Mobility

Westrace

Installation Process

Overview

Name Department Date Signature

Digitally signed by Mahajan Sanjay

Released by Sanjay Mahajan RC-IN MO MM COE DN: cn=Mahajan Sanjay, o=Siemens,

email=[Link]@[Link]
Date: 2016.11.10 [Link] +05'30'
Mahajan Sanjay
Digitally signed by Nema Anand Bhooshan

Approved by Nema Anand RC-IN MO MM SRAPL Nema Anand Bhooshan

DN: cn=Nema Anand Bhooshan, o=Siemens,
email=[Link]@[Link]
Reason: I have reviewed this document
Date: 2016.11.09 [Link] +05'30'

Donke Anul
Digitally signed by Donke Anul
Checked by Donke Anul RC-IN MO MM COE DN: cn=Donke Anul, o=Siemens,
email=[Link]@[Link]
Date: 2016.11.09 [Link] +05'30'
Digitally signed by Palanisamy Saravanan

Author Saravanan. P RC-IN MO MM SRAPL Palanisamy Saravanan

DN: cn=Palanisamy Saravanan, o=Siemens,
email=[Link]@[Link]
Date: 2016.11.09 [Link] +05'30'

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Document history
Version Date Author Sections Change
Int. ID changed
01 2016-03-30 Saravanan P All New Document
02/- 2016-11-02 Saravanan P All Review sheet Comments and template
Updated

Review Information Version – 02/-

Review participant Project role Review objectives
Anul Donke Document manager Formal review
Parth Mehta Engineering Process Engineer Technical review
Bose Babu Engineering Team Lead Technical review
Naval Bhiwandiwala Engineering Team Lead Technical review
Selvam Perumal Engineering Team Lead Technical review
Arunachalam Vinayagam Engineering Team Lead Technical review
Sanjay Mahajan Engineering Process Manager Technical review
Saravanan Jayaraman Engineering Manager Technical review
Prasad Banavath Engineering Team Lead Technical review
Ashish Gulhane Engineering Team Member Technical review
Chapter Changes / Activity
All Refer Review sheets archived in SAP No: A6Z00039706603

Copyright Notice

Transmittal, reproduction, dissemination and / or editing of this document as well as utilization of its contents and
communication thereof to others without express authorization are prohibited. Offenders will be held liable for payment of
damages. All rights created by patent grant or registration of a utility model or design patent are reserved.

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Content
1 Introduction .............................................................................................................. 6
1.2 Purpose and scope .................................................................................................. 6
1.3 Terms and abbreviations ......................................................................................... 6
1.4 References ............................................................................................................... 9

2 Installation Process ............................................................................................... 10

2.1 WESTRACE MK1 site installation activities .......................................................... 10
2.2 Scope of Engineering Team: ................................................................................. 11
2.3 Scope of Project management Team: ................................................................... 12
2.4 Scope of Project Engineer:.................................................................................... 14

3 WESTRACE Installation Practices ........................................................................ 16

3.1 Indoor rack and ladders installation ..................................................................... 16
3.2 Grouting of WESTRACE Rack/Relay Rack ........................................................... 16
3.3 Provision of ladders: ............................................................................................. 17
3.4 Selection of Rack Fixtures: ................................................................................... 19
3.5 Relay rack interface wiring .................................................................................... 20
3.6 Interface wiring between WESTRACE rack and Relay rack ................................. 21
3.7 Input/output wiring................................................................................................. 21
3.8 WESTRACE rack interface wiring: ........................................................................ 21
3.9 Cable Runs ............................................................................................................. 22
3.10 Power Supply wiring of WESTRACE racks ........................................................... 22
3.11 Power supply wiring of Relay Racks..................................................................... 23
3.12 Routing of 230V AC power .................................................................................... 24
3.13 Routing of Communication cables: ...................................................................... 25
3.14 Power supply wiring of cooling fans: ................................................................... 25

4 Installation of DC-DC converters........................................................................... 26

4.1 RDSO approved Power supply equipments ......................................................... 26
4.2 Ethernet Communications ..................................................................................... 27
4.3 Ethernet Communication Wiring ........................................................................... 28
4.4 Optical Communication wiring .............................................................................. 31
4.5 Connection between the Relay room and SM room: ............................................ 33
4.6 Serial Communications ......................................................................................... 33
4.7 Stand-alone WESTRACE EI Systems .................................................................... 34
4.8 Hot Stand-by WESTRACE EI system .................................................................... 35
4.8.1 Single WESTRACE EI system ................................................................................. 35
4.9 Multiple WESTRACE EI system ............................................................................. 35
4.10 Serial Communication Wiring................................................................................ 36

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4.11 Serial Link Wiring................................................................................................... 37

5 Data Logger Wiring ................................................................................................ 38

5.1 External Data Logger Interface.............................................................................. 38
5.2 Selection of wires used for wiring: ....................................................................... 39
5.3 Cable Systems: ...................................................................................................... 39
5.4 Power Wiring:......................................................................................................... 39
5.5 Installation of WESTRONICS (S2) Rack and CCIP................................................ 40
5.6 Usage of tools: ....................................................................................................... 41

6 Earthing .................................................................................................................. 43
6.1 Grounding .............................................................................................................. 43
6.1.1 Earth Pipes .............................................................................................................. 43
6.1.2 Room Earth Bar(REB).............................................................................................. 44
6.1.3 REB-REB Bonding Conductors ................................................................................ 45
6.1.4 Earth Conductors ..................................................................................................... 45
6.2 Equipment Grounding Requirements ................................................................... 46
6.2.2 Grounding of Equipment mounted in racks ............................................................... 46
6.3 Cable Shields ......................................................................................................... 46
6.4 Recommended Earth Resistance Value................................................................ 46
6.5 Indoor Earthing ...................................................................................................... 47
6.6 Outdoor Earthing ................................................................................................... 48
6.7 Construction of outdoor earth pit ......................................................................... 49
6.8 Interconnection/welding of multiple pits: ............................................................. 50

7 Surge Protection .................................................................................................... 52

7.1 Surge Protection Practices.................................................................................... 52
7.2 Power Protection: .................................................................................................. 52
7.3 AC Power Protection: ............................................................................................ 52
7.3.1 Primary AC line protection........................................................................................ 52
7.3.2 Secondary/Tertiary AC line protection ...................................................................... 52
7.4 Dataline Equipment Protection ............................................................................. 53
7.4.2 Twisted pair wiring ................................................................................................... 53
7.4.3 Isolation: .................................................................................................................. 53
7.5 Surge suppressor/ Arrestors ................................................................................. 54
7.6 Vital I/O Interface Protection Requirements ......................................................... 56
7.7 Class ‘A’ Surge Protection .................................................................................... 57

8 Bunching/Dressing up of wires ............................................................................. 59

9 Colour Coding of Wires/Cables ............................................................................. 60

10 Labelling ................................................................................................................. 61
10.1 Labelling & Identification markers ........................................................................ 61
10.2 Termination ............................................................................................................ 61

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10.3 Spare Core Termination......................................................................................... 61
10.4 Insulation................................................................................................................ 61

11 Installation of Operator Terminal (WESTCAD)...................................................... 63

11.1 WESTCAD VDU installation ................................................................................... 63
11.2 Software Installation .............................................................................................. 63

12 Installation of Maintenance Terminal (MoviolaW) ................................................ 65

12.1 MoviolaW Installation ............................................................................................ 65
12.2 Software Installation .............................................................................................. 65
12.3 Precaution against the ESD................................................................................... 66
12.4 As built documentation and training..................................................................... 66
12.5 Maintenance of Westrace EI .................................................................................. 66

13 Maintenance Schedule........................................................................................... 68
13.1 Weekly/Monthly/Yearly schedule .......................................................................... 68
13.2 Measuring Voltages (Performed by Signal Maintainer):....................................... 68
13.2.1 Procedure: ............................................................................................................... 68
13.3 Fuse Check (Performed by signal maintainer): .................................................... 68
13.3.1 Procedure: ............................................................................................................... 68
13.4 Hot-Standby system changeover (Performed by signal maintainer) ................... 69
13.4.1 Procedure: ............................................................................................................... 69
13.5 Earth Resistance measurement (Performed by signal maintainer): .................... 70
13.5.1 Procedure: ............................................................................................................... 70
13.6 Database backup (Performed by signal maintainer): ........................................... 70
13.6.1 Procedure: ............................................................................................................... 70
13.7 WESTRACE System failure registry:..................................................................... 71
13.7.1 Procedure ................................................................................................................ 71

14 Do’s and Don’ts...................................................................................................... 72

14.1 General Do’s and don’ts of WESTRACE EI........................................................... 72
14.2 Do’s ........................................................................................................................ 72
14.3 Don’ts ..................................................................................................................... 72

15 Mk1 Typical installation Photos: ........................................................................... 74

16 List .......................................................................................................................... 85
16.1 List of Tables.......................................................................................................... 85
16.2 List of Figures ........................................................................................................ 85

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1 Introduction

[Link].1 WESTRACE being a safety critical system, the installation of the same is also
of at most importance. The workmanship on the installation greatly contributes
the reliability of the system. There are several factors related to workmanship,
quantity and quality of materials used, installation procedure etc which is
directly proportional to the safe and reliable working of the System. The safety
integrity and reliability of WESTRACE requires good installation practice.
WESTRACE uses high technology electronic components that, when the
equipment is unprotected, are more susceptible to interference from external
electrical noise and extremes of temperature than conventional relay
interlocking. The WESTRACE systems, including its conductive, shielded card
housings and PFM modules, have been carefully designed to protect against
the adverse effects of the harsh, railway signalling environment. Adherence to
the practice detailed in this section, and Maintenance of a clean environment,
will ensure that these are fully effective and that the equipment will operate
safely and reliably.

1.2 Purpose and scope

[Link].1 This process manual provides the basic information’s about WESTRACE MK1
installation practices. Additionally it defines the how to install WESTRACE
Electronic Interlocking systems safely and correctly for railway signalling
applications for Indian Railways.

[Link].2 This manual is aimed for all the site installation engineers, project engineers,
Interface design Engineers, technicians, and subcontractors etc... Whoever
supposed to work on the WESTRACE installation activities.

1.3 Terms and abbreviations

[Link].1 The following terms and abbreviations are used in this document:

Term / abbreviation Explanation

WESTRACE WESting house Train Radio Advanced Control Equipment
WESTCAD WESTinghouse Control And Display
Product Name adopted by Westing House Brakes Limited –Australia
WESTRONICS
covering its telemetry products
S2 WESTRONIC System 2 [S2] Version Telemetry Products
An application where data displayed on a mimic panel is a processed
S2 Panel Processor
list of indications and or/controls.
RDSO Research Development Standard Organization

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Term / abbreviation Explanation

TAN Technical Advisory Note
EI Electronic Interlocking
EC2 CABLE Expansion Cable 2
EC3 CABLE Expansion Cable 3
Blanker System Continuity card
SPN Specifications
WNCM WESTRACE Network Communication Module
CCIP Control Cum Indication Panel
VDU Computer Based Visual display Unit
OFC Optical Fiber cable
SIP Signaling Interlocking Plan
FPD Front Plate Diagram
IPS Integrated Power Supply
EMI Electro Magnetic Interference
EMC Electro Magnetic compatibility
VLM Vital Logic Module
VLE Vital Logic Equipment
NCDM Network Communication Diagnostic Module
VROM Vital Relay Output Module
VPIM Vital Parallel Input Module
VSEV Vital Serial Enable Voltage
HOPC WESTRACE Hot standby Output Power Control Card
PSU24 WESTRACE Power Supply Unit
PFM WESTRACE Protection and Filter Module
UHVBC WESTRACE Universal Hot standby Vital Backplane card
SCN41 S2 Scanner card
DIP S2 Digital input Card
DOP S2 Digital Output Card
PSU41 S2 Power Supply Unit
MBD45 S2 Primary Mother board
MBD50 S2 Extended Mother Board
SDB44 S2 Daughter Board
Highway address strap, Address strapping Signals on the S2 Parallel
HAS 3
Highway.
FRC Flat Ribbon Cable

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Term / abbreviation Explanation

Software common to all installations of a given product. It generally is
used to schedule the execution of the site-specific application
Executive Software programs, run timers, read inputs, drive outputs, perform self-
diagnostics, access and checks memory, and monitor the execution of
the application software to detect unsolicited changes in outputs.
Interlogic S2 Non vital ladder logic
RI14 Round Interface Cable 14 PIN
RI64 Round Interface Cable 64 PIN CABLE
CED Configuration Element Data
IC Integrated Chip
PCB Printed Circuit Board
EEPROM Electronically Erasable Programmable Read Only Memory
EPROM Erasable Programmable Read Only Memory
PROM Programmable Read Only Memory
FMS Fiber Management System
IHCL Inter HVLM Communication Link
INCL Inter NCDM Communication Link
IMB Inter Module Bus
OPCR Output Power Control relay
REB Room Earth Bar
An EIA standard (cross reference standards CCITT V.24, V. 28 and
RS232 Electrical ISO2110). A serial binary interface standard with unbalanced data
Interface circuits in common use for communicating with computer peripherals
and Modems.
An EIA standard (cross reference standards (CCITT) V.11, X.27). A
serial binary interface standard with balanced data circuits used for
RS422/485 Electrical communicating between various parts of the WESTRONIC S2 system
Interface and certain peripheral equipment. It permits use up to 1000m and multi-
dropping is part of the standard. This interface has better noise
immunity than the RS232C interface.
LED Light Emitting Diode
Wago Name of Terminal Manufactures
OC Object Controller
RJ45 [ telecommunications] a connector standardized as the 8P8C
RJ45 connector
modular connector often used with CAT5 and CAT6 cables
M12 connector Type of Ethernet Communication connector
Category 5 cable, commonly referred to as cat 5 is a twisted pair cable
CAT 5 used for carrying signals. Used in structured cabling for computer
networks as Ethernet communication.
Category 6 cable ,commonly referred to as cat 6 is a standardized
CAT6
twisted pair cable used for gigabit Ethernet based computer networks
VHF Very High Frequency

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Term / abbreviation Explanation

OTDR Optical Time – domain Reflectometer
GND Ground potential
AC distribution Alternating Current Distribution
DC distribution Direct Current Distribution
KVA Kilo Volt Ampere
TBR To Be Released
NO Normally Open
NC Normally Closed
Dual VDU Two Visual Display unit
Charger A device for charging or recharging batteries
DC-DC converters Direct Current to Direct Current Converters.
Hologram Three dimensional image with information
Module Electronic circuit consisting of an assembly of electronic components
Analog Electronic system continuously variable signal
Digital Electronics where signals usually takes two levels [ High and Low]

Table 1: Terms and abbreviations

1.4 References
Reference Document title Document ID / Version
source
[R01] WESTRACE MK1: System Overview Manual A6Z00038663526 -
[R02] WESTRACE MK1: User Manual A6Z00038663517 -
[R03] WESTRACE MK1: First Line Maintenance A6Z00038663512 -
Manual
[R04] WESTRONICS S2 Maintenance Manual. A6Z00040046058 -
[R05] Tech Advisory Note_IR_TAN 3012 TSAA A6Z00039033627 A
[R06] Tech Advisory Note Earthing 3006 A6Z00039810818 -
[R07] RDSO specification no : A6Z00039677260 -
RDSO/SPN/197/2008 dated on 19.09.2008
[R08] Checklist for Installation at Site A6Z00038633625 A
[R09] WESTRACE Mk1_Vital Interface Design A6Z00039475440 -
[R10] RDSO Letter_STS/L/SSI A6Z00040039415 -
[R11] Spain Site Visit Report_v01 A6Z00040039419 -
[R12] WESTRACE overall process A6Z00038657942 -
Table 2: References

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2 Installation Process
2.1 WESTRACE MK1 site installation activities

[Link].1 In overall process document [ SAP ID - A6Z00038657942/-] , the chapter 4.2

flow chart can be referred for the detailed WEI installation process activities
carried out by the Project and testing team. Addition to that installation at site
flow chart also can be referred for the site installation activities as per the
table section 8.1 to 8.19. The Site installation activities have the following
category and sub tasks.

• Site Survey [ 8.1]

• Bell testing in Pre wired rack [ 8.2]
• Material shifting [ 8.3 ]
• Floor Marking [8.4]
• Rack Installation & Supporting Equipments installation
• WESTRACE E.I Rack Installation
• Westronic S2 Rack Installation
• WESTRACE and Westronic Housing Installation
• Front plate covers installation in WESTRACE and S2 Housing.
• Relay Rack Installation
• Laddering and Rack fixtures installation. [8.5]
• Relay rack wiring [8.6]
• OFC connectivity [8.7]
• Networking of WESTRACE [8.8]
• Power Wiring[8.9]
• Earthing [8.10]
• IPS installation[8.11]
• Axle counter installation[8.12]
• Labelling and Paint work [8.13]
• Bell test [8.14]
• Plug in cards and relays [8.15]
• Relay and Relay base and Terminals installation.
• Simulation wiring activities [ 8.19]
• Cable Termination Rack Installation
• Data logger Rack Installation
• Data logger protocol Converter installation
• Control Cum indication Panel Installation
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• WESTCAD PC Terminal & Monitor Installation

• MoviolaW PC Terminal & Monitor Installation
• DC-DC Converter Installation
• Serial to OFC converter Installation
• Network Switch Installation
• Fiber Distribution Box Installation
• Communication Rack Installation
• Power Supply Rack Installation
• IPS Rack Installation
• Surge Arrestor installation
• Battery Rack installation
• Earthing Pits and earthing rod installation.
• Remote Changeover Circuits box installation.

2.2 Scope of Engineering Team:

[Link].1 Designing of Station specific vital and Interface wiring circuits based on
approved inputs like SIP, FPD received from Railway & Site Survey inputs
from Project Team. Refer overall process document – [SAP ID
A6Z00038657942/-] chapter 4.2 & Installation at site 8.1 to 8.19 for the
detailed WEI activities during Installation and testing stage.

[Link].2 Release the customer approved Vital interface circuits to Production team to
initialisation of Pre wiring activities at factory premises.

[Link].3 Release of vital and non vital interface Circuits - Wiring copy to Customer
approval.

[Link].4 Release of vital and non vital interface Circuits - Wiring copy to site for
execution of Installation.

[Link].5 Review of site Installation checklist which received from Project team, share
the comments wherever applicable.

[Link].6 Sharing of periodic updates to project and production team if any changes in
Interface wiring circuits of WESTRACE /S2.

[Link].7 Review As made circuits which duly signed by Project &Test Engineers and
Customer.

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2.3 Scope of Project management Team:

[Link].1 It is the responsibility/duty of the Project Manager (PM) to select the work
force depending on the complexity/ amount of work that is to be executed.

[Link].2 The team for carrying out the installation is to be selected based on the
following points apart from the financial implications

• The experience of the team in WESTRACE installation.

• The man power availability with the team.
• The previous track record of the team in other installations.
• The availability of team for post commissioning support.

[Link].3 If the team is new into WESTRACE installation, the PM should take sufficient
care in imparting proper training to them in the installation procedures that is
to be followed. For each project there has to be a preferred list of
subcontractor’s for executing the WESTARCE installation and this has to be
passed on the main contractor with the mutual consent with the end user. Also
the scope matrix of the installation related works has to be clearly defined and
should be clearly explained to the team.

[Link].4 Attaching the scope matrix that the PM has to define with the subcontractor
before the work is being taken up. The same has to be mutually signed by the
subcontractor and the PM. This will avoid all the ambiguity that arises in the
later stages.

[Link].5 Also the PM should depute the SIEMENS representative to respective project.
She/he will act as the primary bridge between the subcontractors, end user
with SIEMENS. She/he should be well briefed about the project by the PM.

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[Link] DESCRIPTION REMARKS
1 Is the team selected from the preferred list of Sub contarctors
If not specify the reasons of selecting the team out of list
2 Does the scope of work defined to the subcontractor and mutually agreed.
3 Define the work scope matrix, this includes
a Supply of site construction materials
I Rubber Sheet ( 10mm Thic k)
II Anc hor f ast ener in ground f or c - Rail size= 12mmX 150mm.
III Anc hor f ast eners in w all support f or angle = 12mmx100mm.
IV Aluminum st rip f or ladder = 25x3mm
V Aluminum angle = 25x25x3mm
VI Ladder insulat ors = 8mm
VII Rac k f ixing nut - bolt = 10x40mm
VIII Riv et s = 1/ 2mm
IX Pv c sleev e f or insulat ing aluminum st rip = 25mm size
X Pv c c hannel = 80x80mm on t he ladder
XI Pv c c hannel = 45x45mm side of relay rac ks
XII Pv c c hannel = 45x60mm inside w est rac e and relay rac k bac k side
XIII Pv c c hannel = 25x25mm inside w est rac e and relay rac k bac k side
XIV Bunc hing t hread
XV Spiral sleev s f or bunc hing
XVI I nsulat ion t apes red/ blac k and green
XVII Crimping t ool f or w ago
XVIII Crimping t ool f or pow er t erminals
XIX Copper lugs ring t y pe 10 sq. mm/ 16 sq. mm
XX Pin t y pe lugs 1. 5 sq. mm, 2. 5 sq. mm, 4 sq. mm, 10 sq. mm and 16 sq. mm
XXI Cable t ies 45mm
XXII Cable t ies 75mm
XXIII Cable t ies 100mm
XXIV F- E0508 WHI TE- - - - 0. 5 Sq. mm ( Art ic le No. 7211102) ( Lugs For Single Wire)
XXV F- TE 0508 WH – 0. 5 Sq. mm ( Art ic le No. 7211111) ( Lugs For Tw in Wire)
XXVI Din rail - C - Channel - ( Phoenix, w ago make)
XXVII Hy lum sheet f or simulat ion board and sw it c h board.
XXVIII Toggle sw it c h one w ay f or t rac k and c rank handles
XXIX Toggle sw it c hes t w o w ay f or point s, bloc k inst rument
XXX Toggle sw it c hes t hree w ay f or point s
XXXI Bulbs and holders 110v / 100w at t .
XXXII Enc losures f or f ixing of surge arrest ors/ FMS boxes/ net w ork sw it c hes if any
XXXIII Numbering sleev es
XXXIV Arrangement f or prov ision of nomenc lat ure w orks/ t agging of eac h w ires.
XXXV Arrangement f or prov ision of t he Operat or PC, Mainat nenc e PC
Sw ic t h boards f or t he 230V pow er. ( Wit h 3 10A pow er soc ket w it h sw ic hes
XXXVI and indic at ion)
b Activities to be carried out
I Grout ing of WESTRACE rac ks, relay rac ks, S2 rac k, Panel
II Fixing of Operat or PC, Mainat anenc e PC
III Wiring of all t he equipment s inst alled
IV Eart hing ac t iv it ies
V Prov ision of simulat ion board
VI Test ing of t he inst allat ion ( t his inc ludes t he bell t est ing, SAT t est ing)
VII Prov ision of nec essary nomenc lat ure
VIII Bunc hing ac t iv it ies and c losing of all t he issues point ed out on inst allat ion
IX Af t er support c ommissiong if required
4 Does the contact details shared to the stakeholders clearly defining the structure.
Table 3: Scope of material matrix

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2.4 Scope of Project Engineer:

[Link].1 The Project Engineer (PE) should make it sure that she/he is well briefed
about the project. Since it’s the PE who will be the face of SIEMENS in front of
the customer, she/he should be up to date on the on goings of the project.
She/he should be having all the necessary documents related to the project.
Project Engineer should fill up the site survey checklist [Refer SAP ID -
A6Z00039417953] and sharing of site preliminary inputs to the Engineering
Team

[Link].2 Attached is the checklist for PE before taking up the project.

[Link] DECSRIPTION
1 Is the PE briefed about the project by the PM
2 Is the PE known about the background people working on the project at office
3 Does the contact details of the PE shared with the Engineering Dept
4 Does the PE having the acess to all the necessary documents of project, This includes
I The Puchase Order (PO) from the client
II Variation Order received if any
III The copy of Letter of Agreement(LOA) between the client and Railways.
IV The copy of Memorandum Of Understanding ( MOU) between the client and SIEMENS
V The Scope definition matrix between the Sub contractor and SIEMENS signed by PM
VI The Packing list of all materials dispatched to site
VII The invoice copy of all the dispatches
VIII The Copy of Purchase requistion (PR) generated by Projects to SCM
5 Is the PE well known on the tools that is to be used on the project.
6 Is the PE briefed about the risk factors involved in the project.
7 Is the PE briefed on the EHS standards that is to be followed
8 Is the PE equipped with proper training and tools to work on the project.
9 Is the PE briefed with plan of completing the project with proper documentation
Table 4: Project Engineer Material Checklist

[Link].3 The PE should full fill the following responsibility apart from his/her day to day
activities

[Link].4 Should strictly monitor the works carried out the subcontractor and should
ensure it is as per the SIEMENS standard of working.

[Link].5 Any discrepancies founded out should be clearly communicated with the PM
and sufficient corrective action to be taken.

[Link].6 The PE should chase up with the PM for the supply of the pending material
supply if any

[Link].7 Any additional requirement that is evolving at the site from the customer
should be properly documented and the feasibility study on the same has to
be carried out with the PM.

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[Link].8 Additional man power requirement for the project has to be predicted in
advance and has to be communicated with PM.

[Link].9 All the documentation activities (including the as built circuit preparation) has
to be up to date.

[Link].10 She/he should be able to establish proper communication between the sub
contractor, end user, client and the office

[Link].11 She/he should monitor the project completion as per the plan and the
deviations from the plan if any has to be projected well in advance.

[Link].12 She/he should aware about the RDSO TAN [A6Z00039033627\A] compliance
and Zonal specific basic signal interlocking principles.

[Link].13 She/he should duly fill the installation checklist-[ SAP ID -A6Z00038633625/A]
once fulfill the all the installation requirements.

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3 WESTRACE Installation Practices

3.1 Indoor rack and ladders installation

[Link].1 As stated before there are certain best practices that is to be followed for each
and every installations. A good installation will always be having better
reliability and be easier for maintenance. As a standard practice pre wiring
racks should be tested thoroughly in factory as per the Pre wiring checklist by
production team representative.

[Link].2 This section is about those practices that are to be followed and any deviation
from this can severely affect the system working in course of time. So it
becomes the duty/responsibility of all the concerned stakeholders to be in lieu
with this document. The WESTRACE Mk1_Design rules _Vital interface
circuits [SAP ID A6Z00039475440], specifically chapter 2.41 –WESTRACE
typical circuits should be referred. Once successful completion of installation,
the Mk1 installation checklist at site [SAP ID -A6Z00038633625/A] should be
shared to the Engineering team.

[Link].3 Addition to that RDSO TAN and specifications as shown in chapter 1.3 of this
document also should be fulfilled to achieve good installation practices.

3.2 Grouting of WESTRACE Rack/Relay Rack

[Link].1 The prewired WESTRACE and Relay racks have to be grouted in such a
manner that there is enough space available in the relay room for the routine
maintenance of the system. Addition to that PE Should do a site survey and
collect the building plan, and all room sizes which are connected with our
work, also prepare an initial draft of equipment installation plan with customer
and should send to designer duly signed checklist for site survey – [SAP ID -
A6Z00039417953] .once receipt of the site survey checklist and inputs, the
designer should make the necessary correction if required and send the final
copy to site to start installation. The following are the guidelines to ensure the
same.

[Link].2 There should be minimum 1000mm leverage space available between the
racks and the adjacent walls.

[Link].3 There should be minimum 100mm leverage space available between adjacent
racks.

[Link].4 The relay room should be having enough space for the free passage of air.
The height of relay room should be minimum of 3000mm.

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[Link].5 If Air-condition of relay room is not provided make sure for the provision of air
exhaust fans.

[Link].6 The grouting has to done taking care of all the equipments coming in the relay
room apart from the EI.

[Link].7 Grouting should also make sure that the overall aesthetics of the installation
looks great.

[Link].8 The laddering that is to be done in the relay room depends on the position of
the racks, so make sure there are no unwanted ladders aroused due to poor
position of racks.

[Link].9 Always try to keep the relay racks in close proximity with the Cable termination
racks and WESTRACE racks can be in proximity with the relay racks, this will
save the extra length of conductors used in interfacing.

[Link].10 The provision of insulators for rack grouting is not mandatory in WESTRACE
installations, but if demanded by customer the same can be provided.

[Link].11 The racks has to be grouted on a 10mm thick rubber mat, this will help in
reducing the vibration effect caused during train movements.

[Link].12 Above the rubber mat, a galvanized steel C channel is placed and is grouted
to the floor (using Anchor fastener c-Rail size=12mmX 150mm.), the racks has
to be fixed on to this C channel (Using Rack fixing nut-bolt=10x40mm).

[Link].13 This galvanized C channel provides better stability to the racks and is a good
conductor so can be used for the earth bonds.

[Link].14 Also the grouting plan followed should ensure the minimum length of earthing
conductor.

3.3 Provision of ladders:

[Link].1 Cable ladders installed horizontally shall have sufficient space to facilitate
cable pulling and cleating/stapping.

[Link].2 It is isolated from racks and wall via rubber bush & hylum sheet or insulators.

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[Link].3 All power cables and I/O cables & interconnection wires shall run different
ladders. Where it is NOT possible, these cables are to be separated at least
by 6 inches gap.

[Link].4 Ladder width shall be 2/3rd of rack width and it is ensured that it carries fewer
amounts of cables & wires to avoid bends/damages.

[Link].5 Maximum distance between the supports is provided every 3 meters.

[Link].6 All surfaces are cleaned prior to bolting together.

[Link].7 Provision of ladders should be in such a manner that there should be no

crisscross connections. Also the routing of ladders determines the wiring
conductor length which has to be kept minimum so that the voltage drops/
chances of cable damage can be avoided. Also it is this ladder that prevents
the mixing of the clean and the dirty cables. In all the WESTRACE
Installations there should be two ladders used, one for the power wires and
the other for the interface wiring.

[Link].8 The following are points to be ensured in achieving a proper laddering

arrangement.

[Link].9 There should a leverage space of minimum 150mm between the top and
bottom ladders.

[Link].10 Also the bottom ladder should be at a height of minimum 100mm from the
rack top surface.

[Link].11 The ladders has to be insulated from the racks and wall using insulators
(Ladder insulators =8mm)

[Link].12 WESTRACE installations usually use the Aluminum ladders which can be
easily made at site as per the site requirements. But there are certain
specifications that are to be followed in selecting these ladders. These are

[Link].13 Aluminum strip/angle for ladder should be minimum of 3mm thickness.

[Link].14 Heat shrink sleeves with minimum of 0.5mm thickness to be used, this
prevents the cable damage due to the rough edges

[Link].15 Where ever possible aluminum rivets (0.5mm) to be used in joining the
ladders, this prevents the sharp edges aroused while joining ladders with nut
and bolts.
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[Link].16 The bottom ladder has to be of minimum of 300mm wide to accommodate a
minimum of 3 PVC troughs, the top ladder can also be of same size to meet
the aesthetics.

[Link].17 The ladders have to be provided with separate PVC troughs to clearly
differentiate between different types of wiring.

[Link].18 The bottom ladder should be equipped with minimum of 3 PVC troughs, one is
meant for WESTARCE system Input wiring, other for output wiring and the
third one is meant for the interface wiring between relay rack and Cable
termination racks.

[Link].19 If there are other interface wirings to be done then a 4rth PVC trough is to be
provided on the bottom ladder and correspondingly the ladder width to be
increased.

[Link].20 Provision of PVC troughs on the power ladder is mandatory to achieve the
standard installation practice with respect to the RDSOTAN
[A6Z00039033627/A].

[Link].21 The troughs should be arranged to provide the proper dropping on cables to
corresponding racks and wherever required proper gaskets is to be used.

[Link].22 Cable trays shall be insulated from the wall, and linked to each other. A
[Link] copper conductor from the cable tray will be connected to the REB.
This cable shall be as short as possible, i.e. the cable tray closest to the REB
will be used for grounding.

3.4 Selection of Rack Fixtures:

[Link].1 The Din rail used for installation should be of proper standards (preferably
WAGO make or Phoenix make), if the same is done with local make in over
course of time it gets rusty and the electrical continuity of the rack fixtures will
be lost.

[Link].2 Also the Din rail used should be of adequate thickness to provide better
stability to the terminals/equipments installed over it.

[Link].3 All the other rack fixtures which used while installation has to be of good
quality and make sure of proper supporting arrangements to the DCDC
converters.

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Figure 1: Different types of Din rail

[Link].4 These are the two different types of ‘top hat’ Din rail that can be used for all
the mountable terminals. Depending on the weight of the equipment to be
mounted selection can be made

3.5 Relay rack interface wiring

[Link].1 The relay rack is provided with a number of PVC troughs for special purposes,
and following this purposes ensures a neat tidy and fail proof wiring

[Link].2 The Racks are occupied with two 45*45mm PVC troughs on both sides of the
racks. Of this one in the left side has to be used for WESTRACE output
interface wiring and one in the right side is to be used for WESTRACE input
interface. Of the other two left over troughs one has to be used for the relay
interface wiring and the other for CT Rack wiring.

[Link].3 The data logger wiring of the interface relays can be clubbed with the CT rack
wiring, but if possible try to follow a different color code for the wires used.

[Link].4 All the Relay interface wiring is to be carried out with Annealed Tin Copper
(ATC) coated wires only as this provides better soldered joint.

[Link].5 A relay contact pin should be soldered only a maximum of 2 wires, forceful
insertion of more than 2 wires in a contact pin is not advisable.

[Link].6 Parallel to each relay row in the relay rack there are two troughs provided
(45*60mm outer and 25*25mm inner), the outer trough is used for relay
interface wiring and the inner trough is used for the coil circuits of the output
relays from WESTRACE.

[Link].7 All the wires terminated on the relay contact have to be with ferrules and
during any of the alteration works make sure to change the ferrules too.

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3.6 Interface wiring between WESTRACE rack and Relay

rack

[Link].1 The interface wiring between relay rack and WESTRACE rack is to be done
with twisted pair cables. as it is mandatory requirement as per the RDSO TAN,
[A6Z00039033627/A] this provides better EMI protection.

[Link].2 Ensure that the numbering ferrules are provided at both ends as per the
interface wiring.

[Link].3 Make sure the connector plugs at the ends of these cables are key-coded, so
that they cannot be inserted to the wrong pair.

3.7 Input/output wiring

[Link].1 The input and output wiring to a particular unit should be separated from each
other and from power wiring and ideally not run in parallel, i.e., all input wires
are bunched together and are routed in a separate trough from output and
power wiring. All output wires are bunched together and are routed in a
separate trough from input and power wiring. All power wires are bunched
together and are routed in a separate trough from input and output wiring.

[Link].2 All output wiring from signalling power supply units to the WESTRACE card
file shall be considered as “clean” wiring and routed by the shortest practical
path, even if it runs via intermediate distribution fuses or terminals. Input and
output should be separated with Power supply cable and communication
cable.

3.8 WESTRACE rack interface wiring:

[Link].1 The Interface wiring of the I/O cards with the connectors has to be carried out
with twisted pair cables. Although it is not mandatory for WESTRACE EI,
however it should be implemented to provides better EMI protection and
compilation of RDSO TAN [A6Z00039033627/A]

[Link].2 Ensure that the numbering ferrules are provided at both ends of this interface
wiring.

[Link].3 The Output Power Control Relay (OPCR) relay wiring has to be thoroughly
checked before the system power up as due to space constraints within the
WESTARCE racks accessibility to this relay bases will be minimum once after
the system is powered up.
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[Link].4 The Con3 and Con4 wiring connectors are to marked clearly, as a polarity
change on the same can damage the NCD PFM.

[Link].5 WESTRACE racks are also equipped with a number of PVC troughs to
segregate between the Input cables, output cables, power cables,
communication cables and earthing. Ensure that the purpose of the same is
achieved.

3.9 Cable Runs

[Link].1 All the cable /wire run will have smooth surface.

[Link].2 Sharp bending will be avoided when coming to racks.

[Link].3 Cable entry holes in the Racks will have correct size rubber beddings.

[Link].4 Ladders will be used for Interconnection of cable runs.

[Link].5 PVC Troughs with cover will be used for Intra-connections

3.10 Power Supply wiring of WESTRACE racks

[Link].1 There are different levels of voltages that are used within a signaling
installation. Of these WESTRACE installations needs an uninterrupted 24V
and 50V DC power supply which in turn is generated from the 110V DC supply
that is drawn from the IPS. The following are the points that are to be ensured
while wiring up this 110V DC supply to the WESTRACE.

[Link].2 The 110V DC supply from the IPS to the EI rack should be provided with
duplicated cable. That is combining the main and standby systems there will
be 4 pair of cables drawn from the IPS rack to the EI rack.

[Link].3 At the IPS end it is to be ensured that this 110V DC is not tapped from a
common fuse and if used in any other circuit should be through separate fuse
protection.

[Link].4 The main and secondary 110V DC supply in the IPS should be isolated from
each other at least through different fuse units, it is better to have separate
110V DC supply for the main and standby systems.

[Link].5 The voltage drop in cable at the WESTRACE rack end should be restricted to
1V and if necessary the conductors has to be increased to decrease the cable
drop

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[Link].6 The minimum area of cross section of the cable carrying this 110V DC should
be [Link]

[Link].7 There has to be separate surge arrestors installed for this main and standby
supply.

[Link].8 The wires laid/bunched should be in such a manner that for every positive
there is a corresponding negative in the same bunch. The dressing/routing of
corresponding pair cable in separate trough/bunch is to be avoided. This will
reduce the chance of surges by increasing the inductance.

[Link].9 The Fuse units provided at the IPS end to be of proper rating and the load
calculation at the IPS end on the 110V DC to be done and should be prior
communicated with the OEM of IPS.

[Link].10 The uninterrupted power supply should be tested by switching off the AC
charging input to the IPS, also the redundancy of the power supply also to be
tested and ensured.

[Link].11 All the power supply cables used in EI circuits should be in the RDSO
approved vendor list ,as well RDSO TAN[A6Z00039033627/A] compliance
should be fulfilled with respect to the wire thickness, redundancy
arrangements .

3.11 Power supply wiring of Relay Racks

[Link].1 Almost all the signaling supplies that are used in the installation come and go
through the relay racks. So sufficient care should be taken while routing the
power supply to the relay racks. The following are points that’s is to be
ensured for a reliable supply in relay racks.

[Link].2 Where ever possible the power supply to be routed in ring manner.

[Link].3 The WAGO terminals that are used should in proportionate with the wire
conductor size. Forceful insertion of wires to terminals with less area of cross
section is to be avoided.

[Link].4 The wires laid/bunched should be in such a manner that for every positive
there is a corresponding negative in the same bunch. The dressing/routing of
corresponding pair cable in separate trough/bunch is to be avoided. This will
reduce the chance of surges by increasing the inductance.

[Link].5 Our relay racks is designed with cable entry along the top surface of the rack.
So power supply wires can be inserted through any of these openings so that
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the mixing of power supply wires with interface wiring while routing through the
sides of relay racks can be avoided.

[Link].6 Always try to stick with the correct conductor size of wires as per the load
calculation, although the increase in conductor size doesn’t create any harm
theoretically, these has to be matched with all the necessary Wago terminals
also which doesn’t happen usually.

[Link].7 Proper labelling of each supply block has to be ensured both at the relay end
and the IPS end.

[Link].8 All the internal wiring circuit has to be strictly on the internal 24V supply and
the external has to be on the external 24V supply. This should not be mixed in
any of the circuitry.

[Link].9 If disconnect type WAGO terminals are used then the alignment of the same
in the racks has to be taken care of, The closed position of the terminal should
be along with the gravity pull and the open position has to be against the
gravity.

[Link].10 The lugs used for the power cable termination has to be of proper size. This
has to be ensured at both the IPS and the relay rack ends.

[Link].11 Unwanted junctions between the IPS room and the relay room have to be
avoided. An intermediate power distribution board is not mandatory, but can
be provided if demanded by customer. But this intermediate board has to be
either in the IPS room or relay room.

[Link].12 Before terminating the wires in the IPS rack the voltage levels has to be
measured and any leakage voltage has to be attended with concerned OEM.

3.12 Routing of 230V AC power

[Link].1 230V AC power is WESTRACE system for the the operator/Maintenance

PC’s. The routing of this 230V AC should be done with at most care and if
planned properly could be completely isolated from the ladder which runs the
signaling cables. The following are the points that are to be ensured in
achieving the same.

[Link].2 The source of 230V AC (Whether inverter/local source is used) to be fixed and
a separate PVC trough could be run through the wall to route the same.

[Link].3 Where ever this power is used in racks (Cooling fans) separate flexible pipes
should be used. 24VDC fans highly recommended as per the RDSO TAN
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[A6Z00039033627/A]. The Cooling fans supply should be fed through
individual fuses and should not be tapped from E.I power supply feed and AC
circuits.

[Link].4 If routed through underground separate DWC pipes should be used for the
same.

[Link].5 There should be proper marking/display of the 230V power that is routed in
the room.

3.13 Routing of Communication cables:

[Link].1 Communication cables will have to lay between the WESTRACE and the Data
logger, Operator terminal, Maintenance terminal and between the
WESTRACE’s, if multiple systems are used. These cables are part of the
clean wiring and should not be mixed with the dirty cables/power wiring
cables. The following are the points that are to be ensured in achieving the
same.

[Link].2 Where ever necessary separate ladder/trough to be provided.

[Link].3 Since this communication and 230V are both coming in Maintenance/operator
terminals routing should be done in such a manner that minimum interference
between the two comes into picture

3.14 Power supply wiring of cooling fans:

[Link].1 Being electronic equipment proper ventilation and cooling is necessary for
reliable functioning of WESTARCE. For this purpose cooling fans are provided
in WESTRACE. But the following points have to be ensured during its
installation.

[Link].2 The fans provided in WESTRACE has to be exhaust type and not the inhaul
type, the inhaul type will result in accumulating of dust in the EI rack.

[Link].3 The power supply used for fans should not be tapped from any other signaling
supply; instead it should be separately drawn from IPS/local source through
the surge arrestors.

[Link].4 Also there has to be separate fuse arrangements provided for the fan supply,
so that the main 230V AC will not be disturbed during failure of cooling fans.
As per the recent RDSO TAN [A6Z00039033627/A]. 230VAC fans should not
be used inside the EI rack, hence 24VDC fans can be used with dedicated
power supply source from IPS.

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4 Installation of DC-DC converters

4.1 RDSO approved Power supply equipments

Figure 2: Gallant make DC-DC converters

[Link].1 WESTRACE works on 24V and 50V DC supply which is generated from the
DC DC converters. Sufficient care is to be taken in ensuring a reliable supply
to the WETSRACE EI. The following points to be ensured for a reliable supply

[Link].2 All the DC DC converters that is to be used is the RDSO approved Gallant
make DD2410V2 and DD5005V2 or higher model as shown in Figure 2.

[Link].3 All the DC DC converters have to be installed in ‘n+1’ mode only.

[Link].4 The current sharing wiring of the DC DC converters is to be done and there
should not be the mixed use of different model of DC DC converters.

[Link].5 The wiring of the DC DC converters can be carried out with 1.5 [Link] wire as
the terminal of the same is designed for the same.

[Link].6 It is always better to keep the DC DC converters within the WESTRACE racks
as there won’t be any significant line drop.

[Link].7 The Normally closed contact of the DC DC converter is to be wired to data

logger and the nomenclature of the same to be clearly defined in the data
logger database.

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[Link].8 There should be enough supporting fixtures to hold the DC DC converters.

[Link].9 There should be enough free space available within the rack for checking the
voltage levels of the DC DC converters as a part of periodic maintenance.

[Link].10 The vertical row for fixing of DC DC converters is to be avoided and follow a
separate horizontal row for the above listed point.

[Link].11 DC-DC converters fixing arrangements can be referred with respect to the
WESTRACE Mk1 Vital interface circuits[SAP ID A6Z00039475440],
specifically chapter 2.41 –WESTRACE typical circuits for better
understanding.

[Link].12 Network Solutions:

[Link].13 The inter-connectivity between the different sub-systems is defined for

different requirements. This section gives an outlook at the different network
architectures for the EI systems. WESTRACE communicates with different
equipments via the NCD-PFM. The NCD-PFM is fitted with the following
external communication ports: One Network port for a 10 base T Ethernet
compliance network Two Serial ports (configurable as RS232 or RS485) for
the serial interface

Figure 3: Communication Ports

4.2 Ethernet Communications

[Link].1 The external network cable terminates at an RJ45 connector on the back of
the NCD-PFM. The NCD-PFM provides transient protection and filtering of the
Ethernet signal lines. It also converts the signal between 10 base Ethernet T
and CMOS levels
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4.3 Ethernet Communication Wiring

[Link].1 WESTRACE is a system which communicates with other peripherals through

Internet Protocol (IP) based network. To establish this connection we use
Ethernet cables called as CAT 5 cables/RJ45 cables. The following are points
that is to be ensured while using these cables

[Link].2 The RJ45 connectors are not designed for handling high vibrations, so the
proper locking of the RJ45 connectors into the sockets has to be ensured.

[Link].3 If crimped at site a vinyl boot to be provided before the RJ45 connector. Also
the tension in the connection end is to be avoided.

[Link].4 Wherever possible the usage of the M12 connectors instead of the common
RJ45 connectors is to be followed, the M12 connectors provides better sealing
and keeps the contact resistance low.

[Link].5 The usage of CAT6 cable instead of CAT5 is to be avoided as it is susceptible

to wide bandwidth noise from various sources. The length of the CAT5 cable
should be exceeding more than 70m.

[Link].6 Keep the power wiring away from the Ethernet cable routing. Minimum of
150mm spacing to be provided between the Ethernet and power cable routing.
This to be strictly followed at the operator/Maintenance terminal also.

[Link].7 The local purchase of the Ethernet connectors and cables should be strictly
avoided, instead the factory supplied Shielded Twisted Pair (STP) CAT5 cable
(Belden make) and metal clipped RJ45 connectors should be used.

[Link].8 Practice the single point grounding of the shields at the source end. Multiple
point grounding at different potential can cause ground loop current to flow
and can create noise distortions on the communication signal.

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Figure 4: Shielded Cable Earthing

[Link].9 Strictly follow with the colour code that is given in the interface circuits while
crimping. A twisted pair cable is intended to carry a signal and its inverse. If
the cables are not paired with the inverse, we are messing with the noise
cancellation technique. For a shorter distance this may work, but longer length
cables are guaranteed to fail.

[Link].10 The CAT6 connectors should not be used for the termination of the CAT5
cables as the CAT6 connectors are designed with higher pin strength to pierce
the thicker insulation of CAT6 cables which can damage the CAT5 cable
conductors.

[Link].11 The shield/outer insulation of the cable should be removed carefully and make
sure that twisted pair cable is open beyond the cable connector. The
maximum length of untwisted part of the cable should not exceed 25mm.

Figure 5: Wrong Crimped Cable

[Link].12 This practice of keeping long length of bare twisted pair open is not to be
followed. Make Sure that after crimping there is proper locking done through
visual inspection.

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Figure 6: RJ 45 Ethernet Connector Crimping method

[Link].13 A cross over cable is to be used to connect between the like devices. ( i.e.
from network switch to network switch it has to be cross cable connection)

Figure 7: Ethernet Cable cross and straight connection color coding

[Link].14 The tight bunching of cables with cables ties has to be strictly avoided. Since
being a single core conductor there are chances that the cable might get
damaged due to tight bunching or sharp bends.( The Ethernet cables should
not be bend for more than 4 times the diameter of the cable)

[Link].15 “”To be avoided in single core cables as it can break the conductor””

Figure 8: Wrong bunching method

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4.4 Optical Communication wiring

[Link].1 Optical fiber communication (OFC) is the mode of communication that is

followed in all WESTARCE installation with

[Link].2 Hot standby system configuration

[Link].3 Whenever main and standby systems are installed it has to be connected by
OFC cables to ensure the seamless flow of data. WESTARCE Installation
uses 1.5mtr long ST-ST patch chord cables for IHCL communication and
1.5mtr long plain OFC cable for INCL communication.

[Link].4 The following points to be ensured for a seamless data flow,

[Link].5 The OFC cables in no way should be bunched with other interfacing cables, it
should not be bunched inside the PVC troughs instead the same can stay
open and if needed can be gently bunched separately to prevent interference
with other cables.

[Link].6 Proper labelling/marking to be done for the OFC cable as it can easily get
confused with the 16/0.2, [Link] Black jumper wires. If needed separate
flexible pipes needs be provide to route the OFC cables.

[Link].7 The plain OFC cable that is used for INCL connection has to be cut in exact
90 degrees; else the same can result in data loss.

[Link].8 As an Object controllers concept the signaling data has to be transferred

between the cabins using single mode OFC cables.

[Link].9 The following are points to be ensured in achieving a fail proof OFC
communication

[Link].10 Always make sure that double ring architecture is followed in communication
network.

[Link].11 Make sure that the ducts/routing of the cable is not along the same path
instead two separate path has to be provided, preferably on the two different
sides of the rail.

[Link].12 Managed network switches have to be used and the port parameters have to
be set accordingly.

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[Link].13 Shielded OFC cables have to be used and the shield of the same has not to
be stripped till the cable entry into the Fiber Termination Box (FTB) rack is
made. This provides better protection to the fibers.

[Link].14 The usage of patch chords (for connecting FTB to the network switches) has
to be limited within the rack. And if not avoidable patch chords can be run on
the ladders only with sufficient protection arrangements for the fibers.

[Link].15 The bends that is provided on the OFC cables has to be gentle.

[Link].16 There has to be a minimum of 3mtr OFC cable coiled and kept as extra spare
to cope up with future demands. This coiling is not to be done in the
WESTRACE racks but separate arrangements has to be made.

[Link].17 All the cores of the cables that are being terminated have to be tested. And
the Optical Time Domain Reflectometer (OTDR) test report has to be signed
mutually.

[Link].18 Proper labelling of all the cable cores and the patch chords has to be ensured.

[Link].19 The unused patch chords/ fibers that are terminated has to properly secured
with protective caps

[Link].20 Since the OFC cables are usually laid between the cabins, the earth potential
at both the end may vary with each other, so the shield of OFC cable is to be
earthed only at one end

Figure 9: SC-SC Type Patch cord

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4.5 Connection between the Relay room and SM room:

[Link].1 The operator VDU (WESTCAD) is connected to the WESTRACE EI over the
same Local Area Connection (LAN), although a simple Ethernet cable
connection (if the distance between SM room and Panel room is less than
100mtrs) can serve this purpose of LAN connection for better reliability and
protection from external surges OFC communication is preferred. The
following are the points to be ensured while establishing such a connection

[Link].2 If possible establish the communication with shielded OFC cable and FTB’s.
However is OFC patch chords are used ensure sufficient protection to the
patch chords are provided. Diversified route has to be provided for the
redundant OFC cable between the two rooms.

[Link].3 Ensure the availability of spare fibers and this should be properly tagged and
secured.

4.6 Serial Communications

[Link].1 The external serial cables terminate at the DB9 connectors on the back of the
NCD-PFM. The NCD-PFM provides transient protection and filtering to
remove high frequency noise for the serial signal lines. It also converts the
signals between RS232 and RS485 and CMOS levels.

[Link].2 Equipment Used: FOSTCDRI-SX: Serial to OFC Converter for

communication between WESTRACE and S2

[Link].3 The FOSTCDRI-Sx is a premium Serial to Single-mode Fiber Optic Converter.

Designed for industry, it extends serial data range up to nine miles and
provides the most versatile connection possible between any asynchronous
full or half-duplex serial equipment.

[Link].4 Some features include:

• Supports RS232, RS485 - 2 wire, and RS485 - 4 wire interfaces
• Supports data rates up to 115.2kbps
• Single mode fibre optic transmission up to 9 miles (15 kms)
• Wide input range of 10VDC to 48VDC
• Operating temperatures of -40 to +80 deg Celsius

[Link].5 Communication between WESTRACE and WESTONICS is over a serial

interface. The serial interface at WESTRACE end (NCD-PFM end), can be
configured either for a RS232 / RS485 characteristics. Communication is

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duplex, and set at a baud rate of 9600bps. RS232 shall be used for single
WESTRACE interface to S2, while RS485 interface will be used for a multi-
drop connection when multiple WESTRACEs are part of the system.

[Link].6 Cables:
• 5-core shielded serial communication cable for the end connections to the
DB9 connectors at WESTRACE end and RI14 connector at
WESTRONICS end.
• Single-mode pair of OFC patch chords is used between Relay room and
SM room whenever the distance between them is less than 30m. For
greater distances, they are terminated using FTBs at either ends.

4.7 Stand-alone WESTRACE EI Systems

[Link].1 A serial communication cable is taken from the DB9 connector in WESTRACE
NCD-PFM Port-2 and is terminated on a 2-in-1-out terminal block placed on a
C channel in WESTRACE rack. This is then discretely wired to a FOSTCDRI-
SX device placed on the same C channel that converts RS232 characteristics
to single-mode optical characteristics.

[Link].2 A pair of single-mode OFC patch chords is laid through a flexible conduit to
another FOSTCDRI-SX device placed on a C channel in WESTRONICS rack
that converts optical to serial with RS232 characteristics. The output of
FOSTCDRI-SX is discretely wired to a RI14 connector placed on the same C
channel. A 14-way flat ribbon cable from the RI14 connector is connected to
Port-1A and Port-1C on the S2 backplane.

Figure 10: Stand Alone system-Serial Communication Diagram

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4.8 Hot Stand-by WESTRACE EI system

4.8.1 Single WESTRACE EI system

[Link].1 A serial communication cable is taken from the main (system A) NCD-PFM
Port-2 DB9 connector, and another from the standby (system B) NCD-PFM
Port-2 DB9 connector, and is terminated in a 2-in-1-out terminal block placed
on a C channel in WESTRACE rack. This is then discretely wired to a
FOSTCDRI-SX device placed on the same C channel that converts RS232
characteristics to single-mode optical characteristics.

[Link].2 A pair of single-mode OFC patch chords from this FOSTCDRI-SX device is
laid through a flexible conduit to another FOSTCDRI-SX device placed on a C
channel in WESTRONICS rack that converts optical to serial with RS232
characteristics. The output of FOSTCDRI- SX is discretely wired to a RI14
connector placed on the same C channel. A 14-way flat ribbon cable from the
RI14 connector is connected to Port-1A and Port-1Con theS2backplane.

4.9 Multiple WESTRACE EI system

[Link].1 A serial communication cable is taken from the main (system A) NCD-PFM
Port-2 DB9 connector, and another from the standby (system B) NCD-PFM
Port-2 DB9 connector, and is terminated in a 2-in-1-out terminal block placed
on a C channel in WESTRACE rack.

[Link].2 Similarly, a serial communication cable is taken from the main (system A)
NCD-PFM Port- 2 DB9 connector, and another from the standby (system B)
NCD-PFM Port-2 DB9 connector from the other WESTRACEs too that require
an interface with S2, and is terminated in another 2-in-1-out terminal block.
The 2 terminal blocks are looped and then discretely wired to a FOSTCDRI-
SX device placed on the same C channel that converts multi-drop RS485
characteristics to single-mode optical characteristics.

[Link].3 A pair of single-mode OFC patch chords from this FOSTCDRI-SX device is
laid through a flexible conduit to another FOSTCDRI-SX device placed on a C
channel in WESTRONICS rack that converts optical to serial with RS232
characteristics. The output of FOSTCDRI- SX is discretely wired to a RI14
connector placed on the same C channel. A 14-way flat ribbon cable from the
RI14 connector is connected to Port-1A and Port-1C on the S2 backplane.

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4.10 Serial Communication Wiring

[Link].1 The WESTRACE EI talks with panel processor (S2) and data logger
(WESTRACE Mk1) in serial mode of communication. The following are points
to be ensured to achieve a reliable serial communication.

Figure 11: DB9 connector pin out

[Link].2 Serial communication is a circuit which uses a conductor designated as

ground (GND) which can conduct electricity along the cable. So this type of
communication should not be used for distances more than 15 meters and
should not be taken from one room to another room. It is always preferred to
use isolators between the serial communication circuit and the WESTRACE.
These isolators can be either line modems or simple RS232 isolators.

[Link].3 The connection between S2 to WESTRACE should be through RS232/485 to

OFC modems. These modems provide metallic separation between the two
rooms. If extra serial communication cable is laid in parallel to the OFC cable
for panel communication, it should not be connected under normal working
and if necessary during failures these OFC mode can be switched manually to
the serial cable for temporary restoration of communication.

[Link].4 As evident from the pin out diagram the pins in a DB9 connector are placed
very close to each other and sufficient care is to be taken while soldering
these pins, also use sleeves round the pin to prevent the shorts that can
arouse from the stranded conductors.

[Link].5 The serial communication cable that is used has to be of shielded type and
make sure to earth the shield at one end only to avoid the ground loops. In a
three wire RS232 circuit what we usually use is the 2 pair STP cable, so make
it sure that 1 pair is designated to the Transmitter (Tx) and Receiver (Rx) and
the other pair can be used for the ground.

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[Link].6 In a 5 wire RS485 circuit use only multi core STP cable, the usage of the
Ethernet cable for the same is to be avoided.

4.11 Serial Link Wiring

[Link].1 For maximum noise mitigation serial data cables must be shielded with an
overall shield and contain no more conductors than required. (The conductors
shall be twisted pairs). The purpose of this structure is to minimize capacitive,
inductive and RF coupling.

[Link].2 The cable shields must be earthed at one end only.

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5 Data Logger Wiring

5.1 External Data Logger Interface

[Link].1 A Data logger system is helpful in monitoring Railway Signal Control and
interlocking relays in order to verify their operation, diagnose faults and in
maintenance. An external Data logger by Efftronics is used in WESTRACE
installations by Invensys.

[Link].2 This Data-logger logs the change of status of relays & voltages of analog
channels connected to it, and transmit event information to the central place to
generate various exceptions, reports and other information by application
software.

[Link].3 Some features of the Data-logger are:

• Minimum 512 - Maximum 4096 opto-isolated digital inputs

• Minimum 32 - Maximum 96 individually isolated voltages
• Non-volatile data storage in Flash RAM
• Data backup of Ten (10) lakhs of events
• Eight (8) serial ports for data network
• Audio Visual alarms on Exceptions and faults
• Connected to a Central Monitoring Unit for remote monitoring.

[Link].4 As per the railway requirement installation and validation of data logger is
mandatory for the commissioning of EI. The following are the points that are to
be taken care while the installation of external data logger.

[Link].5 All the external relay contacts have to be wired to the data logger. If possible
try to fix a contact common for all the relays and wire up that particular contact
to data logger. Back contacts has to be wired to the data logger only if there
are no front contacts available and if possible use a separate colour code for
the data logger wiring circuits.

[Link].6 For a Normally open/Normally close contact terminal provided, wiring has to
be done from the normally close contact only.

[Link].7 Data logger wiring is not to be mixed with the WESTRACE I/O cable wiring,
instead a separate PVC trough to be provided or can be mixed with the CT
Rack wiring.

[Link].8 The power supply to the data logger has to be fed from the IPS and there
should be backup for this supply.

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[Link].9 All the analog voltages used in the signaling installation are also to be wired to
data logger for its monitoring. The 24V, 50V, 110V DC used in the
WESTRACE end also to be wired to data logger. It is better to provide an
RS232 isolator in between the WESTRACE to Data logger serial connectivity
to prevent the surges from the Data logger end damaging the NCD PFM.

[Link].10 Data logger Setup files / Maintenance tools should not be installed in the
MoviolaW maintenance terminal.

[Link].11 Time synchronization of the Data logger and WETSRACE has to be verified
through the reports from the same.

5.2 Selection of wires used for wiring:

[Link].1 All the wires that is used for the interface wiring has to be of ATC, this
provides a better soldered joint.

[Link].2 For any wire break/falling short in length, the patching up of wires is to be
strictly avoided. This type of practices over the course of time can create earth
faults.

[Link].3 Use proper rating of wires as per the vital interface circuits .

5.3 Cable Systems:

[Link].1 Cable shall be separated into Power cable, Serial Communication cable, I/O
cable and Panel cable.

[Link].2 Sufficient cable spare length shall be provided for equipment, which needs
future adjustment.

[Link].3 Cable splicing should be avoided.

[Link].4 Cable insulation resistance must be 20 mega ohms.

[Link].5 Cable should be arranged properly for easy maintenance.

5.4 Power Wiring:

[Link].1 The power supply wiring and equipment should be located close to the
WESTRACE and other electronic equipment to minimize the length of low
voltage power leads.

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[Link].2 The power supply feeding to external equipment will be separated from the
supply that feeds internal equipment to ensure that external surges and
transients are not directly connected to the internal bus bars.

[Link].3 Earth wires associated with main power supply will be installed to the
applicable standards specified but these shall be kept as short as possible and
well away from the signalling power supply and signalling earths.

[Link].4 It will be of reasonable cross-sectional area to minimize noise coupling and

avoid the power sag.

[Link].5 Cables & wires will be kept as short as possible from power supply to
minimize induced noise.

[Link].6 Case/house wiring will also be arranged to minimize noise.

[Link].7 To avoid transient voltage, surge suppression device must be installed for
WESTRACE Housing and Racks.

5.5 Installation of WESTRONICS (S2) Rack and CCIP

[Link].1 S2 is used in all installations where the Control Cum Indication Panel is used;
the following are the points to be noted during the installation of S2 rack.

[Link].2 Usually the S2 rack is supposed to be 1200*600*600 standard rack. But is the
number of Housings in S2 is more than 2 it is better to go for the
2000*600*600mm rack.

[Link].3 The openings provided in the CCIP and S2 rack for cable entry should be
closed to prevent from any external interference.

[Link].4 S2 rack is also equipped with 110/24V DC DC converters and the input to
these converters has to be from IPS with redundancy in conductors.

[Link].5 The wire wrapping done on S2 housings has to be with proper tool and
alternate method of soldering for this wire wrapping is to be avoided.

[Link].6 S2 standard MBD45 and MBD50 PCB and S2 Standard Interlogic should be
followed for the new installations. This should be ensured during initial
designing of NCDM and S2 interface design activities.

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[Link].7 All the power supply connections on the motherboard should be through
closed barrel Fasten receptacle type terminals. There should not be any loose
contact in this connection.

[Link].8 The toggle switch provided on Motherboard for selection of scanners is to be

in Auto mode only.

[Link].9 The RI 40 cables used for interconnecting the S2 and panel has to be of
proper length. The coiling of excess length will increase the inductance and
also a shorter length will increase the tension in conductors, so installation
should be made with sufficient length.

[Link].10 Proper fixtures to be provided to protect these RI 40 cables, also proper

markings to be provided and both end of the cables. An additional 2 cables is
to be laid for each installation.

[Link].11 If possible the Panel supplies (24V) and the operator VDU equipment supply
(24V supply for network switches) is to be isolated from each other so that a
failure of one supply does not disturb the working of station.

[Link].12 The 24V supply to the panel is to be connected in ring manner.

[Link].13 All the internal wiring within the panel is also to be with proper labels /ferrules.

5.6 Usage of tools:

[Link].1 Use of too much solder shall be avoided to prevent lumpy connection.

[Link].2 Soldering iron shall not be held on the wire connection for too long to avoid
damage to insulation.

[Link].3 The usage of inferior fluxing agent has to be strictly avoided.

[Link].4 Strippers shall be used for the purpose of stripping off the wire insulation.
Cutting pliers shall not be used for the purpose.

[Link].5 The wrapping tool used for wire wrapping is to be of proper size. The usage of
improper wrapping tool will make the pins to bend and gives discontinuity,
however this wrapping or soldering process ruled out now a days and S2
standard MDB45 ,MBD50 PCB with S2 standard Interlogic should be used for
new installations.

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[Link].6 The crimping tools used should be of proper matching with the wire to be
crimped

[Link].7 There are different types of screws (Flat head, star headed, Allen key etc)
used in the WESTRACE installation, proper tools to be used in removal of
same.

[Link].8 The relay contact pin once inserted and locked on to the relay base is not be
removed, if some alterations come on same it is always better to change the
contact pin rather than the reuse of the contact pin.

[Link].9 The usage of calibrated measuring tools to be ensured.

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6 Earthing
6.1 Grounding
6.1.1 Earth Pipes

[Link].1 The RDSO TAN earthing 3006 [ A6Z00039810818] should be fulfilled during
Earthing arrangements installation at site .

[Link].2 Earth pipe of standard length of 10 feet and 2 inches diameter, conical at the
end, having number of holes on surface of pipe is buried outside the
equipment room. One copper plate of 1 sq. feet with 3 mm thickness is welded
at the bottom end (conical end) of the pipe. If the above earth pipe is made of
galvanized iron, four bare copper conductor 10 sq. mm stranded is to run from
the four corners of the copper plate. The said stranded wires are to be brazed
at least in five places with the pipe on its run and at the end, all the strands are
to be connected permanently with copper plate by welding surrounding the
entire surface of the plate.

[Link].3 Indian Railway standard earth pipe of aforesaid dimension is to be used with
the reason that earth conductivity will be more and connectivity of the earth
with outer surface of the pipe as well as copper plate connected at the bottom.
Water can also be percolated to earth through pipe holes keeping earth
resistance as low as possible.

[Link].4 To achieve this suitable earth pit is dig of proper depth with required cross
section at the bottom to accommodate copper plate to sit concentrically. After
placing the earth electrode (pipe), the top of earth electrode is kept little above
the ground, keeping the gland of the earth pipe open for accessibility of
coupling of successive earth pipes with the aid of lead wires being connected
at the gland with the help of 3/8” X 1 ½” brass nuts and bolts for greater
reliability and longer life span, as well as to facilitate routine checking of
intactness of earth leads either for the use of interconnection between the
earth pipes or connection to REB.

[Link].5 A trench of 24” deep and 12” wide is to be dug between all earth pipes to
accommodate 3x25 mm copper strap for interconnection of successive earth
pipes.

[Link].6 All the earth pits are to be filled with layers of charcoal, salt and earth water
mix. The entire trench is to be covered with earth water mix.

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[Link].7 The distance between adjacent earth pipes shall not exceed twice the driven
depth. Hence the distance between two earth pipes is maintained within 20
feet. Such earth pipes installed along the perimeter of the equipment room
and power room, will be coupled together forms the building perimeter earth.

[Link].8 Apart from the earth pipe that form the perimeter earth, a separate earth pipe
be installed near the equipment room of the building. This earth pipe forms the
Low Voltage Earth Pit, which will be connected to the star connected
equipment earth and perimeter earth. The Low Voltage Earth pit to Room
Earth Bar is connected with 2x 16 mm stranded insulated copper wires.

[Link].9 All metal work including location case panels, relay frames, doors and hatches
shall be bonded directly to this earth point;

[Link].10 All transformer chassis and earth screens shall be bonded directly to this earth
point;

[Link].11 All electronic equipment earths, including the WESTRACE earth, shall be
bonded directly to this point;

[Link].12 Surge arresters should be located as near as practical to the earth point and
the arrester earths should be solidly bonded to the earth point.

6.1.2 Room Earth Bar(REB)

[Link].1 The equipment room earth bar shall be a copper bus bar with the required
length with 50mm width and 6mm thickness. The REB shall be predrilled with
number of holes required of M10 size suitable for termination of bolted cable
lugs.

[Link].2 There shall be one REB for each of the following rooms:
• Equipment Room
• Power supply room.

[Link].3 To avoid circulating earth loops, the REBs shall be insulated from the building
structure. Each REB shall be installed against the wall, with low voltage
insulator spacers of height 60mm. The REBs shall be installed as per the site
convenience, but the lead length should be very less. Hence the REB is
maintained at a nominal height of 0.5m from the ground level. All terminations
on the REB shall be by bolted lugs with spring washers. The earth leads shall
however be bolted to the lugs.

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[Link].4 All terminations on the REB shall be by bolted lugs with spring washers. The
earth leads shall however be bolted to the lugs.

6.1.3 REB-REB Bonding Conductors

[Link].1 To minimize the effect of circulating earth loops, noise pick-up and to provide
equipotential bonding, star point earthing is required. In this respect,
Equipment room and Power supply room REBs mentioned above, should be
directly connected to the REB within the Power supply room. To facilitate this,
it is proposed that a REB be installed within the Power supply room at a height
of 0.5m.

[Link].2 The bonding is done by bare stranded copper wire run along the wall on
insulators. If the bonding wire needs to cross building wall, it must be isolated
from building structure to avoid circulating current. The bonding conductors
shall be bolted to their respective lugs.

6.1.4 Earth Conductors

[Link].1 Earth conductors are typically those conductors that carry the surge to the
main point of injection into the ground. These would typically are:

• Copper conductors for equipotential bonding or fault protection, that come

out of a building and which are finally terminated in an earth pit.
• The copper conductors that come down the sides of a building (for
lightning protection) and which are finally terminated in an earth pit.

[Link].2 It is recommended that the earth conductors are of stranded insulated copper
cables.

[Link].3 The earth conductor from equipment room REB to the LV earth pit should be
of small piece of 6 core cable. Where this earth conductor is buried in the
ground it shall be mechanically protected. For diversity, it is proposed that
there shall be two such earth conductors up to the first LV earth pit and then
onto the nearest building perimeter earth pit.

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6.2 Equipment Grounding Requirements

[Link].1 The following sections define the requirements of equipment grounding inside
the equipment rooms.

[Link].2 Each rack should be connected to the REB with 10 sq. mm. insulated copper
wire. The racks should be isolated from the floor of the equipment room as
well as from each other. The racks should also be isolated from the top
ladders.

6.2.2 Grounding of Equipment mounted in racks

[Link].1 Card files and chassis of equipment mounted in a rack must be grounded via
the rack. This can be done by connecting the ground stud on each card
file/chassis, to the rack using 4 sq. mm. Insulated copper wires. Terminate this
wire on the rack frame. When no ground studs are provided on the card
files/chassis, ensure good contact between the metallic mounting ears of the
card files/chassis and the rack via proper use of mounting screws and star
washers.

[Link].2 The earth terminal of other surge protecting devices such Isolator/converters
used for serial communications shall also be connected to Rack frame as
done in case of card file/chassis using 4 sq. mm. Insulated copper wire.

6.3 Cable Shields

[Link].1 Shielded cables within a particular location are considered to be non-exposed.

These cable shields should be grounded at one end only. This end should be
at the lowest impedance point with respect to the REB and the end closest to
the REB.

6.4 Recommended Earth Resistance Value

[Link].1 The following values stated are the minimum earth resistance requirements
prior to bonding the Low voltage earth pit (LV earth pit) to the building
perimeter earth.

Earth measurement points Resistance

LV Earth pit Less than 1 Ohm
Building perimeter Earth Less than 1 Ohm
Table 5: Earth Resistance Value

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6.5 Indoor Earthing

[Link].1 There shall not be any possibility of simultaneous human contact with metallic
bodies connected to different earths, where it is not possible to provide
suitable spacing or partition between various metallic objects referred to
above, they shall be connected to a common earth.

[Link].2 Also there can be chances of Galvanic coupling (the two metal objects acting
as an electric source) if the two equipments are in the different equi potential
levels. To avoid this, adjacent equipments without any separation should be
connected to the same earth.

[Link].3 The Earth Leakage Detector (ELD) earth has to be different from the signaling
earth else the purpose of ELD installation may not be achieved.

[Link].4 Make sure that the earth connections are not made on the painted metal
parts, and to be connected to the rack body which is painted scratch the
surface thoroughly and the pain/coated area has to be removed.

[Link].5 Do not ground the shield of the cables in more than one place

[Link].6 Earthing across a hinged door or panel has to be provided with a u loop and
star headed washers to be provided to ensure its stability over the course of
its mechanical motion.

[Link].7 A copper tape has to be provided around the IPS room and relay room which
forms the Bonding Ring Perimetric Conductor (BRC). It provides a low
inductance Common Bonding Network (CBN). All the equipments installed
have to be connected to this BRC in the shortest possible path.

[Link].8 It is not necessary to provide a closed loop for this BRC specially near the
doors, windows etc. but wherever possible try to cover the maximum area of
the equipment room in closed possible.

[Link].9 All earth bonds, cables and wires are classified as ‘dirty’ and must not be run
through cable trays carrying ‘clean’ signaling and power circuits.

[Link].10 Material specifications to be used in indoor earth connections

[Link].11 GI/ Copper strips of 50*6 mm is to be used for interconnecting the earth pits

[Link].12 The main bus bar should be of copper 25* 6*225 mm size minimum

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[Link].13 The BRC is to be formed with 25* 3mm copper tape and to be mounted on
insulated stand offs.

[Link].14 Main earth to bus bar to be welded with either 25*3 mm copper tape or else
with four 35 [Link] multi strand single core PVC insulated copper cable

[Link].15 All the equipments to be connected to the BRC with 10 [Link] multi stranded
single core PVC insulated copper cable

[Link].16 Star earth connections are recommended for the E.I equipments and housing
as shown below. WESTRACE application manual chapter 5 installing
WESTRACE should be followed.

[Link].17 Daisy earth cable connection should be avoided .

6.6 Outdoor Earthing

[Link].1 Earthing is purely an installation related job, so there are many factors related
to workmanship, quantity and quality of material used, installation procedure,
season of installation etc. which determines the quality of earthing thereby the
protection level of equipment. The following are the points to be ensured for a
better protection level

[Link].2 A minimum of 3 earth pit has to be connected in ring manner; the number of
pits is to be increased if the combined resistance achieved is more than 1
ohm.

[Link].3 Earth pits not to be made on high bank or made up soil, instead low lying
areas near to the building to be selected. Also the location close to near water
bodies can be selected, but locations with dry sand, lime stone, granite or any
stony ground to be avoided.

[Link].4 Materials like sand, salt, coke breeze, cinders and ash shall not be used as a
back fill material because of its acidic and corrosive nature.

[Link].5 Wherever the distance between the respective rooms of relay room, power
supply room and station master room is greater than 25 meters, the room/part
of building away from the main building or its part should have dedicated
earthing system. (Same to be followed in case of distributed interlocking also)

[Link].6 The following are the major components that is to be used in outdoor earthing
schemes

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[Link].7 Copper clad steel earth electrodes – Made with steel core and copper exterior.
Approved for 3m length 17mm diameter and copper coating of 250 microns

[Link].8 Earth Enhancement Chemical (LOHM) - resistivity of the earth enhance

compound should be less than 0.2 ohm meter and it should be consisting
mainly of Portland cement and graphite but not bentonite (or any other
chemical). An approximate of 30-35 Kg of earth enhancement compound to be
used for one earth pit where the augured hole dia is 100-125mm

[Link].9 Exothermic Welding kits- Depending upon the plates to be welded the welding
dyes also changes. Care to be taken in selecting the proper dye, else rigid
bonds will not be made.

6.7 Construction of outdoor earth pit

[Link].1 The following points needs to be considered while the preparation of the
outdoor earth pit

[Link].2 A hole of 100mm to 125mm dia shall be augured/ dug to a depth of about 2.8
meters

[Link].3 The earth electrode shall be placed on this hole

[Link].4 It will be penetrated into the soil gently driving on the top of the rod. Here
natural soil is assumed to be available at the bottom of the electrode so that
minimum 150mm of the electrode shall be inserted in the natural soil

[Link].5 An approximate of 30-35 Kg of earth enhancement compound to be used for

one earth pit where the augured hole dia is 100-125mm. The LOHM shall be
filled in a slurry form and is allowed to set. After the material gets set, the
diameter of the composite structure (earth electrode + earth enhancement
material) shall be of minimum 100mm dia covering entire length of the hole

[Link].6 Remaining portion of the hole shall be covered by backfill soil, which is taken
out during auguring/ digging.

[Link].7 The main earth pit shall be located as near to the main equi potential bus bar
in the equipment room as possible.

[Link].8 The distance between two successive earth electrodes shall be minimum 3
mtr and max up to twice the length of the earth electrode i.e. 6 mtr appox

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6.8 Interconnection/welding of multiple pits:

[Link].1 The connection between the earth pits has to be done with copper tapes. The
use of Galvanized Iron tapes is also advised.

[Link].2 All the electrical connections to the earth electrode at the rods and between
and on the GI/copper tapes should be welded (Exothermic) for high
conductivity, long term reliability and reduced maintenance.

[Link].3 The interconnecting conductor shall be buried at a depth not less than 500mm
below the ground level. This interconnecting conductor shall also be covered
with approximately 10Kg of earth enhancing compound for each 3 meters
length.

Figure 12: Earth Electrode Diagram

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[Link].4 Construction of Inspection chambers

[Link].5 The dimension of chamber will be of 525 * 350* 250mm ( Inside dimension) of
RCC with fine finish.

[Link].6 The Marking space should be present on the RCC cover slab for the chamber

[Link].7 The date of testing and earth resistance value shall be written on the cover.

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7 Surge Protection
7.1 Surge Protection Practices

[Link].1 The IEEE specification contains updated and new parts, which provide
detailed guidelines for effective surge protection of signaling equipment and
systems. These guidelines are to be followed to a maximum extent on all
WESTRACE installations. Deviations are allowed when adequate cause or
justification exists and documented. WESTRACE application manual chapter
5 installing WESTRACE should be followed.

7.2 Power Protection:

[Link].1 Power protection is much important in a signaling facility. The power supply is
distributed throughout the equipment rooms and is often toughed with other
wiring. Much of the equipments that are driven from power supply has some
built-in tertiary protection, but in no way can bear the brunt of a major surge.

[Link].2 Such levels must be handled properly by staged protection. The staged
protection refers to primary, secondary & tertiary levels and DC & Data line
equipment.

7.3 AC Power Protection:

7.3.1 Primary AC line protection

[Link].1 In AC line feeds, primary protection begins at the service entrance. In severe
lightning areas, primary protection begins at the service entrance inside the
equipment rooms. The preference for primary side protection is the block type
MOVs. These MOVs are 60mm diameter discs capable of handling enormous
amounts of energy, while maintaining reasonable clamping levels of for an AC
system. It is better to use two or more in a fused, parallel fashion with indicator
lamps across the fuse. In this way, it will be known if one MOV is shorted and
because of the parallel redundant configuration, line protection continues.

[Link].2 Generally the IPS is connected to the AC service entrance and provided OBO
make surge arrestor as primary AC line protection device.

7.3.2 Secondary/Tertiary AC line protection

[Link].1 Secondary protection levels in AC feeds are only effective if sufficient isolation
impedance exists between the primary and secondary protectors. The needed
amount of isolation number is not easy to arrive at. Therefore secondary
protection level is often forgone.
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[Link].2 Tertiary protection is generally found within the equipment itself.

7.4 Dataline Equipment Protection

[Link].1 Data line equipment has become extremely vulnerable to a phenomenon

known as voltage surges and electrical transients. Source of electrical surges
are numerous. The most common is a nearby lightning strike, which will affect
nearby data line through induction. Electrostatic discharge is another form of
an electrical surge that can affect data line equipment. In order to protect the
equipment from incoming surge through data line, the following protections are
to be implemented.

7.4.2 Twisted pair wiring

[Link].1 It consists of two identical wires wrapped together in a double helix. Both
wires in the pair have the same impedance to ground, making it a balanced
medium. This characteristic helps to lower the cable’s susceptibility to noise
from neighboring cables or external source. Twisted pair wiring is adopted in
all Vital I/O circuits and in RS485 standard serial communication circuits. A
pair of twisted wires is loosely twisted at 10 twists per meter.

7.4.3 Isolation:

[Link].1 Isolators block unwanted currents originating on one side from reaching the
other side. Isolators are designed to eliminate ground loops. A ground loop is
a current across the cable created by a difference in potential between two
grounded points. This happens if you have a long cable run of several
hundred feet, or cables run between two buildings.

[Link].2 When two devices are connected and their ground potentials are different,
current flows from high to low by traveling through the data cable ground wire.
If the voltage difference is large enough one of the RS-232 ports can be
damaged. Even a small potential difference can cause trouble even though it
does not cause circuit failure. Small ground loop voltages cause transmission
errors with data signals riding on top the ground loop current. Isolators block
this damaging or interfering current.

[Link].3 A common application of an isolator is that allows a data logger to be

connected to a data line without risk of damage from electrical transients and
also "surges" or "spikes". If a transient occurs on the data line which is
common, the equipment will be unaffected because the optical gap does not
conduct electric current. For this reason, isolators provide superior protection.

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[Link].4 Isolator and Converter cum isolator of “B&B” make may be provided for serial
communication circuits. The Isolator provides 2500V isolation between its DTE
and DCE sides and protection against lightning damages. The Converter cum
Isolator provides 2000V AC isolation between its input and output.

7.5 Surge suppressor/ Arrestors

[Link].1 230V AC to Operator VDU and Maintenance VDU are connected through
Surge suppressor to protect the equipment from lightning damages.

[Link].2 Main 110 DC supplies to DC-DC converters are connected through Surge
suppressor to protect the equipment from lightning damages.

[Link].3 24VDC supplies to S2 Panel Processor supply are connected through Surge
suppressor to protect the equipment from lightning damages.

[Link].4 All the surge arrestors should be falls under Class ‘’C’’ protection. Addition to
that Class ‘’B’’ and Class’c’’ surge arrestors should be ensured in the
Incoming power supply at IPS equipments .

Voltage
Type Make
Range
Phoenix or
Surge suppressor 230V AC
equivalent
Phoenix or
110VDC
Surge suppressor equivalent
Phoenix or
Surge suppressor 24VDC
equivalent
Table 6: Specification of Surge suppressor

[Link].5 There are different types of surge protection devices based on the
zones/levels of protection that is to be provided. Wiring between the zones is
needs to pass through a surge protector Device ( SPD) to limit the possible
magnitude of surges.

[Link].6 Wiring in each zone needs to be physically separated from adjacent zones, so
that the surges does not couple near the SPD’s

[Link].7 The SPD in each zone should be mounted as close to the main earth bus bar
as practical.

[Link].8 If surge protected wiring has to cross the non surge protected wires then it has
to cross at right angles. This has to be taken care at the SPD mounting area

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where the non surge protected wire ( Earth wires) mixes with the surge
protected wires ( power supply wires)

[Link].9 Separate PVC troughs have to be fixed at a minimum of 150mm distance

between the SPD area for the routing of the incoming and outgoing cables.
Also the earth wire is not to be routed with the outgoing cable.

Figure 13: Surge Arrestor Connection

[Link].10 The usage of single trough for the routing of the incoming and outgoing cables
has to be strictly avoided.

Figure 14: Surge Arrestor Wrong connection

[Link].11 If this type of installation is done then the surges can bypass the SPD by
coupling between the conductors.

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Figure 15: SPD

[Link].12 Typical surges due to lightning last for about 1/10,000 seconds with a peak
current flow of about 20,000 Amps. Due to the speed of a lightning surge
event, with fast rise time and short duration, lightening surges behave like high
–frequency signals. Proper discharge of this lightning current is of at most
importance in all the installations. The following are the measures to be
followed in achieving the same.

[Link].13 The typical surge can develop 10,000 volts across a 1 metre length of 16
[Link] earth cable due to its inductance. It is therefore very important to keep
earth wires as short and direct as possible. The Earth wires should not exceed
more than 2 mtr in length and the practice of coiling of wiring before
termination should be strictly avoided.

[Link].14 10,000 volts can flash over an air gap of a centimeter, so separation of the
interface/power wiring from the earth wiring should also be taken care of.

[Link].15 Ideally there should be only one point of entry from external environment into
equipment room for all cables, e.g. power, signaling, telecommunication etc.
But care to be taken to route them separately.

7.6 Vital I/O Interface Protection Requirements

[Link].1 The vital inputs from the field to the WESTRACE equipment are read through
a relay contact. Since reading through relay contacts provides galvanic

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isolation to the vital inputs, there is no need of providing any surge protection
devices for the vital inputs.

[Link].2 The vital outputs from the WESTRACE equipment to the field are through vital
relays. Since output vital relays provide galvanic isolation, there is no need of
providing any surge protection devices for the vital outputs. However, relay
coil snubs are introduced across the coils of the vital output relays. Relay coil
snubs are intended to dissipate large electromagnetic surges that are
dissipated from the inductance of relay coils and to prevent these surges from
interfering with normal operation of WESTRACE system.

[Link].3 Noise reduction in the cables is taken care of by using twisted cables for vital
I/O from the termination racks. All the vital output cables from WESTRACE
equipment should be gathered in a bundle, input wires should be gathered in a
bundle, power wires should be gathered in a bundle. Each of the bundles
should be physically separated from each other (preferably 6”) and all bundles
should be physically separated from other house wiring. It is particularly
important to maintain this physical separation from high current “dirty” wiring.

7.7 Class ‘A’ Surge Protection

[Link].1 Class A surge protection commonly called as building protection is required to

protect the building from the high intensity lightening. The following are the
points to be ensured in achieving a better protection

[Link].2 Class A protection is achieved by providing Franklin rods/ early streamer

emitter terminal at the top of building to be protected.

[Link].3 The purpose of this lightning protection is not to avoid the lightning but instead
to attract the same and to provide an easier conductive path to ground thereby
protecting the building. Due to this, there should be separate earthing pits
provided for lightning protection and in no way should be connected to the ring
earth to prevent the return flow of heavy lightning discharges.

[Link].4 The conductor from the lightning conductor should not be stranded wires
instead it should be copper tapes of size 25*3mm. These tapes should be
insulated from the wall of the building and should be exothermically welded
with the separate earth pit that is provided.

[Link].5 The radius of protection depends on the height at which the rod/ESE terminal
is installed

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Figure 16: Class ‘A’ surge protection- Calculation Method

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8 Bunching/Dressing up of wires

[Link].1 The bunching/dressing of installation not only increases the aesthetic look of
the installation but also minimizes the fault and makes maintenance an easier
task.

An untidy installation A well planned installation

Figure 17: Bunching Procedure

[Link].2 Make sure that there are no ducts kept opened in the closed cabinets. Also it
is to be ensured that the openings provided from one room to another,
beneath the racks, panels etc are properly closed to prevent the entry of any
foreign particles.

[Link].3 The usage of plastic ties for bunching to be minimized, instead the bunching
belts or threads to be used.

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9 Colour Coding of Wires/Cables

[Link].1 Grey sleeved shielded serial communication cable is used for serial
communication wiring.

[Link].2 8 core or 5 core grey sleeved shielded serial communication cable is used for
RS232/485 standard serial ports.

[Link].3 Red/Black color wire is provided for power supply wiring.

[Link].4 Green color is provided for Earth cable wiring circuits.

[Link].5 (16/0.2) Red/Black color twisted pair wire is provided for Vital input circuits.

[Link].6 (16/0.2) Red/Black color wire is provided for vital output circuits.

[Link].7 230VAC /110VAC cables may be provided with yellow color for easy
identification and understanding.

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10 Labelling
10.1 Labelling & Identification markers

[Link].1 All cable ends are provided with proper identification Tags made of non-
deteriorating material.

[Link].2 All the Terminals will have identification markers.

[Link].3 All the wires connected to the terminals will have proper PVC ferrules.

[Link].4 In the racks, Column/Row will be numbered and also, all the major
equipments used in the system/sub system will have proper labels or painting
for easy identification

10.2 Termination

[Link].1 A perfect termination is gastight, therefore corrosion free and amounts to a

cold weld of the parts being connected.

[Link].2 Wires are to be terminated shall match with the correct size of the crimp
contacts.

[Link].3 If these basic requirements are met, highly reliable connections with low
contact resistance and high resistance to corrosive attack are assured.

[Link].4 Conductors of cables are to be correctly identified and are to be connected to

the correct terminals.

[Link].5 Conductors are to be securely held in terminals of fittings and are not subject
to tension at the terminations.

10.3 Spare Core Termination

[Link].1 Cables having spare conductors will be terminated in the spare terminals and
will have proper tags for future use. In case of non-availability of Terminals,
spare conductor ends will be insulated and neatly separated cable wise with
proper identification tags

10.4 Insulation

[Link].1 The following shall be provided with proper Insulation from ground:
• Mat and Rubber bushes between Racks/Panel and floor.
• Hylum sheet and PVC separators between ladders and Racks/Walls.

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• PVC cable trays for all the wires/cables run.

[Link].2 PVC tape/sleeve wrapped over the flat connecting to the angles of the ladder
for insulation between wires/cables and ladder

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11 Installation of Operator Terminal (WESTCAD)

11.1 WESTCAD VDU installation

[Link].1 WESTCAD is a highly effective and adaptable Control and Display system.
This computer based system is suitable for applications from simple local
control up to a fully networked management control system incorporating
multiple operator workstations.

[Link].2 WESTCAD consists of an integrated suite of software packages, with

corresponding configuration data, which is tailored to specific user
requirements and applications.

11.2 Software Installation

[Link].1 WESTCAD software runs on Windows NT, 2000 or XP. It is easy to setup,
highly configurable and uses conventional PC hardware. The software is
capable of allowing the designers to tailor individual screen displays, without
altering the core of the software.

[Link].2 SRAPL provides the familiar Windows XP /Windows 7 based computers in all
its installations for WESTCAD Operating VDU. The software is modular; each
functionality is designed and tested independently. Once the WESTCAD
design is ready, they can easily deploy in the computer at site.

[Link].3 As part of the installation, the tested WESTCAD set of file are merely copied
into a folder in the computer, and can be run [Link] to that disable
the USB port drives to prevent unauthorised pen drive usage.

[Link].4 It is the operator terminal that gives the first impression to an outsider after the
station is commissioned. So sufficient care should be taken to providing a the
clean and tidy workplace to the end user. The following are the points to be
ensured,

[Link].5 The usage of proper fixtures for fixing of monitors and CPU’s to be ensured.
No temporary/patch up fixtures is to be allowed.

[Link].6 Monitor and CPU’s & accessories are should be fixed with proper fixtures and
ventilation for easy access and maintenance.

[Link].7 Some common consumables like the dust cover for the keyboard, mouse pad
for the CPU etc is to be provided. If the monitor is not wall/fixture mounted
make sure that the position of the same is fixed on the table with proper
supporting arrangements.
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[Link].8 The plug board provided at the operator terminal has to be of indicative type
and should of higher grade. (The access of the same should be made
available only to the signaling staff)

[Link].9 All the interconnecting cable between the UPS, CPU, Mouse, keyboard,
Monitor, Speaker etc should be properly dressed up and should be secured
properly. Make sure that the supply to the CPU/Monitor is fed through the UPS
only; UPS not only provides the backup but also acts as a good isolation from
the incoming surges to the equipment.

[Link].10 The WESTCAD PC should be formatted before commissioning and all the
files other than the WESTCAD files should be deleted from the PC. Also the
WESTCAD files has to be in D drive, its shortcut should be in desktop and
should be pinned to start menu. Also WESTCAD exe should be available in
the startup menu. (This helps in guiding the station master in cases of failures)

[Link].11 Also in the boot propertied the PC should be auto bootable without the power
button press. Block diagram on the power and communication wiring in
WESTCAD room to be pasted in WESTCAD room.

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12 Installation of Maintenance Terminal (MoviolaW)

12.1 MoviolaW Installation

[Link].1 MoviolaW is a PC-based graphic display and recording, logging and replay
tool that supports WESTRACE, SSI and relay interlocking (via WESTRONIC
S2). MoviolaW users can see, in real time, the state of one or more
interlocking and object controllers on a familiar mimic panel screen. MoviolaW
displays track circuits, points, signals and other equipment for easy
understanding of their status.

12.2 Software Installation

[Link].1 SRAPL provides the familiar Windows XP/Windows 7 based computers in all
its installations for the MoviolaW maintenance diagnostic terminal.

[Link].2 MoviolaW is configured using a configuration tool called the SAMConfig Tool.
Using the SamConfig tool, one can generate the configuration files for the
specific installation for which MoviolaW will be installed.

[Link].3 MoviolaW generates log files at the end of each day, and they will be archived
every 30 days. It is necessary to take a backup of these files periodically in
order to make space for new logs.

[Link].4 MoviolaW is the diagnostic tool that is provided with WESTRACE for local
trouble shooting and failure rectifications. An installation with MoviolaW
installed properly will be very much helpful in failure identification and in
investigating the root cause for the issue.

[Link].5 The following are the points to be taken care in installing MoviolaW:
• The PC supplied for MoviolaW has to be of Industrial grade fan less PC.
• The Ethernet connection to this PC has to be from both the systems main
and standby. Although the MoviolaW communicates with a single IP
address, the two LAN ports in the PC can be bridged together and a
common IP can be assigned.
• MoviolaW PC should be free from all the unwanted software’s installed.
There should be separate PC’s for MoviolaW and data logger.
• Also in the boot propertied the PC should be auto bootable without the
power button press.
• All the interconnecting cable between the UPS, CPU, Mouse, keyboard,
Monitor, Speaker etc should be properly dressed up and should be
secured properly.
• The yard layout of the MoviolaW PC should be exactly the same replica
of the WESTCAD PC layout.
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12.3 Precaution against the ESD

[Link].1 Electro Static Discharge (ESD) is the transfer of electrostatic charge between
bodies at varied voltages that is caused by direct contact or induced by an
electrostatic field. ESD damage can be unknowingly and this ESD voltage
should be prevented from reaching the ESD sensitive devices. The following
are the preventive measures taken in achieving the same,

[Link].2 Make it as a routine to wear Antistatic wrist strap while working with the
WETSRACE modules. Use antistatic bags for storing/shipping of WESTRACE
equipment. These bags act as a faraday cage and keep the stray voltages on
the external part of the bag thereby protecting the modules. Use Antistatic
mats wherever necessary.

12.4 As built documentation and training

[Link].1 Once the station is commissioned, it is the responsibility of the railways to

maintain the WESTRACE EI and to attend the failures. Proper documentation
and training helps in make the life of maintenance staff much easier. The
following are the points to be kept in mind for in this regard

[Link].2 The As Made documents of the station have to be made ready well before
commissioning. There should not be any last minute hurry in making the as
built documents ready as this call for increased errors.

[Link].3 The Final as built document that is send from site has to cross certified by the
concerned railway staff so that the further time taken in verification can be
reduced.

[Link].4 All the major details that is required to maintain the station has to be laminated
and pasted in the equipment/SM room so that the fault rectification can be
made easier. The training to the Railway signaling staff has to be imparted
gradually and enough practical experience has to be imparted to them.

[Link].5 The confidence level of the signaling staff in maintaining the system has to be
increased by guiding them in WESTRACE installation and fault rectification.

12.5 Maintenance of Westrace EI

[Link].1 Periodically check the air filters; if they are dirty or clogged with dust either
replace/reuse them after cleaning. Do not brush the WESTRACE EI for dust
removal, if required a vacuum cleaner can be used but should be used from
distance of 30cm to prevent ESD damage.

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[Link].2 If air conditioning units are provided then the periodic cleaning of the AC ducts
is to be insisted. The NC/NO contacts that are wired to data logger should be
periodically monitored and alarm has to be configured on this failure.

[Link].3 All the standby arrangements have to be tested periodically for the availability
of the same during failures. Any failure/ fault component have to be
dispatched at the earliest to SRAPL for its failure rectification. If possible a
brief condition that aroused the failure is also to be attached.

[Link].4 The equipment room has to be free from dust and moisture. The spare that is
provided is to be tested periodically and should be stored in safe custody with
necessary protection to the electronic components.

[Link].5 Ensure availability of tool kit and FLM manuals at site for effective and easy
maintenance.

[Link].6 Ensure availability of WESTRACE display boards and final as made bit chart
of WESTRACE and S2 equipments & Fuse /terminal chart.

[Link].7 Ensure that all the E.I equipments rack keys, Card extractor, Remote control
of VDU and Maintenance terminal been handed over to railway staff with join
acknowledgement .

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13 Maintenance Schedule
13.1 Weekly/Monthly/Yearly schedule

[Link].1 SRAPL recommends a periodic maintenance schedule for WESTRACE

Interlocking systems.

13.2 Measuring Voltages (Performed by Signal Maintainer):

13.2.1 Procedure:

[Link].1 24V DC power supply is used for WESTRACE system operation and 50V DC
power supply is used for the inputs and outputs of the WESTRACE
interlocking system. The power supply shall be measured using a multi meter
and recorded.

[Link].2 The 24 V busbarvoltage shall be within the range 20V to 30V. The 50V power
bus bar voltage shall be within the range 40V to 60V.

[Link].3 The PSU PFM and HOPC PFM pin numbers for power supply measurement
shall be verified from the interface circuits available in the station.

24V DC WESTRACE 50V DC OPCR & VROM & VPIM

Sl. Supply Supply
Date Remarks Signature
No.

At PSU At HOPC At OPCR At VROM & VPIM

PFM PFM Relay Bus bar

2
Table 7: Voltage Measurement Schedule

13.3 Fuse Check (Performed by signal maintainer):

13.3.1 Procedure:

[Link].1 All the fuses are provided with LED indications. If any fuse blows then the LED
in the fuse terminals will glow. If there is any fuse blown indication is seen on
any of the fuse terminals, replace the fuses with the correct rating of the fuse.

[Link].2 While verifying the fuses, the fuses shall be ensured that they are fully
pressed into the respective terminals. All the fuse terminals shall be pressed
once.

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[Link].3

Fuse Checking
Panel
Network
Supply
Sl. 24V 50V VROM switch
Date Bus bar Bus bar /VPIM Fuses/ /Modem Remar
No Scanner Signature
ks
fuses fuses Fuses card fuses fuses
WEST WEST WEST WESTRA
RA RA RA CE
CE CE CE S2- Rack Rack

2
Table 8: Fuse Checking Schedule

13.4 Hot-Standby system changeover (Performed by signal

maintainer)
13.4.1 Procedure:

[Link].1 Hot standby test is performed to ensure that the standby system takes over
"as is where" condition from the online system. The system that was online
before conducting this test is indicated as primary system and the other as
secondary system.

[Link].2 Set a route on the primary system. After the signal is cleared, switch off the
primary system by disconnecting the 24V fuse for the primary system. The
secondary system takes over and becomes primary. The signal cleared
condition is not affected. Put the 24V fuses back that were removed. The
system will power up and stabilizes after approximately 2 minutes.

[Link].3 Cancel the signal and give a route release command. When the route release
timer is 50% progressed, switch off the primary system by removing the 24V
fuse. The secondary system shall take over and release the route after the
required time delay. Put the 24V fuse back and the system will power up and
stabilizes after approximately 2 minutes. Record the test results.

[Link].4 Station specific system changeover procedure should be prepared and

explained effectively to maintenance staff for the maintenance of E.I systems.

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13.5 Earth Resistance measurement (Performed by signal

maintainer):
13.5.1 Procedure:

[Link].1 Earth resistance shall be measured at each and every earth pit provided for
the electronic interlocking system / power supply. As all the earth pits are
welded to each other as per the earthing scheme, the earth value shall be
almost same in all earth pits. The earth resistance at each earth pit shall be
measured and recorded.

[Link].2 While measuring the earth resistance in the earth pits, proper connection of
earth pits to the room earth bars of the power supply room, equipment room
and the panel room shall be observed.

[Link].3 Earth resistance measured should be less than 10Ω.

Earth Resistance Value

Sl. Remar Signat
No Date Pit 1 Pit 2 Pit 3 Pit 4 Pit 5 Pit 6 Pit 7 Pit 8 ks ure

2
Table 9: Earth Resistance Schedule

13.6 Database backup (Performed by signal maintainer):

13.6.1 Procedure:

[Link].1 For each day, there is a database file created in the MoviolaW with the event
logs. The event log files shall be copied into a back-up system (thumb drive or
any other equivalent equipment). Also note down the location in the PC drive
where the database is stored. MoviolaW Database Backup should be taken
every 45 days.

Remarks
Sl. Backup MoviolaW Data Storage in
No Date base backup PC drive Signature

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2
Table 10: MoviolaW database backup schedule

13.7 WESTRACE System failure registry:

13.7.1 Procedure

[Link].1 Verify any red color LEDs are glowing in any of the VPIM or VROM modules.
There shall not be any red LED glowing on any of the VPIM or VROM
modules. If any of the modules show red LED, then verify the error code and
take corrective action as given in the WESTRACE First Line Maintenance
Manual.

[Link].2 Verify the red color LEDs on the VLC 6 module as well as the alpha numeric
display on the NCDM module. The alphanumeric display shall be blank and
there shall not be any red color LEDs lit on VLC 6 module. If any red color
LED lit on VLC 6 module or alphanumeric display lit on NCDM module, verify
the error code on WESTRACE First Line Maintenance Manual and take
corrective action.

[Link].3 The error code if any shall be registered in the system failure register, the
faulty module if any shall be replaced with spare module

[Link].4 All the E.I failures should be recorded and reported to office with standard
prescribed format for the detailed investigations.

All the failed modules should be sent to office, once entered all once entered
all , the failure details in the Site return management tool.
Sl. Failure in System Interlocki Details Equipment Corrective Action
No ng of the or
Error Date Time Down Failure Component Descri Date Time By
code Time Failed p
1

Table 11: System Failure registry

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14 Do’s and Don’ts

14.1 General Do’s and don’ts of WESTRACE EI

[Link].1 DOs and DONTs mentioned under this section must be strictly adhered in
installations

14.2 Do’s
• Keep the WESTRACE – E.I room free from dust & Moisture
• Ensure all terminations are fully tightened
• Place the removed faulty Modules with an Identity tag into a anti-static
bag
• Maintain Minimum 24 Volts DC at the WESTRACE power Modules [24
Volts]
• Maintain Minimum 50V DC at the WESTRACE Input/output Modules
[50 Volts]
• Take back up of MoviolaW- Maintenance terminal user data event/Fault
Log files in every 45 days
• Check Network cables connectivity between WESTRACE to
WESTCAD & MoviolaW
• Use Card Extractor for Removing of WESTRACE modules
• Read carefully WESTRACE -Fault codes & Fault Description on FLM
During Troubleshooting
• Switch ‘’OFF’’ the top housing first, during WESTRACE Powering down
manually.
• Switch ‘’ON’’ the top housing Last, during WESTRACE Powering Up
manually.
• Wait 40 secs time delay Between Powering Down & Up Process
• System changeover every fortnight ,but not later a month

14.3 Don’ts
• Attempt WESTRACE trouble shooting if you do not have proper
WESTRACE training
• Remove modules, OPCR relays, Fuses, Links, PFM’s & I/O module
connectors, When the System is ON
• Force modules into the slots during insertion
• Change version Switch settings of VLM 6 & NCDM Modules
• Change Jumper settings in UHVBC & S2- Scanner card
• Touch the module components.
• Repair module on your own

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• Alter WESTRACE settings ,MoviolaW & WESTCAD PC settings

without Authorization
• Delete /modify Application logic programs without Authorization
• Use any kind of solvents, detergents or abrasive cleaners on the
Housing or Internal components
• Use vacuum cleaner/blower INSIDE the Housing
• Remove Optic Fiber cable connector when system is ON
• Installation of Unauthorized software’s in WESTCAD /MoviolaW PC’s
• View optical Laser light on Exposed Eyes.
• Switch “OFF” MoviolaW diagnostic Terminal.
• Use Mobile Phones & Transceivers within 5 meters of
WESTRACE/WESTRONICS [S2] Equipments.

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15 Mk1 Typical installation Photos:

[Link].1 The Mk1 Demo rack and combined with relay rack has been developed at the
prewiring factory to study the feastiblity of the standard wiring activites and
further implementation at ongoing Mk1 installtions .

[Link].2 Some Photos of installed WESTRACE rack and relayrack & accessories are
shown below.

Figure 18 : Mk1 Demo Rack Rear view

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Figure 19: DC-DC converters fittings

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Figure 20: DC-DC converters fittings - standby system

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Figure 21: Network switch & Media converter arrangements

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Figure 22: Main 24V DC -50VDC supply terminals

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Figure 23: FMS box arrangements

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Figure 24: Mk1 Demo Rack Front view -1

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Figure 25: MK1 Demo rack front View – 2

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Figure 26: Earth Busbar arrangements

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Figure 27: Main and Standby Fittings

Figure 28: EC2 -EC3 cable routing and PFM labeling

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Figure 29: Ladder arrangements

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16 List
16.1 List of Tables

Table 1: Terms and abbreviations ..........................................................................................................9

Table 2: References ..............................................................................................................................9
Table 3: Scope of material matrix.........................................................................................................13
Table 4: Project Engineer Material Checklist ........................................................................................14
Table 5: Earth Resistance Value ..........................................................................................................46
Table 6: Specification of Surge suppressor ..........................................................................................54
Table 7: Voltage Measurement Schedule.............................................................................................68
Table 8: Fuse Checking Schedule .......................................................................................................69
Table 9: Earth Resistance Schedule ...................................................................................................70
Table 10: MoviolaW database backup schedule................................................................................... 71
Table 11: System Failure registry.........................................................................................................71

16.2 List of Figures

Figure 1: Different types of Din rail .......................................................................................................20
Figure 2: Gallant make DC-DC converters ........................................................................................... 26
Figure 3: Communication Ports...........................................................................................................27
Figure 4: Shielded Cable Earthing .......................................................................................................29
Figure 5: Wrong Crimped Cable...........................................................................................................29
Figure 6: RJ 45 Ethernet Connector Crimping method ......................................................................... 30
Figure 7: Ethernet Cable cross and straight connection color coding .................................................... 30
Figure 8: Wrong bunching method .......................................................................................................30
Figure 9: SC-SC Type Patch cord ........................................................................................................32
Figure 10: Stand Alone system-Serial Communication Diagram ........................................................... 34
Figure 11: DB9 connector pin out.........................................................................................................36
Figure 12: Earth Electrode Diagram .....................................................................................................50
Figure 13: Surge Arrestor Connection ..................................................................................................55
Figure 14: Surge Arrestor Wrong connection ....................................................................................... 55
Figure 15: SPD ....................................................................................................................................56
Figure 16: Class ‘A’ surge protection- Calculation Method .................................................................... 58
Figure 17: Bunching Procedure ...........................................................................................................59
Figure 18 : Mk1 Demo Rack Rear view ...............................................................................................74
Figure 19: DC-DC converters fittings....................................................................................................75
Figure 20: DC-DC converters fittings - standby system ........................................................................ 76
Figure 21: Network switch & Media converter arrangements ................................................................ 77
Figure 22: Main 24V DC -50VDC supply terminals ............................................................................... 78
Figure 23: FMS box arrangements.......................................................................................................79
Figure 24: Mk1 Demo Rack Front view -1 ............................................................................................80
Figure 25: MK1 Demo rack front View – 2 ............................................................................................81
Figure 26: Earth Busbar arrangements ................................................................................................82
Figure 27: Main and Standby Fittings ...................................................................................................83
Figure 28: EC2 -EC3 cable routing and PFM labeling .......................................................................... 83
Figure 29: Ladder arrangements..........................................................................................................84

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