Lining Control Circuit, UNO/DUO/ CSM/3X /Unimat

Functional Description of Lining Control Circuit .

LINING CONTROL PCBs OF DIFFERENT MACHINES

PCBs which are used in lining control circuit in different machines are given below:

CSM: UNIMAT:
Lining PCB - EK 2038 LV
*Lining PCB - EK 349 LV
Front Input PCB - EK 345 LV Over slew - EK 290 LV
Over slew PCB - EK 290 LV Front input - EK 2072LV
Power supply PCB - EK 813 SV 3-stage Lining - EK 144V
Satellite compensation PCB - EK348 LV Power supply - EK 813 SV
CSM-3X: UNIMAT-3S:
Lining input PCB - EK 2361 LV Input Lining PCB - EK 2173LV
Lining Output - EK 2140LV Output & overslew PCB- EK 2140 LV
& Overslew PCB Front input PCB - EK 2072 LV
Front Input PCB - EK 2343 LV Power supply - EK 813 SV
Satellite compensation PCB -EK 536MC-00/82-14 UNIMAT COMPACT:
Power supply PCB - EK 816SV Input Lining PCB - EK 1.1/17 LV
DUOMATIC: Output & over slew PCB- EK 2140 LV
Lining PCB - EK 335 LV Front input PCB - EK 3049 LV
Overslew PCB - EK 290 LV Power supply - EK 813 SV
Front input - EK 275 LV UNIMAT-4S :
3-stage Lining - EK 80V Lining PCB - EK 504CA
Power Supply - EK 813 SV Microcontroller - EK 628MC-00/176

(i)VERSINE POTENTIOMETER:
This potentiometer is provided in front cabin in panel B4 .This
potentiometer is used to feed versine value in 3-pt lining and Vm
value in 4-pt lining . This potentiometer converts versine value to
electrical signal at the rate of 50 mv/mm, - ve for RH side, +ve for
LH side.

(ii)SLEW POTENTIOMETER :

This potentiometer is also provided in front cabin in panel B4 .This

potentiometer is used to feed slew value . It converts slew(Offset
value in design lining) value into electrical signal at the rate of 50
mv/mm -ve for RH side and +ve for LH side.
Session-39: Functional Description of Lining PCB EK349LV, EK2038LV.

LINING SYSTEM of CSM

Printed Circuit Boards:

4u5 ........ Front Input PCB ........ EK-345LV-00-(02)
4u2 …… Lining Display PCB …… EL-T 5104.00 (02)
4u4 ........ Power Supply PCB ........ EK-813SV-002
10u1 ........ Satellite Compensation PCB ........ EK-348LV-00(02)
10u2 ........ Lining Control PCB ........ EK-349LV-00(02)
10u3 ........ Overslew Control PCB ........ EK-290LV-00 (02a)
10u4 ........ Power Supply PCB ........ EK-813SV-002

Transducers:
1f01 ........ Lining Transducers
1f02 ........ Measuring Transducers

Potentiometers:
2f05 ........ Overslew value ........ 20k Ohms
2f24 ........ 0 Point Correction ........ 20k Ohms
4f1 ........ Versine Adjustment ........ 10k Ohms
4f4 ........ Slew ........ 10k Ohms

Switches:
2b10 ........................ Overslew ON-OFF
2b12 ........................ Alternate Lining
2x39 ........................ 3 Point Lining ON
2x3B/3C ........................ Manual Lining – Left or Right.
2x4E/4F ........................ Datum selector Left or Right.
4b4 ........................ Left or Right for Versine Correction.
33b15 ……………… Lining indication selector

Gauges:
4g2 ……………….. Digital display
9g2 ………………… Lining galvanometer
2h27,33h2 ………………… Left datum indicators
2h28,33h3 ………………… Right datum indicators

Description of Lining Control PCB EK-349LV 02:

The inputs from the front system and the transducers on the measuring and lining trolleys are passed to the
lining control board 10u2.

Inputs:
Input 1. Satellite Compensation: Due to the continuous movement of machine the relationship between the
trolleys will vary and therefore a satellite compensation signal F03 is required. The output of the compensation
card at 50 mV/mm (negative for right hand adjustment) from terminal 6z, is fed to 10u2 on terminal 30z (a
more detailed explanation is provided later). This signal at 50 mV/mm is passed to the summing line via R14,
R18 and P20.

Input 2. Lining Versine: This is used to feed versine values in 3-pt. lining & Vm values in 4-pt lining in
transition curve. This signal is connected at terminal 20d.

Input 3. Zero Adjustment : In order to correct minor errors in the lining system, a potentiometer 2f24 is
provided. The potentiometer is supplied with +10 volts and –10 volts from R52 and R53, the signal from the
potentiometer is @ 2V/mm (negative to the right). This signal can be checked on multiplex F24. This signal
passes to 10u2 on terminal 20z to amplifier OP1B (buffer) onto the summing line via P16, R60 and R59.

Input 4. Front Chord Displacement (3 Point): This signal comes from terminal no. 30d of EK-348LV &
connected at terminal no. 22z of EK-349LV.Signal rate @ 50mV/mm,-ve for RHS. This signal is connected to
summing line via amplifier OP1C (buffer) P17 & R55.

Input 5. Front Cord Displacement (4 Point):As previously explained, the offset in the tower by
potentiometer 4f4 is fed into P.C.B. 4u5 and onto the compensation board 10u1 on terminal 28b which links to
10u2 on terminal 24b via 28z of EK-348LV. This signal @ –50mV (to the right) passes to OP1D (buffer) and
onto the summing line via P18 and R56.

Input 6. Curve Correction: When the machine is on a curve, the lining chord is offset downhill due to
mechanical forces and therefore needs to the corrected. On a curve with 150mm difference between the high
and low rail, the cord is offset by 2mm.
The rear pendulum 1f09, feeds in a signal of 25 mV/mm negative left hand high rail) to P.C.B. 6u5 on terminal
30z which is amplified by OP1D to – 50 mV/mm at terminal 30b. This signal passes to 10u2 on terminal 26d,
therefore on a curve of 150mm with left hand rail high, there will be 50 mV x 150 mm = 7.5 volts = 2mm offset
correction, which can be checked on multiplex F1E. The signal at 26d passes to OP2A(2) where it is inverted
and attenuated by 0.035, and onto the summing line via P19 and R46.

Input 7. Measuring Transducer: The measuring transducer 1f02 feeds in a signal at terminal 28b of 10u2
@ 23.1 mV/mm (positive for movement to the right) which can be checked on multiplex F02. The signal passes
to OP2B and OP3A.
With a positive signal at 28b, the signal passes to OP2B(5) and onto the summing line via D13, R37 and
P14.With a negative signal at 28b (movement to the left), the signal passes to OP3A and onto the summing line
via D9, R16 and P13.

Input 8. Lining Transducer:The lining transducer 1f01 feeds in a signal at terminal 28d of 10u2 at
23.1mV/mm (negative for movement to the right), which can be checked on multiplex F01. The signal passes
to OP2D (buffer) and onto OP3C and OP3D. With a positive signal at terminal 28d (to the left) passes to OP3C
and onto the summing line, via D6, R15 and P10. With a negative signal at terminal 28d, passes to OP3D, and
onto the summing line via D5, R20, and P9.

Summing Line:The various signals are adjusted due to the differing value of resistors, and are added
algebraically together at the summing line. The summing line forms an input to amplifier OP4C (inverting
adder) on pin 9. If the track alignment is correct, then total algebraic sum at summing line is zero hence no
slew is required, and the input voltage to amplifier OP4C is zero. Therefore the output voltage from amplifier
OP4C is zero. Due to slight errors in the mechanical components in the system, the input signals could contain
errors. Therefore two additional signals are connected to the summing line.
1) + 15 volt signal to the summing line via R6 and R7.
2) – 15-volt signal which is adjusted by a group of fixed resistors and a potentiometers depending on
3pt./4pt. & left/right hand pre-load. This is controlled by relays Re1 & Re3 as follows:

S.N. Condition Condition Preload Lining Potentiometer

of Re1 of Re3 Selection
1. OFF OFF LHS 4 point P8
2. OFF ON RHS 4 point P7
3. ON OFF LHS 3point P6
4. ON ON RHS 3point P5

Output of OP4C:When machine moves onto mis-aligned track there will be an input to amplifier OP4C on pin
9 via the summing line. The output of amplifier OP4C pin 8 @ 0.5 V/mm (positive for slew to the right) passes
to terminal 12d and enters the over slew board 10u3 (EK290LV-00) on terminal 30d. The signal is inverted and
kept at the same magnitude by amplifier OP4B, leaving 10u3 at terminal 4d and re-entering 10u2 on terminal
10z Multicheck address of this signal is F04. (See recent modes at rear of book).The signal at –0;5 V/mm (for
slew to the right), passes to earth via R9(14K) and contact Re4/2. this prevents the signal from passing to the
lining servo circuit until it is required, i.e. at start lining signal.

The output of amplifier OP4C at +0.5 V/mm on pin 8, also passes to OP4D(13) which inverts the signal
to- 0.5 V/mm (slew to the right) which passes to the galvanometer 9g2 via R26, R27 and terminal 4z, which
indicates the required slew.

Automatic Lining: To start automatic lining, an output Q0A is required which needs the following to be
completed:
05^3D[(24^25)vs2F)^(4Ev4F)].
05 = Lifting & Lining enable (20^OB)v(30^OB^15)v(30^OB^16)
3D = Auto Lining on, and
24^25 = Sensors ON, or
2F = Sensors bypassed, and
4Ev4F = Pre-load to the left, or right.
If all of these inputs are available, the program will be completed for output QOA which earths
terminals 28d and 16d on the overlsew board 10u3 (EK-290LV-02a).

With the machine selected to line every sleeper, the earth at terminal 28dbz does not affect this circuit.
The earth at terminal 16d passes to terminal 18d via the closed contact Re3/1, which links to terminal 16d of
the lining control card 10u2. The earth at this terminal connects to the coil of relay Re4, which already has a
24V positive supply via terminal 14z, and therefore it energizes.

Contact Re4/1 reverses, completing an earth path to lining bypass relay Re7, which already has a
positive supply via terminal 4d & a 2A fuse Si, causing Re7 to energies. Contact Re7/1 closes, passing the 24
volt supply from terminal 4d to terminal 4b which connects to tank bypass solenoid 1s56 (See hyd. Drawing).
Solenoid 1s56 energizes moving the tank bypass valve to the blocked port position hydraulically. The second
contact of relay Re4 opens, removing the earth between resistors R9 and R17, allowing the lining signal to pass
to the servo valve. The lining signal at 0.5V/mm (negative for slew to the right) is inverted by amplifier OP4B
(1:1) and the output passed to the servo amplifier OP4A via the combination of R39 and R32 in parallel with
D11/D8 and R33. The signal at +0.5V/mm (for slew to the right), is inverted by OP4A and amplified by
approximately 7:1. The output of pin 1 is passed to a potential divider network, which consists of- P1 (20K),
R42 (16K), R52(2.49K) and due to Re4 being energized R53(2.49K) (Re4/2 open).

When the slew required is 4mm or more, the output of OP4A will be –14 volts (i.e. saturated), which
results in –3 volts at pin 2 of OP5. The output of OP5 at pin 5 is approximately – 3 volts which results in a
current of 15mA flowing through the circuit of R44 (100Ω), 1s15 (100Ω) and returning through R68 (200Ω).
With 15 mA flowing through the servo valve, the valve allows maximum flow of oil to the lining cylinders
which moves the track to the right. As the track moves, the lining trolley which is pre-loaded to the rail, moves
with it, reducing the input from the lining transducer. The signal at the summing line reduces and when ≤ 4mm
of track movement is required, amplifier OP4A comes out of saturation. Therefore the current through the
servo valve 1s15 reduces accordingly. Due to this current reducing action in the servo valve, the oil to the
lining rams is reduced, which slows down the movement of the track.

When the track has been slewed to the correct position, the summing line will be balanced, resulting in
no current flowing through the servo valve. The valve is now, in the null position, i.e. blocked, trapping oil
between the servo valve and the lining rams. This maintains the track in the correct position as seen in the
lining galvanometer 9g2, which shows zero slew.

When squeezing has finished, output QOD breaks the program of QOE which in turn breaks the
program of QOE which in turn breaks the program of QOB. The loss of output QOB results in breaking the
program of QOA. Due to the loss of output QOA, the earth is removed from 10u3, terminals 16d and 28dbz.
Therefore removing the earth at terminal 18d, which connects to 10u2.

The loss of the earth at terminal 16d, causes relay Re4 & Re7 to de-energize resulting into inaction of
servo & lining bypass valve. With Re4/2 returning to the de-energized position, an earth is placed again
between R9 and R17, blocking any signal from passing to the servo circuit by earthing it.
Manual Lining to Left: Switch 2X3B/3C is operated towards left, connecting terminal 14d to earth. Relay Re5
now energizes and its contacts reverse. Re5/1 connects a +15 volt signal via R28 to OP4B(6),while Re5/2
provides earth to relay Re7 & operates it. The output path from OP4B(7) is the same as for automatic lining. A
+24V supply is already available at 12b of Relay Re5.

Manual Lining to Right: Switch 2X3B/3C is operated towards right, connecting terminal 14b to earth. Relay
Re6 now energizes and its contacts reverse. Re6/1 connects a -15 volt signal via R34 to OP4B(6) while Re6/2
provides earth to relay Re7 & operates it. The output path from OP4B(7) is the same as for automatic lining.
Terminal. A +24V supply is already available at 12z of Relay Re6.

08-275 POINTs AND CROSSING TAMPING MACHINE

LINING SYSTEM:PCBs:
10u1 Power Supply EK-813SV-002
10u2 Analogue Circuit EK- 2038LV-00(02)
10u3 Overslew Circuit EK-290LV-00a(02a)
10u4 Rear Chord Follow Up EK-719A-00(02)
4u25 Front Input Circuit EK-2072LV-00(02)
4u17 Power Supply EK-813SV-002
SWITCHES:
22b2 Overslew On/Off
22X10 Lining System on & Automatic Start
23X2F/30 Manual lining to left/right
22X4B Alternate lining On
22X11 3 point lining On
23X1A/19 Lining datum to left/right
22b3/22b4 Rear Chord Follow Up system
4b4 Lining versine direction selector
4b5 Lining slew direction selector
INPUTS:
1f21 Lining versine transducer (F01)
1f22 Measuring versine transducer (F02)
1f1 Rear cord follow up transducer (F03)
22f4 0-correction potentiometer (±5mm) (F24)
4f4 Lining versine value potentiometer (E49/F00)
4f5 Lining slew value potentiometer (E48/F06)
22f05 Overslew value (F05)

INDICATIONS:

22h2 3-Pt. lining On

23g2 Lining indicator
33h2 Datum indicator left
33h3 Datum indicator right

Circuit Description:
When the working main switch is turned On terminal 2 is fed at 24 volts. Via circuit breaker 18e2 and terminal
R2 printed circuit 10u1 is fed with 24 volts at terminal 4db. The output terminals of 10u1 will be at the
following voltages:
8db(R52) + 10 volts
20db(R53) – 10 volts
2d (R50) + 15 volts
2z (R51) - 15 volts
32db OA earth
From these five terminals the printed circuits 10u2, 10u3 & 10u4, transducers 1f1, 1f21 & 1f22 and
potentiometer 22f24 are fed with the correct voltages.
Following Eight analogue inputs are fed into the analogue control circuit 10u2 (EK 2038LV-00):
1. Lining Versine:The signal from the lining transducer 1f21 is fed in via terminal 28d at 23.1mV/mm,
the signal is negative when the transducer is deflected to the right. The voltage can be checked using Multi
check F01. From terminal 28d the signal is taken to OP2D(12) via R51, OP2D is wired as a high impedance
buffer of gain 1, the signal leaves the output OP2D(14) and passes to amplifiers OP3C(10) and OP3D(12). Due
to the use of diodes D5 & D6 OP3C will only accept positive signals and OP3D negative signals. The output
from OP3C(10) passes via R15 and P10 to the summing line. The output from OP3D(14) passes via R20 and
P9 to the summing line. P9 is used to calibrate the signal to the summing line when the transducer is deflected
to the right and P10 when deflected to the left.
The output from OP2D(14) via terminal 23z is taken to printed circuit 10u4 to control the automatic follow up
of the lining chord.
Switch S2 on printed circuit 10u3 can be used to connect terminal 30b to earth effectively feeding a “zero” into
OP2D for calibration purposes.

2.Measuring Versine: The signal from the measuring transducer 1f22 is fed in via terminal 28b at
23.1mV/mm, the signal is positive when the transducer is deflected to the right. The voltage can be checked
using Multi check F02. From terminal 28b the signal is fed via R49 to OP2B(5) and OP3A(3). Due to the use of
diodes D13 & D9 OP2B will accept only positive signals and OP3A will accept only negative signals. The
output from OP2B(7) passes via R37 and P14 to the summing line. The output from OP3A(1) passes via R16
and P13 to the summing line. P13 is used to maintain the correct versine ratio in 4 point when the transducers
are deflated to the left and P14 when they are deflected to the right. When 3 point lining is selected Re2 will be
energized and the inputs to OP2B and OP3A earthed.

3.Compensation Input: In order to keep the lining chord in the centre of the machine (see chord follow up) a
compensation transducer is fitted to the rear tightening trolley to compensate for the reduced input signal from
the lining transducer when the chord has been displaced at the rear.The signal from the compensation
transducer 1f1 is fed in via terminal 26z at 23.1mV/mm (negative when displaced to right). The voltage can be
checked using multicheck F03. At terminal 26z this signal is fed via R50 to OP2C(10) and OP3B(5). Due to the
use of diodes D10 & D7 OP2C will only accept positive signals and OP3B negative signals. The output
OP2C(8) passes to the summing line via R8 and P12 while the output OP3B(7) passes via R19 & P11. P11 is
used to calibrate the signal while deflected to the right and P12 when deflected to the left. When 3 point lining
is selected Re2 will be energized and the inputs to OP2C and OP3B earthed.

4. Zero Correction: Due to the possibility of slight inaccuracies in the lining system a zero correction
potentiometer 22f24 is fitted. This can adjust the input signals upto ±5mm.
The signal from the potentiometer is fed into printed circuit 10u2 at terminal 20z. The signal then goes via R71
to OP1B(5). The output OP1B(7) is fed into the summing line via P16, R60 and R59.Potentiometer P16 is used
to calibrate the signal to the summing line.

5.Digital Versine Value: When the machine is used in 3 point Lining mode the inputs from the measuring
transducer and compensation transducers are grounded via contacts Re2/1 and Re2/2 which are now closed.
The signal from the lining transducer is compared directly with required versine, set by potentiometer 4f4 (see
description of front tower).
The signal is fed into printed circuit 10u2 at terminal 20d at 50mV/mm and can be measured using multicheck
F00.From terminal 20d the signal passes to OP1A(3) via R70. The output OP1A(1) goes to the summing line
via R63.

6.Front Chord Displacement(4 Point): Unlike previous machines the front end of the lining chord is fixed.
Fixed point slews are still made in the same manner but the signal is fed into printed circuit 10u2 directly.For4-
point lining the displacement signal from terminal E48 is fed into the printed circuit at terminal 24b via the
normally closed contact(1,6) of relay 7u1/B. From terminal 24b the signal passes through R58 to OP1D(12).
The output OP1D(14) goes via P18 & R56 to the summing line.

7. Front Chord Displacement(3 Point): Due to a different reduction factor for 3 point lining the signal from
terminal E48 is fed into printed circuit 10u2 at terminal 22z via the normally open contact of relay 7u1/B
(which is energized when 3 point lining is selected).The output OP1C(8) passes via P17 and R55 to the
summing line. The values of P18 & R56 (4 point lining) and P17 and R55 (3 point lining) are different and alter
the input of 50mV/mm to 311.5mV/mm (4 point lining) and 159 mV/mm (3 point lining) at the summing line.

8. Curve Correction: When the machine is on a curve, the lining chord is offset downhill due to mechanical
forces and therefore needs to the corrected. On a curve with 150mm difference between the high and low rail,
the chord is offset by 2mm.

The rear pendulum 1f09, feeds in a signal of 25 mV/mm negative left hand high rail) to P.C.B. 6u5 on
terminal 30z which is amplified by OP1D to – 50 mV/mm at terminal 30b. This signal passes to 10u2 on
terminal 26d, therefore on a curve of 150mm with left hand rail high, there will be 25 mV x 150 mm = 3.75
volts = 2mm offset correction, which can be checked on multiplex F07.The signal at 26d passes to OP2A(2)
where it is inverted and attenuated by 0.08, and onto the summing line via P19 and R46.

Summing Line:The eight inputs previously described are connected together at the summing line which forms
the input to OP4C(9) which is wired as an “inverting adder”.If the track is correctly aligned and no slew is
required then algebraic sum of inputs is zero. Therefore the output voltage OP4C(8) will be zero. The system
can be worked in 3 point or 4 point modes with the trolleys preloaded to left or right. Slight errors in the
mechanical system will mean that input signals could contain slight errors. Therefore an additional – 15 V input
is fed into the summing line via the contacts of Relay Re1 & Re3. Relay Re1 is energized from program output
Q18 when 3 point lining is selected. When right hand preload is selected relay Re3 is energized.

This – 15 V signal is fed to the summing line via the resistors shown in the table below.

Mode Relay Re1 Preload Relay Re3 Potentiometers

& Resistors
3 Point Energized Right Energized P5, R4
3 Point Energized Left De-energized P6, R3
4 Point De-energized Right Energized P7, R5
4 Point De-energized Left De-energized P8, R13

The potentiometers are used to trim the summing line to zero in the respective mode. The signal is balanced by
a +15 volt signal via R6 & R7.

Output Stage:The output OP4C(8) is taken to terminal 12d and OP4D(13). The signal is now 0.5V/mm (set
with P21). The output of OP4D(14) passes through resistors R26 & R27 to terminal 4z and finally to the lining
indicator. This signal is negative for a slew to the right.
From terminal 12d the output signal at 0.5mV/mm (slew to right positive) enters the overslew printed circuit
10u3 at terminal 30d. From terminal 30d the signal passes via R33 to OP4B(7). The overslew value enters 10u3
at terminal 6d and via R31 to OP4B(7). If overslew is not selected terminal 6d is connected to earth via switch
22b2. The signal is inverted and the output OP4B(10) is connected to terminal 4d(Multicheck F04). This
terminal is connected to terminal 10z on printed circuit 10u2. The signal (now negative for slew to right) passes
to R9. Unless automatic lining has been selected and the machine is in the correct stage of the working cycle
Re4 will be de-energized and the junction of R9 and R17 connected to earth via Re4/2.

If automatic lining has been selected and the machine is in the correct stage of the working cycle program
output Q0A will be fed to terminals 28d and 16d of 10u3. For normal slew every cycle Q0A at terminal 16d
passes via the normally contact of Re3 to terminal 18d. This terminal is connected to terminal 16d of 10u2. The
earth at this terminal connects to the coil of relay Re4, which already has a 24V positive supply via terminal
14z, and therefore it energizes.

Contact Re4/1 reverses, completing an earth path to lining bypass relay Re7, which already has a
positive supply via terminal 4d & a 2A fuse Si1, causing Re7 to energies. Contact Re7/1 closes, passing the 24
volt supply from terminal 4d to terminal 4b which connects to tank bypass solenoid 1s56 (See hyd. Drawing).
Solenoid 1s56 energizes & it moves the tank bypass valve to the blocked port position hydraulically.The
second contact of relay Re4 opens, removing the earth between resistors R9 and R17, allowing the lining signal
to pass to the OP4B(6) where the signal is inverted again (1:1 ratio slew to right positive). The output OP4B(7)
goes via R38 , R39, R32 to OP4A(2). One side of R38 is connected to terminal 10d & other one to terminal 10b
and R38 can be shorted out by switch 22b1 in order to increase the gain of OP4A.
When the track has been slewed to the correct position, the summing line will be balanced, resulting in
no current flowing through the dc solenoid valves. The valves are now, in the deenergised position, i.e. all port
blocked, trapping oil between the valves and the lining rams. This maintains the track in the correct position
as seen in the lining galvanometer 23g2, which shows zero slew.
The loss of the earth at terminal 16d, causes relay Re4 & Re7 to de-energize resulting into inaction of dc
solenoid valves & lining bypass valve. With Re4/2 returning to the de-energized position, an earth is placed
again between R9 and R17, blocking any signal from passing to the output circuit by earthing it.

Lining By Pass Valve: The lining by pass value is operated directly from the programmer output QL20 which
is available provided that conditions for track slew are met.

Manual Lining to Left: Switch 23X2F/30 is operated towards left, connecting terminal 14d to earth. Relay
Re5 now energizes and its contacts reverse. Re5/1 connects a +15 volt signal via R28 to OP4B(6),while Re5/2
provides earth to relay Re7 & operates it. The output path from OP4B(7) is the same as for automatic lining. A
+24V supply is already available at 12b of Relay Re5.

Manual Lining to Right: Switch 23X2F/30 is operated towards right, connecting terminal 14b to earth. Relay
Re6 now energizes and its contacts reverse. Re6/1 connects a -15 volt signal via R34 to OP4B(6) while Re6/2
provides earth to relay Re7 & operates it. The output path from OP4B(7) is the same as for automatic lining.
Terminal. A +24V supply is already available at 12z of Relay Re6.

Over Slew PCB EK290LV:The input to the overslew printed circuit 10u3 at terminal 30d additional charges
capacitor K8 via normally closed contact Re5/4. The voltage on K8 is equal to the input voltage (including
polarity).

The output voltage at terminal 4d is also used as an input voltage for the two comparators OP3A & OP3B. The
reference voltage is determined by R21, R22, R25 and R26 and is approximately – 0.65V for OP3A and + 0.65
V for OP3B (approx 1mm of slew required). When the output from OP4B(10) lies outside – 0.65 V and + 0.65
V either OP3A or OP3B will switch to an output of +15 volts and in turn will switch T1On. When the
automatic lining signal QOA is received at terminal 28d the earth to Re6 will be completed and Re6 will
energize and its contact closes.

A 24 volt supply is now passed to Re4 coil and contact Re4/1. Due to capacitor K11, Re4 does not energize
immediately and Re4/1 stays closed long enough for Re5 to energize – contact Re5/ (4/5) closes and retains
Re5 On. The charge on K8 is now connected to OP4A(2) via Re5/ (10/11). The output OP4A(12) is connected
to terminal 8d. If the overslew is switched on terminal 8d is switched on terminal 8d is connected to terminal 6d
via 22f05 and 22b2. When the lining indicator shows zero the overslew value from K8 and OP4A is still
present at OP4B(7) . The track is therefore slewed past the zero point until the new signal at 30d cancels the
overslew value at 6d and output OP4B(10) is zero.
When the output OP4B(10) approaches zero the comparator OP3A or OP3B switches to –15 volts. Therefore
T1 is switched off and Re5 deenergises. OP4A(2) is now fed at zero voltage and hence the output is now zero.

Alternate Lining: The machine has the facility for lining at every second working cycle. To enable the
machine to line every second cycle switch 22X4B must be turned On. The output from the programmer Q19 is
made every cycle. When Q19 is On terminal 20d is earthed and relays Re2 & Re3 are energized. At each
automatic start signal “Q0A” relay Re6 energises (see overslew) and the 24V is also taken to Re1 (1 & 6) and
SB1(3). SB1 operates as a flip flop on the first pulse Re1 coil (1 & 12) energises and all contacts reverse. The
signal Q0A passes via Re1/(8-9) & 22d to terminal 18b. Automatic lining now takes place. As the state of SB1
has now changed the next signal QOA allows Re1 coil (6 & 7) to energise which reverts all contacts to the
original state. As Re1/(8-9) is now open Q0A signal cannot pass to terminal 22d and automatic lining does not
take place. On the next cycle Re1 coil (1 & 12) energises again.

Front Tower (Lining):-

Digital Input:The direction switch 4b4 has to be correctly set for the direction of the curve. For right hand
curves 4b4 connects the digital potentiometer 4f4 to the +10 volt supply and the –10 volt supply for left hand
curves. A signal of 50mV/mm (positive for right hand curves) is taken from This signal is connected to the
lining PCB 10u2 at terminal 20d to feed the desired versine into the lining control board.

Front Chord Displacement: The front chord displacement is carried out electrically on these machines either
by the manual potentiometer 4f5 @ 50mV/mm( positive for displacement to left) For 4-point lining the
displacement signal from terminal E48 is fed into the printed circuit 10u2 at terminal 24b via the normally
closed contact(1,6) of relay 7u1/B. From terminal 24b the signal passes through R58 to OP1D(12). The output
OP1D(14) goes via P18 & R56 to the summing line. For 3-point lining the signal from terminal E48 is fed into
printed circuit 10u2 at terminal 22z via the normally open contact of relay 7u1/B (which is energized when 3-
point lining is selected).The output OP1C(8) passes via P17 and R55 to the summing line.

Calibration of Transducers & Input Potentiometer Servo Valve,.

Calibration of Lining Transducer: Lining transducer converts actual versine H1 of track to electrical signal
at the rate of 23.1 mv/mm –ve if chord is deflected to RH side and +ve for LH side.

For calibration of lining transducer keep fork of lining transducer at zero lock select F01 in multicheck then
display of multicheck should show 0V, if it is not showing zero volt then loosen the screw of potentiometer and
rotate potentiometer to get zero volt . After adjustment tightened the screws of potentiometer.
Before calibration of transducer voltage applied to potentiometer should be checked .It should be +10V and –
10V. If there is any variation, then adjust +10v and –10v in EK813SV.

Calibration of Measuring Transducer:Measuring transducer converts value of versine H2 to electrical signal

at the rate of 23.1 mv/mm +ve for RH side and –ve for LH side.
Calibration procedure of measuring transducer is same as lining transducer but for checking of signal of
measuring transducer, multicheck address F02 should be selected and 4 Pt. lining should be ON.

Calibration of Versine Potentiometer(4f1): This potentiometer converts versine value to electrical signal at
the rate of 50mv/mm +ve for RH side and –ve for LH side.
For calibration of versine potentiometer select Multicheck address F00. Select “0” value in versine
potentiometer then output voltage of versine potentiometer should be zero on display. If not , loose the screw of
digital counter and take out the counter and now rotate shaft of potentiometer to get zero volt on display. Now
set all digits to zero of counter then fit counter on shaft of potentiometer.When voltage of versine potentiometer
is checked at multicheck address F00 then polarity will be –ve for RH and +ve for LH side.
Before starting calibration +10V & -10V to this potentiometer should be checked and adjusted by
potentiometer P1 & P2 in EK 813SV of front input .Checking procedure for this potentiometer is under:-
 (i) Check voltage at terminal no. 2 of potentiometer at 0mm, it should be zero volt.
(ii) Check voltage at terminal no. 2 of potentiometer at 100mm left, it should be -5 volt.
(iii) Check voltage at terminal no. 2 of potentiometer at 100mm right, it should be +5 volt.
(iv) Check voltage at terminal no. 2 of potentiometer at 200mm left, it should be -10 volt.
(v) Check voltage at terminal no. 2 of potentiometer at 200mm left, it should be -10 volt.
Calibration of Slew Potentiometer(4f4):This potentiometer is provided in front cabin on panel B4.This
potentiometer converts slew value to electrical signal at the rate of 50mv/mm +ve for RH side and –ve for LH
side.For calibration of this potentiometer , keep slew potentiometer at zero position then output voltage should
be zero, if not then take out the knob of potentiometer then rotate the shaft of potentiometer to get zero volt.
Then by matching the knob at zero position fit on shaft of potentiometer. When voltage of slew potentiometer
is checked at multicheck address F06 then polarity will be –ve for RH and +ve for LH side.
Before starting calibration +10V and –10V should be checked . If there is any variation then adjust by P1 & P2
in EK813SV of front input . Checking procedure for this potentiometer is under:-

(i) Check voltage at terminal no. 2 of potentiometer at 0mm, it should be zero volt.
(ii) Check voltage at terminal no. 2 of potentiometer at 100mm left, it should be -5 volt.
(iii) Check voltage at terminal no. 2 of potentiometer at 100mm right, it should be +5 volt.
(iv) Check voltage at terminal no. 2 of potentiometer at 200mm left, it should be -10 volt.
(v) Check voltage at terminal no. 2 of potentiometer at 200mm left, it should be -10 volt.

CALIBRATION OF LINING PCB EK349LV:

The calibration procedure of EK349LV is explained below:

- Before starting calibration inputs in front cabin slew and versine potentiometer should be
kept on zero.
- Zero adjustment potentiometer should keep on zero.
- Satellite should be locked at front zero position.
- Datum potentiometers P5 to P8 should keep at center.

1. LINING TRANSDUCER VALUE ADJUSTMENT (LH SIDE):

3-point lining should be ON.

Set 180 mm Value in versine potentiometer and turn toggle switch to RH side in front cabin.

Now keep the fork of lining transducer at 180mm in LH direction. Deflection of lining
galvanometer should be zero if not then adjust potentiometer P10 to get pointer of
galvanometer at center(zero).

2. LINING TRANSDUCER VALUE ADJUSTMENT (RH SIDE):

Now turn direction of toggle switch of versine potentiometer towards LH side. Keep fork at
180mm in RH direction then deflection of pointer should be zero if pointer is not at zero then
adjust by P9 to get deflection of pointer at center(zero)
3. VERSINE RATIO ADJUSTMENT (LH SIDE):

Select 4- point lining.

- Move fork of measuring transducer LH side and keep at 200mm (H 2 =

200mm)
- Now keep fork of lining transducer at 242mm in same direction .(H1 = ixH2)
- (H1 = 1,21 x 200 = 242mm)
- In this condition deflection of galvanometer should be at center, if it is not at
center then adjust P13 .

VERSINE RATIO ADJUSTMENT (RH SIDE):

- Move fork of measuring transducer RH side and keep at 200mm.

- Now move fork of lining transducer and keep at 242mm in same direction.
- In this condition deflection of galvanometer should be at center, if not adjust
P14 to get deflection at center.

ZERO ADJUSTMENT POTENTIOMETER CALIBRATION:

For calibration of zero adjustment potentiometer (2f24) turn it anti clock wise (Red
zone) upto 5mm. Now feed 5mm in versine potentiometer and turn toggle switch to
left side. Lining galvanometer should indicate zero. If pointer is not at center then
adjust P16. Untill galvanometer indicate zero.

LINING GALVANOMETER POINTER DEFLECTION ADJUSTMENT:

Feed 1.5mm in versine digital potentiometer and turn toggle switch to LH direction.
Now adjust potentiometer P4 to move pointer to the end of the right side red zone.

DATUM ADJUSTMENT:

After above all calibration datum adjustment should be done. In which we compensate the small
error due to wear & tear of wheels of different trolleys, i.e. lining trolley measuring trolley etc.

During working datum has to be applied LH side or RH side. So both side datum adjustment
should be done one by one in 3- point and 4 -point lining.

LH DATUM ADJUSTMENT:

For datum adjustment machine should be bring on good track put machine in working mode in 4-
point lining and apply LH side datum and move machine forward and watch deflection of lining
galvanometers. Pointer of galvanometer should be deflect around zero. If there is only one side
 deflection then potentiometer P8 in PCB EK 349LV should be adjusted to get proper deflection of
pointer around zero.

Now select 3- point lining in same datum and move machine then in this case pointer should
deflect around zero if it is one side deflection then adjust P6 to get proper deflection of pointer
around zero.

RH DATUM ADJUSTMENT:

Now apply RH datum and select 4 point lining. Now move machine and watch deflection of
pointer. It should deflect l around zero if not adjust P7 to get proper deflection around zero.

Now select 3-point lining. Now move machine and watch deflection of pointer. It should deflect
around zero if not adjust P5 to get proper deflection around zero.

CURVE CORRECTION:

For curve correction adjustment machine should be bring on high cant curve i.e. 150mm. (LH high)
select-3-point lining. Apply Datum accordingly and feed value in versine potentiometer to get zero
deflection of lining galvanometer . Now feed 2mm in zero adjustment potentiometer anti clock wise
(Red zero) in this case pointer of lining galvanometer will deflect. Now bring it to zero by adjusting
potentiometer P19 in EK349LV.
MECHANICAL ADJUSTMENT OF BOGIES:

08-series and 09-series Machines are equipped with single cord lining system. Machine can work in
3-point mode and 4 point mode.
In CSM and 08-series machines in 3-point lining. three trolleys are used and in 4 -point lining 4
trolleys are used.

DISTANCE BETWEEN DIFFERENT TROLLIES OF CSM:

CSM:

AD = 20.75M1 CD = 10.15M

AC = 10.5M BC = 4M

AB = 6M BD = 14.75M

H1 = AC X CD
2R

H2 = AB X BD
2R

Versine Ratio i = H1 AC X CD = 10.6 X 10.15

 H2 AB X BD 6 X 14.75

i = 1.2157

Versine ratio depends upon distance between bogies since these.

Distance are different for different machine therefore versine ratio is also different for different
machines.

UNOMATIC/DUOMATIC: i = 1.33

UNIMAT 2S: i = 1.33

UNIMAT – 3S : i = 1.6

CSM-3X: i = 1.49

DISTANCE BETWEEN FLANGES OF WHEELS OF BOGIES:

Distance between flanges should be gauge-75mm since broad gauge is 1676mm.

Therefore distance between flanges of bogies Should be 1601 (1676-75mm).So Centre of these
bogies should be at 800mm .
So in front bogie and rear bogie lining chord should be fix at 800.1mm from flange . Centre position
of lining transducer and measuring transducer should be at 800.1mm from flange of bogies .

If there is variation in distance (1601)mm between flange of wheels then shim should be provided in
wheels two maintain this distance.

This distance should be maintain in all bogies.

MECHANICAL ADJUSTMENT OF LINING TRANSDUCER AND MEASURING

TRANSDUCER:

Transducers should be mounted in such way that centre position clamp of

transducer should be at centre(800.5mm). There is a scale in mm mounted on lining
transducer and measuring transducer which has range 400mm-0-400mm. This scale
should be fitted in such a way that it’s 0-mark should be at centre of distance
between flange of wheel i.e at (800.5mm). If transducer is not at centre then loose
the mounting bolts of transducers and shift until correct distance is achieved from
flange, tighten the screw after adjustment. If scale also is not at centre then loose
the bolt of scale and shift to achieve correct centre position.

Calibration of Servo Valve: Put machine in working mode. To check null adjustment of servo valve remove
electrical coupler of servo valve used in lining circuit but electrical coupler of lining bypass valve should not
be removed. Then operate manual lining switch to both sides. In this condition there should be no movement in
lining cylinders i.e. lining cylinders should not operate in any direction if there is any movement in lining
cylinders it means null of servo valve is disturbed. If null setting is disturbed then cylinders will move in only
one direction irrespective to the position of manual lining switch.

To adjust the servo valve open the screw plug first then turn the adjusting Allen screw of servo valve 45°
CW/CCW smoothly until movement of cylinders stop.

After null adjustment fit the electrical coupler of servo valve and again operate lining left & right alternatively
with manual lining switch, lining should move accordingly.

Electrical Null adjustment of Servo valve: Put machine in working mode and keep deflection of lining
galvanometer on zero keeping fork of lining transducer and measuring transducer at zero lining potentiometer
and slew potentiometer should be at zero now operate lining without tamping by pedal switch and watch
movement of lining cylinder there should be no movement if there is any movement then adjust P3 in
EK349LV until movement stops.
 TROUBLE SHOOTING FLOW CHART OF LINING CONTROL CIRCUIT OF CSM

NO Lining during tamping

Check Q0A,Automatic lining

command coming or not during
tamping.

Is
Q0A
comi
NO YES
ng

Check X3D should come in

programmer .Automatic lining switch
Check manual lining LH or RH side is
2X3D switch should be ON.If it is ON
working or not If manual lining is
still X3D is not coming then check this
working then check automatic lining
switch ,replace if it is defective . ON relay Re4 in EK349LV, replace if
defective.

Check +24v of lining circuit ,Circuit If manual lining LH or RH is also not working then
breaker ,Power supply PCB EK813SV if check fuse in power supply PCB EK 813SV of
±15v and ±10v are not coming then lining circuit. If fuse is Ok but ± 15v and ±10 v
check fuse in this PCB if it is ok then are not coming then replace this PCB .
replace this PCB.

Check bypass valve fuse and bypass valve

Check X24 and X25 from track sensors relay Re7 in EK349LV
should come or these sensors should
by pass in this condition X2F should
come.

Check coupler of servo valve and bypass

valve

Check X30 should come. This is from

switch 2X30 which enable lining and Check deflection in servo indicator if pointer is
leveling in middle position of tamping not deflecting during tamping then PCB
unit. EK349LV may be defective replace it. If
pointer is deflecting but no lining then servo
valve may be defective replace it.
Check X4E or X4F left side datum or
right side datum should applied.

1. Manual lining Lh side is not working 4 . Right side datum not working .

Check manual
X3B inlining
programmer
LH relay when
Re5 inoperating
Ek349LV Check X4F in programmer if not coming then
manual iflining
replace defective
switch, if not coming then check datum switch , replace if defective .
replace this switch
 If X4F is coming then check Relay QL39 and
fuse ,replace which is defective

2. Manual lining RH side is not working

If Relay QL39(7002/S4) and fuse is OK then
check coupler of datum pneumatic solenoid
(1s271), if coupler is ok then check solenoid ,
repair/replace if defective .
Check X3C in programmer when operating
manual lining switch, if not coming then
replace this switch
5. No deflection in lining galvanometer when switch
ON the lining system and giving deflection to lining
transducer
Check manual lining LH relay Re6 in
Ek349LV replace if defective
Check +24v of lining circuit ,Circuit breaker
Power supply PCB EK813SV if ±15v and ±10v
3 . Left side datum not working . are not coming then check fuse in this PCB if it
is ok then replace this PCB.

Check X4E in programmer if not coming then

check datum switch , replace if defective . Check somebody has shifted the position of switch
S1in the PCB EK349LV which is used to isolate the
output circuit from input .
If X4E is coming then check Relay QL38 and
fuse ,replace which is defective
Check somebody has shifted position of switch S1
in over slew PCB EK290LV, which is used to
If Relay QL38(7002/S4) and fuse is OK then ground the signal of lining transducer .
check coupler of datum pneumatic solenoid
(1s270), if coupler is ok then check solenoid ,
repair/replace if defective .
Check connection of lining galvanometer if it is OK
then lining galvanometer may be defective replace
it.

6. In 3-pt. and 4pt. Lining machine is not doing

lining correctly.

Calibration of lining circuit may be disturb. Check and

calibrate all inputs to lining circuit one by one i.e lining
transducer , measuring transducer slew
potentiometer ,versine potentiometer , zero adjustment
potentiometer ,satellite compensation value.

Servo valve
Datum adjustment
may bemaydisturb
be disturb
.Check .Calibrate
and Calibrate
LH side
mechanical
and RH
side electrical
and datum in NULL
3-pt and
of servo
4pt lining
valve.
In 4-pt lining versine ratio may be disturb .Calibrate it for LH
side and RH side.

by R.K.Dhiman
Chief Instructor/IRTMTC/ALD.