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Hkkjr ljdkj &GOVERNMENT OF INDIA
jsy ea=ky;& MINISTRY OF RAILWAYS
¼dk;kZy;hu iz;ksx gsrq½& (For official use only)
de otuh lgt oguh; fu;a=.k
nwjHkk"k midj.k
LIGHT WEIGHT PORTABLE
CONTROL TELEPHONE
dSeVsd@,l@2005@ ,yMCY;wihlhVh@1-0 CAMTECH/ S /2005/LWPCT/1.0
uoacj 2005 November 2005
Maharajpur, Gwalior – 474020
Centre
for
Advanced
Maintenance
TECHnology Excellence in Maintenance
CONTENTS
Sr.No.
Description
Page No.
Forward ii
Preface iv
Contents vi
Correction Slip viii
1 Introduction 1
2 Brief Description 2
3 Components 4
4 Working 11
5 Specifications 16
6 Installation 18
7 Operating Instruction 19
8 Maintenance 20
9 Testing 21
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dz-la[;k o.kZu ist ua-
çkDdFku iii
Hkwfedk v
fo"k; lwph vii
lq/kkj iphZ ix
1 ifjp; 1
2 laf{kIr fooj.k 2
3 vo;o 4
4 dk;Z fof/k 11
5 fof’k"Vhdj.k 16
6 laLFkkiu 18
7 ifjpkyu vuqns’k 19
8 vuqj{k.k 20
9 ijh{k.k 21
PREFACE
CAMTECH is continuously putting efforts in the
field of documentation & upgradation of information on
Signal & Telecommunication practices. This handbook
has been prepared to help the field staff to help in
installation & maintenance of light weight portable
control telephone equipment.
It is clarified that this handbook does not
supersede any existing provisions laid down in
“Telecom Engineering Manual”, Railway Board
publications and RDSO publications. This handbook is
not statutory and instructions given in it are for the
purpose of guidance only.
We are sincerely thankful to Shri M.K.Yadav,
Director (Tele)/RDSO and field personnel who helped
us in preparing this handbook.
Since technological upgradation and learning is a
continuous process, you may feel the need for some
addition/modification in this handbook. If so, please feel
free to write us. We shall be highly appreciating your
contribution.
CAMTECH A.K.SAGAR
GWALIOR DIRECTOR (S&T)
DATE : 30.11.2005
FOREWORD
It has always been a constant endeavor to utilize
better-upgraded technologies. RDSO has designed light
weight portable control telephone which is not only light
weighted but also can be used on 2-wire as well as 4-
wire communication.
Failure of control telephone may
adversely affect the punctuality of trains. This handbook
covers working, installation, maintenance and operating
instruction of light weight portable control telephone.
I am confident that this book will serve to
enhance the capability and efficiency of the Railway
staff.
CAMTECH R.N. MISHRA
GWALIOR EXECUTIVE DIRECTOR
DATE : 30.11.2005
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dseVsd] Xokfy;j vkj- ,u- feJk
fnukad 30-11-2005 dk;Zdkjh funs’kd
ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this
handbook will be numbered as follows :
CAMTECH/ S /2005/LWPCTE/1.0C.S. # XX date ------
Where “XX” is the serial number of the concerned
correction slip (starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr. No.
of C.Slip
Date of
issue
Page No. and
Item no. modified
Remarks
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Hkkjr ljdkj &GOVERNMENT OF INDIA
jsy ea=ky;& MINISTRY OF RAILWAYS
¼dk;kZy;hu iz;ksx gsrq½& (For official use only)
de otuh lgt oguh; fu;a=.k
nwjHkk"k midj.k
LIGHT WEIGHT PORTABLE
CONTROL TELEPHONE
dSeVsd@,l@2005@ ,yMCY;wihlhVh@1-0 CAMTECH/ S /2005/LWPCT/1.0
uoacj 2005 November 2005
LIGHT WEIGHT PORTABLE CONTROL TELEPHONE
1. Introduction
The conventional mode of communication between
driver / guard and section controller is by means of
emergency control Telephone (ECP set). This
emergency communication is initiated from the site
of emergency by drivers / guards of the affected
train. For this purpose driver/guard have to carry
their ECP set to the nearest emergency post which
may be about 500 meters far.
Considering the difficulties in carrying the
conventional emergency portable control
telephone, RDSO laid the specification for light
weight portable control telephone lighter and
handheld for ease of carrying and using.
This handbook covers brief description, various
components, circuit working and installation of the
equipment according to the RDSO specification
no. IRS:TC:78-2000.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
2
2. Brief Description
The train control is an arbitrary supervision of the
actual movement of the trains between section in
order that section capacity may utilized to the
greatest advantage. This control is exercised by
Section Controller at control office.
Railway control circuits are omnibus telephone
circuits, which provides communication with each
train working point thus facilitating efficient train
operation. They provides satisfactory and reliable
communication between the controller and the
various way side stations, signalling cabins, loco
sheds, yard offices and tapping provided in entire
section.
When control circuits are through under ground
cables, it is difficult to connect a portable
telephones to the control wires to establish
communication between control office and any
point on section. To get over this difficulty taps are
provided from under ground cables at regular
intervals on entire section and these taps are
terminated on sockets.
The control office can be connected by plugging a
telephone in to any of the sockets. These taps are
provided from separate circuit instead of section
control circuit so that the section control circuit is
not un-necessarily disturbed. This speech circuit is
called the emergency control circuit.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
3
The lightweight 4 wire/2 wire control telephone
provides communication between any way side
point along the track to section controller in the
control office. This telephone works with two
pencil cells and has facility to communicate both
on RE area and non-RE area selectable through a
sliding switch.
Lightweight portable telephones are provided with
Drivers, Guards and other maintenance staff to
communicate with section controller as and when
required. For communication on 4-wire they
inserts 6 pin plug of his instrument in emergency
socket and establish communication with
controller. Similarly for communication on 2-wire,
both lines of over head control circuit will be
terminated to the terminals provided on the bottom
of the telephone instrument.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
4
3. COMPONENTS
Lightweight portable control telephone is consist
of the following components.
Body of telephone instrument
Transmitter
Receiver
Transformer / induction coil
Battery compartment
Battery indication
Cord
Internal wiring Terminals and PCB
DC Blocking Capacitor
Changeover Switch
Six-pin Plug
Battery ON-OFF switch
Press to talk (PTT) switch
Terminal for 2 wire
i) Body of telephone instrument
The body of the Lightweight portable control
telephone instrument is made of mild steel or ABS
plastic. The shape of the body is rectangular box.
The weight of this instrument with all components
except cord and connector is 400 grams in case of
mild steel body and 350 grams in case of ABS
plastic body. The simple sketch of the instrument
is shown below:
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
5
Battery
Compartment
Hole for Coiled Cord For 2 wire
Line
ii) Transmitter
Electrodynamic transducers /condenser`
microphone/ ceramic microphone is provided as
transmitter. The transmitter is work on 3 volt DC
with associated amplifier for its operation.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
6
iii) Receiver
Electrodynamic transducer is provided as receiver.
For the protection against acoustic shock, two
rectifiers in parallel and with opposite polarity are
provided across the receiver.
iv) Transformer / induction coil
Two sets of transformers are provided to match the
transmitter and receiver’s impedance with the line.
Transformers are vaccume impregnated and the
complete windings are protected by proper
insulation to avoid ingress of moisture.
v) Battery compartment
Battery compartment is provided on the
instrument. The cover of this compartment is press
& fit type or screwed flush telephone body. The
Lightweight portable control telephone instrument
is work on 3 volt DC for that purpose two numbers
dry pencil batteries of 1.5 volt are used. These are
housed in a plastic holder fitted with springs to
give proper contact pressure to batteries.
The maximum working current of Light weight
portable control telephone instrument during talk
condition is not more than 15 milli amperes.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
7
vi) Battery indication
Dual type LED battery indication is provided in the
front side of the Lightweight portable control
telephone instrument. When battery ON/OFF
switch is put to ON position, green light shall
appear for normal battery voltage and red light for
low battery voltage.
In case of red LED appearing, batteries are
required to be replacing by new ones.
vii) Cord
A cord is provided between 6 pin plug and screw
terminal. This 6 core cord is made of multistrand
PVC insulated wire and not less than 1.5 meter in
length.
Cord’s inserted end is firmly held inside the body
of the telephone instrument so that it can not get
pulled out due to jerks, dangling of the plugs,
repeated usage, rough handling etc.
viii) Internal wiring Terminals and PCB
Glass epoxy PCB of 1.6 mm is used. The PCB is
coated with epoxy base antifungal varnish to
provide protection against dust, humidity, fungal
infection and mechanical abuses.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
8
ix) DC Blocking Capacitor
Capacitor made of mettallised polyster is provided.
1.5 to 2.2 micro farad capacitor of operating
voltage minimum 400 volt is used to avoid tripping
of the circuit breaker of the control circuit.
x) Changeover switch
Sliding type switch is provided on the side of the
instrument. It works on one side with 2-wire
control line and opposite side with 4-wire control
line. “2 Wire” and “4 Wire” is printed on the body
to signify the exact position of the switch.
xi) Six pin plug
6-Pin plug is connected with the cord and provided
for inserting in emergency socket. Connections of
six-pin plug’s are such that two outer most pins are
connected on receive, next two on trans and central
two pins are connected to terminals for 2-wire
working.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
9
L2
L1
Tx
Rx
Tx
Rx
PLUG CONNECTION DIAGRAM
xii) Battery ON-OFF switch
A sliding type switch is provided on the body of
the Lightweight portable control telephone
instrument for battery make ON or OFF.
This switch is provided in the series with batteries
and extend power to receive amplifier of the circuit
when pressed to ON position. It also extend power
to LED when in the ON position which will glow
to indicate that the telephone instrument is ready
for use.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
10
xiii) Press to talk (PTT) switch
Press to talk switch is provided on the body of
lightweight portable control telephone. When this
PTT switch is pressed, it will extend power to trans
amplifier & when released, it will disconnect
supply to this amplifier.
xiv) Terminals for 2 wire
Separate optional terminals at the bottom of the
telephone body are provided for 2-wire connection.
In case if on our requirement these separate
terminals are provided, central two pins of six-pin
plug will be with out any connection. These
separate terminals are banana type terminals.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
11
4. Working
Block diagram of lightweight portable control
telephone instrument is given below:
The circuit consisting of electrodynamic inset and
a condenser microphone. In the transpath the
speech output signal from condenser microphone is
low, hence the signal is amplified through an
inbuilt IC amplifier. Another feature in this
telephone is that it has a multi colour LED to
indicate status of battery. A green light indicate
normal condition of battery, red indicates low
battery status.
The wiring diagram and a typical Circuit Diagram
of the instrument manufactured by Epsilon
Electronic Equipment & Components Pvt.Ltd is
shown on next pages.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
12
A low voltage IC amplifier U1 is used for trans and
transistor amplifier is used for receive. The trans
amplifier receives the voice from the condenser
microphone and the gain of the amplifier is
adjusted to get 0-dB output across Tx / (L1-L2).
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
14
COMPONENTS – LIST
Part No.
Description
Type
Make
Qty
/Pcs
RESISTORS
R1,R4,R5,R17 1K/ .25W MFR Philips/Keltron 4
R2 680R/.25W MFR Philips/Keltron 1
R3 100K/.25W MFR Philips/Keltron 1
R6 43K/.25W MFR Philips/Keltron 1
R7,R12 1M/.25W MFR Philips/Keltron 2
R8 68R/.25W MFR Philips/Keltron 1
R9 33K/.25W MFR Philips/Keltron 1
R10 470R/.25W MFR Philips/Keltron 1
R11 56K MFR Philips/Keltron 1
R13 39R/.25W MFR Philips/Keltron 1
R14 1R/.25W MFR Philips/Keltron 1
R15,R16 560R/.25W MFR Philips/Keltron 2
R18 330R/.25W MFR Philips/Keltron 1
CPACITORS
C1, C9 .22MFD/100V PPC Philips/Keltron 2
C2 1MFD/63V Electrolytic Philips/Keltron 1
C3, C10 .1MFD/100V PPC Philips/CTR/FEC 2
C4,C6,C8,C12,
C13
10MFD/25V Electrolytic Philips/Keltron 5
C5 100MFD/40D Electrolytic Philips/Keltron 1
C7 .33MFD/100V PPC Philips/CTR/FEC 1
C11 1.5MFD/400V PPC Philips/Advance 1
DIODES
D1, D2 1N4148 Switching CDIL/ECIL 2
D3 1N4007 Rectifier CDIL/ECIL 1
ZD1, ZD2 4.7V/1WATT Zener CDIL/ECIL 2
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
15
TRANSISTORS
Q1 TO Q4 2N2222A NPN BEL/CDIL 4
POTENTIOMETERS
P1 20K Multi Turn 3296 Bourns/Spectrol 1
P2 500R Multi Turn 3296 Bourns/Spectrol 1
INTEGRATED CIRCUITS
U1 MC34119 OP-AMP National/Signetics 1
MISCELLANEOUS
RECEIVER RX RT160 RAJAMANI 1
CONDENSER MIC TX CZN-15E SIEMNS 1
SW1 SLIDE SWITCHES GILARD/IEC 1
PTT MICRO SWITCH OEN/IEC 1
PTT BUTTON ----- EPSILON 1
6CORE CORD ------ ASWANI 1
6PIN FLAT PIN ------ EPSILON 1
BI-COLOR LED COMMON CATHOD Fairchild/Quality 1
PC 8 EEE 9935/4 EPSILON 1
EE25 BOBBIN 5 PIN VERTICAL BHAGYA LAXMI 1
EE20 BOBBIN 10PIN VERTICAL BHAGYA LAXMI 1
MOULDED CABINET ABS PLASTIC EPSILON 1
CONNECTORS 6PIN RELAMETE UNICON 1
CONNECTORS 4PIN RELAMETE UNICON 1
CONNECTORS 2PIN RELAMETE UNICON 1
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
16
5. Specifications
1. Maximum working current
during talk condition.
< 15 mA
2. Insulation resistance at 500
VDC, between all terminals of 6
pin plug connected together and
the main body.
> 100 Mega Ohms
3. High voltage at 2 KV, 50 HZ
AC sinusoidal r.m.s. when
applied between the body and
all the pins of the 6 pin plug
connect together for one minute.
No breakdown
2 wire side
Send Efficiency
4. Send level –44dBm, 1000 Hz
across MIC with 160 ohms
impedance
> 0dBm (across
line terminals with
600 ohms
impedance)
5. Side tone across receiver < - 18 dBm
6. Total harmonic distortion < 3%
7. Frequency response 300 Hz to
3400 Hz
±0.5 dB
Receive efficiency
8. Receive level –12dBm, 1000 Hz
across MIC with 600ohms
impedance
> -18dBm (across
receiver with 160
ohms impedance)
9. Total harmonic distortion < 3%
10. Frequency response 300 Hz to
3400 Hz
±0.5 dB
11. Insertion loss < 0.2 dB listen
condition
<0.8 dB talk
condition
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
17
4 Wire side
Trans efficiency
12. Send level –44dBm, 1000 Hz
across MIC with 160 ohms
impedance
> +3.8dB (across
Tx terminals
with 1120 ohms
impedance)
13. Side tone across receiver ±0.5 dB
14. Total harmonic distortion < 3%
Receive Efficiency
15. Receive level at input of –20
dB, 1000 Hz across mic
terminals with 1120 ohms
impedance
>-26 dBm
(across receiver
terminals with
160 ohms
impedance)
16. Frequency response 300 to 3400
Hz
±0.5 dB
17. Insertion loss < 0.5 dB listen
condition
< 1 dB talk
condition
Dimensions
18. Long 175 mm
19. Wide 50 mm
20. Deep 40 mm
21. Weight 400 gram (max)
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
18
6. Installation
The lightweight portable control telephone is
supplied duly packed in a waterproof pouch and is
provided with 6 pin plug. Pin configuration is as
given below:
L1 & L2 are available in the centre pins of the plug
as well in the binding terminals provided in the
telephone body. Normally as per the existing
wiring the 2 wire lines are not terminated in the
middle pins of the emergency socket.
Remove the telephone from the pouch and ensure
that 2 numbers of dry cells are inserted in the
battery compartment properly and close the lid.
Switch ON the power by sliding the switch to ON
position. The green LED shall glow. Keep the
second slide switch to 4 wire. The lightweight
portable telephone is ready to use. To talk to the
controller, press the PTT switch. After the use,
power OFF to avoid battery drain and keep the
telephone inside the pouch.
Rx Tx L1 L2 Tx Rx
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
19
7. Operating Instructions
Keep 2-wire/ 4-wire switch towards 2-wire
side for 2 wire operation and 4 wire side for 4
wire operation.
Insert 6 pin plug in emergency socket for 4
wire operation or connect L1 & L2 to over
head line for 2 wire operation.
Now switch ON the power of the instrument.
Press PTT (Press to Talk switch) to talk.
After conversation switch OFF the power.
If battery indication is RED, replace the
batteries with new one.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
20
8. Maintenance
The lightweight portable control telephone
equipment is a solid state, very handy, easy to
operate and maintenance free instrument.
However, following checks may be done for
trouble free operation.
If the power ON LED shows red, the battery
has fallen below 2.7 volt DC. The battery has
to be replaced.
Cleaning of instruments from dust and
moisture.
Continuity of cord.
Since the circuitry works on 3 volts DC and the
operating power is as low as 1mili watt. No
components shall fail. However, while using the
telephone heavy induction due to lightning may
effect the telephone, even though adequate
protection is provided in the line with MOVR and
GD tube.
CAMTECH/S/2005/LWPCT/1.0
Lightweight portable control telephone November’2005
21
9. Testing
Lightweight portable control telephone instrument
can be tested for insulation and insertion loss tests.
Insulation Test
The insulation resistance between all terminals of
six-pin plug connected together and body of
lightweight portable control telephone instruments
shall not be less than 100 mega ohms when tested
with 500-volt DC meggar at ambient temperature.
Insertion loss tests
2-Wire Listen Condition
It shall not be greater than 0.2 dB.
2-Wire Talk Condition
It shall not be greater than 0.8 dB.
4-Wire Listen Condition
It shall not be greater than 0.5 dB.
4-Wire Talk Condition
It shall not be greater than 1.0 dB.