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Contact person:
Director(S&T)
Indian Railway Centre for Advance Maintenance Technology
Maharajpur, Gwalior(MP)-474020
Ph:0751-2470185, FAX:0751-24700841
E-mail: [email protected]
भारत सरकार - GOVERNMENT OF INDIA
रल मतरालय - MINISTRY OF RAILWAYS
कवल काराालरीन उपरोग हत
For official use only
CAMTECH/S/PROJ/2021-22/SP3A
May 2021
Target Group: SSE/JE (Signal) of Indian Railways
SMPS based
Integrated Power Supply (IPS) System
Introduction
The SMPS based Integrated Power Supply (IPS) system is meant
to give continuous supply to both AC & DC signalling circuits for
wayside and medium size signalling installations without AFTC
(upto 15KVA signalling load) in RE & Non-RE areas.
In Indian Railways, IPS systems conforming to following
specifications are in use:
RDSO Specification No. RDSO/SPN/165/2004 (Old)
RDSO Specification No. RDSO/SPN/165/2012 (New)
RDSO Approved firms for manufacture & supply of
IPS
M/s AMARA RAJA Power Systems Ltd., Tirupati
M/s STATCON Electronics India Ltd., NOIDA, G.B.Nagar
M/s HBL Power Systems Ltd., Hyderabad
Main modules of IPS System
SMPS based Float cum Boost Charger (FRBC) Panel
DC Distribution Panel
AC Distribution Panel
Status Monitoring panel for ASM's room
Battery bank
Lightning & Surge protection arrangements
1
FRBC Panel
FRBC Panel consists of two or more
Switch Mode Rectifier (SMR) modules
provided in (N+1) configuration.
Each module is rated for 110V/20A.
All the modules are connected in parallel
and share the load equally.
Output of the FRBC Panel is connected
to Battery Bank and to other two panels
DCDP and ACDP which require 110V
DC.
2
Controls & Indications of FRBC Panel
3
Indications on SMR module
Indication Description
Mains Mains supply to the module is on
Float The module is in float mode of charging
Boost The module is in boost mode of charging.
Overload/Short Ckt The module is overloaded
Under voltage The output DC voltage of the module is low
or it is sensing a discharged battery voltage
when all the three modules are off.
Output Fail The output DC of the modules is not
available.
Over voltage The output DC Voltage of the module have
Exceeded normal output operating range
Over Temperature The temperature of the module inside is more
than 75 C.
Fan Fail The cooling fan of the module has failed
Display panel Displays various parameters, of SMR panel.
Microcontroller based Distribution/Supervisory Control/
Alarm (DSA) Unit
All operating parameters of the System, SMR modules and
Battery can be changed through the menu driven LCD
provided in the DSA..
The above is the example of Statcon Make IPS. The indications
may differ from manufacturer to manufacturer.
DC Distribution Panel (DCDP)
These converters feed power to
different loads such as Axle
Counters, Point Machines, Relay
Internal, Relay External etc.
DC-DC converter for internal
circuit shall be in n+2 configuration
& for other circuits in n+1
configuration.
Push buttons are provided to scroll through the LCD menu and
to set parameters
LEDs to indicate the status of the system.
A typical DSA unit of Amararaja make IPS is shown below. It
may vary for other manufacturer’s IPS.
DCDP consists of DC-DC converters with different ratings.
All converters work on 110V DC input which is coming from
FRBC panel.
4
The standard converter ratings as per RDSO Specification are:
Sr.
No.
Converter Rating
1 Relay Internal 24-32V, 5A/10A OR 60-66V, 5A
2 Relay External 24-32V, 5A/10A OR 60-66V, 5A
3 Axle Counter 24-32V, 5/10A
4 Block Local UP 12-40V, 1A OR 40-60V, 1A OR
60-100V, 1A OR 100-150V
5 Block Local DN 12-40V, 1A OR 40-60V, 1A OR
60-100V, 1A OR 100-150V
6 Panel Indication 12-28 V,5/10A
7 Block Line UP 12-40V, 1A OR 40-60V, 1A OR
60-100V, 1A OR 100-150V
8 Block Line DN 12-40V, 1A OR 40-60V, 1A OR
60-100V, 1A OR 100-150V
9 Block Tele UP 3-6V, 0.1A
10 Block Tele DN 3-6V, 0.1A
For block proving by axle, the DC-DC converter of 24V-40V/5A
or 10A shall be used in place of block line DC-DC converters.
Common DC
Voltmeter
3 1/2 digit LCD/LED display with patch
cords To measure output DC voltages
Test sockets on each
Converter
To measure output DC voltages
ON/OFF Switch on
each Converter
To put the particular unit ON or OFF.
Indications on each
Converter
Input ON (Amber), Output OK (Green),
Conv. Fail (Red)
Controls & Indications of DCDP
5
AC Distribution Panel (ACDP)
ACDP is a combination of
Inverters, Step-Down Transformers
and Automatic Voltage Regulators
(AVR).
Inverter: Converts 110V DC to 230V
AC to cater for all signal 230V/110V
AC step down transformers in the event
of Mains 230 V AC failure.
There are three Inverters out of which
two are in hot standby mode while third
is in cold standby mode.
Automatic Voltage Regulator (AVR): Converts 150 – 275V AC to
constant 230V AC supply to cater for all signal/Track circuits
230V/110V AC step down transformers.
Step Down Transformers: Converts 230V AC to constant 110V AC
supply to cater for all signal/Track loads. The secondary of step
Down transformers have 100, 110, 120 & 130 AC taps.
AC Voltmeter & AC Ammeter: To measure AC Voltages & Signal
load current.
6
Inverter
Input MCB Extends input 110 V DC to the Inverter.
Switches ON, OFF /Reset switches
Indications Mains, Output, Inverter Fail, On Load, Fan
Fail
AVR
Input MCB Extends input 230 V AC to the AVR
Indications Output ON, Output Fail, Input ON
Test sockets For measurements of output AC voltages
Step Down Transformer
Input MCB Extends input 230 V AC to the Transformer
Indications Output ON, Output Fail, Input ON
Test sockets For measurements of output AC voltages
Controls and Indications of ACDP
Status Monitoring panel for ASM's room
This panel consists of status indications and critical alarms of IPS which
can be monitored from ASM's room. The monitoring panel shall be of
wall mounting type. 03-06V/0.1A DC-DC converters for Block Tele (Up
& Dn) are also provided in status monitoring panel.
7
Description Indication
& Alarm
Condition
Start
Generator
RED LED
& Audio
Alarm
Battery 50% DOD* (Approx 109
V). Audio alarm can be
acknowledged for audio cut off
Emergency
start
Generator
RED LED
& Audio
Alarm
Battery 60% DOD* (Approx 107
V) . Audio alarm can be
acknowledged for audio cut off.
System Shut
Down
RED LED
& Audio
Alarm
Battery 70% DOD* (Approx 105
V) Signal feed cut off and all DC-
DC converters to work. Audio
alarm will continue till Generator
is started.
Call S&T
staff
RED LED
& Audio
Alarm
Failure of any module or in case
battery gets disconnected from
circuit will give the alarm in
panel. Alarm can be
acknowledged for audio cut-off.
Stop
Generator
GREEN
LED &
Audio
Alarm
Senses availability of generator
and charging condition of Battery.
If Battery charge completes, stop
generator indication glows.
Indications on Status Monitoring Panel
*DOD –Depth of Discharge
Battery bank
IPS system is suitable for charging 110V battery bank of Low
Maintenance cells as per IRS:S 88/2004 or VRLA Maintenance
free cells as per IRS:S 93/96(A). The battery is to be installed in a
separate room.
8
Copper cable of suitable dia as per IS:
694 and grade 1100V: for connecting IPS
to Battery bank should be provided:
For 120AH battery – 10 Sq.mm
For 200AH battery – 16 Sq.mm
For 300AH battery – 25 Sq.mm
Lightning & Surge Protection
Stage 1 Protection (at the entry point of input 230V
AC supply in the power/ equipment room)
Class I/ B & II/ C type SPDs shall be provided at the entry point
of input 230V AC supply in Power /Equipment room in TT
configuration in a separate wall mountable box. The Class I/B
SPD shall be provided between Line to Neutral & Neutral to
Earth. They shall be spark gap type voltage switching device. The
Class I/ B SPD will be followed by Class II/ C SPD adjacent to it
and connected between Line & Neutral. It shall be voltage
clamping device, thermal disconnecting type. This will provide
least resistance path from line to neutral and neutral to earth when
surges & lightning spikes hits the line there by bypassing the
system. Earth pit resistance should be <2Ω.
9
How to identify that SPD has gone defective?
Class B SPDs work on spark gap technology. Whenever a heavy
lightning surge occurs, class B SPD passes this to the earth. If the SPD
is gone defective due to surges, a short circuit occurs in line & neutral.
The 63 Amp fuse will be blown and this is the only indication that SPD
has gone defective. Another identification is burning of SPD. Hence if
lightning/surges have suspected to be occurred, check for any burning
smell near LPD Box.
Class C SPD passes the lighter surges and do not affect the circuit.
Through the potential free contacts, the status of SPD can be extended
to the ASM Panel. In latest versions, indications are also provided on
the SPD. Green indication shows SDP healthy and Red indication
shows SPD is defective. 10
Additional Requirement as per RDSO SPN/165/2012:
Stage 2 Protection (at the output side inside the
distribution panel)
The Stage 2 protection shall consist of Class II/ C type SPDs
for ≥24V-110V AC/DC supplies at the output side inside the
rack of IPS. These shall be provided for External circuits i.e.
Relay external circuit, Axle counter circuit, point machine
circuit and at Inverter output. The Class II/C type SPD shall be
a single compact varistor of proper rating and in no case a
number of varistors shall be provided in parallel. It shall be
voltage clamping device and thermal disconnecting type.
Provision of class C SPDs in common and differential mode of
relay external, axle counter, point machine circuit and at
inverter output
Point Operation Inverter Output Relay External
& Axle Counter
11
Earthing Arrangement
The IPS systems and its individual modules shall have earth
terminals and shall be properly earthed to the IPS cabinets. Earthing
arrangement shall be done in conformity to Code of practice for
earthing and BondingRDSO/SPN/197/2008. The connections shall
be as given below:
Component/Bonding Material Size
Individual equipments to
SEEB using copper lugs
with stainless steel nut and
bolts.
Multi-strand single core
PVC insulated copper
cable as per IS:694
10
sq.mm
SEEB to MEEB using
copper lugs with stainless
steel nut and bolts.
Multi-strand single core
PVC insulated copper
cable as per IS:694
16
sq.mm
Surge protection devices
(SPD) to MEEB using
copper lugs with stainless
steel nut and bolts.
Multi-strand single core
PVC insulated copper
cable as per IS:694.
16
sq.mm
MEEB to main earth
electrode
Multi-strand single core
PVC insulated copper
cable as per IS:694
(Duplicated)
35
sq.mm
LPD Box
12
13
Brief Description of Working
Input Mains supply 230 V (150-275 V) AC comes to Lightning
Protection Device (LPD) Box.
From LPD Box, the 230 V AC goes to (i) FRBC Panel (ii) AVR
(Track) (iii) AVR (Signal).
SMRs in FRBC Panel Convert 230 V AC to 110 V DC which
are paralleled and fed to DC-DC Converters, Point operation
through a fuse and Inverters.
Normally both the Inverters are powered ON and both are
delivering the Output voltage but only Inverter1 is connected to
the Load.
Inverter 1 gives output 230 V AC supply to Step Down Signal
Transformers 230/110 V AC for feeding to Signals.
If Inverter 1 fails, Inverter 2 will take over and feed to the
signals.
In the event of AC Mains supply failure, Inverter will give 230
V AC output through 110 V DC Battery Bank.
As per RDSO SPN/165/2004, the output of both the inverters
shall be linked in such a way that on failure of one inverter, the
other shall supply to load automatically within 300ms. This
switching time is reduced to 60 ms in IPS as per RDSO
SPN/165/2012 to avoid blinking of signal aspect. As soon as
one of inverter becomes healthy, the load shall be automatically
transferred back to inverter.
14
As per RDSO SPN/165/2012, Ferro resonant Automatic
Voltage regulator (AVR) for Signal load shall always be in
‘switched on’ condition and shall supply the load within 60 ms
(300 ms in IPS of RDSO SPN/165/2004) in case of any failure
in Inverter/s and/or inverter changeover arrangement to
prevent blanking of signals.
The change over from inverter to inverter or AVR shall be
achieved through Static switch.
DC-DC Converters convert the 110 V DC input extended from
SMPS to the required voltage.
These converters feed different loads such as Relay Internal,
Relay External, Axle Counter, Block Line, Block Tele UP &
DOWN, Panel Indication, HKT etc.
All the groups of converters are provided in (N+1) or (N+2)
configuration to ensure uninterrupted supply.
Testing of Auto Changeover operation in ACDP
Connect one of the signal transformers outputs to the Digital
Voltmeter provided.
Stop Inverter1 by pressing STOP button.
The load should shift to Inverter 2.
Check ‘Load on Inverter’ LED on Inverter2.
Check voltage on digital display.
Now stop Inverter2.
15
The load should shift to AVR
Check voltage on display.
The voltage displayed indicates load on AVR.
For checking Auto-Changeover in Reverse order:
Start Inverter2 – load should shift on Inverter2 automatically.
Start Inverter1- load should shift on Invertrer1 automatically.
Manual Changeover operation in ACDP
A manual changeover switch is provided in the backside of
ACDP.
At the time of Auto-Changeover failure, this switch can be used
to connect signal loads to Inverter1 or Inverter2 or CVT (AVR)
manually.
This switch has four positions namely:
AUTO, INVERTER1, INVERTER2 & CVT
In normal working, the switch position is kept at AUTO.
16
Adjustment of Converter Output Voltage
Turning clockwise will increase the voltage and turning anti-
clockwise direction will reduce the voltage.
Adjust potentiometer with the help of pre-set driver (pot
adjuster) to get the desired output.
Ensure that output voltage of all converters in a group is same
in order to ensure proper load sharing among the modules in a
group.
Switch OFF DC-DC Converter and take out from the slot by
removing connectors.
Connect test points to Common Digital Voltmeter.
Connect input connectors and Switch ON the module.
Each DC-DC Converter is provided with a potentiometer on the
PCB which is accessible from the bottom side of the converter.
Potentiometer
17
Maintenance Required Period
Check if the O/P voltages are set as per requirement. If
not, correct them.
Once in 15
days
Switch OFF main Converter and observe if the stand-
by is taking the load.
Once in a
month
Switch OFF Stand-by Converter and observe if the
main one is taking the load.
Once in a
month
Check if all the converters are inserted properly. Once in 3
month
Remove one by one and clean the converter using a soft
cloth. Gently blow some air from top or Bottom to
remove the dust inside.
Once in 3
months
Maintenance Check points of DCDP
Note: It is advised to check these points as per above frequency
and only when there is in no train movement.
Ensure that all the screws to the modules/racks are tight.
If the total load is too low compared to the installed rectifiers
capacity use only necessary rectifier modules.
Provide good ventilation to the IPS/battery room.
Ensure the exhaust fan is working properly
General Maintenance
Check and ensure that feeder supply is between 150-275V.
Ensure that battery set is fully charged by taking its specific
gravity and voltage of each cell.
Check voltage drop from IPS to battery ≤ 0.5V.
Check battery-charging current.
Check leakage from AC to earth, DC to earth and Rack to
Rack earthing and Earthing to all the modules ER shall be less
than 1.0Ω.
18
Maintenance Check points of ACDP
Maintenance Required Period
Check that intake and exhaust air openings are not
obstructed.
Weekly
Remove dust and foreign particles within the Chassis
using compressed air or blower. Check mounting bolts
and terminals looseness. Tighten them.
Weekly
Inspect transformers for evidence of over heating,
damaged insulation or loose mounting screws. Correct
any malfunctioning before operating the unit. 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 3
Months
Check all controls for operability. Replace if any damage
or malfunctioning is observed.
6
Months
Check the cable for input and output power and internal
wiring to components. Check for cracks or broken
insulation. Replace as indicated.
12
Months
Inspect the general conditions of PCB. Check the
components for evidence of over heating cracks or
peeling. Repair or replace board if necessary
12
Months
Inspect Diodes, Silicon Controlled Rectifiers (SCRs) &
MOSFETS and their heat dissipaters for loose mounting
or defective electrical connections. Tighten screws and
nuts.
12
Months
Inspect SCR’s, PCB, sockets for loose electrical
connections. Tighten the mounting screws and replace
defective sockets, if any.
12
Months
19
Do’s & Don’ts
Do’s
Keep the AC Input MCBs of at least 2 SMRs always ON.
Keep the Inverter Input MCBs always ON.
In case of emergency or any problem, switch OFF all the
MCBs.
Remove control cable connector accessible from backside,
before pulling out inverters/ step Down Transformers /
Bypass CVTS
Whenever any module is removed and inserted again , ensure
that it is properly inserted and fixed on to the rack.
Whenever any PCB is Replaced, connect the wires as per
schematic drawing only. Else a severe damage to PCBs may
occur.
Keep the AC Input switches always ON in Step Down
Transformers.
In case of emergency or any problem, switch OFF all the
switches.
Keep the DC Input switches always ON in Converters
Keep the AC Input switches always ON in Bypass CVT
Regulator.
Check the healthiness of SPD periodically and whenever you
feel surge is occurred.
Keep the Auto-Manual bypass switch provided in the panel in
Auto position.
20
Don’ts
Do not take out plugs of modules when in working.
Do not connect batteries when modules are on.
Do not switch off the MCBs of both or in fact any one
inverter.
Do not remove the Inverter Input/Output connectors with
Inverter Input MCB ON.
Do not switch off the incoming of AVR.
Do not remove the flat cable connected to a DC-DC
converters.
Do not run AVR at no load.
Do not short output of transformer.
Do not connect Battery Bank to IPS without removing the
battery fuse.
Do not disturb the factory adjusted potentiometers used in
PCBs.
Do not restart the system without knowing the basic
cause.
Do not use wire fuses.
DISCLAIMER
The information given in this pamphlet does not supersede any existing
provisions laid down in Signal Engineering Manual, Railway Board
and RDSO publications. This document is not statutory and instruction
given in it are for the purpose of guidance only. If at any point
contradiction is observed, then SEM, Railway Board/RDSO guidelines
or Zonal Rly. Instructions may be followed. 21