7-10 ARE12000004 PCB-MOV-Class D Protection Bd-1ph A041 AREPL-P12000004 4.000 NOS yes
37 0 RL 1 40474323400V Relay-110VDC-3C/O-PC solde-110D-pcb-3c/o P008 3C/O PCB 110 D 1.000 NOS
38 0 SC 1 42500000245V SOCKET-3PIN-5A A008 Anchor 1.000 NOS
39 3 SCR UV/OV MOD SCR-MOD-270-090SCR BASED OV/UV PROTECTION MODULE A041 AREPL 1.000 NOS yes
40 0 SMR 1-5 AR6110020HM 110V/20A with 2 Switch forward converter A041 AREPL 5.000 NOS yes
41 0 SMR Comm Cables 50100000007 Comms Cable Addres PCB to SMR-AR4-48/25A A010 ARP 4.000 NOS yes
42 0 TB 1-2/5-6 41005002060V Terminal block-power-60A-2W E008 Essen-TPB-60/2 4.000 NOS
43 0 TB 11-14 41005003030V Terminal block-power-30A-3W E008 ESSEN 4.000 NOS
44 0 TB 3 41003003010V Terminal strip-PCB-barier-2row-10A-3W E005 ELECT-TB-130-3W 1.000 NOS
45 0 TB 4 41005003060V Terminal block-power-60A-3W E008 Eessen-TPB-60/3 1.000 NOS
46 0 TB 7 41005002030V Terminal block-power-30A-2W E008 Essen-TPB-30/2 1.000 NOS
47 0 TB 8-10 41003002010V TS-PCB-2row-10A-2W With Mounting hole E005 ELECT-TB-130-2W 3.000 NOS
48 0 Terminals (CON1-8) 41100000315 Power Connector-Female -terminal-42024 M014 MOLEX-.02-08-1002 36.000 NOS
49 0 Terminals(CON9-12) 41100000126V Connector-power-crimp terminal-F-5556 M014 Molex-5556 8.000 NOS

Use components of other vendors which are mentioned in Annexure approved from RDSO other than specified in BOM

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 14:59:42 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 2 Of 2
 POWER SYSTEMS Pvt. Ltd. Bill Of Material Report Doc Ref No: ENG-SFS-08/REV 0
Item Code IPS-SPA-001-B Variant A010 Description IPS SPARES-ARPSL Qty 1 UOM NOS Rev 2
S.No Rev Circuit Designation Item Code Description Variant Var Description Qty / System UOM SUB Remarks

1 1 Capacitor 40740600360V Capacitor-AC oil-36mfd-600V D010 Dhandapani 1.000 NOS

2 1 Capacitor 40740600480V Capacitor-AC Oil-48mfd-600VAC-Bolted Typ D010 Dhandapani 1.000 NOS
3 0 DC-DC Converter DC012040010 12-40V/1A DC-DC CONVERTER A041 AREPL 1.000 NOS yes
4 0 Fan 44500000008V Fan-24vdc-axial-80mm-8414.80-MOD-8314 S048 Sunon-KD2408PTB1-6 1.000 NOS
5 0 Fan 44500000014 Fan-240VAC-20W-120x120x38mm S048 Sunon-DP201A 2123HST 1.000 NOS
6 1 Fan (Exhaust) 44500000015 Fan-Exhaust-240vac-380mm-900rpm A057 Alstom- GRN38061 1.000 NOS
7 1 Fuse 47503014050 HRC fuse-slow-50A-415/550V AC-offset tag B017 Bussman-50T07 1.000 NOS
8 1 Fuse 47503014063 HRC fuse-slow-63A-415V/550VAC-offset tag B017 Bussmann-63K07 1.000 NOS
9 1 Fuse 47503074020 HRC fuse-slow-20A-415VAC-clip on B017 BUSSMAN-20F06 1.000 NOS
10 1 Fuse 47503074032 HRC fuse-slow-32A-415VAC-clip on B017 Bussman-NSD32 1.000 NOS
11 1 Fuse 47504320100V Glass Fuse-fast-1A-250VAC-32MM P011 PROTECTRON 1.000 NOS
12 0 Fuse (Trip Ind) 47599990000V Fuse Trip indicator G001 GEC-TI300 1.000 NOS
13 0 Tool Kit 44601000002 D.E Spanner 10-11 T010 Taparia 2.000 NOS
14 0 Tool Kit 44602000001 Screw driver set(6-blades)-821 spannerse T010 taparia-821 1.000 NOS
15 0 Tool Kit 44602000006 Screw driver No.902 T010 Taparia-902 1.000 NOS
16 0 Transformer 43199000040 500VA Step down Xfr-Toroidal type B048 Benaka Elect 1.000 NOS

BOM Status : Authorized KISHORE KUMAR.T.N NARAYANA REDDY.P KRISHNAMURTHY NAIDU.G

Report Run Date & Time 30/12/2005 15:00:31 Prepared By Checked By Approved By BOM Ref Doc No
Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,
Page No 1 Of 1
 1 2 3 4 5 6 7 8
ENG-SFS-06/Rev.0

BATTERY
TEMP. INTER CONNECTION DRAWING
SENSOR
BATTERY

37
2
AC INPUT SUPPLY From Gen. Set 72D

+
L

-
46A

TB4
(FROM AC DISTRIBUTION Supply
73D TX (UP) SIGNAL-1
N
D PANEL) D

37G
2G
74D
L

TB5
L N G 75D TX (UP) SIGNAL-2
N
X17

+
-
1A 1
1 76D
L

37
TB3

2
85A

TB6
3 85 77D TX (DN) SIGNAL-1
ACDP
I

I
I

TB6 16A N
4 16

PC5(CN.4)
TB11 L 78D
5 18A
TB1

TB7
18
79D TX (DN) SIGNAL-2
TB1 A34I 6 19A N
19
L 20A
7 20 80D
LPD BOX A30I L

TB8
8
N
81D TX (UP) Track
+
N
TB2 + 37A
37 34
TB3 TB9 TB14 L 82D
- 7A - TB2 TB13 TX (DN) Track
NC C NO 7 33

TB9
83D
N
L A3E L
3

22
3
TB1

8
5
TB2 A30E N
30 N - + L N
31B

30
32B

33B

SMPS PANEL
C C

22F
2F
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited.

5A
8A
POTENTIAL FREE CONTACTS

9A
9 - + L N
TB5

TB10 34 A34A L

22
10A 34

2
TB1

8
5
A30A N
30 30 TB2
25A TB3 TB1
1 PC5(CN.4-2nd PIN) 25
2
43A -
ASM PANEL

43 3
PC5 (CN.3)

+
42A
TB1

42 4
44A
44
45A
5
2G -
DCDP
45 6 2 2
71A TB5 22G TB4
TB3

TB4

71 +
7 22 22
72A
72 8
+

+
-

SUB RACK-1 SUB RACK-2 SUB RACK-3 SUB RACK-4

SUB RACK-5
TB7

PC5 (CN.6) PC5(CN.7)

B - + B
D
D

D
D

TB11

TB15
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

TB12

TB13

TB16

TB17
TB7
TB5

TB8

TB9

TB19
+

+
-

-
+

+
-

-
+

+
-

+
-

+
-
39E
2E
+

+
-

-
Block Tele (Dn)
Block Tele (Up)

3 - 6V/0.1A
3 - 6V/0.1A

D
D

D
D
D
D

D
D

D
D

D
D
D
D
F
F

D
D

D
D

F
F
MAINS FAIL P.F.C

DCDP FAULT P.F.C

SMR FAIL P.F.C

CALL S&T STAFF P.F.C

INVERTER-1 FAIL P.F.C

INVERTER-2 FAIL P.F.C

OPERATION

BATTERY LOW P.F.C

POINT

+
-

Block Line (DN) -

+

+
-

Block Line (UP) -

-
+

+
-

Relay External -

+
-

Panel Indication -

+
-
HKT & Magneto
INTERNAL

Data Logger
24-32V/15A

Axle Counter

Block Local

Spare Cell
24-32V/5A

12-40V/1A

24-32V/15A
24-32V/5A
12-40V/1A

2-12V/5A
12-28V/5A
Relay Int.

12-28V/5A

12-28V/1A
CABLE DETAILS

12-28V/1A

SSI
DESIG- CABLE SIZE
NATION IN Sq.mm

A 0.5
A D 2.5 A

A M A R A R AJ A
PROJECT ---------
:
E 4.0
CUST Indian Railways
:
F 6.0
10.0 POWER SYSTEMS LTD P.O.NO. : ------------
G
Registered Office & Works, DWG.NO : ICD - 0648 - 05
H 16.0
karakambadi - 517520
25.0 Ph(0877) 2285561 to 2285565. TITLE :
I INTERCONNECTION DRAWING
REV ECO REMARKS DATE APPD DRAWN CHKD RECHKD APPD.
FILE NAME C:\WINDOWS\Desktop\Intrcon-007-05.sch KISHORE DATE : 30/11/2005 SHEET 1 OF 1 REV. 0

1 2 3 4 5 6 7 8
Proprietary material of M/s AMARA RAJA POWER SYSTEMS LTD., Thirupathi. All rights reserved no copying permitted unauthorised prohibited ENG. SFS-06/Rev.0
1 2 3 4

12E
TB11
FILE NAME : D:\IPS Schematics\schematics\ACDP\Rev-2\ACDP-B278.sch

From INV - 1 O/P

RL3
RL1

1 2 3 4 5 6
RED (TB 1) 38A 32A
L 4A 43A 6

TO INVERTER
20A 3 (TB 2)

MODULE-1
13E 20A

RL4
RL3
CONN.7
H1 H2
PC 1
BLACK INV.FAULT -2 19A 19A 4

TO SMPS PANEL
RL1 3
14E 21A 21A TB14 (110V DC RELAY) N 5D (TB 1) 36A
(TB 2)
YELLOW
33A

SMPS PANEL
L L
15E INV FAULT -1 16A 16A

From INV - 2 O/P

X1 X2 - 10 2
RL1 6A RL1 39A 41A
BLUE

L (TB 1)

TO
P1
85A 85A 2A + 4
SYSTEM 34A 1 (TB 2)

RL2
T1 SHUTDOWN PC 1
1A 1A 2
12E ACDP FAULT N 5A 5
(TB 1) 5A
1 2 3 4 5 6

RED
TO INVERTER (TB 2)

20A
MODULE-2

16A
21A
19A
13E CONN.7
H1 H2 COMMON

From INV - 2 O/P

2A RL2
BLACK
51A 52A
14E
L 6A (TB 1)
6
1 2
LED1 3 (TB 2)

RL5
YELLOW

15E 22A PC 1 29A 1A

C1
PC 2
X1 X2 4 R1
TB 2 TB 2
N 5A 3
BLUE

P1 ACDP FAULT (TB 1)

P2 (TB 2) 44A 53A
RL 4
4D L 4D 50D
T2 L

3 2 1
K INV 1 5D N 4D YELLOW
K

INVERTER N
FROM TRANS- 17D 5D BLUE
FORMER MODULE-1 E
5D 5D
TB2 1.5KVA 50D
L1 P1 A1
+
+
-
- INVERTER

- P3 4D
MODULE-3

2DD 11D BLACK AUTO

FROM DCDP

CONN.7 - 16A A2
1.5KVA

1 2 3 4
1
INV 3

11D BLACK 21A

8D

PFC
2A - INV.1

4 3 2
22DD 1A
PFC + A3
6D 1

50D
2A

YELLOW
RED INV.2
+

BLUE
N
L

+
E

5D
18D

8D
RED A4
22DD
COLD STANDBY CVT

CONN.7
FROM T1
B1
22A

AUTO
2A

FROM CVT INPUT

YELLOW
B2
J T3 12E J
RL 4 RL 5 INV.1 3E
1 2 3 4 5 6

RED P2
INV 2 6D 6D SW1 B3
TO INVERTER

L 2 31E

3 2 1
INVERTER INV.2
MODULE-3

13E
P1
CONN.7

H1 H2 42D 50D
BLACK
11D MODULE-2 N 5D B4
17D
- E CVT

YELLOW
14E
1
1.5KVA

50D
11D
YELLOW

15E

18D
-
22A

3 2

X1 X2 C1
+ P3 AUTO
BLUE

FROM CVT OUTPUT

P1 19A CON.1 C2

1 2 3 4
+
4

R2 20A

18D
PFC
2A 22DD INV.1 7D
1A
C3
REV.

35A

RL3 2A INV.2 3 18D

1
2

CONN.7
FROM T2

BLUE
CON.1
C4

YELLOW
35A 25A 2A CVT
I I
ECO

TO SW 1
028
030

RL2 5D
BLUE

7D

18D

TO FRONT PANEL
31E
TB1 P1 5A
31D P2 CON.1
31E

L 3E CON.1 L
3E

18D
1

7D L 7D 48A

TB 12
31D L
AC INPUT

2 1

CVT 5D 5D 5D 47A
3 2

TO SW 1 N N
30D
N 1.5 KVA BLUE 8A
BLUE 30D
SIGNAL
5 4

N BLUE P3
E RL3 RL2
GREEN 17D 1A 47A
1 2

37A 40A

CT1
48A
DL1 PB1 2A

8D
H H
27A 3A

YELLOW
L YELLOW 8D L 8D
30A
TESTING COMMENTS

YELLOW
TESTING COMMENTS

N BLUE 5D N 5D
REMARKS

BLUE
TB10 P2
TB4
MOLEX CONN.
17D P1 72D YELL0W 72D
GREEN L
L
3 2 1

E 73D
3 4

73D

MOV.1

MOV.2
N BLUE
BLUE STEPDOWN
5D XFR
N N
1 2

8D P3
L 500VA
YELLOW 1A TX (UP) SIGNAL -1
1 2

G 2A G
5A

8A

P2
MOLEX CONN.
TB5
17D P1 74D YELL0W 74D
GREEN L L
3 2 1

E 75D BLUE 75D

3 4

MOV.3

MOV.4
N
STEPDOWN
5D
N XFR N
1 2

8D P3
L 500VA
YELLOW 1A
TX (UP) SIGNAL -2
1 2

2A

P2
TB6
P1 MOLEX CONN.
13/10/05

76D 76D
25/10/05

YELL0W
DATE

17D L
3 2 1

E 77D L
3 4

GREEN BLUE 77D

MOV.6
F

MOV.5
N F
STEPDOWN
5D XFR
N N
1 2

8D 500VA P3
APPD

L
YELLOW 1A
TX (DN) SIGNAL -1
2 1

2A

P2
MOLEX CONN.
TB7
P1 78D 78D
DRAWN

17D YELL0W
KISHORE

L
GREEN L
3 2 1

E 79D BLUE 79D

3 4

MOV.8

MOV.7

N
BLUE STEPDOWN
5D
N
XFR N
1 2

8D 500VA
Ph(0877) 2285561 to 2285565.
karakambadi - 517520
Registered Office & Works,
POWER SYSTEMS (PVT.) LTD
AMA R A RAJA

P3
L
1A
E YELLOW TX (DN) SIGNAL -2 E
2 1

2A
CHKD

YELLOW
P1 VM
3D L P2 L
RECHKD

9D IN LO TP1
3D L
2 1

IN HI
3 2

30D CVT N 10D M1 N

FROM ACDP FRAME DRAWING
5
8

N TP2
30D
1.0 KVA
TRACK TB12
5 4

BLUE
E P3 8 8 L
GREEN 17D 1A AM L
5 5 N INV./CVTO/P
1 2

N
APPD.

D D
8A
5A

2A 47 47
IN LO
48 48 TO CT1
IN HI
A1

TB3 M2
YELLOW L 9D YELLOW
EARTH EARTH
DWG. NO.
P.O. NO.
CUST
PROJECT :
TITLE
DATE

BLUE N 10D BLUE

FRONT PANEL

TB8
:

P2
MOLEX CONN.
:

80D
:
:

17D P1 80D 80D YELL0W

L L
13/09/2005

3 2 1

GREEN
E 81D 81D BLUE 81D
MOV.10
2 3 4

MOV.9
IPS-ACD-001-B

N
---------------

-----------

BLUE
INDIAN RAILWAYS

STEPDOWN
C 10D XFR N C
N
FRAME DRAWING FOR ACDB

9D P3
500VA
SCHEMATIC DRAWING OF

L
1

YELLOW 1A
TX (UP) TRACK
1 2

2A
5A

8A

P2 TB9
MOLEX CONN.
B278

17D P1 82D 82D YELL0W 82D

GREEN L L
3 2 1

E STEPDOWN 83D 83D BLUE 83D

MOV.11
MOV.12
4

N
BLUE XFR
2 3

INTERNAL 10D F2 N
500VA F1
CABLE DETAILS N
9D P3
SHEET

L FAN-2 FAN-1
DESIG- CABLE SIZE 1A
1

B YELLOW B
1 2

NATION IN Sq.mm
2A
L N L N TX (DN) TRACK
A 0.5
45A
45A

FU 1
5A

5A

D 2.5 8A
1 OF

5A
CABLE COLOUR

AC Line YELLOW
INVERTER/
1

AC Nue BLUE TB13 BYPASS CVT

DC +VE RED OUTPUT
A5A
A8A

DC -VE BLACK
EARTH GREEN
ACDP FRAME DRAWING
REV.

A A
CONTROL
GREY
CABLE TO DCDP
PANEL
(METERS)
0

1 2 3 4
 1 2 3 4 5 6 7 8
ENG-SFS-06/Rev.0

D YELLOW D
P1 CB1 P2
T1
FROM INV O/P
SW1
1D 4D 3D YELLOW
L 2 1 H1 X1 BLUE 6D
1 L
1
N BLACK 7D
2 N
3 2

FRAME DRAWING
TB 1 3

TO ACDP
17D RED X2 100V BLACK 6
4

H2 P3
X3 110V GREY 7D 8
1

BLUE
X4 120V YELLOW

1
GREEN 2
X5 130V ORANGE 9

GREEN
17D
RED
BLUE

7
C RED BLUE C

2D 2D 7D 7D
AC RELAY
TB2

8
9
6
BD.
TB1 N 7
2
1

6 6
5
PC1
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Tirupathi. All rights reserved. No copying permitted unauthorised use prohibited.

7 4 5
3 L 4
1 L
INTERNAL 2 3
2 NC 2
CABLE DETAILS

RL1
1 N
C 1
DESIG- CABLE SIZE
NATION IN Sq.mm

A 0.5

7
TP1 TP2
7

B D 2.5 B

CABLE COLOUR

AC Line YELLOW

AC Nue BLUE

EARTH GREEN

CONTROL
GREY STEP DOWN TRANSFORMER
CABLE
ACDP
NOTE: -
(1) ALL COLOUR CONTROL CABLES ARE 0.5Sq.mm - GREY
(2) ALL EARTH POINTS SHOULD BE INTERCONNECTED
AMA RA RAJA PROJECT : ---------
A CUST
:
INDIAN RAILWAYS A
POWER SYSTEMS LTD :
P.O. NO. ---------
Registered Office & Works
IPS-SDT-005-B (A010)
:
karakambadi - 517520 DWG. NO.
Ph(0877) 2285561 to 2285565. A3 SCHEMATIC DRAWING OF
TITLE
REV. ECO REMARKS DATE APPD. DRAWN CHKD. RECHKD. APPD. 0.5 KVA STEPDOWN TRANSFORMER
FILE NAME D:\IPS Schematics\schematics\SDT\FINAL 0.5 KVA SDT.sch KISHORE DATE : 25/07/05 SHEET 1 OF 1 REV 0
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
ENG-SFS-06/Rev.0

T1 P3
9

TO ACDP FRAME
H4 H5 4F 8

1
1F

DRAWING
D YELLOW H3 D
P1 YELLOW P2
SW1 FU 1 H1 H6
L 2DD 1F 6D
(150 - 275 VAC)

D 5F YELLOW L
2 1

2 1
6D
AC INPUT

D YELLOW C N
10F
N D

1
4 3

D X1A

BLUE
BLUE
C1 X1B

4F

6
C2
5

X1C
17D

X2

3
3DD X3 7D
BLUE BLUE
EARTH
3DD X4 7D
X5
C C
X6

11F

12F
Y1

GREEN Y3
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Tirupathi. All rights reserved. No copying permitted unauthorised use prohibited.

3
2

7
6

8
AC RELAY
BD. N 7
6
INTERNAL 5 6
CABLE DETAILS 7
4 PC1 5
2 4
DESIG- CABLE SIZE 3 L
NATION IN Sq.mm 2 L 3
B B
3 NC 2
N

RL1
1
D 2.5 TB1 C 1
TB2
F 6.0 17D
G
CHASIS
CABLE COLOUR GROUND TP1 TP2

AC Line YELLOW

AC Nue BLUE
BYPASS CVT REGULATOR
NOTE: - ACDP
(1). ALL COLOUR CONTROL CABLES ARE 0.5Sq.mm - GREY
AMA RA RAJA PROJECT : ------------

A (2). ALL EARTH POINTS SHOULD BE INTERCONNECTED CUST

:
INDIAN RAILWAYS A
POWER SYSTEMS LTD :
P.O. NO. ------------
Registered Office & Works
:
karakambadi - 517520 DWG. NO. IPS-CVT-010-B (A010)
Ph(0877) 2285561 to 2285565. A3 SCHEMATIC DRAWING OF
TITLE
REV. ECO REMARKS DATE APPD. DRAWN CHKD. RECHKD. APPD. 1.0 KVA BYPASS CVT REGULATOR
FILE NAME D:\IPS Schematics\schematics\CVT\FINAL 1 KVA CVT.sch KISHORE DATE : 25/07/05 SHEET 1 OF 1 REV 0
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8
ENG-SFS-06/Rev.0

T1 P3
9

TO ACDP FRAME
H4 H5 4F 8

1
1F

DRAWING
D YELLOW H3 D
P1 YELLOW
SW1 FU 1 P2
L 2DD 1F H1 H6 6D
(150 - 275 VAC)

D 5F YELLOW 6D L
2 1

2 1
N
AC INPUT

D YELLOW C 10F
N D

1
5 4 3

D X1A

BLUE
BLUE
C1 X1B

4F

6
X1C C2
17D

X2

3
3DD X3 7D
EARTH BLUE BLUE
3DD X4 7D
X5
C C
X6

11F

12F
Y1

Y3
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Tirupathi. All rights reserved. No copying permitted unauthorised use prohibited.

3
2

8
7
6
AC RELAY
BD. N 7
6
INTERNAL 5 6
CABLE DETAILS 7
4 PC1 5
2 4
DESIG- CABLE SIZE 3 L
NATION IN Sq.mm 2 L 3
B B
3 NC 2
N

RL1
1
D 2.5 TB1 C 1
TB2
F 6.0 17D
G
CHASIS
CABLE COLOUR GROUND TP1 TP2

AC Line YELLOW

AC Nue BLUE
BYPASS CVT REGULATOR
NOTE: - ACDP
(1). ALL COLOUR CONTROL CABLES ARE 0.5Sq.mm - GREY
AMA RA RAJA PROJECT : ------------

A (2). ALL EARTH POINTS SHOULD BE INTERCONNECTED CUST

:
INDIAN RAILWAYS A
POWER SYSTEMS LTD :
P.O. NO. ------------
Registered Office & Works
:
karakambadi - 517520 DWG. NO. IPS-CVT-015-B (A010)
Ph(0877) 2285561 to 2285565. A3 SCHEMATIC DRAWING OF
TITLE
REV. ECO REMARKS DATE APPD. DRAWN CHKD. RECHKD. APPD. 1.5 KVA BYPASS CVT REGULATOR
FILE NAME D:\IPS Schematics\schematics\CVT\FINAL 1.5 KVA CVT.sch KISHORE DATE : 25/07/05 SHEET 1 OF 1 REV 0
1 2 3 4 5 6 7 8
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited. ENG-SFS-06/Rev.0
1 2 3 4
FILE NAME

CABLE DETAILS
DESIG- CABLE SIZE
NATION
D:\IPS Schematics\schematics\ASM\ASM PANEL.sch

H IN Sq.mm H

A 0.5

CABLE COLOUR

DC +VE RED
BLACK
DC -VE BLACK
A
EARTH GREEN
CONTROL
CABLE GREY
G
TB3 G

Block Tele (Up)

VIOLET A +
GREY A +
3 - 6 V/0.1A
-
C
PC 2 -
E

NC CN.1
CN.2
YELLOW
BLACK

A +
A +
-
C
PC 3 -
TB2
E
RED A +
NC CN.1
F F
CN.2 BLACK A -
TB4 GREEN A E
Block Tele (Dn) WHITE A +
REV

3 - 6 V/0.1A BLUE A +
-
C
PC 4 - YELLOW 44A
E A
ECO

NC CN.1
CN.2
YELLOW

GREEN
BLACK

A +
A +
-
C
PC 5 -
E E
E
REMARKS

NC CN.1
CN.2

YELLOW CALL S&T STAFF

A

B
B
BLACK
DATE

A
APPD

D D

(TB1) TB1
PC1
KISHORE
DRAWN

TO SMPS MUIB (PC3) 42A

+

TB5 + BATTERY.
C1

- + - SUPPLY
Registered Office & Works,
POWER SYSTEMS LTD
AMARA
Ph(0877) 2285561 to 2285565.
karakambadi - 517520

43A
-
LED1 D1 +12V
CHKD

BLACK R1 5A
9A 1A 4A
A
STOP GEN
44A CALL S&T
RECHKD

STAFF
FROM SMPS PANEL
R AJ

C C
ASM PCB

45A SYSTEM
SHUTDOWN
APPD.

A
A2 TITLE
DATE

DWG.NO
P.O.NO.
CUST
PROJECT

71A
:
:
:

:
:

BATT.
LOW
IPS-ASM-000-B

INDIAN RAILWAYS
SCHEMATIC DRAWING OF ASM PANEL

-------------------
25/07/2005

72A

B B
A010
SHEET
OF1
1

NOTE : - USE COLOUR CABLES

A ALL EARTH POINTS SHOULD BE INTERCONNECTED A
REV.
0

1 2 3 4
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited. ENG-SFS-06/Rev.0
1 2 3 4
FILE NAME
D:\IPS Schematics\schematics\DCDP\DCDB(27) - B514\DCDP Table.sch

H H

G G

1 2 3 4 5 6

VOLT
Relay Internal
Relay Internal
METER 1
24-32V/5A -1No
24-32V/5A - 4Nos
F F
REV

Relay External Axle Counter

ECO

Panel Indication

24-32V/5A - 2Nos 24-32V/5A - 2Nos 12-28V/5A - 2Nos 2

E E
REMARKS

Block Local HKT & Magneto Block Line - UP 3

12-28V/5A - 2Nos 12-28V/1A - 2Nos 12-40V/1A - 2Nos

Subrack
DATE
APPD

D D
DRAWN
KISHORE

Block Line - DN Spare cell Data Logger 4

Registered Office & Works,
POWER SYSTEMS LTD
AMARA
Ph(0877) 2285561 to 2285565.
karakambadi - 517520
CHKD

12-40V/1A - 2Nos 2-12V/5A - 2Nos 24-32V/5A - 2Nos

RECHKD

R AJ

C C
APPD.

SSI
A
A2 TITLE

24-32V/5A - 4Nos 5
DATE

DWG.NO
P.O.NO.
CUST
PROJECT
:
:
:

:
:
29/11/2005

INDIAN RAILWAYS
IPS-DCD-027-B
-------------------

-----------
POSITION DRAWING OF DC-DC CONVERTERS

B B
B514

DC - DC CONVERTERS
SHEET
1 OF 1

A A
REV.
0

1 2 3 4
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited. ENG-SFS-06/Rev.0
1 2 3 4

NOTE : - USE COLOUR CABLES

FILE NAME

CABLE DETAILS
ALL EARTH POINTS SHOULD BE INTERCONNECTED
DESIG- CABLE SIZE 2A
NATION IN Sq.mm BLACK

A 0.5 P2
D
D:\IPS Schematics\schematics\DCDP\DCDB(27) - B514\DCDP-1.sch

H 1 P1 TB6
D 2.5 CONV-11 H

D 2 3
2
F 6.0 P3 RED C
1 1
2 RED D
CABLE COLOUR
D P2 RED C
1 P1
DC +VE RED CONV-12
D 2 3
2
DC -VE BLACK P3 BLACK C
1 1
EARTH 2 BLACK
GREEN
TB5 D
CONTROL RELAY INTERNAL RED D P2 BLACK C
GREY 1 P1
CABLE 24 - 32 V / 5A CONV-13
BLACK D 2 3 GREEN D
Qty: 4 Nos 2
P3 1 GREEN C
1
2
G
E G
D P2
1 P1
CONV-14 3
D 2
2
P3
1 1
2

RELAY INTERNAL CONV-15

24 - 32 V / 5A
(COLD STANDBY) (COLD
STANDBY)

F F

TB7 P2
RED
REV

D P1
Relay External 1 CONV-21
24 - 32 V / 5A BLACK D 2 3
Qty: 2 Nos 2
P3
1 1
2
ECO

D P2
1 P1
CONV-22
D 2 3
2
P3 1 1
2
TB8 TB10
YELLOW D P2
Axle Counter 1 P1
CONV-23
E
24 - 32 V / 5A BLUE D 2 3 RED C E
REMARKS

2
Qty: 2 Nos P3
1 1 RED C RED D
2
RED C

D P2
DCDP FRAME DRAWING

1 P1
CONV-24
D 2 3 BLACK C
2
P3
1 1
BLACK C BLACK D
2 BLACK C
TB9
DCDP

Panel Indication WHITE D P2

P1
DATE

1
12 - 28 V / 5A CONV-25
BROWN D 2 3 GREEN C GREEN D
2
Qty: 2 Nos P3 1
1
E
2
APPD

D D P2 P1
D
1
CONV-26
D 2 3
KISHORE

2
DRAWN

P3
1 1
2
Registered Office & Works,
POWER SYSTEMS LTD
AMARA
Ph(0877) 2285561 to 2285565.
karakambadi - 517520
CHKD

TB11 P2
Block Local RED D P1
1 CONV-31
12 - 28 V / 5A BLACK D 2 3
Qty: 2 Nos 2
RECHKD

P3
1 1
2

D P2
R AJ

1 P1
C
CONV-32 C
D 2 3
2
APPD.

P3 1
1
A

2
A2 TITLE

TB12 TB14
YELLOW D P2
HKT & Magneto P1
DATE

DWG.NO
P.O.NO.
CUST
PROJECT

1
CONV-33
12 - 28 V / 1A BLUE D 2 3 RED C
2
Qty: 2 Nos P3
1 1 RED C RED D
2
RED C
:
:
:

:
:

D P2
1 P1
CONV-34
SCHEMATIC DRAWING OF DC-DC CONVERTERS (FRAME)
29/11/2005

RAILWAYS
IPS-DCD-027-B
-------------------

-----------

D 2 3 BLACK C
2
P3
1 1 BLACK C BLACK D
2 BLACK C
B TB13 B
Block Line (UP) WHITE D P2
1 P1
12 - 40V / 1A CONV-35
BROWN D 2 3 GREEN C GREEN D
B514

2
Qty: 2 Nos P3
1 1
E
2
22G

2G

D P2
SHEET

1 P1
CONV-36
D 2 3
2
P3
BLACK
GREEN

1 1
2
1

RED
OF

10A
TO SHEET 2 OF 2
2

A FROM SHEET 2 OF 2 A
REV.
0

1 2 3 4
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited. ENG-SFS-06/Rev.0
1 2 3 4
FILE NAME

CABLE DETAILS
DESIG- CABLE SIZE TO SHEET 1 OF 2 TO SHEET 1 OF 2
NATION IN Sq.mm

A 0.5 BLACK

10A
D:\IPS Schematics\schematics\DCDP\DCDB(27) - B514\DCDP-2.sch

H
2A H

D 2.5
TB15 P2
F 6.0 Block Line (DN) RED D P1
1 CONV-41
12 - 40 V / 1A BLACK D 2 3
CABLE COLOUR Qty: 2 Nos P3 2
1 1
DC +VE RED 2
P2
DC -VE BLACK D
1 P1
CONV-42 3
D 2
EARTH GREEN 2
P3
CONTROL 1 1
CABLE GREY 2
TB16 TB18
YELLOW P2
Spare Cell D P1
1
CONV-43
G
2 - 12V /5A BLUE D 2 3 RED C G
Qty: 2 Nos 2
P3 RED D
ALL EARTH POINTS SHOULD BE INTERCONNECTED
NOTE : -

1 1 RED C
2
RED C
P2
D P1
1
CONV-44
D 3 BLACK C
2
2
BLACK D
P3 BLACK C
1 1
USE COLOUR CABLES

2 BLACK C
TB17
Data Logger P2
WHITE D P1 GREEN D
1
24 - 32 V / 5A CONV-45
BROWN D 2 3 GREEN C
Qty: 2 Nos 2
P3
1 1
E
2

P2
D
1
P1
F
CONV-46 3
F
D 2
P3 2
1 1
2
REV
ECO

P2
D
1 P1
D
CONV-51
2 3
P3 2
DCDP FRAME DRAWING

1 1
2
E E
P2
REMARKS

D P1
1
CONV-52 3
D 2
DCDP

2
P3
1 1
2
TB19 TB20
RED P2
SSI D P1
1
CONV-53
24 - 32 V / 5A BLACK D 2 3 RED C
2
Qty: 4 Nos P3
1 1 RED C RED D
2
DATE

RED C
P2
D P1
1
CONV-54
D 3 BLACK C
2
2
BLACK D
APPD

P3
1 1 BLACK C
D D
2
BLACK C

GREEN D
KISHORE
DRAWN

E
Registered Office & Works,
POWER SYSTEMS LTD
AMARA
Ph(0877) 2285561 to 2285565.
karakambadi - 517520
CHKD

GREEN
BLACK
RED
RECHKD

R AJ

C C

PC1 R1 D1 LED1
APPD.

6 7
42A 4A 1A 2A
10A
A

C NO
A2 TITLE

22A

( RL.BD ) DCDP FAULT

DATE

DWG.NO
P.O.NO.
CUST
PROJECT

15 2 22A 22F
RED
PC1
22G

2G

PC1
25A
:
:

2F
:

:
:

11 10 2A
C NO BLACK
SCHEMATIC DRAWING OF DC-DC CONVERTERS (FRAME)

25A
IPS-DCD-027-B

22F
29/11/2005

F2 F1
Indian Railways
-------------------

-----------

2F

TO PC5 (2 nd PIN IN CN.4) TB4

FAN-2 FAN-1 TB3
SMPS PANEL
L N L N
- + -
B
DL1 PB1
+ B

A34A TO ACDP FROM SMPS PANEL

135A

135A

5A
5A
B514

A9A FROM AC I/P

5A
A30A (SMPS PANEL)
8A

FU 1 TB2
SHEET

M1
2

TP1 8A LINE
OF

7A L FROM INV/CVT O/P

+ +
5A NUE FROM ACDP FRAME
2

VM N
- 6A
-
A TP2 GREEN A
E
17A TB1 FRONT PANEL
REV.
0

1 2 3 4
 1 2 3 4 5 6 7 8
ENG-SFS-06/Rev.0

TB1 TB2
D D

( FROM AC DISTRIBUTION PANEL)

L FU1 L
Line A1H A34H A34H Line
YELLOW YELLOW

A34H
A34H

TO SMPS PANEL
AC INPUT SUPPLY
3 31B

TO TB3
SPD1
LPD1
1 32B
2 33B

A30H
A30H
N N
Nue A30H A30H A30H Nue
C BLUE BLUE C

A30H
LPD2
Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Tirupathi. All rights reserved. No copying permitted unauthorised use prohibited.

CABLE DETAILS

GREEN
TB 4 DESIG- CABLE SIZE
NATION IN Sq.mm
G
B 1.0

EARTH
H 16.0
B B

FROM SPD 1
NOTE:-
INSTALL THE LPD BOX NEAR TO THE AC DISTRIBUTION. MAINTAIN
ATLEAST 5mts DISTANCE BETWEEN MAIN AC DISTRIBUTION
32B

33B
31B

(WHERE LPD BOX IS INSTALLED) AND THE POWER PLANT TO HAVE

AN EFFECTIVE LIGHTNING PROTECTION.

1 2 3 TB3
NC C NO

POTENTIAL FREE CONTACTS AMA RA RAJA PROJECT : ---------

A CUST
:
INDIAN RAILWAYS A
POWER SYSTEMS LTD :
P.O. NO. ---------
Registered Office & Works
IPS-LPD-000-B (A010)
:
karakambadi - 517520 DWG. NO.
Ph(0877) 2285561 to 2285565. A3 SCHEMATIC DRAWING OF
TITLE
REV. ECO REMARKS DATE APPD. DRAWN CHKD. RECHKD. APPD. LIGHTNING & SURGE PROTECTION DEVICES
FILE NAME D:\IPS Schematics\schematics\LPD\LPD MODULE.sch SASI DATE : 15/07/05 SHEET 1 OF 1 REV 0
1 2 3 4 5 6 7 8
Proprietary material of M/s AMARA RAJA POWER SYSTEMS LTD., Thirupathi. All rights reserved no copying permitted unauthorised prohibited ENG. SFS-06/Rev.0
1 2 3 4
FILE NAME : D:\IPS Schematics\schematics\SMPS\SMPS-05-B014\SMPS-05-B014.sch

TB3
35A
FROM GEN. SET
SUPPLY
36A
L L

X61 10 PIN FLAT

11A

X31
FROM PC 3 TO MUIB
PC2 CABLE

10A MMIB3
TO TB 10
X60
B61

4 CORE CABLE

A30A
A3A
50Hz ± 5%, SINGLE PHASE

K SCR UV/OV K
TB1 TB2
AC INPUT 150-275 VAC,

A34 I A34 I Module CT1

A3 I A3 I A3E A3E
Line in

Line Out
LINE

FRAME DRAWING
A3A
Nue

A3H

TO ACDP
A30D
TO PC4
A30 I A30 I A30E A30E
NUE

EARTH EARTH A11D A11D A11D FRAME EARTH

BOLT
GREEN
A3H
A30H
A34D

A30D

J J
EARTH
L1

A11D
A11D

A11D

A11D
TO DCDP FRAME

A34A A34D SC1

TB4
TO PC4 &

L
17D A6H A6H
A30A E
A34A

A30D N A4H A4H

5A,230AC
A30A
PB1

A11D
A11D

A11D

A11D
A4E

A6E
A4E

A6E

A4E

A6E

A4E

A6E
DL1
REV.

A9A
TB17 TB18 TB19 TB20
I E E E E I

PC 10
PC 8
PC 7

PC 9
ECO

L L L L
SMR5 SMR6
N N N N

A11D
A11D

A11D

A11D
A4D
A4D
A6D
A6D
A4D
A4D
A6D
A6D

A4D
A4D
A6D
A6D

A4D
A4D
A6D
A6D
SMR3 SMR4
6 CORE CABLE
+VE

-VE

6 CORE CABLE
SMR1 SMR2
6 CORE CABLE

6 CORE CABLE

X11

X11

X11

X11
X2
X8

X2
X8

X2
X8

CONN.4
CONN.3

X2
X8
CONN.2
CONN.1

PC1 E L L N N E L L N N E L L N N E L L N N

TO CSU
H
1 2 3 4 5 3 1 4 2 5 3 1 4 2 5 3 1 4 2 5 3 1 4 2 5 H
X13
AC I/P SMR AC I/P SMR AC I/P SMR AC I/P SMR AC I/P SMR
DATA DATA DATA DATA DATA
SMR-5
SMR-1 SMR-2 SMR-3 SMR-4
(COLD STANDBY)
REMARKS

CN. DC O/P CN. DC O/P CN. DC O/P CN. DC O/P CN. DC O/P
2 1 4 3 2 1 2 1 4 3 2 1 2 1 4 3 2 1 2 1 4 3 2 1 2 1 4 3 2 1
CONN.10

CONN.11

CONN.12
CONN.7
CONN.6

CONN.8
CONN.5

+ + + + + +
CONN.9

- - - - - - - - + +
TB8
81A 81A
82A 82A
4 CORE CABLE

22H
G TO MUIB 2H
G

22H
2H
TB5
BLACK 2G 2G
2G TO DCDP FRAME
RED 22G 22G TO TB 4
X1 C1 22G
TO MUIB & TB9

2B 123B 23B
2A
PC3

CON.1 RL1
AR CSU 37A
DATE

TB6
23G 4 3 2 1 FU1
F F
22G RED RED 37G 37G
X73
23G
23A

(CON BB) 6471 TO BATTERY

37A

JX1 -13
APPD

CT2 2G
GREEN
YELLOW

BLUE

RED
2B

BLACK
2G 2G BLACK 2G
TB7
KISHORE
DRAWN

BLACK 2E
37A
23A

POINT
COMMUNICATION

34 FLAT CABLE

MOV.3

MOV.2

MOV.1

FU2
OPERATION
CABLE

4 CORE CABLE

1 2 RED 39E
TO BATTERY
Ph(0877) 2285561 to 2285565.
karakambadi - 517520
Registered Office & Works,
POWER SYSTEMS (PVT.) LTD
AMA R A RAJA

PC6
E FUSE TRIP BOARD E
CHKD

10 8
37A
2A

RL1
50A

51A

2A

2B
22A
37A
2A

2A

37B
YELLOW

GREEN
BLUE
81A

82A

RED
RECHKD

15A

14A
Bus+

Batt+
Batt-
Bus-

4
3

NO C X23
2
2139

MXS12

AC INPUT
COMMUNICATION RL2 X65
X50 BAT.
CABLE X2 X39 SW
A30A
37A

POWER
A3A
X1

2A

I/P BATT. 1
34 FLAT CABLE
CURRENT CONN.13 CONN.15
APPD.

2A

D D
BATTERY
46A PC3 4 3 2 1 1 2
X17

TEMPERATURE
NO C
RL4

SENSOR CN.5 CN.2

MUIB WITH
X2

+ -
A1

N/C LOGIC 10 PIN FLAT CABLE

37B
CN.3

PC4
CN.5

1
10 PIN FLAT CABLE PFC BOARD 63 2B
DWG. NO.
P.O. NO.
CUST
PROJECT :
TITLE

TO PC2
DATE

28A

2
X32

2A
X22

MMIB3 RL5 RL1 3

43A -
10 PIN FLAT CABLE 42A
CN.4

CN.8

X64 C NO C
+
NC CN.1 CN.6 4
44A Call S&T Staff
CN.3

64
5
2A

1 2
11A

1 2 3 4
9A

2A TO ASM PANEL
:

45A System Shut DN.

12A

7A
13A

6
:

INTERNAL
:

71A
:

Battery Low
CONN.16
CONN.14

CABLE DETAILS 7
72A Battery Low
TO TB10

TO PC 2

TO TB9
66A
60A
61A
62A

RL1
INDIAN RAILWAYS

8
25/07/2005

--------- -

--------- -

DESIG- CABLE SIZE 23A

IPS-SMR-005-B

23A

NATION IN Sq.mm 1
P.F.C INTERFACE BOARD

C C
2
A 0.5 1
MAINS FAIL P.F.C
3
D 2.5 28A 2
DATA LOGGER (CUSTOMER CONNECTIONS)
CN.2

4
E 4.0 3
SCHEMATIC DRAWING OF

SMR FAIL P.F.C

62A

Reverse 5
F 6.0 TO BE Polarity 40A 4
CN.6
MAINS FAIL

6
10.0 MOUNTED 5
MAINS ON

G 41A 7
DCDP FAULT P.F.C
LED 2

ABOVE TB6
LED 1

6
SMPS PANEL

H 16.0
LED3 8 7
I 25.0 CALL S&T STAFF P.F.C
8
B014

ACDP Fault 1A
CABLE COLOUR 1
FROM ACDP System Shut dn. 25A
60A 2
AC Line YELLOW FROM PC3 85A 1
3 INVERTER-1 FAIL P.F.C
BLUE
66A FROM DCDP 16A 2
AC Nue 4
CN.4

PC5

18A 3
SHEET

DC +VE RED 5 INVERTER-2 FAIL P.F.C

37A

10A

19A 4
7A

9A

B FROM ACDP 6 B
DC -VE BLACK 20A 5
CN.7

7
EARTH GREEN TB9 + - TB10 8
6
BATTERY LOW P.F.C
7
CONTROL GREY
CABLE 1 8
TO ACDP TO ASM PANEL 2
1 OF

3
CN.1

4
5
1

6
7
SMPS PANEL 8

NOTE: (I) ALL DOORS PROVIDED WITH ELECTRICAL COMPONENTS TO BE EARTHED PROPERLY
REV.

A A
(II) ALL COLOR CONTROL CABLES ARE 0.5 & 2.5 Sq.mm. - GREY

(III) ALL EARTH POINTS SHOULD BE INTERCONNECTED

0

1 2 3 4