NS0-R-SIG-14-0009-PDP-Maintenance Manual

NOIDA - Greater NOIDA Metro Rail Project
Delhi Metro Rail Corporation Ltd.

Contract: Design, Manufacture, Supply, Installation, Testing,
and Commissioning of Signalling and Train Control
and Telecommunications Systems, Supply of
Spares and Training of Operation & Maintenance
Personnel for NOIDA – Greater NOIDA Metro
Project
DMRC CONTRACT NUMBER - NS01
Contractor:
ASTS - ZTE Consortium
A-153, Sector – 63, NOIDA – 201 301
Document Title:
Power Distribution Panel - Maintenance Manual
Document Number: NS01-R-SIG-14-0009
Revision after Customer comments 16 OCT 2018

Narendra Singh
R.M.Chandrasekaran Partha Ghosh
Deo
Author Reviewer Approver Description of Revision Date
Doc No: NS01-R-SIG-14-0009 Title: Power Distribution Panel - Maintenance Manual Page 1 of 57
Revision: 02
TRACEABILITY OF THE REVISIONS
Rev. Date Author Reviewer Approver Revision Description
20-03- Anurag
00 2018
Chandrasekaran.R.M
Aggarwal
R.E.Baker First Issue
Revision after Customer comments

18-05- Partha Narendra
01 2018
Chandrasekaran.R.M
Ghosh Singh Deo
(DMRC/S&T/SIG/NGN/NS01/2018/733
of 19/04/2018
Revision after Customer comments

16-10- Partha Narendra
02 2018
Chandrasekaran.R.M
Ghosh Singh Deo
(DMRC/S&T/SIG/NGN/NS01/2018/764
of 14/06/2018
© 2018 ASTS -ZTE Consortium. All Rights Reserved.

THIS DOCUMENT AND ITS CONTENTS ARE THE PROPERTY OF ASTS ZTE CONSORTIUM, FURNISHED TO YOU ON THE
FOLLOWING CONDITIONS:
(1) NO RIGHT OR LICENSE UNDER ANY PATENTS OR ANY OTHER PROPRIETARY RIGHT IN RESPECT TO THIS DOCUMENT
OR ITS CONTENTS IS GRANTED OR CONVEYED BY ASTS ZTE CONSORTIUM, TRANSMITTING THIS DOCUMENT AND ITS
CONTENTS TO YOU, NOR SHALL SUCH TRANSMISSION CONSTITUTE ANY REPRESENTATION, WARRANTY,
ASSURANCE, GUARANTY OR INDUCEMENT BY ASTS ZTE CONSORTIUM. WITH RESPECT TO INFRINGEMENT OF
PATENT OR ANY OTHER PROPRIETARY RIGHT OF OTHERS, UNLESS OTHERWISE AGREED BY THE PARTIES IN THE
CONTRACT TO WHICH THE PROPRIETARY RIGHTS REFER TO.
(2) THIS DOCUMENT OR ITS CONTENTS ARE NOT TO BE USED OR TREATED IN ANY MANNER INCONSISTENT WITH THE
RIGHTS OR INTERESTS OF ASTS ZTE CONSORTIUM, OR TO ITS DETRIMENT AND ARE NOT TO BE COPIED,
REPRODUCED, DISCLOSED TO OTHERS, OR DISPOSED OF EXCEPT WITH PRIOR WRITTEN CONSENT.
Revision: 02
Table of Contents
1 INTRODUCTION .......................................................................................................... 7
1.1 Purpose ................................................................................................................. 7
1.2 Applicability............................................................................................................ 7
1.3 Document References ........................................................................................... 7
1.3.1 Project Submittals .......................................................................................... 7
1.3.2 Other References ........................................................................................... 7
1.4 Description Of Changes From The Previous Revision .......................................... 8
1.5 Terms, Acronyms and Abbreviations ..................................................................... 8
1.5.1 Acronyms ....................................................................................................... 8
1.6 Symbol Description.............................................................................................. 10
2 SAFETY AND HEALTH REQUIREMNETS ................................................................ 11
2.1 General Safety and Health Requirement ............................................................. 11
2.2 Work Permit System ............................................................................................ 12
3 POWER DISTRIBUTION PANEL PDP-1.................................................................... 13
3.1 PDP-1 .................................................................................................................. 13
3.2 PDP-1 Rack and Sub-Systems............................................................................ 13
3.3 Isolation Transformer........................................................................................... 14
3.4 Step Down Transformer ...................................................................................... 14
3.5 PDP-1 AC Power Distribution .............................................................................. 14
3.6 PDP-1 Rack Sub – Assembly Modules: .............................................................. 15
3.7 PDP-1 Rack Front View ....................................................................................... 16
3.8 General................................................................................................................ 16
3.9 PDP-1 Front View ................................................................................................ 16
3.10 PDP-1 Rear View ................................................................................................ 18
4 POWER DISTRIBUTION PANEL PDP - 2.................................................................. 20
4.1 PDP-2 .................................................................................................................. 20
4.2 AC Power Distribution Panel - 230 V AC ............................................................. 20
4.3 AC Power Distribution PANEL - 415 V AC .......................................................... 21
4.4 AC to DC Convertors ........................................................................................... 21
4.5 AC to DC Convertors and Power distribution ...................................................... 21
4.6 Power Distribution panel PDP-2 FRONT View .................................................... 22
4.7 General................................................................................................................ 22
Revision: 02
4.8 Depot PDP-2 Front View ..................................................................................... 22

4.9 PDP-2 Rear View ................................................................................................ 24
5 POWER DISTRIBUTION PANEL- AC-DC.................................................................. 26
5.1 PDP –AC-DC distribution .................................................................................... 26
5.2 AC Power Distribution ......................................................................................... 26
5.3 AC to DC Convertors and Power distribution ...................................................... 26
5.4 Power Distribution panel AC – DC...................................................................... 27
5.5 General................................................................................................................ 27
6 CORRECTIVE MAINTENANCE AND TROUBLESHOOTING PROCEDURES ......... 33
6.1 Introduction .......................................................................................................... 33
6.2 Tools required...................................................................................................... 33
6.3 Pre-checks for Troubleshooting ........................................................................... 33
6.4 Troubleshooting electrical faults .......................................................................... 34
6.5 Faults in meters ................................................................................................... 34
6.6 Faults in Lamps ................................................................................................... 34
6.7 Faults in Power Transformers.............................................................................. 34
6.8 Faults in AC-DC Converter Power Supplies ........................................................ 35
6.9 Faults in MCB/MCCB .......................................................................................... 35
6.10 Faults in ELD ....................................................................................................... 35
6.11 Corrective Maintenance Fault Restoration .......................................................... 36
6.12 Corrective Maintenance Flow chart ..................................................................... 38
6.12.1 Faults in Meters ............................................................................................ 38
6.12.2 Faults in Lamps ............................................................................................ 38
6.12.3 Faults in Transformers Internal Fault ............................................................ 39
6.12.4 Faults in Transformers External ................................................................... 39
6.13.1 Faults in AC-DC Convertors ......................................................................... 40
6.13.2 Faults in MCB / MCCB ................................................................................. 40
7 PREVENTIVE MAINTENANCE AND SERVICING INSTRUCTIONS I ....................... 41
7.1 Maintenance and Servicing of AC PDP ............................................................... 41
7.2 General Guidelines .............................................................................................. 41
7.3 Recommended unit servicing log and maintenance task..................................... 41
7.4 Monthly ................................................................................................................ 42
7.5 Quarterly .............................................................................................................. 42
7.6 Half Yearly ........................................................................................................... 42
Revision: 02
7.7 Yearly .................................................................................................................. 42

7.8 Maintenance Schedule - AC PDP........................................................................ 42
7.9 Equipment Required ............................................................................................ 42
7.10 Preliminary Requirement: .................................................................................... 43
7.11 AC - PDP Power on Maintenance Record ........................................................... 44
8 PREVENTIVE MAINTENANCE AND SERVICING INSTRUCTIONS II ...................... 49
8.1 General Guidelines .............................................................................................. 49
8.2 Recommended unit servicing and maintenance task .......................................... 49
8.3 Monthly ................................................................................................................ 49
8.4 Quarterly .............................................................................................................. 49
8.5 Half Yearly ........................................................................................................... 49
8.6 Yearly .................................................................................................................. 49
8.7 Maintenance Schedule AC- DC PDP .................................................................. 50
8.8 Equipment Required: ........................................................................................... 50
8.9 Preliminary Requirement: .................................................................................... 51
8.10 AC-DC - PDP Power on - Maintenance Record .................................................. 52
Revision: 02
List of Tables
Table 1: Maintenance Schedule of AC PDP ...................................................................... 43

Table 2: AC-PDP Power on Maintenance Check ............................................................... 44
Table 3: Maintenance Schedule of AC - DC PDP .............................................................. 51
Table 4: AC- DC PDP Power on Maintenance Check ....................................................... 52
List of Figures
Figure 1 PDP-1 rack power Indications R-Y-B ................................................................... 16

Figure 2 MCCB, CT1, CT2, CT3, PD (ROW-T1 to ROW-T2) ............................................ 16
Figure 3 Transformers TR1, TR2 Front View ..................................................................... 17
Figure 4 SPD 1 to SPD 6 (Row T 5) .................................................................................. 18
Figure 5 BX 230 and NX230 Distribution (ROW-T3 to ROW-T4)....................................... 18
Figure 6 Transformers TR2 and TR1 Rear view. ............................................................... 19
Figure 7 AC-DC Converters Module 1 – 4 (Row-1 to Row-4) ............................................ 22
Figure 8 ELD and 230 V AC Distributions (Row-5, Row-T3, and Row –T4) ...................... 23
Figure 9 Rear side AC-DC Convertors (Row-1 to Row-4).................................................. 24
Figure 10 DC Power Distribution (Row-T6 to Row-T8) ...................................................... 25
Figure 11 AC/DC PDP Rack power Indication ................................................................... 27
Figure 12 MCCB, SPD, MCB, (Row-T1 to Row-T3) ......................................................... 28
Figure 13 230V AC Distribution (Row T4-RowT5) ............................................................. 29
Figure 14 AC-DC Convertors, ELD .................................................................................... 30
Figure 15 DC Distribution (ROW T 7 – ROW T 11) ........................................................... 31
Revision: 02
1 INTRODUCTION
1.1 PURPOSE
The purpose of this document is to provide the Maintenance Manual for AC Power
Distribution Panel and AC-DC Power Distribution Panel deployed in Noida Metro Rail
Project.
1.2 APPLICABILITY
This document is applicable to the Power Distribution Panel that is supplied for Noida
Metro Railway system.
1.3 DOCUMENT REFERENCES
1.3.1 Project Submittals
Ref Document Number Document Title

Signalling and Train Control System - System
[1] NS01-E-SIG-9-0034 Architecture Specification (System and Sub-
system Overview)
Signalling and Train Control System - System
[2] NS01-E-SIG-9-0027
Requirements Specification (SRS)
PDP Rack Post Installation and Inspection Test
[3] NS01-L-SIG-12-0046
Procedure
[4] NS01-G-SIG-9-0033 – AC 2 Depot PDP 1 Layout Drawings
[5] NS01-G-SIG-9-0033 – AC 12 Depot PDP 2 Layout Drawings
[6] NS01-G-SIG-9-0013 – AC 2 Sector 50 AC/DC PDP Layout Drawings
1.3.2 Other References

Employer’s requirements – particular
[1] DMRC- Contract NS01 Part - 1
specifications.
DMRC/20/III-246/ 2015
[2] Letter of acceptance
dt.13.04.2016
Employer’s requirements – General
[3] DMRC-Contract NS01 Vol 3
specifications.
Doc No: NS01-R-SIG-14-0009 Power Distribution Panel Maintenance Manual. Page 7 of 57

Revision: 02

[4]
1.4 DESCRIPTION OF CHANGES FROM THE PREVIOUS REVISION
Description of change Chapter(s) affected by the modification(s)

Corrective maintenance flowchart New section 6.12 Corrective maintenance
covering all the failure Scenarios Flow chart introduced
Details for AC-DC PDP Included in Section 5.00
1.5 TERMS, ACRONYMS AND ABBREVIATIONS
1.5.1 Acronyms
The following table provides definitions for terms, acronyms and abbreviations relevant to
this document.
Terms Definition
AC Alternate Current
AC PDP Alternate Current Power Distribution Panel
AC–DC PDP Alternate Current & Direct Current Power Distribution Panel
ASTS Ansaldo STS
AXC Axle Counter
ATS Automatic Train Supervision
CBTC Communication Based Train Control
DC Direct Current
DMRCL Delhi Metro Rail Corporation Limited
ELD Earth Leakage Detector
EXT External
HV High Voltage
INT Internal
IR Insulation Resistance
LED Light Emitting Diode
MCB Miniature Circuit Breaker

Revision: 02
Terms Definition
MCCB Moulded Case Circuit Breaker
MLK Microlok
MOHM Mega ohm
N/A Not Applicable
NR Not Required
NS01 NOIDA-Greater NOIDA Metro Rail Project
OCC Operational Control Centre
PDB Power Distribution Box
PDP Power Distribution Panel
PS Power Supply
SCR Station Control Room
SER Station Equipment Room
SMR Signal Maintenance Room
SPD Surge Protection device
SYS System
UPS Uninterruptible Power Supply
V Voltage

Revision: 02
1.6 SYMBOL DESCRIPTION

Read this Manual carefully before starting any work/operation and pay the utmost attention
to the instructions marked with the following symbols. Safety-related Symbols used in this
document
Symbols Description
DANGER
Death or Serious injury will occur if you do not take the precautions
described.
CAUTION
Symbol and text indicate important instructions and /or user
information. Failure to comply with these instructions may impair
the availability of the system and, as a direct result and/or
combined with noncompliance with other instructions or errors have
a negative impact on safety.
WARNING
Symbol and text indicate important instructions to be followed.
Failure to comply with these instructions may impair the availability
of the system and, as a direct result and/or combined with
noncompliance with other instructions or errors have a negative
impact on safety
NOTICE
Damage or an undesirable result or state may occur if you do not
take the precautions described.
AUTHORIZED PERSONNEL ONLY

Access restricted to authorized personnel only. Going without
authorization may harm you.
ELECTRICAL HAZARD
Electrocution or shock due to electrical live component.

Revision: 02
2 SAFETY AND HEALTH REQUIREMNETS

REQUIREMNETS
2.1 GENERAL SAFETY AND HEALTH REQUIREMENT

• ASTS-ZTE Consortium will ensure that only authorized persons are allowed to carry
out this work.
• Before start of work, tool box talk about the activity and its associated hazards/risks
will be briefed by the supervisor to all the personnel’s engaged in the activity.
• Work Permit system to be followed issued by the supervisor before start of the
activity refer DMRC/NS-01/SHE/04 for general work & DMRC/NS-01/SHE/05 for
heavy lifting operation given in SHE Plan
• All the personnel’s engaged in the activity should wear appropriate Personal
Protective Equipment (PPE) i.e. Safety Shoes, Helmet, Reflective Jacket, Nose
Mask, Safety Goggles etc.
• Proper means of access/egress to be provided before start of the work.
• Before start of the activity inspect all tools and tackles to ensure its safe to use.
• First aid and Fire Fighting arrangements to be made at all the important site
locations.
• Ensure proper housekeeping after completion of the activity.
• Ensure all the safety rules and regulations.
• All supervisors/Engineers/workers should be trained on emergency preparedness
like fire extinguisher operation to know what action is to be taken in case of an
emergency.
DANGER
described.

Revision: 02
2.2 WORK PERMIT SYSTEM

Before start of the work supervisor will generate the work permit system.
Format of Work Permit System

Revision: 02
3 POWER DISTRIBUTION
DISTRIBUTION PANEL PDP-
PDP-1
3.1 PDP-1
The PDP (Power Distribution Panel) is the source of supply for all signalling and Train
control systems in Noida Metro Railway System. The Input Power supply to PDP-1 is
drawn from two independent power supply sources from state Grid. The State Grid Power
Supply is from two independent feeders and the power supply from supply feeders are
connected to the UPS-1 and UPS-2. The PDP-1 input Power supply is from two
independent UPS systems. The PDP-1 Rack is installed at the UPS Room. This Rack
PDP-1 is also referred as AC-PDP.
The PDP-1 rack installation locations at Noida Metro Railway are given below.
• Depot
• Depot Station
• Parichowk
• Sector 144
• Sector 142
• Sector 81
• Sector 71
It is to be noted that AC-PDP installed at the stations mentioned above may varry in PDP
lay out and ratings of the transformers used. The PDP Maintenance Manual covers and
explains the common engineering principle adopted through out the Noida Metro Project.
For restoration of PDP failures NMRC Maintenance Personal are advised to Refer Station
based PDP Layout drawings.
3.2 PDP-1 RACK AND SUB-SYSTEMS

The PDP-1 Rack consists of the sub systems and modules as listed below:
• 3- Phase input supply ( R-Y-B ) indications.
• Current Transformer to monitor load current.
• Micro Circuit Breakers
• Volt meter & Ammeter
• Isolation Transformer
• Step down Transformer
• Catridge Fuses
• Terminals and Fuses
• Surge Protection Device
• Earth Leakage Detectors
• Circuit Breakers

Revision: 02
• AC – DC Convertor Modules
• Fuse Links
3.3 ISOLATION TRANSFORMER

The Isolation Transformer specification is PRI-415 V AC and SEC- 415 V AC, Three
Phase, Delta. The Transformer primary is connected to 415 V AC- 3 Phase and the
secondary is delivering 415 V AC- 3 Phase. The Transformer 30 KVA or 15 KVA rating
varies based on the station requirement. Please refer the Station based PDP Layout
drawings.
The Isolation Transformer provides isolation of common neutral return path to state grid.
The Isolation Transformer is mounted at the bottom of the PDP-1 rack.
3.4 STEP DOWN TRANSFORMER

The Step down Transformer is used to convert high voltage potential to a low voltage
potential. The step down Transformer specifications are:
• PRI-415AC/SEC-0V-110V-115-120V AC.
• PRI-415 AC/ SEC-0V -220V-230-240V AC.
There are two types of step down transformers used in Noida Metro Railway. The
Transformer ratings 2KVA or 3 KVA rating varies based on the station requirement. The
Transformer is mounted at the bottom of the PDP rack.
3.5 PDP-1 AC POWER DISTRIBUTION

The PDP-1 distributes the AC power supply to the following equipments, rooms and
appliances listed below.
• To PDP-2 BX 110, NX 110
• Three Phase lamp Indication R-Y-B -230 V AC
• Volt meter, Ammmeter 230 V AC
• To SER - 415 V AC
• To PDP Rack 1 – 415 V AC for Point Machine
• To SER 230 V AC

Revision: 02
3.6 PDP-1 RACK SUB – ASSEMBLY MODULES:

Main Elements of AC Power Distribution Panel and the function of the modules are listed
below.
Sub-assembly Description/Function
A circuit breaker is an automatically operated electrical switch
Circuit Breaker designed to protect an electrical circuit from damage caused
by overload and short circuit.
A surge protector device is used to protect electrical and
Surge Protection Device electronic devices from high voltage spikes entering the power
supply.
A current transformer can be used to provide an isolated lower
current in its secondary which is proportional to the current in
Current Transformer the primary circuit. It is used to Monitor current flow in the
electrical circuit. There are three current transformers in the
rack
Isolation Transformer 415 V / 415 V for Point Machine
To eliminate common Neutral in Electrical Connections, and to
Isolation Transformer
establish BX 230 and NX 230, BX 110 and NX 110.
It is used to Step-down Input 415 V to 230V and 110 Volts for

Step-down Transformer
equipment and outdoor signals
Indication Lamps Lit when Power supply is available
Intelligent Temperature Equipment used to control Equipment Rack Temperature.
Monitor and Fan Controller
To disconnect Electrical circuit under short circuits and
Micro Circuit Breakers
overload
AC- DC Convertors Modular type Easily Replaceable DC Power supply
To detect the Leakage current through the power supply
Earth Leakage Detectors
conductors.
Surge Protection Device To protect the Electronic Equipment due to lighting surges

Revision: 02
3.7 PDP-1 RACK FRONT VIEW
3.8 GENERAL
Various general views of Power Distribution Panel PDP-1 cabinets are shown below. The
reference drawing is Depot PDP-1 Layout Drawing Number: NS01-G –SIG-9-0033 Sheet:
AC 2. The actual architecture of PDP may vary for different locations and stations as per
the requirement.
3.9 PDP-1 FRONT VIEW
Figure 1 PDP-1 rack power Indications R-Y-B
Figure 2 MCCB, CT1, CT2, CT3, PD (ROW-T1 to ROW-T2)

Revision: 02
Figure 3 Transformers TR1, TR2 Front View

Revision: 02
3.10 PDP-1 REAR VIEW
Figure 4 SPD 1 to SPD 6 (Row T 5)
Figure 5 BX 230 and NX230 Distribution (ROW-T3 to ROW-T4)

Revision: 02
Figure 6 Transformers TR2 and TR1 Rear view.

Revision: 02
4 POWER DISTRIBUTION PANEL

PANEL PDP - 2
4.1 PDP-2
The PDP-2 rack also referred as AC-DC PDP (AC-DC Power Distribution Panel) is the
source of supply for all signalling and Train control systems. The Input supply to PDP-2
rack is extended from PDP-1 rack.
The PDP-2 rack is installed at the following interlocking station locations listed below.
• Depot
• Depot Station
• Pari Chowk
• Sector 144
• Sector 142
• Sector 81
• Sector 71
AC-DC PDPs are installed at SER (Station Equipment Room). The arrangement in the AC-
DC PDP can be sub dived into two major areas in power supply distribution. This break up
is for our better understanding of the PDP.
• AC Power Supply Distribution.
• AC to DC conversion and DC Power Supply Distribution
It is to be noted that PDP-2 installed at the stations mentioned above May vary in PDP lay
out. The PDP Maintenance Manual covers and explains the common engineering principle
adopted throughout the Noida Metro Project.
For restoration of PDP-2 failures NMRC Maintenance Personal are advised to refer Station
based PDP-2 Layout drawings.
4.2 AC POWER DISTRIBUTION PANEL - 230 V AC

The arrangement is the PDP-2 rack is getting 230 V AC Power Supply from PDP- 1 Rack.
The 230 V AC distributions are listed below along with equipment and room identity.
• DCS – 230 V AC
• Signal – 110 V AC
• Indication of 110 V AC ( within this Rack )
• ELD – 1
• ELD – 2
• Inteligent Fan Controller – 230 V AC
• CBTC Normal 230 V AC
• CBTC Reserve 230 V AC
• MLK II Normal 230 V AC
• MLK II Reserve 230 V AC

Revision: 02
• Axle Counter Normal 230 V AC

• Axle Counter Reserve 230 V AC
• EI Rack 230 V AC
• ATS work Stations 230 V AC
• Fan Controllers 230 V AC
• Zone Controllers 230 V AC Normal
• Zone Controllers 230 V AC Reserve
• SMR ATS 230 V AC Normal
• SMR ATS 230 V AC Reserve
• SER ATS 230 V AC Normal
• SER ATS 230 V AC Reserve
• FTM 230 V AC Normal
• FTM 230 V AC Reserve
4.3 AC POWER DISTRIBUTION PANEL - 415 V AC

The arrangement is the PDP-2 rack is getting 415 V AC Power Supply from PDP- 1 Rack.
The 415 V AC distributions are listed below along with equipment and room identity.
• SER ( Station Equipment Room ) 415 V AC
• SCR ( Station Control Room ) 415 V AC
• SMR ( Station Maintenance Room ) 415 V AC
• Crew Control Room in sector 71 and Depot 415 V AC
• Point Machine 415 V AC
4.4 AC TO DC CONVERTORS
The AC to DC convertors is of modular type Dc power supply units, and the input voltage
to the unit is 230 V AC and the output is DC. The units are of Plug in Type and the
modules can easily be replaceable without disconnecting the running power of working
equipment.
4.5 AC TO DC CONVERTORS AND POWER DISTRIBUTION

The AC to DC Convertors and the Power distribution are Listed below.
• MLK II Power Supply 12 V DC Normal

• MLK II Power Supply 12 V DC Reserve
• CBTC Power Supply -1 24 V DC
• CBTC Power Supply -2 24 V DC
• INT Power Supply 24 V DC

Revision: 02
• EXT Power Supply 24 V DC

• Axle Counter Power Supply 24 V DC Normal
• Axle Counter Power Supply 24 V DC Reserve
• EI Rack 24 V DC
• ELD-1, 12 V DC
• ELD-2, 24 V DC
• Zone Controller 24 V DC Normal
• Zone Controller 24 V DC Normal
4.6 POWER DISTRIBUTION PANEL PDP-2 FRONT VIEW
4.7 GENERAL
Various general views of Power Distribution Panel PDP-2 cabinets are shown below. The
reference drawing is Depot PDP-2 Layout Drawing Number: NS01-G –SIG-9-0033 Sheet:
AC 12.The actual architecture of PDP may vary for different locations as per the
requirement.
4.8 DEPOT PDP-2 FRONT VIEW
Figure 7 AC-DC Converters Module 1 – 4 (Row-1 to Row-4)

Revision: 02
Figure 8 ELD and 230 V AC Distributions (Row-5, Row-T3, and Row –T4)

Revision: 02
4.9 PDP-2 REAR VIEW
Figure 9 Rear side AC-DC Convertors (Row-1 to Row-4)

Revision: 02
Figure 10 DC Power Distribution (Row-T6 to Row-T8)

Revision: 02
5 POWER DISTRIBUTION PANEL

PANEL-
ANEL- AC-
AC-DC
5.1 PDP –AC-DC DISTRIBUTION

The PDP (AC-DC Power Distribution Panel) is the source of supply for all signalling and
Train control system equipment. The Input supply to this Rack is 415 V AC. The AC-DC
PDP is installed at SER of non-interlocking stations. The arrangement in the AC-DC PDP
can be sub dived into two areas for our better understanding as AC Power Distribution
Panel and DC Power Distribution Panel in one rack.
5.2 AC POWER DISTRIBUTION

The power supply input the PDP is 415 V AC.The Power supply 415 V AC passes through
the current transformers and MCCB and connected to the Transformer.
The Transformer Specification is PRI-415 V AC/ SEC-0V-220V-230-240V 1KVA.
The 230 V AC Power Supply Distribution from this panel is listed below.
• To DCS – BX230 /NX230 Normal
• To DCS – BX230 /NX230 Reserve
• To SCR – BX230 /NX230
• To ATS– BX230 /NX230
• To FAN– BX230 /NX230
5.3 AC TO DC CONVERTORS AND POWER DISTRIBUTION

The AC to DC Convertors and the Power distribution are listed below.
• MLK II Power Supply 12 V DC Normal

• MLK II Power Supply 12 V DC Reserve
• MLK II I/O 24V DC
• INT Power Supply 24 V DC
• EXT Power Supply 24 V DC
• Axle Counter Power Supply 24 V DC

Revision: 02
5.4 POWER DISTRIBUTION PANEL AC – DC
5.5 GENERAL
Various general views of Power Distribution Panel AC – DC cabinets are shown below.
The reference drawing is Sector-50 AC/DC PDP Layout Drawings NS01-G –SIG-9-0013
Sheet: AC 2.The actual architecture of PDP may vary for different locations as per the
requirement.
Figure 11 AC/DC PDP Rack power Indication

Revision: 02
Figure 12 MCCB, SPD, MCB, (Row-T1 to Row-T3)

Revision: 02
Figure 13 230V AC Distribution (Row T4-RowT5)

Revision: 02
Figure 14 AC-DC Convertors, ELD

Revision: 02
Figure 15 DC Distribution (ROW T 7 – ROW T 11)

Revision: 02
………………………………………Page Left Free Intentionally………………………..

Revision: 02
6 CORRECTIVE MAINTENANCE
MAINTENANCE AND TROUBLESHOOTING
TROUBLESHOOTING PROCEDURES
6.1 INTRODUCTION
The purpose of this section is to provide troubleshooting procedure for Power Distribution
Panel. This document briefly explains the methods of fault rectification during run of PDP.
It guides personal to troubleshoot errors or electrical faults in PDP, ensuring smooth run of
the unit.
DANGER
described.

ELECTRICAL HAZARD
6.2 TOOLS REQUIRED

a) Mechanical tool kit (Spanner set, screw driver set, wire cutter, pliers, crimping tool,
insulation tapes etc.)
b) Multimeter (AC/DC), Clamp meter (AC/DC), probes
c) Wires (ref. drawings for wire sizes) and wiring accessories (Lugs, connectors,
terminals etc.)
6.3 PRE-CHECKS FOR TROUBLESHOOTING

1. Make sure that proper tool kit and spares are been carried for troubleshooting.

Revision: 02
2. Check availability of correct drawings, bill of material, manuals, etc. before start of
troubleshooting procedure.
3. Check the unit if it is cleaned regularly, if not clean the dust.
4. Presence of authorized personal is required in case of any shutdown needed.
Proper permission must be taken before shutdown.
5. Follow all the safety precautions and wear safety gears.
6.4 TROUBLESHOOTING ELECTRICAL FAULTS

Following section explains the faults that can occur in the Power Distribution Panel and
their rectification methods. Before starting problem rectification, measure all the AC/DC
voltages and currents feeding to different workstations/equipment and operating circuits.
Ensure authorized permission for shut down of power of any workstation/equipment.
6.5 FAULTS IN METERS

If in case of meters mounted inside the unit are not showing any readings, follow the steps
to rectify the issue.
a) Check drawings for Panel supply and input signal wirings.
b) Check whether all the wires are in good condition, no damage observed. Also check
if any wire is loose or lugs broken from the terminals. If anything observed,
shutdown corresponding switches and re-wire or refurbish meter wiring.
c) Now check supply voltage at the supply terminals. If voltage is not observed, check
the tightness of wires.
d) Check voltages at the input signals terminals and check tightness of wires.
6.6 FAULTS IN LAMPS

Indications for different signals are provided at door using AC/DC lamps. When lamp is not
glowing,
a) First check whether wiring of the lamp is OK or not. Replace it if fault observed.
b) Check supply voltage at the input terminals of the Lamps. If not ok check wiring and
terminations.
6.7 FAULTS IN POWER TRANSFORMERS

Transformer Faults can be of two types,
1) Internal faults in power transformer;
a) Insulation breakdown between winding and earth. This can be measured with
Megger.
b) Insulation breakdown faults between phases.
c) Insulation breakdown between adjacent turns i.e. Inter turn faults. In this case input
current can be higher & overheating can be observed.
d) Transformer core faults.
Since these faults cannot be rectified at site, contact manufacturer for replacement or
repair of the transformers as agreed by both parties.

Revision: 02
2) External faults in power transformer;

a) Loose connections at the transformers terminals.
b) Damaged wires due to bending, crimping etc.
c) Loose terminations at load side.
These problems can be rectified by refurbishing wiring of the transformer. After termination
measure voltages at the terminals verify with the test results.
6.8 FAULTS IN AC-DC CONVERTER POWER SUPPLIES

PDP also designed to supply DC power to different operating circuits. This power is
distributed via MCBs and output terminals to different equipment. Also these power
supplies are fed through MCBs which protects them. Power supplies are provided with
LED Display indicating output voltage and current values. If any of the DC power source is
not working then,
1. First check complete wiring of the DC Power supply section for any damage,
shorting, loose wiring, and loose termination. Refurbish it as needed.
2. Then check input supply MCB for any tripping due to over current or overvoltage.
Reset the MCBs (i.e. reset supply power). Check output voltages of the DC power
supply verify with the test reports. Check display readings.
3. Check output fuse if it is blown, replace it with proper ratings.
4. If problem still persists (due to internal damage), contact manufacturer for
replacement or repair of the unit.
6.9 FAULTS IN MCB/MCCB

Various workstations and equipment are fed by Power Distribution Panel through MCBs.
Ratings of these devices are selected as per ratings of the consuming circuit. MCCBs are
used at the input supply. When PDPs are installed, it is must to measure voltages and
currents of each operating circuit to ensure uninterrupted operation of the circuit and
ensure there won’t be any frequent tripping of these devices. If power to any of the
workstation/equipment fails due to failure of the MCB then,
1. First check wiring of the respective workstation for any damage due to bending,
loose termination, lugging etc. If observed rewire it. Also observe if any mechanical
damage.
2. Check ratings of the MCBs matching with the specified ratings of the system.
3. After refurbishment, switch ON the device and measure voltages and currents.
4. If the device is burn out due to excess load, replace it with higher ratings as
required. Record of changes/maintenance log should be maintained in such cases.
6.10 FAULTS IN ELD

Earth Leak Detector (ELD) is used to detect earth faults in the signalling cables and
circuits. An audio-visual alarm is activated when the insulation reaches the pre-set value,
which can be adjusted through a potentiometer for insulation value of 2kΩ to 1MΩ. ELD
comprises of 4 channels for use on signalling circuits of 110V AC/24V DC/12V DC. Actual
value of the insulation resistance of the signalling circuit can be measured by inbuilt

Revision: 02
Insulation Resistance Meter during offline condition. A selector knob is provided to

configure ELD for specific value and operation.
Before troubleshooting ELD following points must be checked,
a) Check supply voltage of all the ELDs (110V AC from AC PDP)
b) Check all the sensing voltages (110V AC/ 24V DC/ 12V DC)
c) Ensure Selector Knob is on Insulation Test position and all the channels are well
configured as desired.
ELD faults can be of following types,
a) Meter showing infinity fault Light and buzzer ‘ON’- 110V ac supply failed, E1 and E2
are not properly connected. Check supply voltage at AC PDP side.
b) Instrument working properly but no visual indication on the channel panel- Display
card inside ELD not properly placed. Contact supplier for any such help.
c) Also refer Operational manual provided for ELD in case any other fault.
6.11 CORRECTIVE MAINTENANCE FAULT RESTORATION

The PDP rack have been designed in due consideration of Maintenance Stand point of
view. The Modules inside the Rack is protected by MCCB, which trips mechanically and
electrically breaks the circuit thus preventing further damages to Transformers, wiring
within the PDP. The Trip in MCCB ensures the Isolation the PDP. There are multiple out
puts in AC power supply and DC power supply is fed from the PDP rack to external
circuits. The output power supplies from the PDP rack to external circuits are individually
protected by MCB (Micro Circuit Breakers). AC power supply distribution and DC power
supply distributions from the PDP Rack to External circuits are wired individually through
MCB. The MCB will Trip in case if the external load draws more power than its rated
power, thus prevents the damage to the internal modules in the PDP.
Please follow the simple steps to restore a failure in PDP
Step 1: Check for Input power supply to PDP Rack
Check for the Input Power Supply source to PDP Rack

Check the input power Supply 415 V AC
Check R-Y-B Indication
Step 2: Check for output power supply to External
Check for 110 V AC to signalling circuits.

Check for 230 V AC to SER, SMR Rooms
Check for 440 V AC to Point machine
Check for 230 V AC to AC – DC Convertor Modules
Check for 12 V DC to MLK-II
Check for 24 V DC to MLK-II
Check for 24 V DC to External Circuits
Check for 24 V DC to Internal Circuits

Revision: 02
Step 3: AC-DC Convertors
Check for output Voltage display

Check for output current display
Step 4: MCB Trip
Check for MCB Trip
Step 5: MCB Trip-Reset
Reset MCB
MCB –on, MCB-off, MCB-on
Step 6: Observe MCB working
Observe that the tripped MCB after reset operation never trips again within 15
minutes.
If you observe the MCB is stable and never trips, the Fault is restored. Record this event in
failure register and inform the concerned Authorities in your organization.

Revision: 02
6.12 CORRECTIVE MAINTENANCE FLOW CHART
6.12.1 Faults in Meters
•Check drawings for Panel supply and input signal wirings

•Check whether all the wires are in good condition, no damage observed.
Faults in Also check if any wire is loose or lugs broken from the terminals
Meters
• If anything observed, shutdown corresponding switches and re-wire or

refurbish meter wiring
Corrective •Check voltages at the input signals terminals and check tightness of wires.
Action
•Check the displayed voltage/ Current in the Meter

• Compare the displayed voltage/ Current in the external calibrated Meter.
Restoration • If OK Record the events
6.12.2 Faults in Lamps
•First check whether wiring of the lamp is OK or not.

Faults in
Lamps
• If anything observed, shutdown corresponding switches and re-wire or refurbish Lamp wiring
• Replace it if fault observed.
Corrective • Check supply voltage at the input terminals of the Lamps. If not ok check wiring and terminations.
Action
•Check the Lamp is glowing

Restoration

Revision: 02
6.12.3 Faults in Transformers Internal Fault
•Internal faults in Power Transformer

• Insulation breakdown between winding and earth. This can be measured
Faults in with Megger
Transformer • Insulation breakdown faults between phases.
Corrective •This can be measured with Megger

Action
•Since these faults cannot be rectified at site, contact manufacturer for

replacement or repair of the transformers as agreed by both parties.
Restoration
6.12.4 Faults in Transformers External
•External faults in Power Transformer

• Loose connections at the transformers terminals.
Faults in •Damaged wires due to bending, crimping etc.
Transformers
•These problems can be rectified by refurbishing wiring of the transformer.

Corrective After termination measure voltages at the terminals verify with the test
Action results.
•Loose terminations at load side to be corrected.

Restoration

Revision: 02
6.13.1 Faults in AC-DC Convertors
•Power supplies are provided with LED Display indicating output voltage and current values. If any of the DC
power source is not working then,
Faults in AC-DC
Convertors
• First check complete wiring of the DC Power supply section for any damage, shorting, loose wiring, and
loose termination
•Then check input supply MCB for any tripping due to over current or overvoltage. Reset the MCBs (i.e. reset
supply power). Check output voltages of the DC power supply verify with the test reports. Check display
Corrective readings.
Action •Check output fuse if it is blown, replace it with proper ratings.
•If problem still persists (due to internal damage), contact manufacturer for replacement or repair of the unit.
Restoration
6.13.2 Faults in MCB / MCCB
Faults in •If power to any of the workstation/equipment fails due to failure of the MCB then,
MCB/MCCB
•First check wiring of the respective workstation for any damage due to bending, loose
Corrective termination, lugging etc. If observed rewire it. Also observe if any mechanical damage.
Action •Check ratings of the MCBs matching with the specified ratings of the system.
•If the device is burn out due to excess load, replace it with higher ratings as required.
Record of changes/maintenance log should be maintained in such cases.
Restoration

Revision: 02
7 PREVENTIVE MAINTENANCE
MAINTENANCE AND SERVICING INSTRUCTIONS
INSTRUCTIONS I
7.1 MAINTENANCE AND SERVICING OF AC PDP
DANGER
described.

ELECTRICAL HAZARD
7.2 GENERAL GUIDELINES

Switch OFF incoming power supply before opening the door (Only under authorized
personal).
Voltages employed are sufficiently high to endanger human life.
Measure voltage at input terminals to ensure that units are de-energized.
Isolate the source used for remote monitoring / alarm.
Ensure that only qualified and trained personnel are instructed and permitted for carrying
out the maintenance.
Ensure that material / tools are not left inside the unit after maintenance, as these can
cause faults.
7.3 RECOMMENDED UNIT SERVICING LOG AND MAINTENANCE TASK

Purpose of this section is to provide procedure maintenance schedule for PDP. All
necessary checks have been included in this document regarding tests to be carried out
on PDP. However, specific tests in addition to this may be carried out based on
requirement.

Revision: 02
7.4 MONTHLY
Remove the dust from the cabinet with vacuum cleaner. Clean the complete equipment
Check that all the meters (Voltmeters, Ammeters, etc.) are showing appropriate values
Inspect all devices periodically to ensure that the equipment is in proper working order
Check tightness of connections and fitments
7.5 QUARTERLY
Monitor and record input voltages respective phase input currents, DC power supply
voltages and output currents of PDP.
7.6 HALF YEARLY

Check IR values
Verify all output terminals for connection tightening
7.7 YEARLY
a) Inspect all wiring for wear and cuts
b) Inspect power and control contacts of MCBs, MCCBs, changeover switches, Surge
Protection devices and Transformer connections, etc. Replace the worn
out/defective contacts/devices.
c) Inspect all auxiliary and control circuits for desired functioning
d) Check gasket of the door
7.8 MAINTENANCE SCHEDULE - AC PDP

For servicing and maintenance of the unit following schedule is recommended. Also based
on site condition and customer requirement appropriate maintenance and servicing should
be done by the user. Maintenance schedule and tests for AC Power Distribution Panel are
given below.
7.9 EQUIPMENT REQUIRED

1. Mechanical toolkit (Spanner set, screw driver set, wire cutter, pliers, crimping tool,
2. Multimeter (AC/DC), Clamp meter (AC/DC), probes
3. AC Power Source (Single or Three phase as required)
4. High Voltage Tester
5. Million Mega Ohm Meter
6. Any specific equipment as required
All equipment used in testing should have valid calibration.

Revision: 02
7.10 PRELIMINARY REQUIREMENT:

Before commencing maintenance, person should ensure availability of approved drawing
for relevant PDP. Maintenance schedule for AC Power Distribution Panel is given in the
table below,
Table 1: Maintenance Schedule of AC PDP
Sr. Half
Checkpoints Monthly Quarterly Yearly
No Yearly
1 Visual Inspection √
2 Dust Cleaning √
Insulation Resistance
3 √
Test
4 Input MCCB/MCB √
5 Changeover Switches √
6 Lamps √ √
7 Meters √ √
8 Transformers √ √
9 Power Supplies √ √
10 Filters √
11 Panel Ambient Light √
12 Earthing √
13 Fan Tray √
14 Wiring wear and tear √

Tightness of
15 √ √
contact/Terminals
16 Surge Protection devices √

Revision: 02
7.11 AC - PDP POWER ON MAINTENANCE RECORD

Table 2: AC-PDP Power on Maintenance Check
Station: Maintenance Report No:

Location Equipment ID:
Date of Testing: Time of Testing:
Reference Drawing Number / Revision :

Measured
Test Activity Expected Results Pass /Fail Remarks
Results
Check the continuity The buzzer should
between the earth stud at Beep in the Multi-
1
AC PDP Rack and Room meter.
earth.
Check the potential The potential
difference between the difference between
2
earth and neutral of the earth and neutral of
AC PDP Rack AC PDP Rack
should be less than
1 volt.
Locate the incoming
circuit breakers of the
Power
Circuit breakers are
3 Distribution Panel (PDP).
in the off position.
Ensure that all circuit
breakers are in the off
position.
With the circuit breakers
in the off position, switch
on the Main UPS. Measured voltage is
Measure and verify the expected as
input voltage at all input 415VAC ±1%V AC
4
circuit breaker of the (3-phase)
Power Distribution Panel 230VAC±5%.(Phase
(PDP). Record pertinent Voltage)
Voltages in the Testing
Copy.
Ensure that Secondary Secondary Tap
5
Tap Setting is at 110 V Setting is at 110 V
AC on TR1 Step down AC on TR1 Step
Transformer. down Transformer.
Turn on all the Input Measured voltage is
6
circuit breakers of the expected as

Revision: 02
Power Distribution Panel 230VAC±5%.(Phase

(PDP) Voltage)
MCCB ( Q1)
Using SD1 (Source Input supply from
Change Over Switch) UPS is redundant
7
check the redundancy of and Voltage
Input supply from UPS. Appears.
Switch On M1 (MCB) and
8 ensure that R, Y and B Indication Lamps lit
phase Indication Lamp Lit
Check Readings at
Voltmeter & Ammeter Voltmeter and
9
Display. Record pertinent Ammeter Displays
Voltages in the Input voltage and
“Measured Results” Current.
section
Check Voltage at the Input voltage is 415
10
input of M2 (MCB). ± 1%.V AC
Check Voltage at the Output voltage is
11
Output of M2 (MCB). 415 ± 1%.V AC
Measure Voltage at Input Input Voltage is 230
and Output of ± 5%.V AC and
Transformer TR1. Record Output Voltage is
12
pertinent Voltages in the 110 ± 8%.V AC.
“Measured Results”
section
Check Voltage at the
Voltage at the Input
Input of 230VAC/110VDC
13 of power supply is
power Supply Rectifier.
230 ± 5%.V AC
(for Depot only)
Check Voltage at the Voltage at the
Output of 110V DC power Output of power
14
Supply Converter. (for supply is 110 ± 8%.
Depot only) VDC
input of Intelligent Voltage at the Input
15
temperature controller is 110 ± 8%.V VDC
and Fan Controller
Fans are working as
Check the functioning of per the temperature
Intelligent temperature Controller and all
16
controller and Fan relevant indications
Controller are working.
Below 30*C

Revision: 02
All Fan Off.

Between 30*C to
33*C One Fan On
Between 33*C &
36*C - Two Fan On
Above 36*C-
All Fan On.
All indication will be
displayed in Fan
display Screen.
Voltage at the
Check Voltage at Output
Output terminals
of PD terminals extending
17 Extending DC
110 VDC supply to DC
supply to DC PDP is
PDP.
110 ± 8%.V VDC
Output PD terminal
feeding supply to ATS
Equipment’s (Normal &
Voltage at the
Reserve), DCS
18 output Terminal is
Equipment’s (Normal &
230 ± 5%. VAC
Reserve), CBTC (Normal
& Reserve) & AXC, MLK
Relay, Racks Fan and
Workstation Console.
Check Voltage at Input of
TR2 Isolation Voltage at the Input
19
Transformer is 415 ± 2%.V AC
Check Voltage at Output

Voltage at the
of TR2 Isolation
20 Output is 415 ±
Transformer
2%.V AC
Measured voltage is
If Point Machines at site
expected as
then Check Outgoing
415VAC ±2%V AC
21 Voltage at the PD
(3-phase)
terminals feeding Power
230VAC±5%.(Phase
Supply
Voltage)
Check Voltage at the PD Voltage at the PD
terminals of VMR. ( terminals of VMR is
22 Restore the system 415VAC ±2%V AC
before preceding for the (3-phase)
next test) 230VAC±5%.(Phase

Revision: 02
Voltage)
Voltage at 415VAC
Power OFF panel.
Power Indication
Reverse the phase
Outgoing Terminals
sequence by
is 0V AC and
23 interchanging the R with
Corresponding PAC
Y phase. (Interchange
OK Indication
any two Phases). Switch
disappears from NV
on the panel.
Board.
Voltage at 415VAC
Power Indication
Power OFF panel. Outgoing Terminals
Remove R phase wire is 0V AC (and
24
from L1 terminal of VMR. Corresponding PAC
Switch ON the panel. OK Indication
disappears from NV
Board.)
Voltage at 415VAC
Power Indication
Outgoing Terminals
Repeat Test 3.22 for Y & is 0V AC (and
25
B phase also. Corresponding PAC
OK Indication
disappears from NV
Board.)
Voltage at the
Check Voltage at PD Output of PD
26
terminals of ELD Terminals of ELD is
110 ± 8%.V AC.
Check Voltage at
Voltage at the
Outgoing 230V AC power
27 output Terminal is
Alarm Indication
230 ± 5%. V AC
Terminals.
Open Corresponding
Fuse or Negative link of Voltage at the
supply feeding to 110V output Terminal is
28 AC power Alarm 0V AC. ( BX AC OK
Indication Terminals. bit at NV Board
(Restore after noting Disappears)
down the voltage)
Check Voltage at Voltage at the
29 Outgoing 110V DC power output Terminal is
Alarm Indication 110 ± 8%.V DC.

Revision: 02
Terminals.
Open Corresponding
Fuse or Negative link of Voltage at the
supply feeding to 110V output Terminal is
30 DC power Alarm 0V DC. ( BX DC OK
Indication Terminals. bit at NV Board
(Restore after noting Disappears)
down the voltage)
Switch off Power supply Voltage at the
1. Check Voltage at output Terminal is
31 Outgoing 110V DC power 0V DC. ( BX DC OK
Alarm Indication bit at NV Board
Terminals. Disappears)
Restore supply at PS1
and Switch off Power
supply 2&3 one by one &
Voltage at the
Check Voltage at
output Terminal is
Outgoing 110V DC power
32 0V DC. ( BX DC OK
Alarm Indication
bit at NV Board
Terminals. ( Restore the
Disappears)
power supply
connections after noting
down the voltage)
Measured voltage is
Check Voltage at PD expected as 415V
terminals feeding supply AC ±2%V AC (3-
33
to Power Distribution Box phase) 230V
in SMR AC±5%.(Phase
Voltage)
Measured voltage is
Check Voltage at PD expected as
terminals feeding supply 415VAC ±2%V AC
34
to Power Distribution Box (3-phase) 230V
in SCR AC±5%.(Phase
Voltage)
Name Designation Signature Date

Revision: 02
8 PREVENTIVE MAINTENANCE
MAINTENANCE AND SERVICING INSTRUCTIONS II
8.1 GENERAL GUIDELINES

Switch OFF incoming power supply before opening the door (Only under authorized
personal).
a) Voltages employed are sufficiently high to endanger human life.
b) Measure voltage on input terminals to ensure that units are de-energized.
c) Isolate the source used for remote monitoring / alarm.
d) Ensure that only qualified and trained personnel are instructed and permitted for
carrying out the maintenance.
e) Ensure that material / tools are not left inside the unit after maintenance, as these
can cause faults.
8.2 RECOMMENDED UNIT SERVICING AND MAINTENANCE TASK

For servicing and maintenance of the unit following schedule is recommended. Also based
on site condition and the ongoing requirement appropriate maintenance and servicing
schedules should be drawn by the NMRCL.
8.3 MONTHLY
a) Remove the dust from the cabinet with vacuum cleaner. Clean complete equipment.
b) Check that all the meters (Voltmeters, Ammeters, etc.) are showing appropriate
values.
c) Inspect all devices periodically to ensure that the equipment is in proper working
order.
d) Check tightness of connections and fitments
e) Clean filters
8.4 QUARTERLY
a) Monitor and record input voltages and respective input currents, DC bus voltages
and output currents of PDP
8.5 HALF YEARLY

Verify all output terminals for connection tightening
8.6 YEARLY
a) Inspect all wiring for wear and cuts
b) Inspect power at all the MCBs and replace warn out contacts
c) Inspect all auxiliary and control circuits for desired functioning
d) Check gasket of the door
e) Check functioning of Earth Leakage Detector (ELD)

Revision: 02
8.7 MAINTENANCE SCHEDULE AC- DC PDP

The purpose of this section is to provide procedure maintenance schedule for AC-DC
PDP. All necessary checks have been included in this document regarding checks to be
carried out on PDP. However, specific tests in addition to this may be carried out as
deemed necessary.
8.8 EQUIPMENT REQUIRED:

1. Mechanical toolkit (Spanner set, screw driver set, wire cutter, pliers, crimping tool,
2. Multimeter (AC/DC), Clamp meter (AC/DC), probes
3. AC Power Source (Single or Three phase as required)
4. High Voltage Tester
5. Million Mega Ohm Meter
6. Any specific equipment as required
7. All equipment used in testing should have valid calibration.

Revision: 02
8.9 PRELIMINARY REQUIREMENT:

Before commencing maintenance, person should ensure availability of approved drawing
for relevant AC-DC PDP. Maintenance schedule for Power Distribution Cubicle is give in
chart below,
For servicing and maintenance of the AC-DC PDP unit following schedule is
recommended. Also based on site condition and customer requirement appropriate
maintenance and servicing should be drawn by the user. Maintenance schedule and tests
for AC- DC Power Distribution Panel is given below.
Table 3: Maintenance Schedule of AC - DC PDP
Half
Sr. No Checkpoints Monthly Quarterly Yearly
Yearly
1 Visual Checks √
2 Dust Cleaning √
Insulation Resistance
3 √
Test
4 Meters √ √
5 DC-DC Converters √
6 Filters √
7 Panel Ambient Light √
8 Earthing √
9 Earth Leak Detector √
10 Fan Tray √
11 Wiring wear and tear √

Tightness of
12 √
contacts/terminals

Revision: 02
8.10 AC-DC - PDP POWER ON - MAINTENANCE RECORD

Table 4: AC- DC PDP Power on Maintenance Check
SCR Name: Maintenance Report No:

Location Equipment ID:
Date of Testing: Time of Testing:
Reference Drawing Number / Revision :
Measured
Test Activity Expected Results Pass /Fail Remarks
Results
Check the continuity The buzzer should
between the earth stud Beep in the Multi-
1
at AC-DC PDP Rack and meter.
room earth
Check the potential The potential
difference between the difference between
earth and neutral of the earth and neutral
2
AC-DC PDP Rack of AC-DC PDP
Rack should be
less than 1 volt.
Locate the incoming
Power Circuit breakers
3 Distribution Panel (PDP). are in the off
Ensure that all circuit position.
breakers are in the off
position.
With the circuit breakers
in the off position,
Measure and verify the Measured voltage
4 input voltage at all input is expected as 415
circuit breaker of the AC V AC.
Power Distribution Panel
(PDP).
Turn on all the Input
Measured voltage
Power Distribution Panel
5 is expected as 415
(PDP)
V AC.
Measure Voltage at the
Output of Circuit breaker.
Check Readings at Voltmeter and
6
Voltmeter & Ammeter Ammeter Displays

Revision: 02
Display. voltage and

Current.
Repeat step for all
MCB’s and record the
7
Input and Output
voltages for each.
8 Input of AC-DC
Convertors
Record the AC Input to
9
Modules
Check voltage at the
Voltage at the
Output Terminals feeding
10 Output terminals
Supply to MLK (M1/M2)
12V+15%V DC.
Normal
Voltage at the
11 Output terminals
12V+15%V DC.
Reserve ( Redundant )
Check voltage at the Voltage at the
12 Output Terminals feeding Output terminals
Supply to ELD-2 12V+15%V DC
Input Terminals of
13 Intelligent Temperature
Monitor and Fan
Controller
Input of 230 V AC/
14
24VDC AC-DC
Converters.
Voltage at the
Output of
15 Output of 230 V AC/
Converters
24VDC Converters.
24+15%V DC
Voltage at the
16 Output terminals
24+15%V DC
I/O + Relay.
Input Fuse Terminals Voltage at the
17 feeding Supply to 12V Output terminals
MLK Normal Power 12+15%V DC
Indication.

Revision: 02
24V MLK Reserve Power

Indication.
24V MLK Power
Indication
24V Ext Power Indication
24V Int Power Indication
24V CBTC1 Power
Indication
24V CBTC2 Power
Indication
24V CBTC3 Power
Indication
24V AC Power Indication
ELD-1 Indication
ELD-2 Indication
ELD-3Indication
Output of Interfacing
Terminal
12V MLK Normal Power
Indication.
12V MLK Reserve Power
Indication.
24V MLK Power
Indication
24V Ext Power Indication
Voltage at the
18 24V INT Power
Output terminals
Indication
24V CBTC1 Power
Indication
24V CBTC2 Power
Indication
24V CBTC3 Power
Indication
24V AC Power
Indication.

Output of Interfacing
Terminal Voltage at the
19 ELD-1 Indication Output terminals 0
ELD-2 Indication V DC
ELD-3Indication
(Restore the same)

Revision: 02

Input of 230V AC/
20
24VDC External Power
Converters.
Input of 230V AC/ Output of AC-DC
21
24VDC External Power Converters
Converters. 24+15%V DC
Voltage at the
22 Output terminals
24V DC Supply to Relay
24+15%V DC
Rack (VI1/VI2).
Output of Fuse terminal Fuse terminals is
23
feeding Supply to expected as
Ammeter and ELD -3. 24+15%V DC
24 Input of 110VDC/ 24VDC Input of Converters
Internal Converters. 110±10%V DC
Voltage at the
Output of 230 V AC/
25 Input of Converters
24VDCInternal
24+15%V DC
Converters.
Output Terminals feeding Voltage at the
26 24V DC Supply to Relay Output terminals
Rack ( VI1/VI2) 24+15%V DC

Voltage at the
27 Output terminals
24V DC Supply to ELD -
24+15%V DC
3
Voltage at the
Input of 230 V AC /
28 Input of Converters
24VDC AC-DC
110±10%V DC
Converters.
Output of 230VAC/ Output of
29
24VDC AC-Dc Converters
Converters. 24+15%V DC
Check voltage at the Voltage at the
30 Output Terminals feeding Output terminals
24V DC Supply to AC. 24+15%V DC

Revision: 02

Voltage at the
31 Output terminals
24+15%V DC
3
Input of 230 V AC/
32
24VDC CBTC 1, 2 & 3
Converter.
Output of 110VDC/ Output of
33
24VDC CBTC 1, 2 & 3 Converters
Converter. 24+15%V DC
Voltage at the
34 Output terminals
24+15%V DC
1
ELD Tests: After the ELD
power on, Switch on the
connected channels from
Reset One By one
the rear Terminal Strip.
all channels from
Red LED is on and
front panel green
Buzzer starts Ringing,
35 LED (For Normal
after resetting
Indication) Lit and
pushbutton & Mute
RED alarm LED is
buzzer Button from front
OFF.
panel. Red Led is off and
green LED lit for Normal
Indication.
Position Name Signature Date

Revision: 02
End of the Document

Revision: 02

NS0-R-SIG-14-0009-PDP-Maintenance Manual

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NOIDA - Greater NOIDA Metro Rail Project

Delhi Metro Rail Corporation Ltd.

Document Number: NS01-R-SIG-14-0009

Revision after Customer comments 16 OCT 2018

Author Reviewer Approver Description of Revision Date

TRACEABILITY OF THE REVISIONS

Rev. Date Author Reviewer Approver Revision Description

Revision after Customer comments

Revision after Customer comments

© 2018 ASTS -ZTE Consortium. All Rights Reserved.

4.8 Depot PDP-2 Front View ..................................................................................... 22

7.7 Yearly .................................................................................................................. 42

Table 1: Maintenance Schedule of AC PDP ...................................................................... 43

Figure 1 PDP-1 rack power Indications R-Y-B ................................................................... 16

1.3 DOCUMENT REFERENCES

1.3.1 Project Submittals

Ref Document Number Document Title

[5] NS01-G-SIG-9-0033 – AC 12 Depot PDP 2 Layout Drawings

[6] NS01-G-SIG-9-0013 – AC 2 Sector 50 AC/DC PDP Layout Drawings

1.3.2 Other References

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Ref Document Number Document Title

1.4 DESCRIPTION OF CHANGES FROM THE PREVIOUS REVISION

Description of change Chapter(s) affected by the modification(s)

1.5 TERMS, ACRONYMS AND ABBREVIATIONS

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1.6 SYMBOL DESCRIPTION

AUTHORIZED PERSONNEL ONLY

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2 SAFETY AND HEALTH REQUIREMNETS

2.1 GENERAL SAFETY AND HEALTH REQUIREMENT

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2.2 WORK PERMIT SYSTEM

Format of Work Permit System

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3.2 PDP-1 RACK AND SUB-SYSTEMS

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3.3 ISOLATION TRANSFORMER

3.4 STEP DOWN TRANSFORMER

3.5 PDP-1 AC POWER DISTRIBUTION

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3.6 PDP-1 RACK SUB – ASSEMBLY MODULES:

It is used to Step-down Input 415 V to 230V and 110 Volts for

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3.7 PDP-1 RACK FRONT VIEW

3.9 PDP-1 FRONT VIEW

Figure 1 PDP-1 rack power Indications R-Y-B

Figure 2 MCCB, CT1, CT2, CT3, PD (ROW-T1 to ROW-T2)

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Figure 3 Transformers TR1, TR2 Front View

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3.10 PDP-1 REAR VIEW

Figure 4 SPD 1 to SPD 6 (Row T 5)

Figure 5 BX 230 and NX230 Distribution (ROW-T3 to ROW-T4)

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Figure 6 Transformers TR2 and TR1 Rear view.

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4 POWER DISTRIBUTION PANEL

4.2 AC POWER DISTRIBUTION PANEL - 230 V AC

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• Axle Counter Normal 230 V AC

4.3 AC POWER DISTRIBUTION PANEL - 415 V AC

4.5 AC TO DC CONVERTORS AND POWER DISTRIBUTION