दक्षिण मध्य रे लवे

South Central Railway

मल्टी क्षिक्षिप्लिनरी जोनल ट्र े क्षनिंग इिं प्लिट्यूट् - एि एिं ि ट्ी कैम्पि
Multi Disciplinary Zonal Training Institute - S&T Campus
मौला-अली / क्षिकिंदराबाद
Moula-Ali / Secunderabad

WELCOME
Presentation on
I N T E G R AT E D P O W E R S U P P LY ( I P S )
Integrated Power Supply(IPS)
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 Integrated Power Supply(IPS)
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 Latest version of IPS –

(RDSO/SPN/165/2012) Version 3

 (RDSO/SPN/165/2004 with Amendment-5)

Modified and issued as……..
RDSO/SPN/165/2012.

 Amendment 5-related to Class B,C & D type

Lightning & Surge Protection - Jan 2006
 Integrated Power Supply(IPS)
4

Manufacturers of IPS
 Amara Raja
 HBL Nife .
 Statcon
 Shukila
Integrated Power Supply(IPS)
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• A complete
solution for all
power supplies
for signalling
and telecom
equipment
• Efficient and
cost effective
 Integrated Power Supply(IPS)
6

Advantages of IPS
 No blank Signal for the approaching drivers
.
 Reduces Maintenance

 Centralized Power System

 Module Based - Occupies less space

 Replacement of Defective Modules is easy

 Integrated Power Supply(IPS)
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Advantages of IPS

 System can
. be easily configured to suit load
requirement
 The diesel generator set running (Non-RE
area) is reduced almost to ‘NIL’
 continuous display of working status of
system
 Integrated Power Supply(IPS)
8

Advantages of IPS
 visual & audible indication -Defect in sub-
units of system
.

 Reflects the condition of battery with

warning

 Highly reliable-Uses (n+1) modular

technology
Integrated Power Supply(IPS)
9

Components of IPS
 SMR panel…
SMR/FRBC, CSU,LVDS,
(Terminations and PCB’s are
also provided)
 DCDP….
DCDC Converter
 ACDP ….
Inverters, CVT(Signals),
CVT(Tracks), Step down
transformers,Choke, Auto
Change Over Circuit.
Integrated Power Supply(IPS)
10

Components of IPS
 Lightning & Surge
Protection….
Class B, &
Class C
Class D … provided
inside the panels
Integrated Power Supply(IPS)
11

Components of IPS
 Status Monitoring
Panel……
Provided in
Station
Master
room/Panel
Integrated Power Supply(IPS)
12

Components of IPS
 Battery ……

Provided in
Battery room
Lightning & Surge Protection
13

 Stage 1 Protection ……
(at the entry point of input
230V AC supply in the
power/ equipment room)
 The Class B SPD shall be
provided between Line to
Neutral & Neutral to Earth.
 They shall be spark gap
type voltage switching
device
Lightning & Surge Protection
14

 The Class C type SPD…

between Phase and Neutral
…shall be a single compact
varistor of proper rating

 Stage 2 protection…
(at the output side inside the
ACDP/DCDP/SMR
distribution panel)
 Provided for External circuits
i.e. Relay external circuit,
Axle counter circuit, point
machine circuit and at
Inverter output. etc
Lightning & Surge Protection
wiring
15
EARTHING SYSTEM… RDSO
16
 Earthing for IPS
17

 The Earthing Value should be less than 1 Ω as measured by megger.

 If the Megger is not available at site, then we should measure the N-E
Voltage of Mains Supply on class B protection Box. It should be less
than 5V. SMR PANEL DC PANEL AC PANEL

MCD50-B MCD125-
FUSE VDE B NPE
32A/63A

X1 X2 X3 X4
L N N L

FROM TO
IPS
MAINS

CUSTOMER
EARTH
Integrated Power Supply(IPS)
18

SMR
 Provision for Five
rectifier modules
 Rated -110V-20A,
2.7kW
 Number of FRBC
modules…………
(n+1) parallel
configuration
 Integrated Power Supply(IPS)
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Working Of SMR

• SMPS charger
BATTERY
CHARGING

A.C input-150V
STATUS
MONITORING
INVERTERS
IN ACDP
AC to 275V AC
PANEL

SMR with single-phase

O/P 48 Hz to 52 Hz.
• Out put of SMR -
POINT
110 V.D.C ..Used
DCDP
OPERATION
at five points
Integrated Power Supply(IPS)
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Other components in SMR cabinet

 LVDS Switch
 Terminations for
supply distributions
..(AC input supply,
Battery supply,
DCDP, ACDP)
..Data logger &
..Monitoring Panel
terminations etc.
Integrated Power Supply(IPS)
21

Other components in SMR cabinet

 Different PBC’s provided
PC1 – SMR Address
Board
PC2 – MMIB
PC3 – MUIB
PC4 – PFC Board
PC5 – PFC Interface
Board
PC6 – SCR gate
Protection Board OR
SCR OV/UV Module
PC7 – AC Input MOV
Board.
Integrated Power Supply(IPS)
22

DCDP
 I/P to all - 98-138V.
 Out put as required by
the customer.
 Adjust the potentiometer
to get the desired output.
 Voltages pertaining to
individual applications to
be equal.
 All supplies…N+1
configuration
 Internal… N+2
configuration.
Integrated Power Supply(IPS)
23

AC Distribution Panel (ACDP)

consists of:
 Inverters …110vDC
/230 V AC.
 CVT/AVR………
230 V /230 V AC.
 Transformers..
230VAC/110 V AC for
Signals and Tracks.
 Auto/Manual change
over switch with PCB.
Integrated Power Supply(IPS)
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Auto/Manual change over

 Normally switch in auto
mode
 Inv 1 takes the load. If inv 1
fails, load changes to inv 2
automatically.
 If inv 2 fails load shifts to
CVT automatically.
 Any failure in auto mode,
(both inv fail or PCB failure),
then change auto/manual
switch to manual mode.
Integrated Power Supply(IPS)
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Auto/Manual change over

 Any failure in auto mode
(both inv fail or PCB
failure), then change
auto/manual switch to
manual mode.
 select the available
output…inv 1 or inv2 or
CVT.
Integrated Power Supply(IPS)
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LVDS (Low Voltage Disconnect

LVDS TRIP; 98 V
Terminals should be
shorted during the
contactor relay
failure
 This Voltage can be
adjusted through
CSU.
 Keep LVDS in AUTO
Mode in CSU.
 Integrated Power Supply(IPS)
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LVDS WIRING
TO BATTERY FROM SMR’S +VE
+
FU1 63
A
TO LOAD +VE

TO BATTERY -
VE

TERMINAL
TO LOAD -VE
Integrated Power Supply(IPS)
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Integrated Power Supply(IPS)
29

CSU Panel-Important settings

SMR I Limit – To be set
as required – Based on
Battery Capacity and
Load at Station.
(C/10+Load).
If 200 AH and Load 15A
then 20 + 15=35A. Then
If 3 SMR’s are ON, then
Set SMR Current Limit
to 12 (12 x 3=36).
 Integrated Power Supply(IPS)
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CSU Panel-Important settings

SMR I Limit – To be set Float and boost voltage
as required – Based on adjustment: To be adjusted
via battery setting
Battery Capacity and
Load at Station.
(C/10+Load).
If 200 AH and Load 15A
then 20 + 15=35A. Then
If 3 SMR’s are ON, then
Set SMR Current Limit
to 12 (12 x 3=36).
 Integrated Power Supply(IPS)
31

DATALOGGER INPUTS
7 inputs to DL from IPS..
 1) Inverter 1 fail
 2) Inverter 2 fail
 3) FRBC fail
 4) DC-DC converter
 fail
 5) Mains fail
 6) Call S & T staff
 7) Battery low
(50% Deep discharge)
 Integrated Power Supply(IPS)
32

STATUS MONITORING PANEL

Instruction Condition LED Remarks
(DOD)
Ind

A Run
Set
Gen 50% RED Audio/visual alarm can be ack for audio
cut off

B Emergency
start
60% RED Audio/visual alarm can be ack for audio
cut off
generator

C System
down
shut 70% RED System feed cut off and all DCDC
converters to work. Audio alarm will
continue till generator started
 Integrated Power Supply(IPS)
33

STATUS MONITORING PANEL

Instruction Condition LED Remarks
(DOD)
Ind

D Call
staff
S&T Equipme
nt fail
RED Failure of any module or in case
battery gets disconnected from circuit
will give alarm in panel. Alarm can be
ack for audio cut off.

E Stop Gen
Set
FRBC
change
Green Audio/visual alarm

over to
float
mode
 Integrated Power Supply(IPS)
34
STATUS MONITORING PANEL
Sl. LED
Instruction Condition Remarks
No indication

50% DOD Audio/ visual alarm can be acknowledged for audio

1. Start Generator RED
(2V/Cell)=109V cut off.
Emergency Start 60% DOD Audio/ visual alarm can be acknowledged for audio
2. RED
Generator (1.95V/cell)=107V cut off.

Signal feed cut off but all DC-DC converters

System Shut- 70% DOD
3. RED continue to work. Audio alarm will continue till
down (1.9V/cell)=105V
Generator is started.

Equipment Failure of any module will give the alarm in ASM’s

4. Call S & T Staff RED
fault. panel. Alarm can be acknowledged for audio cut off.

FRBC change
5. Stop Generator over to float GREEN Audio / Visual Alarm.
mode

* Note:

 DOD – Depth of discharge of battery bank.

 At 90% Depth of Discharge (DOD) (1.85 V per cell=99V) of the battery bank, 110VDC Input supply will
be cut-off to all the DC-DC converters, except to Block Tele DC-DC converters
 Integrated Power Supply(IPS)
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230 V not available to SMR

Mains fail alarm in SMPS panel

Call S & T Staff

109V…Start Generator…
50% DOD (Approx. 2V/Cell)

107V…Emergency Start Generator…

60% DOD (Approx. 1.95V/Cell)

105V…System Shut-down and inverter trips..

70% DOD (Approx. 1.9V/Cell)

99V…LVDS trip….Input supply will be cut-off to all DC-DC converters

except to Block Tele DC-DC converters..90%DOD (1.85V/Cell)
 SMR Module
36

 Do’s  Don’ts
 Keep all the modules  Do not take out plugs
in ON position. of modules when
working.
 Set equal voltage for
 Do not connect
float and boost in all battery when modules
modules for proper are ON.
current sharing.  Do not connect
 Set battery path battery in reverse
current to AH/10. polarity.
 Set battery voltages  Do not disturb
according to type of battery under-cut
battery. setting.
 DC-DC Converters
37

 Do’s  Dont’s
 Always connect
 Do not put connectors
connectors and then
switch on DC-DC of different circuits in
converters. one paralleling
 Keep the DC Input group of connectors
switches always ON in on a paralleling
Converters. card.
 Ensure input DC
voltage is within the  Do not disturb
range of 98-138V. voltage of Converter
 Always set SAME beyond 0.5 V when
voltage for modules working
working in parallel. .
38
 दक्षिण मध्य रे लवे
SOUTH CENTRAL RAILWAY
क्षिगनल व दू रििंचार प्रक्षििण ििंस्थान
Signal and Telecommunication Training Centre
मौला-अली Moula-Ali
39

VI DEO FI L M ON M A I N TEN A N CE
A N D A DJ USTMEN T OF I PS
 दक्षिण मध्य रे लवे
SOUTH CENTRAL RAILWAY
क्षिगनल व दू रििंचार प्रक्षििण ििंस्थान
Signal and Telecommunication Training Centre
मौला-अली Moula-Ali
40

ANY QUEST IONS PLEASE

???????
 दक्षिण मध्य रे लवे
SOUTH CENTRAL RAILWAY
क्षिगनल व दू रििंचार प्रक्षििण ििंस्थान
Signal and Telecommunication Training Centre
मौला-अली Moula-Ali
41

ధన్య వాదములు
धन्यवाद
T H A N K Y O U
 दक्षिण मध्य रे लवे
South Central Railway
मल्टी क्षिक्षिप्लिनरी जोनल ट्र े क्षनिंग इिं प्लिट्यूट् - एि एिं ि ट्ी कैम्पि
Multi Disciplinary Zonal Training Institute - S&T Campus
मौला-अली / क्षिकिंदराबाद
Moula-Ali / Secunderabad

WELCOME
P resen t at i o n o n
Power Equipments.. Cells and
Battery
Power Equipments
2
 Power Equipments
3

 Important power equipments used in

Railway Signalling can be divided into five
broad classifications

AC to DC converters
DC to AC Converters
AC to AC converters
DC to DC converters
Others
 Power Equipments
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 AC to DC converters

• Track Feed Chargers

• Battery Chargers

• Switch Mode
Rectifiers

• Transrectifiers
 Power Equipments
5


DC to AC Inverters
Converters

AC to AC • Constant Voltage
converters Transformers(CVT) or
Automatic Voltage
Regulators(AVR)
• Transformers
• Stabilizers
 Power Equipments
6


DC to DC  DCDC Converters
converters
Others • Flooded type Lead Acid cells
• Flooded type Low
Maintenance Lead Acid Cells
( IRS S- 88/95.)
• Diesel Generators
• Solar Voltaic Cells
 Power Equipments
7

SECONDARY CELLS
• reversible to a high degree, chemical as well as
physical states of electrodes after discharge
(current flow in opposite direction)
• electrical energy is stored in the form of chemical
energy
• on demand is converted into electrical energy to
drive an external circuit.
Power Equipments
8

CUT SECTION OF
A CELL AND ITS
PARTS
 Power Equipments
9

Parameters of secondary cells. IRS Specification : IRS S-88/2004.

Voltage of a fully charged cell: 2.2v

Voltage of a fully discharged cell: 1.85v

Specific gravity of electrolyte of a fully 1215+/- 5.

charged cell:

Specific gravity of electrolyte of a fully 1180

discharged cell:
Internal resistance of a cell: Not more than 2 ohm

Codal life of a secondary cell 4 years.

 Power Equipments
10

 INSTALLATION OF LEAD ACID CELLS:

 Dos:
 Batteries should be kept in well ventilated rooms &
provided with exhaust fans.
 The floor should be acid proof & acid resistant.
 Wipe the top of the battery with wet cloth to make
it free of dust.
 Apply petroleum jelly on contact surfaces
,threading of bolts, and nuts before bolting up.
 Power Equipments
11

 INSTALLATION OF LEAD ACID CELLS:

Donts :
 Never carry/lift cells by their electrodes. Lift them with the
base
 Do not keep loose metallic parts/tools on cell top.
 Care should be taken that no effluents such as chloride,
acetic not kept or taken to battery room.
 Smoking or use of naked flames in the battery room is
strictly prohibited.
 Power Equipments
12

 MAINTENANCE: --
 Dos:

 1) Electrical connections should be kept tight.

 2) A thin layer of petroleum jelly …….. prevent corrosion
 3) Vent plugs …kept in position & tight to avoid spilling of
electrolyte.
 4) Electrolyte lost due to spillage...replaced with same
specific gravity as that of the other cells.
 5) Level of electrolyte …. 12 to 15 mm above the plates.
 ……Wipe the top of the battery with wet cloth to make it
free of dust.
 Power Equipments
13

 MAINTENANCE: --
 Dos:

 6) Use acid of specification IS266 and Distilled water of

spec. IS 1069
 5) Avoid under charging or over charging.
 6) Take frequent voltage reading (Once in 15 days).
 7) If any one of the cells loses its specific gravity, give an
equalizing charging of the total bank.
 8) Batteries which are defective, or reverse polarity should
be replaced with new one.
 9) Use calibrated meters for measuring current, specific
gravity & voltages.
 Power Equipments
14

 MAINTENANCE: --

 Donts:
 Do not use combustible material like diesel
for cleaning cells.
 Do not pour oil/greese etc on terminals of
secondary cells..
 Never carry/lift cells by their electrodes. Lift
them with the base
 Power Equipments
15

Frequently asked questions on Secondary Cells

and its Maintenance:
Q1.What is the life of a secondary cell….4 years
 given in terms of charge-discharge cycles.
 It is 1100 cycles with 80% Depth of Discharge
for LMLA cells.
 in signaling Float mode is used. Life of cell used
in float mode are not specified.
 As such, the codal life of cell is considered as 4
years. Beyond which they may work but with
less efficiency.
 Power Equipments
16

Frequently asked questions on Secondary Cells

and its Maintenance:
Q2.One of the cells in the battery bank has low
specific gravity or low terminal voltage compared to
other cell?.......
 Give equalizing charge to the complete battery bank
………….OR
 Remove the cell from the bank. Boost charge the cell
until the cell regains its capacity.
 Connect back when fully charged condition.
 Power Equipments
17

Frequently asked questions on Secondary Cells

and its Maintenance:
Q3. Under what circumstances one of the cells in a
bank assumes reverse polarity?..
 If the cell is accepting less charge than the other
cells in the bank
 over a period of time the cell slowly looses its
capacity
 assumes negative voltage if discharged.
 Power Equipments
18

Frequently asked questions on Secondary Cells

and its Maintenance:
Q4. What is Equalisation charge?
 charging the bank to make the capacity of all
cells equal.
 done normally once in three months.

Q5. What is the maximum charging current permitted

and the Maximum current that can be drawn from a
cell?
 C/10 where C is capacity of the cell in AH.
 Power Equipments
19

Frequently asked questions on Secondary Cells

and its Maintenance:
Q6. Is it possible to find the “state of charge” of the
cell by measuring its voltage.
 No. Voltage remains between 2.2v to 1.8 v
through out its shelf life.
 better to measure Specific Gravity to find out its
state of charge.
 Power Equipments
20

Frequently asked questions on Secondary Cells

and its Maintenance:
Q7. What is the chemical reaction that takes place while
discharging and charging a cell?

While Discharging..
 PbO2 + Pb+2H2 SO4 Pb So4 + PbSo4 + 2 H2O
While charging..
 PbO2 + Pb+2H2 SO4 Pb So4 + PbSo4 + 2 H2O
 Power Equipments
21

Frequently asked questions on Secondary Cells

and its Maintenance:
Q8. What happens if we overcharge a cell?

 This causes gassing of the cell. Water is required

to be added more frequently.

 plates get damaged.The temperature of cell

rises and can damage the cell.

 It leads to corrosion of positive grid.

.
 Power Equipments
22

Frequently asked questions on Secondary Cells

and its Maintenance:
Q9. What happens if we over discharge a cell?

 If discharged below 1.85v, it may not be revived

by charging it again.
 Power Equipments
23

VARIOUS DEFECTS IN SECONDARY CELL & THEIR PREVENTION

CAUSE/INDICATION REASON REMIDIAL ACTION
Sulphation:
White patches are a)Excessive discharge boost charge separately
formed on the plates and less charging. until gassing point is
and capacity becomes b)Keeping the cells in
reached,
low. discharged condition for
Specific gravity more time.
becomes low and does c)Not using proper
not pick up by distilled water or acid.
charging d) Rapid discharge.
e) Broken or jar leaking
g) Nil electrolytes
 Power Equipments
24

VARIOUS DEFECTS IN SECONDARY CELL & THEIR PREVENTION

CAUSE/INDICATION REASON REMIDIAL ACTION
REVERSE POLARITY
OF CELLS:
The positive and Due to short circuit this Remove the cell from the
negative terminals will be charged in bank.
shows opposite reverse direction. This
polarity. acts in opposite
direction to the main
EMF
 Power Equipments
25

 MAINTENANCE: --
Dos:
 1) Electrical connections should be kept tight.
 2) A thin layer of petroleum jelly …….. prevent corrosion
 3) Vent plugs …kept in position & tight to avoid spilling of
electrolyte.
 4) Electrolyte lost due to spillage...replaced with same
specific gravity as that of the other cells.
 5) Level of electrolyte …. 12 to 15 mm above the plates.
 ……Wipe the top of the battery with wet cloth to make it
free of dust.
 Power Equipments
26

 MAINTENANCE: --
Dos:

 6) Use acid of specification IS266 and Distilled water of

spec. IS 1069
 5) Avoid under charging or over charging.
 6) Take frequent voltage reading (Once in 15 days).
 7) If any one of the cells loses its specific gravity, give an
equalizing charging of the total bank.
 8) Batteries which are defective, or reverse polarity should
be replaced with new one.
 9) Use calibrated meters for measuring current, specific
gravity & voltages.
 Power Equipments
27

 MAINTENANCE: --

Donts:
 Do not use combustable material like diesel
for cleaning cells.
 Do not pour oil/greese etc on terminals of
secondary cells..
 Never carry/lift cells by their electrodes. Lift
them with the base
 दक्षिण मध्य रे लवे
SOUTH CENTRAL RAILWAY
क्षिगनल व दू रििंचार प्रक्षििण ििंस्थान
Signal and Telecommunication Training Centre
मौला-अली Moula-Ali
28

ANY QUEST IONS PLEASE

???????
 दक्षिण मध्य रे लवे
SOUTH CENTRAL RAILWAY
क्षिगनल व दू रििंचार प्रक्षििण ििंस्थान
Signal and Telecommunication Training Centre
मौला-अली Moula-Ali
29

ధన్య వాదములు
धन्यवाद
T H A N K Y O U