PROJECT REPORT ON

“MEDHA EI”

Guided By: Course Director:

Er. Piyush Kumbhakar Shri K Uma Maheshwara Rao
(ADSTE/KLBG) (APS)

PROJECT DONE BY:

VINAY KUMAR SINGH
APP. JE (Signal), SUR/CR

ISJE/02/04/2021/BATCH-4, PHASE-02
 ACKNOWLEDGMENT

We wish to express our sincere thanks to IRISET ,Secunderabad and our respected
director of IRISET for giving me an opportunity to undertake this project on MEDHA
ELECTRONIC INTERLOCKING.
We wish to express our gratitude sincere thanks to our course director Shri. K Uma
Maheshwara Rao (APS) Sir, For allocating us and guiding us on this project.
Among the panorama of people who provided me inspiring guidance and
encouragement, We take this opportunity to thank the controlling officer of our project
ADSTE/KLBG/SUR/CR. We also explicitly acknowledge my indebtedness to
SSE/SIG/KLBG/SUR/CR for his Whole hearted support and guidance in completing
my project .
we also like to thank to all Faculty Members of IRISET, who provided necessary
infrastructure in analysing this project .Last but not least I am thankful to all the
individuals who have directly or indirectly helped me to complete this project.

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 ABSTRACT

Interlocking is an integral part of Railway Signalling, by which functions in a yard are

controlled in a manner that ensures safe passage of the train through the controlled
area. Railway signalling has come a long way from un-interlocked signalling system,
mechanical and electro-mechanical interlocking to the present day modern
signalling. Electronic Interlocking (EI) is one such type of signalling arrangement
which has several advantages over Electro-Mechanical or Conventional Panel
Interlocking. The interlocking logic in the EI System is based on software and hence
any modification is easy without the need for any wiring changes. The EI System is a
processor based system which have extensive diagnostic tests built into them. This
improves the reliability of the system and leads to minimal system down time even in
case of failures.

As there are continuous improvements in technology, we need to keep pace with the
latest trends and keep ourselves updated. Medha MEI633 EI System is an
indigenously developed Electronic Interlocking system and has been installed on a
number of stations of Indian Railways and more number of installations are likely to
be added in future. This project aims to study about Medha Electronic Interlocking
architecture their cards theirs functions and also how to troubleshoot the system in
case of failure.

Under Guidance of : Submitted By :

ADSTE KLBG VINAY KUMAR SINGH
SUR DIVISION / CR APP. JE SIGNAL/ SUR/CR

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 Table of Contents

Acknowledgemnt…………………………………………………………………………………….
Abstract……………………………………………………………………………………………….
Table of contents………………………………………………………………………………………

MEDHA ELECTRONIC INTERLOCKING

1. CHAPTER- 1 (Introduction)....................................................................................................... 1
1.1 Salient features ........................................................................................................................ 1
1.2 Sub-systems of MEI633 .......................................................................................................... 2
1.3 System operation ..................................................................................................................... 3
2. CHAPTER 2 (Functions of sub-systems) ................................................................................... 5
3. CHAPTER 3 (Hardware) ............................................................................................................ 10
3.1 Sub – Systems of Central Interlocking Unit........................................................................... 10
3.2 Sub-Systems of Object Controller ...................................................................................... 14
3.3 Sub –Systems of Panel Processor ......................................................................................... 16
4. CHAPTER 4 (Functions & Indications of various cards) ......................................................... 18
4.1 Vital Interlocking Computer (VIC ) Card (CVC Card)......................................................... 18
4.2 Communication Processor (COMP CPU) Card (CCC Card) ................................................ 19
4.3 Communication Interface (CIF) Card ................................................................................... 20
4.4 Voltage & Health Monitoring Card (CVHM ) ...................................................................... 21
4.5 IOCOM CPU Card ................................................................................................................. 22
4.7 WFM Input CPU (OCI) Card................................................................................................. 23
4.8 WFM Output CPU (OCCO) Card ......................................................................................... 24
4.9 Fail Safe Relay Driver (ORLD) Card ..................................................................................... 25
4.10 Vital Cut Off (OVCO) Card ................................................................................................. 26
4.11 Panel Processor CPU (PPCC) card ....................................................................................... 27
4.12 PP Voltage & Health Monitoring (PVH) card ...................................................................... 28
4.13 Panel Processor Input (PIP) card........................................................................................... 29
 4.14 Panel Processor Output (POP) Card ..................................................................................... 29
4.15 RS485-OFC Bi-directional converter card (Ring Modem) ................................................... 30
4.16 Power Supply (PPSA) Card (For Type A Power Supply) ..................................................... 31
4.17 Power Supply (CCPSB) Card (For Type B Power Supply) ................................................. 31
4.18 Power Supply (OPSC) Card (For Type C Power Supply) .................................................... 32
5. CHAPTER 5 (Maintenance) ....................................................................................................... 34
6. CHAPTER 6 (Troubleshooting)................................................................................................. 38
6.1 Troubleshooting with help PCB front panel indications ......................................................... 38
6.2 MEI633 Maintenance tools program ...................................................................................... 38
6.3 Troubleshooting through Maintenance Terminal.................................................................... 38
6.4 Troubleshooting through MEI633 Fault Codes ...................................................................... 39
1

CHAPTER - 1
MEDHA MEI633 Electronic Interlocking System
1. Introduction
MEI633 is a microprocessor based system with interface to the Points, Signals, Track
Circuits, Axle Counters, Level Crossing Gates, Ground Frames, Block Instruments for Block
working with adjacent stations, and crank handles for manual operation of Points. It has the
provision to interface with an External Data Logger through Serial Link to log events.
MEI633 is a self-contained independent system, which can be used standalone to control the
train movement in the Yard. MEI633 system conforms to RDSO Specification No.
RDSO/SPN/192/2005.

1.1 Salient features

• MEI633 system can be installed as a centralized system or a distributed system.
• Substantial cost savings can be achieved by using optical fibre communication cable in
place of signalling cable for distributed system.
• MEI633 system implements Two-out-of-Two Hardware architecture with identical
Hardware and identical Software for Vital modules.
• MEI633 provides Hot Stand-by with automatic changeover for all modules, except the
field modules.

Figure 1: Two out of Two Architecture

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Figure 2: Two out of Two System with Hot Standby

• The number of Object Controllers, the number of Input and Output WFMs in each OC,
and the Input and Output modules required for the Panel Processor can be selected as
per the Yard I/O requirement.
• The number of Object Controllers, the number of Input and Output WFMs in each OC,
and the Input and Output modules required for the Panel Processor can be selected as
per the Yard I/O requirement.
• MEI633 system operates on a cycle time basis, where the Interlocking equations are
executed every cycle. Accidental usage of stale data is avoided.
• MEI633 system is capable of handling the Yards up to 350 routes.

1.2 Sub-systems of MEI633

The MEI633 comprises of the following sub-systems:
(a). Central Interlocking Unit (CIU)
(b). Object Controllers (OC)
(c). Panel Processor Unit (PP)
(d). Power Supply Module
(e). Control Cum Indication Panel (CCIP)
(f). Counter Box Module
(g). Data Logger (DL)
(h). Video Display Unit Control Terminal(VDU CT )
(i). Maintenance Terminal (MT)
(j). Front Panel Display Unit (FPD)

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Figure 3: MEI633 Sub Systems

1.3 System operation

• The major building blocks of MEI633 are Central Interlocking Unit (CIU), Object
Controller Modules (OCM) and Panel Processor (PP).
• Cycle time of MEI633 is 333 ms.
• The actual state of the yard is displayed on CCIP/VDU CT.
• CIU collects the Yard information from OCMs and operator commands from PP/CCIP
/VDU CT.
• CIU validates and executes interlocking equations based on the available information
from field units and received commands from CCIP/VDU CT.
• The outcome of the equation execution is the OCM output data and PP/VDU CT
indication data.
• OCM output data is used to drive the output relays. Driving an output relay generally
clears a signal or operates a point.
• In other words, CIU generated field outputs, are transmitted to field modules, and
indication output is transmitted to PP/VDU CT.

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Figure 4: Medha MEI633 EI System Block Diagram

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CHAPTER - 2
SUBSYTEMS AND FUNCTIONS MEDHA EI
2.1 Functions of sub-systems

Central Interlocking Unit (CIU)

Central Interlocking Unit (CIU) Performs the Vital Interlocking functions and Communicates
with the other Sub-Systems. It consists of VIC, COMP, CIF and VHM cards, which are
enclosed in a single box. Input data from PP/VDU CT Modules, OCMs is received by CIU.
The received input data is processed for interlocking by CIU and output data is generated
based on the input data. The respective output data is sent to PP/VDU CT Modules, Counter
Box, MT and OCMs.

Figure 5: Central Interlocking Unit

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Object Controller Module (OCM)

Object Controllers acquire the Vital Field Input Data and drive the Vital Field Outputs. The
Object Controller Module (OCM) consists of two IOCOMs namely IOCOM-A, IOCOM-B
and a maximum of 8 WFMs. There can be at most 32 OCMs in a system. WFMs are
connected to IOCOM-A and IOCOM-B through RS485 interface. IOCOM-A and IOCOM-B
are connected to COMP-A and COMP-B respectively, through OFC interface. Input WFM
gets the status of the wayside functions in the yard. Output WFM receives the wayside
function output data from CIU through IOCOMs and drives the wayside functions connected
to it. Each Input WFM can read at most eight wayside function inputs and each Output WFM
can drive at most 8 wayside function outputs.

Figure 6: Block diagram of Object Controller

Figure 7: Object Controller

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Command Cum Indication Panel (CCIP)

CCIP consists of Push Buttons/Knobs, Keys, LEDs and Buzzers. Push Buttons/Knobs are
used to issue commands to System. Keys on CCIP can be in, Key In/Key Out position to
enable/disable processing of the commands issued by operator to System. LEDs on CCIP
indicate the yard status e.g. colour light signal on/off status, point position and track
occupation status. Buzzers are used to indicate the Button stuck condition or signal blank
condition. CCIP is connected to PP Modules through Input and Output Cards. PP module’s
link status with CIU and its Health status are indicated on CCIP.

Figure 8 : Control Cum Indication Panel

Panel Processor (PP)

Panel Processor module consists of two Panel Processors and each is connected to a common
set of Input and Output cards through parallel interface. On the other hand, each Panel
Processor is connected to COMP through Optical Fiber Interface. Each Panel Processor scans
the state of the inputs on CCIP through Input cards, and sends the same to VICs via the
respective COMP. Each of them receives Indication Information from Active VIC and drives
the same to CCIP through output cards, providing visual indication to operator. Indication
Information represents the current Yard status.

Figure 9: Panel Processor

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Power Supply Module (PS)

MEI633 uses three types of Power Supply modules viz, Type A, Type B and Type C Power
supplies. These power supplies are designed specifically to meet the requirements of various
cards in the CIU, OC and PP modules. All the three types take +24V as input.
M633PSA-01 O/p: 4.5V @ 8A ---------- ( in PP )
M633PSB-01 O/p: 4.5V @ 3A ---------- ( in OC & CIU , PP,CB)
M633PSC-01 Dual Output type –O/p-1: 4.5V@6A, O/p-2: 5.8V @2A (in OC)

Counter Box
Counter Box consists of CPU card and Output card. Output card is used to drive the counters
and buzzers. CPU card is connected to Output card and on the other end it is connected to
COMP-A and COMP-B, through Optical Fiber Interface. CPU card receives messages from
both COMPs. Ultimately it takes data to drive counters and buzzers from the Active COMP
channel. Counter Box module also indicates VIC-A and VIC-B status (Active, Standby and
Not Available), wrong side failure information from OC and CIU by the corresponding
LEDs.

Figure 10 : Counter Box

Video Display Unit Control Terminal (VDU CT)

Video Display Unit Control Terminal (VDU CT) is a
PC based application Software. VDU CT is connected
to CIU through OFC interface. Operator can issue
commands using the simulated buttons on the VDU
CT screen. It sends the command and receives the yard
status from COMP and displays the same on the VDU
CT screen. With a redundant VDU CT arrangement,
CCIP and PP can be eliminated and thus achieving substantial Figure 11 :VDU CT
cost-effectiveness.

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Front Panel Display (FPD)

LED Display is connected to CIU through RS232 interface. The system consists of two units,
namely Display-A and Display-B. They are used to display the system faults/recovery
messages.

Figure 12 : Front Panel Display

Maintenance Terminal (MT)

MT (Maintenance Terminal) is a PC based application
Software. MT is connected to CIU through RS232-OFC
Interface. MT screen shows the status of the system, logs the
events/faults received from CIU and generates alarm signal
if any critical fault is received from the CIU. Proprietary
serial communication protocol is used for communication
between CIU and MT. Diagnostic facility is available from
the MT in easily understandable language. Facility or replay
of recorded events through MT for offline analysis is Figure 13 : Maintenance
Terminal
available.

Data Logger (DL)

Data Logger (DL) is a device connected to CIU through RS232-OFC interface. DL is used to
log the yard and system status in every cycle. Proprietary serial communication protocol is
used for communication between CIU and Data Logger.

Figure 14 : Data Logger

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CHAPTER - 3
HARDWARE OF MEDHA EI

3.1 Hardware

The hardware for MEI633 can be divided broadly into the following three modules:
• Central Interlocking Unit
• Object Controller Module
• Panel Processor Module

Each Module further consists of two sub-systems that are physically arranged in two separate
mechanical enclosures that can be stacked one over the other. Each sub-system is housed in
standard 19” racks (with the exception to PP which is housed in 27” rack). Each enclosure
houses individual PCBs pertaining to a logical sub-system of MEI633.

3.1.1 Sub – Systems of Central Interlocking Unit

Figure 15 : Sub - Systems of Central Interlocking Unit

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Table 1 : Central Interlocking Unit Rack – (Bottom Bin)

PCB Name Qty Basic Function(s)
CIU Bottom Backplane 1 Mother board for the CPU, CIF and VHM
cards
Vital Interlocking Computer 2 Performs the vital interlocking and indication
card (CVC card or VIC logic computation
Card)
Communication Processor 2 Bridges the field modules and PP with the
card (CCC CPU card Vital Interlocking computer through serial
or COMP CPU Card) interface
Communication 2 CIF Card provides Isolated, Full Duplex
Interface card (CIF RS485
card) Interface to the Communication Processor
Card in the CIU module.
CIU Voltage and Health 2 Monitors the voltage and health of COMP
Monitoring card (CCC) and CVC (VIC) cards
(CVHM card)

Figure 16 : Central Interlocking Unit Bottom Bin

Table 2: Central Interlocking Unit Rack - (Top Bin)

PCB Name Qty Basic Function(s)

CIU Top Backplane 1 Mother board for the Power supply cards
Power Supply Type 4 To provide power to COMP CPU cards (2
B
no.s) and VIC cards (2 no.s)
4.5V@3A

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Figure 17 : Central Interlocking Unit Top Bin

Table 3: Central Interlocking Unit Rack – (Front Panel Display) – 2 Nos.

PCB Name Qty Basic Function(s)

Front Panel Display Card 1 To display Fault codes and System status
messages received from SVP

Figure 18 : Front Panel Display (FPD)

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Ports Connected to CIU (For Ch-A and Ch-B each) :

▪ CIU has 12 serial communication ports
• 8 ports are used for 32 OCMs (on each port, a max 4 OCMs can be connected)
• 1 port is used for PPs and VDUs (Max.4 PPs and/or 4 VDUs can be connected)
• 3 ports for OEIS/CTC/MSDAC/TCAS/ any ATP system
(1- port is reserved for OEIS, 1- port is reserved for CTC, 1 port remaining is used for
future use)

▪ CIU also connected to MT, DL,CB,& FPD

Figure 19 : Ports of Central Interlocking Unit

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3.1.2 Sub-Systems of Object Controller

Figure 20: Sub - Systems of Object Controller

Table 4: Object Controller Rack – OC (Bottom Bin)

PCB Name Qty Basic Function(s)
OC Bottom Backplane 1 Mother board for the WFM cards
Input Wayside 5 Reads the status of input relays
Function (Max.)
Module CPU Card OCCI
(Input WFM CPU Card)
Output Wayside Function 3 Drives the field output relays
(Max.)
Module Output Card through the Relay Driver card
OCCO (Output WFM
CPU
Card)
WFM Relay Driver Card 3 Drives the field output relays in a
(Max.) fail-
(ORLD Card)
safe manner
Vital Cut-off Card (OVCO 1 Monitors the health of Output WFM
Card) CPU cards

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Figure 21 : Object Controller Rack Bottom Bin

Table 5: Object Controller Rack –OC (Top Bin)

PCB Name Q Basic Function(s)
ty
OC Top Backplane 1 Mother board for the CPU, CIF
& VHM cards
OICC - IO Communication 2 Transfers information
Processor Card (IOCOM CPU between COMP and WFMs
card)
OPSB - Power Supply Type B 2 To provide power to IOCOM
O/p: 4.5V @ 3A CPU cards (2 Nos.)
OPSC - Power Supply Type 2 To provide power to
C Dual O/P– O/p-1: 4.5V @ WFM CPU cards (2
6A Nos.)
O/p-2: 5.8V @ 2A
OVH - OC Voltage and Health 2 Monitors the Voltage and
Monitoring card Health of IOCOM CPU card

Figure 22 : Object Controller Rack Top Bin

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3.1.3 Object Controller Voltage Cut-Off Relay (VCOR)

• Each OC has a Vital Cut-Off Relay (VCOR) to power Vital Output functions connected
to that OC.
• Primary Negation is triggered by dropping VCOR, in case of a Wrong Side Failure. Thus
forcing all the Vital Output functions connected to that OC in to Safe State.
• Secondary Negation: In cases, where VCOR is not getting dropped and still WSF
persists, CIU will shut-down and forcing safe state in whole yard.

Figure 23 : VCOR QN Series

Capacity of OC Rack
Single OC Rack can handle upto 64 I/Os
Each Card consists of 8 Bits
i.e. 5 X 8 = 40 I/Ps, 3 X 8 = 24 O/Ps, Total I/Os = 64
Twin Racks can handle 128 I/Os
i.e. 10 X 8 = 80 I/Ps, 6 X 8 = 48 O/Ps, Total I/O=128

3.1.4 Sub –Systems of Panel Processor

Table 6: Panel Processor Rack – MPP (Bottom Bin)
PCB Name Qty Basic Function(s)
PP CPU Backplane 1 Mother board for the CPU,
PVH, PSB and PExD cards
PP CPU card 2 Scans the CCIP buttons and
drives the indication
Power Supply Type B 2 To provide power to the PP
CPU cards (2 Nos.)
PP Extender Driver Card 2 Interface between the CPU
(Max.) backplane and IO backplane
PP Voltage and Health 2 Monitors the Voltage
Monitoring card and Health of PP CPU
(PVH card) card

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Figure 24 : Panel Processor Rack Bottom Bin

Table 7 :Panel Processor Rack – MPP (Top Bin)

PCB Name Q Basic Function(s)
ty
PP IO Backplane 4 Mother board for PExR, PP
Input
and Output cards
PP 4 Interface between the CPU
Extende backplane and IO backplane
r
Receiver Card
PP Input Card 1 Interface card for scanning the
1 CCIP buttons
PP Output Card 3 Interface card for driving the
8 CCIP indication outputs
Power 8 To provide power to PExR, PP
Suppl Input and Output cards
y
Card -A 4.5V@8A

Capacity of Non-Vital I/O Card - 64 bits, It can handle 672 inputs + 2400 outputs = 3072

Figure 25 : Panel Processor Rack Top Bin

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CHAPTER - 4
FUNCTIONS AND INDICATIONS CARDS
4.1 Functions & Indications of various cards

a. Vital Interlocking Computer (VIC ) Card (CVC Card)

Nameplate: CVC-A and CVC-B

Functions
1. VIC card receives the inputs from OCMs, PP Modules, VDUs, OEIS, and CTC, and
sends the output to the Communication Module.
2. It performs Vital Interlocking and Indication Logic Computation and Supervisory
processor checks.
3. It has a Serial Communication Interface with MT for sending the Data Log and System
Health information.
4. It is designed as a Dual Electronic Structure based on composite fail-safety with fail-safe
comparison.

Table 8: CVC Indications

Indication/Interfac Description
e
LED (POWER) Availability of input power to the card
Dual digit 7 Visual indication of fault-codes
segment display
LED (CYC) Cyclic activity status of SVP. Toggled every
cycle
LED (ACT) VIC is in active mode
LED (STD BY) VIC is in standby mode
LED (MRST) Provided for future use
LEDs (COM A Active status of COMP A and COMP B
and COM B) respectively

9 Pin D-Female Used for Data Logger, Maintenance Terminal

Connector and Front Panel Display communication
(RS232) during normal operation and for Application
Data
Figure 26 : VIC Card
Front display download during offline mode.
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b. Communication Processor (COMP CPU) Card (CCC Card)

Nameplate: CCC-A and CCC-B

Functions
1. COMP CPU card transmits and receives vital data.
2. It receives vital inputs from various IOCOMs, commands from Panel
processor, slots from any other SSI (if connected) and commands
from the CTC through various serial interfaces.
3. It receives the output messages through the DPRAMs and transmits
these messages to the respective destinations.
4. Provision is provided in card for connecting to PC parallel port for
Programming and debugging interface.

Table 9: CCC Indications

Indication/Interface Description
LED (POWER) Availability of input power to the card
Dual digit 7 Visual indication of fault-codes
segment
display
LED (CYC) Cyclic activity status of COMP. Toggled
every cycle
LEDs (VIC A and VIC Active status of VIC A and VIC B
B) respectively
9 pin Female connector Used for Debug port & Application data
(RS 232) download during offline mode
Figure 27 : CCC Card Front display

c. Communication Interface (CIF) Card

Nameplate: CIF-A and CIF-B
Functions
1. The CIF card facilitates conversion of TTL communication signals
(Tx, Rx and RTS) to RS485 signals.
2. It provides an Isolated RS485 Full Duplex communication interface
to the serial channels.
3. Each Card can support six or twelve channels depending upon the
system configuration.
4. The Rx, Tx and the RTS signals of all the channels are provided with
protection against overvoltage and surges.
5. It facilitates the COMP CPU card to check whether the CIF card is
present and is powered or not.

Table 10 : CIF Indications

Indication/Interfac Description
e
LED (POWER) Availability of input power to the card
Two 50 pin D type Provides full duplex RS485 interface
connectors with
communication processor card
Figure 28: CIF Card Front display

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d. Voltage & Health Monitoring Card (CVHM )

Nameplate: CVHM-A and CVHM-B
Functions
1. CVH Card generates Power Good signal if all the voltages are within predefined limits
2. It monitors the status of the COMP CPU and SVP CPU activities and indicates health of
CPU.
3. In case of the voltages going beyond limits or the CPU activity being not correct it shuts
down the power input to the corresponding CPU.
4. CPU Health monitoring is performed by pattern check, pattern struck, reset count, reset
struck and shunt down command.

5. LED indications are provided for Power ON, VIC Voltage within limits, VIC Health
Status, COMP Voltage within limits, COMP Health Status, VIC power cut-off and
COMP power cut-off.
Table 11: CVHM Indications

Indication/Interface Description
LED (POWER) (Amber) Availability of input power to the CVH card
LED (VIC VS) Glows Green:
VIC card voltages monitored by the Power
Manager are within predefined limits
Glows Red:
Any of the VIC card voltages monitored by the
Power Manager has gone beyond limits.
LED (VIC HS) Glows Green and starts blinking:
VIC CPU Health OK
Glows Red:
VIC CPU Health Not OK
LED (VIC CO) Glows Green:
CPU is operating normally
Glows Red:
CPU Power is cut-off by the VHM card.
LED (COM VS) Glows Green:
COMP voltages monitored by the Power
Manager are within predefined limits.
Glows Red:
Any of the COMP voltages monitored by the
Power Manager has gone beyond limits.
LED (COM HS) Glows Green and starts blinking:
COMP Health OK
Glows Red:
COMP Health Not OK
LED (COM CO) Glows Green: CPU is operating normally
Glows Red: CPU Power is cut-off by the VHM
card
Push button (VIC SD) When pressed power manager turns OFF the
Power
supply to VIC card
Push button (VIC ON) When pressed power manager turns ON the Power
supply to VIC and continues to function
Figure 29 : CVHM normally.
Push button (COM SD) When pressed power manager turns OFF the
Card Front display
Power
supply to COMP
Push button (COM ON) When pressed power manager turns ON the Power
supply to COMP and continues to function
normally

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e. IOCOM CPU Card

Nameplate: OICC-A and OICC-B
Functions
1. IOCOM CPU card transfers data between the Communication Processor and the
Wayside Function modules.
2. It receives the input messages from WFP and sends output messages to COMP.
3. It has provision for BDM/JTAG for connecting to PC parallel port for Programming and
debugging interface.

Figure 30 : IOCOM Card Front display

Table 12 :IOCOM Indications
Indication/Interface Description
LED (POWER) Availability of power to the card
Dual digit 7 segment display Visual indication of fault-codes

LEDs (WFP TX and WFP RX) Transmission and reception of data from
WFP’srespectively
LED (CYC) Status of cyclic activity of the CPU.
LEDs (COM TX and COM RX) Transmission and reception of data from
COMP card respectively
15 Pin Male Connector Provides serial communication between the
(RS485) OIC card and COMP card.

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f. OC Voltage & Health Monitoring (OVH) Card

Nameplate: OVH-A and OVH-B
Functions
1. OVH card generates Power Good signal if all the monitoring voltages are within limits.
2. Shuts down the power input to CPU in case of the monitoring voltages going beyond
limits or the CPU activity not being correct.
3. It monitors the status of the IOCOM CPU activity and indicates the status of CPU health.

Figure 31: OVH Card Front display

Table 13: OVH Indications

Indication/Interface Description
LED (POWER) Availability of power to the OVH card
(Amber)
LED (V. STS) Glows Green:
All the monitoring voltages are within predefined limits.
Glows Red:
Any of the monitoring voltage has gone beyond limit.
LED (H. STS) Glows Green: IOCOM CPU Health OK
Glows Red: IOCOM CPU Health Not OK
LED (CUT. OFF) Glows Green: Card is operating normally
Glows Red: IOCOM CPU power is cut off by OVH card.
Push Button When pressed, OVH Card ON the power to the OIC card
(RESET) when
it is in OFF condition

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g. WFM Input CPU (OCI) Card

Nameplate: OCCI-1, OCCI-2, OCCI-3, OCCI-4 and OCCI-5

Functions
1. OCI Card scans the state of the input relays.
2. It frames the input data based on the state of the connected input relays. The framed
input data is sent to IOCOM when they requested.
3. It indicates Input Relay connect status which is a Yard specific configuration setting.

Figure 32: OCI Card Front display

Table 14: OCI Indications

Indication/Interface Description
LED (POWER) (Amber) Availability of power to the card
LEDs (B TX1 and B TX0) Slave CPU status of communication with IOCOM-
(Amber blinking) B
CPU and IOCOM-A CPU respectively.
LED (B STS) (Green blinking) Status of cyclic activity of the Slave CPU
LED (A STS) (Green blinking) Status of cyclic activity of the Master CPU
LEDs (A TX1 and A TX0) Master CPU status of communication with IOCOM-
(Amber blinking) B, CPU and IOCOM-A CPU respectively
LEDs (IP1 to IP8) Input Relay State (Picked Up/Dropped)
(Relay Picked up -Green)
Relay Dropped - Not
glowing)
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h. WFM Output CPU (OCCO) Card

Nameplate: OCCO-1, OCCO-2 and OCCO-3

Functions

1. OCCO card receives Output relay drive data from IOCOMs

and drives the relays.
2. It reads the Output Relay contact states to know whether the
Output relays are in their commanded state.
3. It sends the read back data to IOCOMs.
4. It indicates Input Relay connect status which is a Yard
specific configuration setting.
5. It performs self-test at power ON to detect any possible
errors.

Figure 33: OCCO Card front display

Table 15: OCCO Indications
Indication/Interface Description
LED (POWER) (Amber) Availability of power to the card
LEDs (B TX1 and B TX0) Slave CPU status of communication with IOCOM-B CPU
(Amber blinking) and IOCOM-A CPU respectively.

LED (B STS) (Green Status of cyclic activity of the Slave CPU

blinking)
LED (A STS) (Green Status of cyclic activity of the Master CPU
blinking)
LEDs (A TX1 and A TX0) Master CPU status of communication with IOCOM-B CPU
(Amber blinking) and IOCOM-A CPU respectively.

24
25

i. Fail Safe Relay Driver (ORLD) Card

Nameplate: ORLD-1, ORLD-2 and ORLD-3

Functions

1. It can drive 8 External QN Type Fail-Safe Relays.

2. When the relay is to be driven it supplies 24V to the
external relays.
3. It has reverse voltage, high voltage protection and
against shorting of the drive signal.
4. Power input from two external power supplies for
redundancy.(Provided from the power supply cards)
5. Optical isolation is provided by Opto-couplers and
Galvanic isolation by transformers between the WFM
and external relays.

Figure 34: ORLD Card Front display

Table 16: ORLD Indications

Indication/Interface Description
LED (POWER) (Red) Availability of vital power to the relays
LEDs (OP1 - OP8) Drive status of the eight relays
Glows Orange:
Relay connected to that particular section is driven
Glows Red:
Drive signal is present but the relay is not driven as the fuse
is blown due to over load condition
Glows Green:
External feed to the Relay during the fuse blown out
condition

25
26

j. Vital Cut Off (OVCO) Card

Nameplate: OVCO

Functions
1. OVC card monitors the voltage outputs (+3.3 V) of the
regulators on the WFP Output CPU cards and indicates
whether the voltages are within permissible limits.
2. It monitors the status of the Output WFP CPU activity and
indicate the CPU health status.
3. It shuts down the power to the external relays in case of the
voltages going beyond limits or the CPU activity not being
correct.
4. Power Input +24 V DC (On board DC-DC Converter
generates the required voltages.
Table 17 :OVCO Indications
Indication/Interfac Description
e
LED (POWER) Availability of input power to the
(Amber) Vital Cut-off card.
LED (VCOR) Vital Cut-off relay is being driven
(Amber) by the CPLDs
LED (STS A) Starts Blinking:
(Green blinking) All the ‘A’ CPUs sends correct
status pattern and the
Figure 35 : OVCO status of all the ‘A’ CPUs is OK
Card Front display
LED (STS B) Starts Blinking:
(Green blinking) All the ‘B’ CPUs sends correct
status pattern and the
status of all the ‘B’ CPUs is OK
LEDs (OP1 to They are driven by CPLD B and
OP3)
represent the connect
(Green)
status of Output WFM card 1, 2
and
3.
LED (VCOR VCOR drive power is available to
POWER) OVC card.

26
27

k. Panel Processor CPU (PPCC) card

Nameplate: PPCC-A and PPCC-B

Functions
1. PCC card scans the state of the buttons on CCIP and sends the same to COMP.
2. It receives the indication data from COMP and drives the indication LEDs on the
Command cum Indication Panel.
3. Provision for BDM/JTAG is provided for connecting to PC parallel port for
Programming and debugging interface.

Table 18: PPCC Indications

Indication/Interfac Description
e
LED (POWER) Availability of the power to the card

Dual digit 7- Visual indication of fault codes

segment
display
LED (CYC) Status of cyclic activity of the CPU

LED (OE) Reception of Password from the COMP for

driving the output cards
LEDs (COM Rx Status of communication with COMP
and COM Tx)
15 pin Female Provides external communication interfaces
connect for serial ports with RS232 levels
or
(RS232)
15 pin Male Provides RS485 communication interface
Figure 36 :
connect with RS485-OFC Bi-directional
PPCC Card
Front display or converter
(RS485)

27
28

l. PP Voltage & Health Monitoring (PVH) card

Nameplate: PPVH-A and PPVH-B

Functions

1. PVH card generates Power Good signal if all the monitoring

voltages are within limits.
2. It monitors the status of the PP CPU activity and indicates the
CPU health status.
3. It shuts down the power input to the CPU in case of the
voltages going beyond limits or the CPU activity being not
correct.

Figure 37 : PPVH Card Front display

Table 19 : PPVH Indications

Indication/Interfac Description
e
LED (POWER) Availability of input power to the PVH card
LED (V.STS) Glows Green: All the voltages monitored by the
Power Manager are within limits
Glows Red: Any of the voltage monitored by the Power
Manager has gone beyond limit.
Third LED Glows Green: PP CPU Health OK
(H.STS)
Glows Red: PP CPU Health Not OK
Fourth LED Glows Green: CPU is operating normally
(Cut Off) Glows Red: CPU Power is cut-off by the VHM card
Push-button When pressed, VHM card restarts the PP CPU card when it
switch is
(RESET) in Power OFF condition.

28
29

m. Panel Processor Input (PIP) card

Nameplate: PPIP-1

Functions
1. PIP card
2. facilitates the scanning of the buttons on the CCIP by the PP
CPU card.
3. It has a provision to interface with two PP CPU cards at the same
time.
4. Maximum of 64 PIP cards can be accommodated in a system.

Table 20 :PPIP Indications

Indication/Interfac Description
e
LED (POWER) Availability of the power to the card

Two 37 pin D- Provides external communication interfaces

Male Connectors for 64 inputs coming from the CCIP

Figure 38 : PPIP Card Front display

n. Panel Processor Output (POP) Card

Nameplate: PPOP-1
Functions
1. POP card facilitates the driving of indication outputs on the
CCIP by the PP CPU card.
2. It has a provision to interface with two PP CPU cards at the
same time but drives the CCIP indications with the data sent by
only one CPU card at any instant of time.
3. Maximum of 64 Output cards can be accommodated in a
system.

Table 21: PPOP Indications

Indication/Interfac Description
e
LED (POWER) Availability of the power to the card

Two 37 pin D- Provides external communication interfaces

Male Connectors for 64 inputs coming from the CCIP

Figure 39 : PPOP Card Front display

29
30

o. RS485-OFC Bi-directional converter card (Ring Modem)

Figure 40 : RS485 OFC Bi-Directional Converter Card Front display

Table 22 : Converter Card Indications

Indication/Interface Description
LED (POWER) (Amber) Availability of input power to CPLD / OFC section of
the
card
LED (POWER) (Amber) Availability of input power to RS485 section of the card

LED (PTX) (Amber Data transmitting through primary channel

blinking)
LED (PRX) (Green blinking) Data receiving on primary channel
LED (STX) (Amber Data transmitting through secondary channel
blinking)
LED (SRX) (Green blinking) Data receiving on secondary channel
LED (M/S) ON (Green)- The Card is programmed for Master.
OFF (Blank) - The Card is programmed for Slave.
LED (P/S) ON (Green)- The Card is using primary channel for
communication.
OFF (Blank) - The Card is using secondary channel for
communication

30
31

p. Power Supply (PPSA) Card (For Type A Power Supply)

Nameplate: PPSA1 and PPSA-2
Functions
1. PPSA card provides an output +4.5V with a capacity of
delivering up to 8Amps of current.
2. The output voltage is used to operate Input and Output cards in
Panel Processor Module.
3. The input of the card is provided with under voltage, over
voltage and reverse polarity protections.
4. The output of the card is provided with under voltage, over
voltage and over load protections.
Table 23 :PPSA Indications
Indication/Interface Description
LED (24 V) (Amber) Availability of power to the
card
LED (ERROR) (Red if not Power supply Input out of
blank) limits
LED (4.5V) (Green) 4.5V Output voltage OK

Figure 41 : PPSA Card front display

q. Power Supply (CCPSB) Card (For Type B Power Supply)

Nameplate: CCPSB-A, CCPSB-B, CVPSB-A, CVPSB-B, OPSB-A, OPSB-B, PPSB-A and
PPSB-B

Functions
1. PSB card provides an output +4.5V with a capacity of delivering up to
3Amps of current.
2. The output voltage is used to operate CIU cards, IOCOM cards and PP
cards.
3. The input of the card is provided with under voltage, over voltage and
reverse polarity protections.
4. The output of the card is provided with over voltage and over load
protections.
Table 24 : CCPSB Indications
Indication/Interface Description
LED (24 V) (Amber) Availability of power to the
card
LED (ERROR) Power supply Input out of
limits
(Red if not blank)
LED (4.5V) (Green) 4.5V Output voltage OK

Figure 42 : CCPSB Card Front display

31
 r. Power Supply (OPSC) Card (For Type C Power Supply)

Nameplate: OPSC1 and OPSC2

Functions
1. PSC card provides an output voltage of +4.5V @ 6A and +5.8
@ 2A which are isolated form earth.
2. The output voltage is used for the operation of the CPU and
Relay driver cards in the OC Module.
3. The input of the card is provided with under voltage, over
voltage and Reverse polarity protections.
4. The output of the card is provided with over voltage and short
circuit protections.

Table 25 :OPSC Indications

Indication/Interfac Description
e
LED (POWER) Availability of power to the
(Amber) card

LED (ERROR) Power supply Input out of

(Red if not blank) limits

LED (5.8V) 5.8V Output voltage OK

(Green)
LED (4.5V) 4.5V Output voltage OK
(Green)

Figure 43 : OPSC Card Front display

32
33
 CHAPTER- 5
MAINTENANCE

5. Maintenance
• Maintenance personnel must be familiar with the recommended methods for operating,
testing, and repairing the MEI633 system equipment.
• Periodically check the Battery for the electrolyte level & top up if necessary.
• Check the SPD devices for any signs of physical degradation.
• Ensure Maintenance Terminal data is backed up during maintenance schedules.
• Ensure that MT PC/ VDU is always ON and communication link is working for both A
& B channels. Also ensure that time is in Sync. with Data Logger time.
• Adequate quantities of spare cards should be kept in the station to handle any situation
that calls for replacement of the cards. The spare cards to be periodically checked and
verified for correct functional.
• Earthing for the installation should be checked once in every six months and regular
maintenance activities should be carried out.

Table 29 : Monthly Maintenance Schedule

Sr. Location Description Action Taken/ Observations Remarks
No. Note the Voltage
levels
1 MT PC Backup the MT data logs Both channels
Event and Fault
logs data
downloading
should be done
Ensure the MT PC is
always ON and
communication link is
working for both A & B
channels; Also ensure
time is in Sync. With DL
time
2 DL PC Ensure DL is always ON
and Data is backed up
3 IPS Room Check the Voltage levels 150V to 275V If Medha
at 230V IPS Mains Input full IPS is
voltage to FRBC modules provided

34
4 Battery Measuring Cell, Battery Battery bank If Medha
Room voltage & specific fully charged full IPS is
Gravity condition should provided.
level maintenance as per be 110V & SG Switch off
Railways Battery level 1190 to Mains and
checklist 1220 take the
readings
5 Equipment / Clean the Dust filters, To be free from

35
Sr. Location Description Action Taken/ Observations Remarks
No. Note the Voltage
levels
Relay Room Exhaust fan filters as well dust
as fans
Clean the EI Equipments To be free from
dust
Check the ommunication Relevant
status of the EI Modules Communication
and Ring Modems and LEDs should
Glow/Blink
Check all Health Status LEDs should
LEDs,i.e System health Glow/Blink
Indication, Output
Voltage Indication of
system and VCOR power
LED indication
Check the voltages at 23V to 24.5V to
Equipment End of Ch-A be observed
& Ch-B
Check the voltages at 22V to 24V to be
Equipment End of observed
INTERNAL
Check the voltages at 22V to 24V to be
Equipment End of observed
EXTERNAL (FMC)
Check the Panel 19V to 21V to be
Indication Power voltages observed
at Equipment End
Visually examine all the Ensure the
S/A cards are locked & tightness of the
Inserted properly, tighten cards
the corresponding screws
Check the all wago fuse Disconnect type
indications fuse indications
should not glow
6 Earthing, Clean surface of the Earth Surface should be
LA & SPD Electrode /MEEB /SEEB kept clean
/BRC
Measure the Earth Should be <1Ώ
Resistance of the (Ohm)
each Earth Pit &Ring
Earth Resistance. Fill
water in the Earth Pits to
keep low soil resistance
Check the SPD devices Check the
for any signs of physical Indication LED
degradation status of SPD
Check Lightning Arrestor

36
Sr. Location Description Action Taken/ Observations Remarks
No. Note the Voltage
levels
connection at copper wire
to Ring earth. Tighten all
the connections
/Terminations

37
 CHAPTER- 6
TROUBLESHOOTING

6.Troubleshooting
Troubleshooting of MEI633 system can be done in following ways:

6.1Troubleshooting with help PCB front panel indications

The front facia of all the MEI633 system printed circuit boards are provided with LED
indications. These indications assist the operator to know the status of the card at any point of
time. These indications may help the maintainer in troubleshooting upto some extent. The
details of these indications are provided in section.

6.2 MEI633 Maintenance tools program

Maintenance engineers and application engineers use MEI633 Maintenance Terminal (MT)
to view and monitor Events/Relay status and MEI633 system faults. MT provide wide range
of options:
• Viewing the current status (On line data) of the MEI633 system.
• Reviewing stored system event and error data (Off line data).
• Cautions when any fault occurs in the system so as to take necessary action.
Shows faults and critical faults in both Channel-A and Channel-B

6.3 Troubleshooting through Maintenance Terminal

CIU logs the generated events and fault codes in external flash memory in every cycle. It
transmits event log to Data logger, fault information to FPD, and both event, fault
information to MT.

GIU based MT is developed as a user-friendly application providing hassle-free interface,

thus making the life easy for the Maintainer to pinpoint the problems during troubleshooting.

MT is a password-protected application, where unauthorized access is not allowed.

The Event log/Fault analysis can be performed over a required time frame, chosen by the
maintenance staff. Print facility is also available.

The Playback feature of MT provides the Operator/Maintainer to visualize the Yard status
over a required time frame and thus making the analysis easier.

38
Fault messages are in simple English and greatly help to pinpoint the error location within the
shortest time frame.

Example:
A) If the communication messages from IOCOM0 to COMP are corrupted – Fault code
displayed on MT is “Channel Noisy – IOCOM0”

B) If the communication messages from IOCOM0 to COMP are not available – Fault code
displayed on MT is “Link Fail – IOCOM0”
C) If the position of the Point18 in the field is undetermined - Fault code displayed on MT is
“Point Detection Failed – PT18”

D) If HR Relay of Signal1 is picked up unintentionally, a wrong side failure is indicated

along with safety action – Fault code displayed on MT is “HR Wrong Side Fail – SIG1”

6.4 Troubleshooting through MEI633 Fault Codes

Troubleshooting the MEI633 system involves careful analysis of observable fault codes
displayed on Maintenance Terminal tool program and front panel display, and the ability to
perform standard electrical and electronic troubleshooting operations.

System event log information associated with different modules of MEI633 are captured in
Maintenance terminal tool program contain great deal of historical information regarding the
performance of MEI633. These event logs are useful while troubleshooting. The information
placed in the event logs contain Fault Codes, which are categorized into Critical and Non
Critical Faults.

The Critical Faults are the Faults, which may cause Restart or Shutdown of the Faulty
module, or they indicate a serious error, which needs immediate attention.

The Maintainer is alerted about the Critical Fault by a Fault Buzzer in the Front Panel
Display and also in the Maintenance Terminal, if it is connected to the System.

Non Critical Faults are the faults, which do not cause the System to restart, or shutdown, but
the System may continue to operate through the other redundant channel or in a de-graded
mode of operation

39