PRESENTATION ON

INTEGRATED POWER SUPPLY

G.K U M A R A NA D S T E .BPA

Present system of power supply arrangement in signaling.

In signaling we use two different types of sources i.e. DC & AC supply

DC-supply All the interlocking circuits are powered

with DC supply. Every DC circuits are provided with

individual chargers and Batteries During power failures DC circuits are

continuously powered with individual battery bank backup

AC SUPPLY All the line side signals are fed through AC supply During AC supply failure all the line side signals

will become blank. No solution is available to avoid blank signals in

the present signaling arrangement. As a rule if signals become blank treated as

defective signals. Which implies non-interlocking of signaling system. Though the interlocking is well intact.

During blank signals due to AC supply failures in the face of an approaching train can create panic among the crews to control the high speed trains

CONVENTIONAL POWER SUPPLY ARRANGEMENT OF

RAILWAY SIGNALLING

110V AC SIGNALS

SP SP SPBATTERY

CHARGER

110V

BATTERY

CHARGER

24V

BATTERY

CHARGER

12V

CVTINV. INV.

CVT

230V AC 230V AC 110V DC

110V AC 110V AC TRACK CIRCUITS

110V AC

110V BATTERY BANK

24V BATTERY BANK

12V BATTERY BANK

230V AC 230V AC230V AC

SIGNALS

NEED FOR IPS.

To avoid these contingencies- Un – interrupted power supply is required.By this principle integrated power supply system was developed i.e. complete power solutions from one system to all signaling circuits for a station

What is in Integrated power supply system

1

•Single battery bank is used

•110V (55 nos of cells)/200 AH in RE ,300 AH in NON - RE

•To replace defective cells in the battery bank additional 05 Nos of cells are kept as spare cells.

2

•To charge the batteries SMPS based switch mode rectifiers are used in parallel redundancy.

3

•To feed DC- supply to various circuits different ranges of DC-DC converters are used.

4

•All the signals are powered by AC supply derived from inverters with hot standby.

•All the field track circuits supply taken from main source through CVT.

1. Ensure the availability of stable grid supply minimum voltage of 200V-AC.

2. In RE-AREA ensure that 70sq.mm cable is available between 10kVA AT transformer to CLS panel to keep minimum voltage drop on cable (Ref: TI/PSI/Project/CLS/01 dt. 04.01.2002)

3. Measure the load currents of various DC & AC circuits.

4. Pre-commissioning check list for IPS should be followed .

Pre-request items before planning for IPS at stations

Standard rating of IPS components approved by RDSO

SMR DC-DC converter

Inverter CVT Transformer

110V-20A

24V - 32V/5A,12V-28V/ 5A12V-28V / 1A, 60V-66V/5A12V-40V / 1A, 60V-110V/1A3V-6V / 0.1A, 2V-12V / 5A24V-32V/10A, 12V-28V/10A24V-40V/10A, 12V-40V/10A

1.5kVA2.0kVA3.0kVA

1.5kVA2.0kVA3.0kVA

500VA1kVA

9

IPS Specifications – Revision History and Improvements

Sl. NoSpecification

N0 Features Added /Modified Advantages

1 Amendment – 1 (Ver.1)

Introduction of SMPS based IPS

2 Amendment - 2Introduction of LPD & SPD protections at the I/P stage of IPS.

Achieved protection of IPS from heavy lightning & surges during raining season & improves the system reliability.

3 Amendment - 3 New clause has been added to provide ventilation for individual modules.

1) Better heat dissipation . 2) Reliability improvement.

4 Amendment - 4 * IPS cabinet dimensions have been standardized.

* Ear thing guidelines are formalized. * Can avoid ear thing related issues and improves overall system reliability

* Pre-commissioning check list for installation & commissioning of IPS has been added.

Proper installation & commissioning can be ensured.

* Over load & Over voltage protections, have been added for IPS system.

Improves module and load reliability as well.

5 Amendment - 5 *Class-’C’ protection is added in Data & Signaling lines.

Improves data & signaling loads reliability and power interruption to the load is avoided.

*Guidelines given for Installation of LPD & SPD Devices.

Proper LPD & SPD co-ordination can be achieved,

TYPICAL BLOCK SCHEMATIC OF IPS AS PER RDSO/SPN/165/2004

REMOTEASM

PANEL

INCOMING230V AC SUPPLY

SMR110V/20A

SMR 110V/20A

BY PASS CVT1000VA

INV 11500VA

INV 21500VA

FUSE FUSE

FUSE

C7 CVT

1500VA

TX500VA

C7

C5

C6

110V ACTRACK CKT.

230V AC BUS

110 V DC BUS

FUSE

110V DCTO POINT MACHINE

TX500VA

110V ACSIGNAL UP

TX500VA

110V ACSIGNAL

DNFU

SE

SICK CELL CHARGER

2-12V

DC-DCCONV

DC-DCCONV

DC-DCCONV

DC-DC CONV

RELAY EXTERNAL24-32V/5A X 2

BLOCK LINE (BLOCK LOCAL)12-40V/1A X 2

DC-DCCONV

DC-DCCONV

DC-DC CONV

DC-DCCONV

BLOCK LINE (DN)12-40V/1A X 2

DC-DCCONV

DC-DC CONV

BLOCK LINE (UP)12-40V/1A X 2

DC-DC CONV

PANEL INDICATION & HKT

12-28V/5A X 2

DC-DCCONV

RELAY INTERNAL24-32V/5A X 2

DC-DCCONV

DC-DC CONV

SMR 110V/20A

Battery 1 Set

110V/300AH

LM LA

C11

FUSE

C

SMR 110V/20A

COLD STANDBY

150- 275V AC

Typical Block Diagram of IPS as per RDSO / SPN / 165 / 2004

110V/20A1.5 KVA

110 V DC BUS

TRACK CIRCUIT UP

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

24-32V/ 5A-4Nos RELAY INT.

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

230V AC BUS

SMR

1.0 KVA

1.5 KVA

TRACK CIRCUIT DN

SIGNAL UP

SIGNAL DN

COLD STAND BY

AVR

110V/20A

110V/20A

110V/20A

SMR (FRBC)

110 V DC BUS

1.5 KVA

INVERTER

ASM INDICATION PANEL

230/110V,500VA

230/110V,500VA

230/110V,500VA

230/110V,500VA

230V AC BUS

STEP DOWN TRANSFORMERS

230/110V,500VA

230/110V,500VA

110 V BATTERY

230V AC BUS

TO POINT MACHINE

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

DC-DC CONV

AVR

LPD PANELCLASS -B&C

DC-DC CONV

24-32V / 5A-1NoRELAY INT.

(COLD STANDBY)

24-32V/ 5A-2Nos RELAYEXT-1.

24-32V/ 5A-2Nos AXLE COUNTER

12-28V/ 5A-2Nos PANEL IND.

12-28V/ 5A-2Nos BLOCK LOCAL.

12-28V/ 5A-2Nos Datalogger

12-40V/ 1A-2Nos BLOCK LINE UP.

12-40V/ 1A-2Nos BLOCK LINE DN.

3-6V/ 0.1A-2Nos BLOCK TELE UP.

3-6V/ 0.1A-2Nos BLOCK TELE DN. 2-12V/ 5A-2Nos

FOR SPARE CELLS

24-32/ 5A-2Nos BPAC North

24-32V/ 5A-2Nos

BPAC south

FUSE(20A)

LVDS

ST

AT

IC S

WIT

CH

24-32/5A02 Nos

Relay Ext-2

MANUFACTURES OF IPS

RDSO APPROVED FIRMS ARE

M/S AMARA RAJA POWER SYSTEM

STATCON POWER CONTROL SYSTEM

HBL NIFE POWER SYSTEM

INSTALLATION OF IPS IPS comes with three panels namely1. FRBC or SMR panel Five rectifier modules Rated modules 110V-20A, 2.7kW output of the panel is connected to battery

bank and other panels2. DC distribution panel It can accommodate Max. of 39 converters it consists of different rating of DC-DC

converters3. AC distribution panel Combinations of inverters, step-down

transformers and CVT

Layout of 3 Panels, Class ‘B’ Protection Box & ASM Box

Class ‘B’Protection

SMR PANEL DC PANEL AC PANEL

ASM BOX

ALL FAIL SIGNALSI/P SUPPLY FROM

PANEL

AUTO C/O

LOADS

Battery

INSTALLATION PROCEEDURES System should be installed with

sufficient space at rear and front side minimum of one meter.

Keep the cabinets side by side with a spacing about one foot between them

Grout the cabinet to floor Draw the 10sq.mm copper wires from

IPS panels to power panel. Earthing of IPS

The Earthing Value should be less than 2 Ω as measured by megger.

Earthing of IPS panel

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.

TYPICAL PROTECTION SCHEME SHOWING LIGHTNING &SURGE PROTECTION AT INPUT OF POWER SUPPLY

X4

TOIPS

X1

FUSE32A/63A

X3

DC PANEL SMR PANEL

NL

FROMMAINS

AC PANEL

N L

MCD50-B VDE

X2

MCD125-B NPE

CUSTOMER EARTH

Before connecting the load to the IPS

DC-DC converters, signal transformer voltages should be adjusted to required voltages.

According to load current, number of DC-DC converters should be selected as N+1 redundancy. It means if any one converter fails our circuit should not go to failure mode.

COLOUR SCHEME FOR WIRING PRACTICE

DC CIRCUITS POSITIVE : RED ,

NEGATIVE :BLACK AC CIRCUITS PHASE : BLUE ,

NEUTRAL :YELLOW EARTH :GREY/GREEN

TYPICAL INSTALLATION OF BATTERY ROOM

IPS ROOM

STATUS MONITORING PANEL

FIXED AT ASM OFFICE. INDICATES HEALTHY OF COMPLETE IPS

SYSTEM. AFTER COMMISSIONING OF IPS. LETTER

TO BE SERVED TO ASM ,REGARDING SMP WORKING TILL CORRECTION IS MADE IN SWR.

IN PANEL BLOCK TELE PHONE SUPPLY FOR CONVERTERS ARE AVAILABLE.

Start generator: 50% DOD or Approx. 109V Emergency start generator: 60% DOD or Approx 107V System shut down: 70% DOD or Approx 105V Call S&T staff: Failure of FRBC, Converters, Inverters,

CVT’s & Transformers. PF contacts are available for DATA

LOGGERS.

MONITORING PANEL

MAINTANANCE OF IPS SMR Maintenance SMRs are fully alarmed and operate in an active loop

sharing arrangement. However , some regular checks can be an early warning of problems waiting to happen.

Current sharing (Applicable , when number of modules is

more then one number) Under normal conditions the currents contributed by every

rectifier should be within +/-2 Amps of each other. It is possible however, for internal loop parameters to change to such an extent that a unit does not share to the extent that it should.

Maintenance check for DC-DC converters

S No CHECK POINT ACTION REQUIRED FREQUENCY

1. Converter O/P voltage

Check if the O/P voltages are set as per requirement. If not, correct them

Once in 15 days

2. Paralleling of Converters

Switch OFF main Converter and observe if the stand-by is taking the load.

Once in a month

3. Paralleling of Converters

Switch OFF Stand-by Converter and observe if the main is taking the load.

Once in a month

4. Converter Mechanical Alignment

Check if all the converters are inserted properly

Once in 3 months

5. Converter Cleaning Remove one by one and clean the converter using a soft cloth . Gently blow some air from top or Bottom to remove the dust inside.

Once in 3 months

Maintenance Check Points for ACDP

SNo Check Point Action Required Frequency

1. O/P voltages of Inverters, CVTs Step- Down Transformers as per requirement

Check if the O/P voltages are set as per requirement. If not , check for fusescontactors.

Once in 15 days

2. Inverter O/P current Check if the DPM is showing the signal current as per original settings.

Once in 15 days

3. Auto changeover between Inverters and Bypass CVT

Check for this changeover operation as described in instruction manual

Once in a month

4. Connector Mechanical Alignment

Check if all the connectors of various sub systems are inserted properly

Once in amonth

5. Sub System Cleaning Remove one by one and clean them using a soft cloth . Gently blow some air to remove the dust inside.

Once in 3months

BATTERY MAINTANANCELow Maintenance Battery IRS 88/93

Cleaning of all cells around top cover and terminals periodically. Applying petroleum jelly over the terminals. Periodically recording of all cell voltages and their specific gravity. Periodically checking of electrolytic level of cells. Periodically recording of all cell voltages with Battery Charger

switched OFF. Boosting of Sick cell using Sick cell Charger. Replacement of non-reparable cell in a bank by fresh charged

cell.

Cleanliness Apart from these instructions regular cleaning of IPS and battery

room should be done. Cleaning of dust collected inside the IPS panels (SMPS, DCDP & ACDP) should be done with the help of blower once in a month.

EFFECT OF DUST ON WORKING OF IPS

Since IPS uses double side PTH PCB’s having high component density and compact module construction

It needs clean environment around it. It is true for any modern electronic equipment.

• The floor should be pucca with mosaic/tiles or with PVC flooring.

• There should be windows with glass doors so that they can be closed.

• Doors and windows should have gaskets.• There should be provision for exhaust fan and

dampers on outside.• The windows should preferably have wire mesh or

Netlon type jali.

Equalizing charge Measure the voltage of each individual

cell while the battery is at REST. Variation of 0.05V between cells and

variation of 20 points in the specific gravity indicates imbalance in the bank. Battery bank needs equalizing charge.

In IPS equalizing charging can be done by operating manual start EQ in CSU.

LOW VOLTAGE DISCONNECT SWITCH

HOUSED IN SMR PANEL

LVDS TRIP; 98 V TERMINALS SHOULD

BE SHORTED DURING THE CONTACTOR RELAY FAILURE

Problems faced in IPS after commissioning

SLNO PROBLEMS ACTION TAKEN

1 CLS PANEL MCB TRIPPING SMR CURRENT LIMITED TO MAX 10A

2 LVDS OPEN LVDS SHOULD BE IN AUTO

3 BLOCK TELEPHONE HEAVY HUMMING

DISCONNECTED BLOCK TELEPHONE CONVERTER

4 D2 SIGNAL BLANK,AND HOME SIGNAL FOR LOOP LINE NOT OBEYED ON IPS SUPPLY BACKUP

AC SUPPLY FEEDING TO SIGNALS WERE EXTENDED TO D2’s AND HOME SIGNAL ROUTE INDICATORS.

IMPROVEMENT NEEDS IN IPS

ELECTRONIC SWITCH MAY BE AVAILABLE PARALLEL WITH LVDS TO MAKE USE IN EMERGENT CONDITIONS.

UNIFIED CAPACITY OF CONVERTERS 12V – 32V/5 AMP

HIGHER CAPACITY TRANSFORMER ,CVT REMOTE DIALINIG FEATURE MADE COMPULSERY. SUFFICIENT LENGTH OF CABLE TO BE MADE

AVAILABLE BETWEEN SMR TO BATTERIES. Cable entry hole to be provided on top of modules. Extra converter slot made available in dcdp for

circuit expansion.

THANK YOU