Maintenance Manual Training Presentation - R.A

OCS950 Maintenance Training
Pakistan Railways Rehabilitation Signalling Project
OCS950 Maintenance Training Course
100174081 OCS950 Maintenance Manual Training Material Rev.A
Bombardier Inc. or its subsidiaries. All rights reserved.
OCS950 Basic Course
OCS950 Basic Course
OCS950 Basic Course
OCS950 Basic Course
OCS950 Basic Course
Features
Features
OCS950 Basic Course
10
System Overview
11
System Overview
12
System Overview
13
System Overview
14
System Overview
15
System Overview
16
OCS950 Basic Course
17
Concentrator
18
Concentrator
19
Concentrator
20
Concentrator
RS232 Fiber optic
RS232
PCM : Pulse Code Modulation

21
Concentrator
22
Concentrator
23
Concentrator
24
Concentrator
25
Concentrator
26
Concentrator
27
Concentrator
28
OCS950 Basic Course
29
Object Controller
Object Controller 1 to 4 in First Sub-rack
Max 4 OC per sub-rack CCM-E board in first slot of each OC Control boards 1 CCU with 2 COM boards 1 OCT board
30
Object Controller
Object Controller 5 to 8 in Second Sub-rack
Max 4 OC per sub-rack CCM-E board in first slot of each OC Control boards 1 OCT board
31
Object Controller
32
Object Controller
CCM-E: Controller and Contact Monitoring Enhanced Board
4 vital inputs for Track Circuit Status (Occupied, Free, Out of Control), Relay Detection (ML, Photo cell and so on), and Relay Interface between CBI and Non-CBI. Main board to put EEPROM for signal software, point software, and Transparent Input Output software. Always exist in the first slot of every OC position.
33
Object Controller Front panel LED indicators CCM-E

LED PWR Green Description ON Power on (5V) indication
Hints for fault tracing
OFF Power missing
- Check corresponding 24V pushbutton on the OCT board. - Check the PWR LED on the OCT board indicating 24V system voltage from the power supply unit. - Check fuses. - Replace CCM-E board.
RD Green
ON Receive Data from CCU OFF No Receive Data from CCU Check COM board status
CPR Green
ON Processor running OFF Processor halt Check for OC error codes in interlocking processor alarm log.
34
Object Controller
35
Object Controller
36
Object Controller
37
Object Controller
38
Object Controller
39
Object Controller
40
Object Controller
41
Object Controller
COM: Communication and Modem Board
COM3(Serial Connection)
Bombardier Inc. or its subsidiaries. All rights reserved. 42
Object Controller
43
Object Controller
44
Object Controller
OCT: Power Supply Board
One per sub-rack Power the sub-rack with 24V Switches for disconnection of each OC
45
Object Controller
LED PWR Green
Description ON Power on (24V) indication OFF Power missing
Hints for fault tracing
- Check fuses. Check the power supply unit.
46
Object Controller
47
Object Controller
48
Object Controller
49
Object Controller
50
Object Controller
Power Supply Units
PSU 72 PSU 330 PSU 321
51
Object Controller
PSU 72
Input Voltage 220 Vac Output Voltage 24 Vdc Used for OC subracks and fan unit
52
Object Controller
PSU 330
Input Voltage 220 Vac Output Voltage 110 Vac and 24/50 Vdc Used for LMP and SRC
53
Object Controller
PSU 321
Input Voltage 3x380 Vac Output Voltage 3x380 Vac Used for MOT
54
Object Controller
55
OCS950 Basic Course
56
Data Transmission
57
OCS950 Basic Course
58
Tools
59
Tools
60
OCS950 - Configuration of Subrack and Address Strapping (based on Pakistan Rehab project)
Configuration of subrack and address strapping

Tools for generate the address for OC and CCU and generate configuration file for board strapping.
62
Why we address the system?

A name indicates what we seek. An address indicates where it is. Addressing indicates the logical location of the object. If wrongly coded, the object controller will not start.
Addressing in the System

The object controller addresses are built on the following data Interlocking area Communication loop Object controller
Concentrator unit (CCU)
64
How addressing work ?
First address will generate from Config subrack and board strapping file. ILS team will map address with the wayside object. Now the interlocking know that where each address is. When CIS want to communicate with wayside they send the telegram which contain address and order. To identify which part of telegram stand for the OCgentab file is required.
65
Where each address comes from ?

A1 = 0X AB A=Loop no. then transform to Hex B={IL no (0-7) x 2} Hex
A2 = 0X AB A=CCU no. (0,1,2,) then transform to Hex B = {(OC no.(1-8)x2 )-1} then transform to Hex IND : Individualization Note : IND is not directly use for addressing but itll tell us about configuration of each combination of board for example CCME-SRC CRC
CRS is abbreviation for Cyclical Redundancy Check and the CRC-program is used to calculate and verify checksums for our config subrack we use CRC8 Note : The calculation for A1 and A2 is for the same understanding between the team only it can change depend on designer or type of IPU.
66
CCU Address
Loop No. Range 1-13
CCU address Rang 0-14
CCU COM1 A X 8 X 7 X 6 X5 X 4 X 3 X 2 X 1 SW33
CCU COM1 B X X X X X X X X SW34
Cable data
Not used
67
Object Controller Address Field
Loop No. Range 1-13
Interlocking area Range 0-6 Always 0
X X X X SW9
CCU address Range 0-14 A2 X X X X X X X SW10 8 7 6 5 4 3 2 X1 CRC X X X X X X X X SW12
OC No. Range 0-7
CRC
Always 1
68
A1 X X X
8 7 6 X5 4 3 2 1
IND X X X X X X X X SW11
Type of object
Back Plane Address Strapping Fields
69
Back plane DIP Switches

A1
0 1
8 7
IND
0 1
MSB 7 5 6 8
LSB
A1 = 32 (Hex) A2 = 01 (Hex) IND = 38 (Hex)
A2
0 1
8 7
CRC
0 1
MSB 7 8
CRC = C4 (Hex)
LSB
ON
70
ON
ON
ON 6
Board and Position Strap

To avoid shifting positions of connectors in between boards in same sub-rack If wrongly coded or placed the object controller will not start
OCS950 - Configuration of Subrack and Address Strapping

The position and board straps will protect the OC from going into operation if the wrong boards are used in the wrong position.
The position and board straps used for all boards except COM and OCT.
72
OCS950 - Configuration of Subrack and Address Strapping
OFF P1 C O N N E C T O R
SW2 SW1
ON
1 2 3 4 5 6 1 2 3 4 5 6
A6 A5 A4 POSF5 POSF4 POSF3 NR1 NR0 POSF2 POSF1 POSF0
Board Straps (Address) Position Straps
Board Straps (Number) Position Straps
73
Board Strap
The board straps are used to make a distinction between boards of the same type within the same OC.
OFF P1 C O N N E C T O R
SW2 SW1
ON A6 A5 A4 POSF5 POSF4 POSF3 NR1 NR0 POSF2 POSF1 POSF0
1 2 3 4 5 6 1 2 3 4 5 6
A4-A6 will depend on the type of board.
Protect wrongly place for the same type of board in the OC in case that more than 1 same type board is used in 1 OC
74
LED indication
Frontpanel Three LEDs indicating the status
LED1 LED2 LED3
LED 1 Off
LED 2 Off
LED 3 Off
Description CCM-E board is powerless.

P2
Connectors P2 and P4
On On
On
Off
CCM-E board is powered. The CCM-E board receives data from the CCU. But, the CPU is not triggering one of the RTWs. The board is either performing a start up or is not working correctly. The SW is executing.
On
On
On
P4
75
OCS950 - Object Controller Cabinet
Outline
Cabinet Layout and Components Power Distributions Power Supply Units Power Cables Boards Communication Controller Unit (CCU) Coding Pin
77
Cabinet
Indoor OBC
3NSS004544-11 HxWxD: 2260x1400x600mm 4 OCS950 sub-racks 16 OC 4 Compact PSUs Base 3NSS005039-02

HxWxD:100x1400x600mm
78
Subrack
The sub-rack should preferably be ordered completely assembled with OC boards and dummy panels and with address strapping coded in the back plane.
79
Subrack 3NSS001503-01: Indoor use only
80
Connection Unit (Voltage Input)
Power from PSUs to Connection Units 20% Spare needed for each unit 1 function per 1 Unit Use with Power Cable
81
Connection Unit (Voltage Input)
6x2 2 Voltage Levels
82
Connection Unit (Terminal Block)
Power from Voltage Input to Board (Except CCM-E) Feed power to Board Outputs from Boards Use with Connection Cable (for inputs and outputs)
83
Connection Unit (Terminal Block)
CCM-E
LMP
MOT1
Have fuses and Terminals For Power
SRC
84
Connection Unit Voltage Input Connecting with Connection Unit
From PSU Connection Unit Voltage Input (3x2) Connection Unit (Terminal Block)
85
Connection Cable
Connection between board and Connection Unit Power (except CCM-E) Inputs from equipment to board via Cable Rack Cabinet Outputs from board to equipment via Cale Rack Cabinet
86
Connection Cable
CCM-E
LMP
MOT1
Have Inputs for Power
SRC
87
Outline
88
Power Distribution Terminal
Receive power from Power Supply Panel (through Circuit Breaker) Feed power to PSU Main components Terminal Fuse, Protective Earth Terminal, Disconnection
89
For PSU 72: Subrack and Fan Unit
90
For PSU 72: Subrack and Fan Unit
91
For PSU 330: Signal and Magnetic Key Locked Point
92
For PSU 330: Signal and Magnetic Key Locked Point
93
For PSU 321: Electrical Point Machine
94
For PSU 321: Electrical Point Machine
95
Connecting: 220 VAC to PSU 72 Power Supply Panel
BX220 / NX220 Power Dist Terminal PSU72
OBC Cables beyond OBC and Circuit Breakers

96
Power Cables CRSC
Connecting: 220 VAC to PSU330 Power Supply Panel
BX220 / NX220 Power Dist Terminal PSU330

97
Power Cables CRSC
Connecting: 3x380 VAC to PSU321 Power Supply Panel Power Dist Terminal PSU321

98
Power Cables CRSC
Outline
99
Power Supply Unit
Feed Power to Subracks and Power Connection Unit Voltage Inputs PSU72, PSU330 and PSU321
100
Receive power from Power Distribution Terminals
Power Feeding Arrangement
PDC
Power Distribution Terminal
PSU Subrack
Board
Fan Unit
101
Connection Unit Voltage Input
PSU72
Input 220VAC Output 24VDC to Subracks and Fan Unit
102
Pin Designation: in Application Document
103
Pin Designation: in OBC
104
PSU321
Input 3x380VAC Output 3x380VAC Electrical Point Machine
105
106
107
PSU330
Output 110VAC for Signal Output 28 VAC for Night Mode Signal Output 50VDC for External Logic (SRC for Magnetic Key Locked Point, Axel Counter, Level Crossing
108
Input 220VAC
109
110
Outline
111
Power Cables
Number and Size of Cores
Cable Type
Length (mm.)
112
3NSS005965-xxxx 2x2.5 sq.mm. 3NSS005202-xxxx0 3x1.5 sq.mm.

113
3NSS005966-xxxx 3x2.5 sq.mm.
3NSS008732-xxxx0 4x1.5 sq.mm.
114
3NSS005745-xxxx DSUB15 Female - Male OCT and PSU72
115
3NSS003446-xxxx DSUB9 Female - Male Fan Unit and PSU72
116
117
118
Outline
119
CCM-E: Contact Monitoring-Extended Board
4 Inputs
For detection (relay contact status) Ex. Track Circuit, Alarm, Magnetic Key Locked Point Detection EEPROM: burn according to boards in the same OC as CCM-E
120
CCM-E: Pin Designation
CCO = Contact Code Output CCI = Contact Code Input
121
Numbers of connected pins are defined according to order of channels of inputs.
CCM-E: Controller and Contact Monitoring Enhanced Board
122
CCM-E: Circuit: Track Circuit Detection
Connection Cable
Connection Unit
Single Connection of Contact Monitoring
4 Inputs: 3 Used 1 Spared (Unused)
Interface: CRSC
123
CCM-E: Connection
Connection Cable
Connection Unit
124
CCM-E: Circuit: Level Crossing
125
LMP: Lamp Board
Controls Signal 6 Outputs = 4 Proceeds 2 Stops Maximum 2 LMPs in 1 OC IND Specified by Type of Signal Control
126
LMP: Inputs and Outputs
110/230 V* 110/230 V* 28/56 V* 0V 1 3 2 4
1 2 3 4
MAINS_SUPPLY_PROCEED MAINS_SUPPLY_STOP MAINS_RETURN_NIGHT MAINS_RETURN_DAY Proceed4 Proceed4_return Stop1 Stop1_return Stop2 Stop2_return Proceed2 Proceed2_return Proceed3 Proceed3_return
x x x x x
Proceed lamp no 2
Proceed lamp no 3
Proceed lamp no 4
Mandatory fuse* Optional fuse*
Stop lamp no 1
Stop lamp no 2
LMP board
* Application specific
127
Proceed1 Proceed1_return
Proceed lamp no 1
LMP: Inputs and Outputs
128
LMP: Pin Designation
129
LMP: Connection
Connection Cable
Connection Unit
130
LMP: IND
131
MOT1: Motor Control Board Type 1
Maximum two MOT1 in one OC In voltage 80-400 VAC Out voltage 80-400 VAC IND Specified by Type of Point Control
132
Controls AC point machine, both one phase and three phase
MOT1
CCO2, CCI2 must be internally looped according to the software requirement
Power to Drive Motor
2 Channels are CMO (CCO1 and CCO2) 2 Channels are CMD (CMD1 and CMD2)
Detection
Use CMD because of Normal and Reverse Position
133
Use CMO (CCO, CCI) and CMD (CMD) for Contact Monitoring
MOT1: Pin Designation
134
Power to Drive Motor
Detection
135
Power to Board
136
MOT1: Connection
Connection Cable
Connection Unit
137
MOT1: IND
138
SRC: Safety Relay Controller Board
Maximum three SRC in one OC Input/Output voltage 1260VDC 4 Vital Outputs
139
Controls wayside equipment such as Magnetic Key Locked Point, Level Crossing, Axle Counter, typically relays
SRC: Pin Designation
140
SRC: Pin Designation

Power
Equipment (Relay)
141
SRC: Connection
Connection Cable
Connection Unit
142
SRC: IND
143
OCT: Power Supply boards (Octopus)
To have the +24 V power supply switches for each OC (position) for the on/off control. To be the interconnection point between two sub-racks for the CCU-OC transmission links having one mutual CCU. Part of CCU The OCT board is a mandatory board for every sub-rack.
144
To be the power transfer of +24 V to the back plane and the I/O-boards and the CCU-unit from the power supply unit and to control the current to each OC.
OCT: Pin Designation
145
P2 Power from PSU 24 VDC from PSU to Subrack
OCT: Pin Designation and Connection
P4 Communication between Subrack 1 and Subrack 2 (same CCU)
3NSS002775-xxxx 37 female poles only for OCT Communication with next Subrack
146
COM-3: Communication and Modem Board
Can be the communication between 2 OC Cabinets (same Communicating Loop) Part of CCU
147
Communication between OC (via OC Cabinet) and Interlocking System (via IPUC)
COM-3: Pin Designation
P6 P4
DB9 DB25
Outside Cabinet Inside Cabiinet

From CCU in another cabinet / from IPU in IPUC
To Next CCU in the same Cabinet
148
COM-3: Connection
IPUC
IPUC
3NSS003442-0120 9 Poles IPU and CCU
149
COM-3: Connection
IPUC
IPUC
3NSS003831-0020 25 Poles CCU and CCU in the same Cabinet
150
COM-3: Connection
IPUC
OBC
3NSS003442-0085 9 Poles CCU and CCU in another cabinet
151
Fan Unit
24VDC from PSU72 6 Fans The fan unit should be placed in-between sub-racks, providing the fan unit to use both suck and blow air technique.
152
Fan Unit: Position
153
Fan Unit: Pin Designation and Circuit

-Fan unit
-X2 1 2 3 -X3 1 2 3 -X4 1 2 3 1 2 3 -X6 1 2 3 -X7 1 2 3 -X8 1 2 -X1 1 2 Relay -X9 Female 9 pin Dsub connector for alarm Pin 1 Normally closed Pin 5 Common Pin 9 Normally open 3
Fan 1
Fan 4
-X5
Temp. sensor
Fan 2
-X12
Fan 5
Pin -P1 1 5 9 SC -P4 8 4 7 3 SC
1 2
Male 9 pin D-sub connector for power supply
Fan 3
Fan 6
154
Fan Unit: Connection
3NSS003446-0020 DSUB9 Fan Unit and PSU72
155
Dummy Panel
Fulfil the space in OC and Subrack
156
Dummy Panel: for Board Space
6 available sizes Defined in Configuration of Subrack and Address Strapping but not in OC Distribution List
157
Dummy Panel: for PSU Space
3NSS003646-01 used with cassette (at least 1 PSU in the row)
158
Dummy Panel: for PSU Space
3NSS004967-01 entire row +H5 (replaces cassette if there are not PSU in the row)
159
Dummy Panel: for Position +H6
3NSS008898-01 and +H7
between subrack +H5
160
Board Size
161
Board Position in Subrack
162
163
164
165
Outline
166
CCU: Communication Controller Unit
2 COM-3 + 1 OCT 1 CCU handles 2 Subracks (8 OCs)

Communication between OC (OC Cabinet) and CIS (IPU) and between 2 OC Cabinets (same communicating loop) Loop number, IPU number, Interlocking Area number are defined in Loop Communication Diagram 1 IPU per 1 Station except BQM (2 IPUs)
167
Loop Communication Diagram

1 IPU can be used up to 12 loops (8 for this project)
Interlocking System Loop Port Concentrator Loop Concentrator Controller Link Object Controller Object Cable Wayside Object 1 ... ... (n) 1 ... ... 8 1 ... ... 15 1
Loop 3 and 4 for communication for IPU Loop Loop 1, 2, 5-8 for communication between OC Loop IPU950 R3
Central Interlocking System
Standby Main Central Computer ... ... (n)
Object Controller System
From Paki Rehab OC Distribution List Training Material by Wichit Inuthai
168
Loop Communication Diagram
169
OC Cabinet and IPU Cabinet
NWS OBC_DN1 Sheet 51
NWS IPUC Sheet 6
170
OC Cabinet and IPU Cabinet

NWS IPUC NWS OBC_DN1
171
Loop Communication Diagram and IPU Cabinet
172
Outline
173
Coding Pin
Prevents the mismatching between Connection Unit and Connection Cable
Defines in OBC drawing, assigned according to the position of Connection Unit in OC Cabinet
174
Coding Pin
Break fingers and insert to Connection Unit

175
Insert to Connection Unit female plug number as assigned
OCS950 Maintenance Manual
Prerequisites
Persons who need to perform the maintenance shall have the knowledge of OCS950 and able to read and understand the OC Cabinet drawing before performing the work. The following prerequisites shall be considered during maintenance and faultfinding: All OCS950 components should be handled in accordance with the guideline for Electrostatic Discharge for handling electronic equipment, Good workmanship is required. Maintenance and fault finding should be performed by personnel with proper education and training.
177
178
Electrical Isolation
High voltages are distributed in object cables and interconnection cables.
All the necessary safety precautions required to handle electrical appliances shall be taken. This includes the following: Isolate appropriate supply voltages before removing front connector replacing boards in the sub-rack replacing fuses accessing terminals Remove the front connector before a board is to be replaced. Ensure that cables are handled carefully to avoid accidental damage. Ensure that proper earthing of the equipment is maintained
179
The site specific drawings should be referred to if isolation is required at this level. Generally isolation should be performed at the lowest practical level based on the need to keep trains running. Reference must be made to the appropriate wiring diagrams and product application manuals. The methods to isolate supply voltages are detailed below: Switching off the OC Logic 24 V DC circuit breaker on the front of the System Power PSU 72 to remove power to all object controllers in a subrack. Selective breaking of the 24 V DC supply to one of the four object controllers in a sub-rack is accomplished via the POS1 to POS4 24 V push buttons on the OCT board, see Figure in next slide.
180
OC1
OC2
OC3
OC4
CCU
OC sub-rack
OCT
181
The methods to isolate supply voltages (cont.): Observe that only the 24 V DC supply is broken and not the supplies that may be required for the objects connected to the object controller in question. This supply also removes the coded signal from the 4 CMO inputs on the CCM-E board. Selective breaking of the supply voltage for signal lamps, point machines and relays is accomplished by removal of the individual circuit protection devices for each board i.e. LMP, MOT, COM-3 or SRC. The circuit protection devices, i.e. fuses, are placed in the cable connection units for each board. Isolation of the supply voltage for signals and point controllers can be achieved by using one of the installed isolation switches. Isolation of the 24 V DC to the fan unit is achieved by switching off the relevant circuit breaker on the front of the PSU72.
182
183
184
185
186
Preventive Maintenance
No periodic adjustments are necessary to sustain continuous system operation. Some simple preventive maintenance, such as inspection and cleaning activities, should be done to maintain high availability, ensure long component life, and simplify corrective maintenance. If the maintenance is done periodically, it may help to prevent system malfunction.
187
Preventive Maintenance:
Interval 12 months
Check Locks, Doors and Covers Unlock, open, close, and lock all doors. Check that all doors close properly and seal against incoming dust. Check that all door seals are OK. Tighten Board, Unit, Plug and Socket Screws Tighten all screws securing the electronic boards in the racks. Tighten all screws holding the contacts on the front of the electronic boards. If a screw is missing, replace it with a new screw.
188
Interval 12 months
Check for Outside Damages on Indoor Cabinets Check the exterior of the cabinet for damages. Check the doors, especially that they connect to the seal properly when closed, and that they do not let any dust in. Paint scratches on the surface to prevent rust. Remove rust and re-paint the cabinet stand. Damaged doors must be replaced. Damaged lock covers or locks must be replaced.
189
Interval 12 months
Check COM-3 Board Redundancy Reset the active COM-3 board and check that the standby COM-3 board takes control and stays in control of the OC. Check with the dispatcher that there is no loop split and that there is still central control of the OC. Repeat the test above for the now active COM-3 board. If this test fails, one of the COM-3 boards is probably broken.
Notify the dispatcher before performing the test or replacing the COM-3 boards.
190
Interval 12 months

Vacuum Clean Cabinet Use plain nozzle to vacuum the cabinet floor and any surface that can assemble dust. Use nozzle with long brushes to further clean the surfaces above and to also vacuum all other visible surfaces and parts. Excessive dust inside the cabinet indicates that door seals might have to be replaced or that seals of incoming cables are insufficient. Clean Cabinet Exterior, Indoor Cabinets Brush off dust from the cabinet roof. Check Seal of Incoming Cables Inspect the grommets for incoming cables to make sure that dust, water or insects cannot enter.
191
Interval 3 months
Check Fan Unit Alarm Indication Check the LEDs on the optical display on the front. Green The fan is OK. Red Fan failure. There may be an acoustic alarm if the red LED is lit. It can be turned off via a reset button on the front panel.
192
Corrective Maintenance
The OCS is designed to minimize the frequency of corrective maintenance and to provide a high degree of system reliability and availability. Corrective maintenance involves performing fault isolation to a failed system component, replacing the system component, and checking out the system for correct operation. Additional diagnostics to aid in fault isolation is available in the form of LED indicators that reveal the operating status of relevant boards. Exchanging components such as EEPROMs is considered as reinstallation and not maintenance.
193
Replacement of Boards If a board is found to be defective, it must be replaced by a spare board. Board replacement from spares requires that the hardware used to configure an object controller for a specific wayside object remains intact. Therefore, if the CCM-E board is replaced, the contents of the EEPROM on the spare must be identical to those on the failed board (i.e. microprocessor instructions for CCM-E.
194
Replacement of Boards (For both OC boards and COM-3 boards)
Turn off the power to the OC. Replace the board. Check serial number and revision state of the board to be changed. Check that the object controller board is properly fastened. Check that the board connectors are in the correct position and properly fastened. Check that the board connectors are free from defects. Check that the board connectors are labelled correctly. Start the OC and check that it is running and in control. If a COM-3 board is replaced, check that the replaced board is online. If the replaced board is not online, push the reset button on the other COM-3 board.
195
Test after Replacement Turn on the power to the concerned object controller position using the corresponding button on the OCT board. Test of Signal Object Controller A replacement test shall be performed either by the interlocking or Win OC-test version 2.0. The test procedure must cover the following inspections: Signal aspects: Stop, Proceed (All combinations of the signal). Contact detection: Check all used functions according to circuit diagrams. To perform the above test it is necessary to use the existing object or an object simulator.
196
Test of Point Object Controller A replacement test shall be performed either by the interlocking or Win OC Test version 2.0. The test procedure must cover the following inspections: Point in control in both directions and out of control. Contact detection: Check all used functions, according to circuit diagrams. If local mode exists, check the above-mentioned inspections in local mode. To perform the above test it is necessary to use the existing object or an object simulator. Test of Other Object Controller Start the OC and check that it is running and in control. A replacement test shall be performed either by the interlocking or Win OC-test version 2.0. The test procedure must cover the following inspections: Check that all used functions are tested, according to circuit diagrams. To perform the above test it is necessary to use the existing object or an object simulator.
197
Replacement of Fan Unit Isolate the 24 V DC supply using the appropriate isolation switch on PSU72. Disconnect the d-type connectors from the front of the unit and unscrew the TORX fittings holding the unit in the 19 frame. Remove the whole unit. Insert the replacement fan unit into the same location and secure with the TORX fittings. Reconnect the d-type connectors and switch the 24 V DC supply back on. Check if the system is OK.
198
Replacement of Cables: System Cable Replacement System cable replacement is considered to be unlikely since these cables are contained entirely within the housing. Since the interface modules are provided with front connectors, all cable connections can be reached from the front of the subrack. A cable shelf is provided below each sub-rack to support the cables. To prevent any hazards resulting from the misplacement of interface modules or front connectors, the front connectors are provided with electrical coding to match the configuration on the OC sub-rack back-plane. The front connector DIP switch settings are shown on the Configuration of Sub-rack and Address Strapping of each of 23 stations in the project.
199
Replacement of Cables: System Cable Replacement
The front connectors are only uniquely coded within a sub-rack and not across sub-racks. When connectors from different sub-racks are swapped over, then if the swapped connectors are for identical output board types (i.e. SRC, LMP or MOT) in the same position (i.e. position 1, 2, 3 or 4) within the sub-racks, the object controller will drive the wrong signal, point or relay. If the front connectors were removed from adjacent sub-racks simultaneously it is important to verify the functions of the wayside objects concerned. Check that the correct wayside object is controlled from the corresponding object controller.
200
Replacement of Sub-Rack A sub-rack breakdown is considered to be unlikely. The replacement of a sub-rack will affect a number of signals, points or relay interfaces. The impact on railway operation may be significant, especially if a second sub-rack is connected to the same CCU (via a cable between the OCT boards on each sub-rack). Isolate the sub-rack, including all 24 V DC, and other power supplies Disconnect all front connectors and let the cables remain in the tracks in the cable shelf Do not remove the lid. Remove all boards, observing ESD precautions and storing the boards in anti-static bags and preferably the correct cardboard boxes whilst replacing the sub-rack.
201 Bombardier Inc. or its subsidiaries. All rights reserved.
Replacement of Sub-Rack (cont) A Replace the sub-rack by a spare one. Adjust all backplane DIP switches i.e. A1, A2, IND, and CRC according to the site specific Configuration of Sub-rack and Address Strapping in the new sub-rack. This step can be done before the new rack is inserted, if preferred. Verify that the switch settings match the old sub-rack for extra confidence by using the IND Tool in the start-up kit. Check again in a methodical manner that the DIP switches are set correct. Insert all the boards, and attach all the front connectors EXCEPT for the loop communications cables on the front of the COM-3 boards. Seal the sub-rack
Replacement of Sub-Rack: test after replacement The new sub-rack, including OC boards, shall be verified with the following check list: Restore all the 24 V DC and other power supplies as required. Restart all the object controllers and ensure that the CPR lamps on the CCM-E boards are lit and steady For object controllers, check the following: CCM-E boards: all three LEDs are lit. For all CCUs, check the following: COM-3 boards: appropriate LEDs are lit. OCT board: LED is lit. Verify all object controller addresses with Win OC-test. After the replacement the sub-rack must be protected by a seal again
Replacement of PSU Isolate the faulty PSU from the mains. All power supplies have a mains power switch either on the unit or on the associated cassette. Remove the faulty PSU. Note that some PSUs may weigh up to 30 kg. Remove the protective cover from the faulty PSU. Inspect and make notes of how the input voltage selection devices are set. Copy the setting of the input voltage selectors to the spare PSU. Install the spare PSU. Be sure to tighten all screws securing the PSU to the metal frame. Restore the mains power. Ensure that all PSU output voltages are available.

204
Sealing instructions Sealing of double connector Disconnect the double connector. Clean the area around the dip switch area to remove grease etc. Apply the seal label. Connect the double connector. Fasten the double connector with the screws.
205
Sealing instructions Sealing of sub-rack All sub-racks shall be protected by a seal when they are mounted in a rack. This is an extra precaution, because the addresses of the spare sub-rack must be exactly identical to the replaced sub-rack. These addresses are placed inside of the backplane of the sub-rack.
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Sealing instructions
Sealing of sub-rack: Tie Strap

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Sign the label area of the tie strap with date and signature. Make a small bend of the tip of the tie strap. Pull the tie strap through in a suitable hole in the subrack on the left hand side and through a hole in the bar. Connect the tie strap and pull gently. Cut the over length of the tie strap.
Sealing instructions Sealing of sub-rack: Seal Label

208
The seal shall be glued on both the sub-rack and the standing bar. The location is on the right-hand side of the sub-rack on the upper part. Sign the label area of the seal with date and signature. Clean the area where the seal is to be applied (to remove grease etc.). Apply the seal label.
Fault Finding on EBI Lock Systems

The most likely starting point for a fault finding is an alarm reported on the Maintenance Terminal. This should pinpoint the address of the affected object controller. CCU Alarms / Error Codes CCU faults will generate a number of alarm codes. Information regarding hardware status as well as external conditions affecting wayside objects may be retrieved. A list of alarms and the associated actions can be found in the Alarm Code List. Object Controller OC faults will generate a number of alarm codes. Information regarding status of OC hardware as well as wayside objects may be retrieved.
209

Signal Controller Alarm 50: Open Circuit / Lamp Failure and AspectDegradation - Lamp Failure - LMP board fault - Cable break - Fuse failure Lamp circuit failure is detected by measuring current as for any other type of interlocking. Aspect degradation is therefore beneficial in terms of reducing delays, because LED signal only return to stop when absolutely necessary.

Signal Controller
Alarm 5C: LMP Output Low Current Limits The OCS determines failure of a lamp or its circuit by current measurement as for other types of interlocking. The used current limits are programmed into the PROM software and cannot be adjusted. The low current limits determine the threshold for alarm generation and aspect degradation.
211

Signal Controller Alarm 52: Short Circuit/Over-current Failures on LMP Board Output Circuits If there is a circuit failure such as a damaged cable resulting in an over-current, the object controller will detect this excess current by measurement and degrade the signal in the same way as for lamp failures.
212

Signal Controller Alarm 56: Lamp 110/120 VAC Voltage Level Error and Fuse Pulling If the voltage is absent, an alarm is generated and the safety relays drop internal to the LMP board. the voltage detector is attached to the STOP circuit in the LMP board. If the PROCEED fuse blows, the alarm is not produced. Open circuit alarms will be produced if a PROCEED output is being driven when the PROCEED fuse is pulled.
213

Signal Controller Alarm 58: Invalid Order for Signal Aspect Alarm when software has an error. Contact Bombardier for solving.
214

Signal Controller Alarm 5B: Frequency Error This alarm will occur if the power supply frequency drifts out of tolerance. This is expected to be a very rare event for a grid supplied system. However fuse pulling or total power supply failures can produce this alarm spuriously and it should be ignored in these cases, especially if Voltage Level error alarms are also seen.
215

Signal Controller Alarm 59: Current Through a Lamp that Should be Off
One possible failure mode of the SSRs used for LMP board outputs is a short circuit failure on the output. When the SSR fails, supply voltage will be applied to the output and light any lamp connected. LMP detects failure by current measurement circuit determining that a current above a certain threshold is flowing. The controller software detects that there is current through a lamp that should be off. An alarm is generated and drops the safety relay to put the signal back to its most restrictive aspect.
216

Signal Controller Alarm 5D: Signal Controller Earth Faults
The earth fault is tested for every 5 minutes and an alarm is generated if an earth fault is detected. In addition to issuing an alarm, restrictive status dark signal can be configured as a market specific parameter. An earth fault in one of the cables will expand to all object controllers connected to the same winding in the power supply unit.
217

Signal Controller Alarm 5E: Return Current out of Limits Check and replace LMP board for this error.
218

Point Controller Alarm 20: Point Movement Failure (Start Error )
When any point machine does not leave the initial position within a defined time after a point operation is initiated. The point operation is also stopped. Alarm 21 (22): Point Movement Failure (Point machines connected to 1st (2nd) MOT board are in undefined position) If the point fails to reach the ordered position or the position detection is lost due to some failure the point controller will send status Out of correspondence to the CIU and generate alarm for diagnostic purpose.
219

Point Controller Alarm 24: Motor Current Out of Limits (Run Current Out)
The total load current to point machines supplied by a MOT board exceeds 15 A for more than 1,700 ms. This will occur if a fault in the point machine or object cable causes excessive load current that does not blow the fuse within the 800 ms time. Point operation is stopped. A short circuit is detected in the solid state relays (SSRs) during hardware integrity tests before point operation is started. The point controller halts. Replace the MOT board
220

Point Controller Alarm 25: Motor Current Out of Limits (Stop Current Out)
A short circuit is detected in the solid state relays (SSRs) during hardware integrity tests when point operation is completed. The point controller halts.
221

Point Controller Alarm 2D: MOT Board AC Power Supply Failure
When the point machine power supply to the MOT board is lost.
222

Point Controller Alarm 2F: Earth Fault When a fault is detected internally in the earth fault detector on MOT. The possibility to determine that the alarm is caused by an external earth fault or an internal fault:
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Q&A
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Thank You
232

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