Part 1

MSDAC (Alcatel / Thales)

AzLM

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Introduction: Track Occupancy Detection

To ensure safe operation of the trains, the track is divided into sections.
Each section is usually protected by a signal.
The signal aspect is thus closely linked with the Free/Occupied status of the track section ahead.
Trains are normally not permitted to pass a signal unless the section ahead has been completely cleared of
all vehicles.
With increasing speed, traffic density and high demand for safety, process of automatic track occupancy /
vacancy detection became desirable

Two popular means to achieve the automatic track occupancy detection are:
1. Track Circuits &
2. Axle Counters.(MSDAC AND SSDAC)

MULTISECTION DIGITAL AXLE COUNTER ( MSDAC)

WHY MSDAC ?

Can monitor virtually unlimited length of track sections

No insulated joints
No ballast problems
No need of special type of sleepers
Safe and reliable train detection on rusted/sanded track
No restrictions on earthing/bonding of rails for traction current return
Simplification of track works,
Reduced Life Cycle Cost through less maintenance requirements

CONSTRUCTIONAL FEATURES:
The axle counter system can be divided into - Software & Hardware parts.
SOFTWARE:
Considerable importance is attached to the ACE software, both from the point of view of reliability and of safety. The
programs have been written in the high-level programming language C, which was chosen due to the high degree
of availability of both tools and of standard well proven software. Using the following criteria, stringent requirements
have been set on the software concept.
HARDWARE :
The Hardware can further be divided into:

Indoor Equipment ,
Transmission Path
Outdoor Equipments.

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1. OUTDOOR EQUIPMENT
Trackside equipment

The Detection Point Zp30H consisting of the Electronic Junction Box EAK30H and the rail contact Sk30H resp.
Sk30.
The main features of the detection point Zp30H are:
Double rail contact which can be adjusted to fit commonly used rail
Detects all commonly used wheels of main lines
Extremely high counting reliability
Immunity to AC and DC traction current and harmonic interference
Immunity to magnetic and eddy current vehicle track brakes
Fault tolerant data transmission to the evaluator (ACE)
Straight-forward installation procedure

profiles

Vehicles whose wheels do not meet the specification can cause axle counter faults or may not be recorded or
detected. The operator must take measures (e.g. blocking the track) to ensure that vehicles with unspecified wheel
types and vehicles that reach the section without crossing over a section detection point do not cause any hazards.
The operator must prepare specific operational rules to cover this issue.

Electronic junction box

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The electronic junction box contains the electronic to drive and supervise the rail contact, to detect the wheels and
count the passing axles, to run self tests and to transmit telegrams containing count and supervision information to
the ACE. The counting, supervision and telegram generation functions are performed by two independent
Microcontrollers supervised by the vital module in the ACE. Power is conveyed from the interlocking room to the
trackside equipment on the same two wires used for data transmission to the ACE. Alternatively local power may be
used. The Detection Point operates over a wide range of DC input voltage to allow for the voltage drop over long
cables.
The Zp30H is supplied with a Uninterruptible power supply with a nominal voltage of normally 60V to 120 V DC .This
supply voltage must be indirect-connected to the battery voltage by a DC/DC converter. If a trackside 24 V battery
is available, the Zp30H can be equipped for this as an option.

2.Transmission path
The system has been designed to use standard communication cable - twisted pair or star quad for the
communication link between the trackside equipment and the ACE. The security of data transmission is guaranteed
by the special security code in the telegram. The protocol used is equally suitable for transmission over multiplexed
digital transmission systems.
The

data transmission to the ACE uses the physical and the communication layers
of ISDN.
Serial (Ethernet) connection to N-ACE:
Serial interface which can be used from the ACEs to exchange Detection Point information to build a
common section with Detection Points of both ACEs. This function is suitable for long sections like block sections
typically to handle the long distances and to save the copper wires between the neighboring stations. Due to the
enlarged reaction times for the train detection this function is not recommended for short sections.

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3.Indoor equipment
Axle Counter Evaluator ACE
The basic indoor equipment consists of the ACE comprising:
Vital computer module
Power supply Module
Serial I/O Module
Parallel I/O Module
The ACEs are designed for installation in both open racks and enclosed cabinets.

Vital computer module

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The computer module is designed as a vital and redundant 2 out of 3 computer system. As an option, a lower cost 2
out of 2 computer version is available without redundancy for reliability but with the same safety standard. Vital
processing by means of software comparison is achieved by exchanging messages between the computer
channels. After exchanging messages the computers perform a voting procedure to determine if all the computer
channels are in agreement. If not, a safety reaction is executed. This mechanism also serves to synchronise the
computers. In order to reduce failure disclosure times, RAM, ROM and CPU tests are run in background mode and
the results compared as above. In the case of the 2 out of 3 version, loss of one of the computer channels due to a
fault means that the module continues working as a 2 out of 2 module maintaining the full functionality and allowing
a repair to be planned as a routine measure.

Power Supply Module

Each CPU channel has its own DC/DC converter which feeds the electronics with 5V and 12V.

Serial I/O Module

Data from the trackside equipment is received via serial I/O modules. These are preprocessor boards which convert
the serial data from the detection points to the I/O busses of the vital module. The industrial standard CAN bus is
used to interface the preprocessors to the vital module. Each detection point preprocessor is assigned to one
(Redundant ACE) or two detection points (Non redundant ACE). It occupies one I/O-slot in the ACE. To use a
Detection Point in more than one ACE it is possible to daisy chain the telegrams of a Detection Point to an
additional ACE. Loss of a detection point due to a fault will result in the disturbance being restricted to those
sections associated with that specific detection point.

Parallel I/O Module

The track occupancy information is output from the vital module via parallel I/O preprocessor modules via the same
CAN bus as used for the serial I/O. The serial and parallel I/O modules are electrically compatible and inserted in
the required combination in the I/O slots provided in the evaluator subracks. The parallel I/O module occupies one
I/O-slot per section.

Configuration of ACE
Configuration of the ACE is divided into hardware configuration and data preparation. The main features of the cost
effective, user-friendly possibilities for hardware configuration are described in the following chapters. Nonredundant ACE. To customise the hardware to the respective application case, ACEs may consist of one to three
subracks.

Basic equipment

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Principle of operation
The rail contact consists of two physically offset coil sets, Sk1 and Sk2, on the same rail. On the outside of the rail
are the two Tx coils generating an electromagnetic field with two slightly different frequencies of approx. 30 kHz
around the rail. On the inside of the rail are two Rx coils. These supply two time-offset induced voltages with which
the presence and direction of passing wheels is determined in the electronic unit. For reliability reasons, there are
no other electronic components other than coils in the heads. Both voltage and phase in the receiver coil are
evaluated to ensure extremely high wheel detection reliability. The frequencies used, the shape and material of the
receiver housing and the corresponding coil arrangement of the heads are chosen to ensure that interference from
the harmonics of traction current and track brakes will not disturb the wheel detection process. Further protection
against severe electromagnetic interference such as catenary shorts and the magnetic fields of track brakes is
provided through a variety of measures such as phase sensitive rectification, frequency shift keying and the use
of non-ferrite coils in the heads.

Safety principles
The System is compliant with EN 50129 having the highest safety integrity level 4 (SIL 4).
Hazard rate 2oo2: 8,977e-11
Safety is ensured by:
Independent computer channels
Clearly structured software
On-line hardware self-tests
Defined reactions to process errors
Vital monitoring of trackside equipment
Vital monitoring of data communication
Defined fault detection and disclosure times
Use of interface protocols with code protection,

multiple transmission, and

many other checks
Clearly defined verification and validation procedures, according to the EN
50129 and EN 50128 standards.

Reference Count Direction (RCD):

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The reference count direction (RCD) must be defined for the track layout independent of the direction of travel. The
use of RCD ensures that the correct order of counting into and out of a section is maintained throughout a series of
detection points. Without the RCD the system cannot be correctly configured.
According to figure above, axles are counted in the section when a train passes Rail Contact1 in the direction of the
arrow or a train passes Rail Contact2 in the opposite direction of the arrow. Axles are counted out of the section
when a train passes Rail Contact1 in the opposite direction of the arrow or a train passes Rail Contact2 in the
direction of the arrow.

Basic counting logic

The ACE evaluates the differences of the count values from the detection points of a section.

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The detection points count the number and direction of axles passing the rail contacts and transmit this data to the
ACE. With this information, the logic of the ACE defines the section to be clear or occupied. In case of a failure
of the equipment, the section will be treated as failed. This information can be provided to the interlocking logic
and MMI, e.g. via a connection to the interlocking module. A standardised axle counter reference direction (see
Figure above), is defined to give a fixed correlation of the direction of travel and the count direction for all detection
points of the line independent of the track. Axles are counted into the section 1, when:
section when a train passes Zp1 in the direction of the arrow or
a train passes Zp2 in the opposite direction to the arrow Axles are
a train passes Zp1 in the opposite direction of the arrow or
a train passes Zp2 in the direction to the arrow

counted out of the section when:

Track configurations
A detection point is positioned at each end of a track section. At each boundary between track sections a detection
point utilised by both sections is needed. The track section arrangements can be complex. The following are
examples of possible configurations of track sections:
Simple section (without crossings or points)
Terminus track
Points
complex point arrangements
crossings
string of sections
string of points, a crossing and block lines

Reset procedure
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The reset is required to clear an axle counter section during commissioning or when it has a malfunction, i.e. when
there is no train in the section but the axle counter indicates occupied for safety reasons as the result of a
malfunction. The reset is carried out manually. Resetting axle counter sections is a safety relevant operational
procedure which must be clearly defined in rules for the operator and maintainer.

Diagnostic Features
A diagnostic interface on each central computer is used to scan the diagnostic data stored on the central computer
by means of a standard PC with a special software. The information extracted from the CPUs is evaluated and
displayed in a readable form and is used for fault finding both with regard to the ACE and the trackside equipment.
A second means of diagnostics is the use of LEDs which indicate the correct operation of significant functions both
in the ACE and in the trackside equipment.

Reliability
Hardware reliability is ensured by:
Use of commercial industrial standard microprocessors
Factory burn-in of the complete equipment
Quality management conforming to the requirements of ISO 9001
Fault tolerant data transmission from the detection points to the ACE considerably reduces the possibility of axle
counter disturbances due to electromagnetic interference on the cabling (e. g. lightning or catenary short). The use
of cage clamp terminals improves the reliability of connections in comparison to screw terminals. The trackside and
the indoor equipment are maintenance-free. An annual inspection of the equipment is sufficient to ensure reliable
and safe performance. The reliability of counting is extremely high.A reliability figure of 0.05 disturbances per
section per year is achievable in practice.

Values for an ACE with parallel interface:

MTBFf = 7.2 years (Functional failure of one section)
MTBFS = 12.5 years (System failure)
Values for an ACE with serial interface to SSI:
MTBFf = 1.3 years (Functional failure without consequence for a section owing to
the redundancy)
MTBFS = 466.0 years (System failure)

Repair time
Repair times are kept short by
The small number of boards used in the vital computer module
The modular system concept
The detailed PC supported diagnostics of internal ACE faults, communication deterioration and faults in the
trackside equipment.

Technical data
System
Highest safety integrity level (SIL 4) compliant with EN 50129.
The product Az LM is designed for a life time of 20 years.
Maximum train speed: 380 km/h
Optional : 440 km/h

Axle Counter Evaluator (ACE)

The following ACE configurations are available:

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Non-redundant (2 out of 2) or redundant (2 out of 3) vital computer Interfaces to 1 to 32 detection points

Supervision of 1 to 32 track sections
Serial interface to neighbour ACE for transmitting data of detection points
Serial interface to solid state interlocking module with compatible interface to the ACE
Parallel relay/optocoopler interface to other interlocking or block equipment

The following power supply options are available (UPS or battery):

60 V +20 % 10 %
48 V +20 % 10 %
24 V +20 % 10 %
Nominal supply voltage:
60V to 120 VDC central supply
24V DC local supply
Power consumption Detection Point
9 W (Standard transmitter power)
11,5 W (High transmitter power)
Environmental Conditions
Operating temperature of the ACE: 25 C to +55 C,
Humidity: 95% relative humidity

INSTALLATION PROCEDURES:
1. Track-Side Electronic Unit
Detection Point

The detection point is designed for use on a large variety of rail profiles, such as:
UIC54, UIC54E, UIC 60, S41, S49, S54, S64, R50, R65, 90R , SBB 1, B, C, T, 50T,
63T, 50 kg, 60 kg.

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It is suitable for all commonly used steel wheels with the following dimensions:
Measurement circle diameter of wheels >= 330 mm
Width of tyre/wheel rim 130 to 150 mm
Height of wheel flange 26 to 38 mm
Width of wheel flange 20 to 33 mm

Rail contact:

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Approximation formula a = (0.409 * h)

It is important to note that, this formula is only a general one for an intial guideline. Experience from a pilot
installation is more indicative for actual height. Same applies for old rails or rail with other profile.

Connections
To obtain the correct direction of counting, an axle counter reference direction has been defined. This would
normally be the direction of increasing mileage. The rail contact that is first crossed by an axle in the axle counter
reference direction is defined as rail contact 1 (Rx1/Tx1) and the other rail contact as rail contact 2 (Rx2/Tx2).

The screen of the rail contact cables is connected to the earthing bar:
Remove the cable insulation for a length of approximately 45mm.
Fasten the screen to the earthing bar by means of a cable tie and connect the screen to the earthing bar using the
clip supplied.
The pairs of wire have to be twisted properly as shown in Figure

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Earthing of the Equipment

The EAK has to be connected to the earth return rail with a copper cable of minimum 25mm 2 or an iron cable of
minimum 50 Sq. mm. If an earth return rail is not available, the housing has to be earthed to a suitable low
inductance (approximately L<40H) and low resistance (approximately R<4 ) earth. The earthing rules of the
railway must be adhered to.

Terminations
All service wires of EAK (viz. Power, Communication, are recommended to be properly terminate preferably with
cage-clamp type of terminals of proper matching of cable cross sections.

Communication Link
For communication with the axle counter central evaluator, a physical communication link must be needed.The
system uses two wire ANSI T1.601communication protocol with ISDN modulation. The maximumtransmission
distance is 13KM with a good quality communication cable having maximum resistance of56ohm/KM and
capacitance of 45nF/KM. Though the transmission level of the system is 0dBm, yet a maximum attenuation in the
communication link is 24dB.For better reliability the correct pair of star quad cable should be used with proper
terminations.

Axle Counter Central Evaluator (ACE)

Axle Counter Central Evaluator is the decision making unit for multi section digital axle counter. It has the following
sub components.
CPU Card acts as the brain of AzLM. Two CPU Cards are required for 2oo2 system. These CPU Cards have
diagnostic interfaces and an alphanumeric display. For a specific application, the CPU Cards used must be loaded
with the site specific software. Diagnostic interfaces are available on CPU Card to connect it to a PC and check the
system status, health messages etc. with the help of a diagnostic software.
Power Supply Card has DC-DC converters. It works on 24VDC and generates 5VDC and 12VDC required for the
electronic circuitry. Two Power Supply Cards are required for 2oo2 system.

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Serial Card receives information from detection points through ISDN communication link and provides this
information to CPU Cards. One Serial Card can monitor maximum two detection points.
Parallel Card is responsible for providing section information. This card takes instruction from CPU Cards and
gives section clear/occupied output through potential free contact of relays in it. The reset of a section is
commanded through the Parallel Card. A Parallel Card has two non-vital outputs which are also configurable
through site specific software for getting different signals, for example, indication of acceptance of reset by the
system or a technical defect in a section etc. All the cards are housed in a SUBRACK. The nomenclature indicates
the number of Power Supply and CPU Cards and the number of I/O slots present in the subrack. Different possible
configurations are:
ACE-2-10 is a 2oo2 system with 10 I/O slots.
ACE-2-26 is a 2oo2 system with 26 I/O slots.
ACE-2-42 is a 2oo2 system with 42 I/O slots.
Connection of PDCU
PDCU is the interface between outdoor equipment (Detection Point) and indoor equipment (ACE). It has a
superimposing circuit for using same conductor for power and data. One PDCU is used for one detection point only.
There is a 315mA fuse inside the PDCU. The power to the EAK goes through this fuse and if it is blown then there
will be no power at detection point and a red LED within the PDCU will glow.

Power Supply Card

There are three LEDs on power Supply Card.

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Serial Card
The I/O Interface consists of two independent ISDN transmission paths. e.g. in a 2oo2 CPU system they
are used for two detection points.

CPU Card

Ethernet
Reset
LED 1-4
Alphanumeric
Display
Serial Interface

Parallel Card

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Arrangement of Serial and Parallel Cards in ACE

Connection Diagram of EAK, PDCU, Serial Card and Parallel Card in a 2 DP Single
Section Configuration

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Part 2
Microlok II
(Ansaldo / US&S)

Electronic Interlocking -- Microlok II (US&S)

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SYSTEM OVERVIEW
The Microlok II system operation is controlled by proprietary executive software running on the system hardware.
The user application logic is written in a proprietary Microlok II programming language and is compiled by a
proprietary compiler into a set of data tables which are interpreted by the executive software during run-time. The
high-level block diagram of the Microlok II system is shown below. The system uses diversity and self-checking
concepts in which critical operations are performed in diverse ways, using diverse software operations and critical
system hardware is tested with self-checking operations. Permissive outputs are allowed only if the results of
diverse logic operations correspond and the self-checks reveal no failures. It uses a combination of vital and nonvital hardware, and an executive software performing critical operations on the site-specific application logic tables
using dual-path processing and double storage techniques along with continuous monitoring of the hardware
through the use of extensive built-in diagnostics. Any failure in any critical portion of the equipment will result in the
controlled system returning to a safe state.

SYSTEM DESCRIPTION
The Microlok II interlocking system is a multi-purpose monitoring and control system, which performs the following:

Drive Signal, Point, Crank Handle, LC Gate and Siding control relays
Monitoring of Point position, track circuits occupancy and other field inputs
Vital CPU for overall system monitoring, control, diagnostics and data recording
Executive and application logic for vital interlocking functions
Executive and application logic for non-vital control Panel & Operator VDU functions
Serial I/O channels for communicating with MLK II to MLK II, MLK II to CAB/ Other Non-Vital application,
Maintenance and Diagnostic function

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MICROLOK II HARDWARE
The Microlok II system consists of modular card file-mounted equipment and external peripheral devices that are
used to interface the card file circuitry to the field gears and other associated control systems. The following
sections provide an overview of the hardware.

ENVIRONMENTAL

The Microlok II product will operate in a standard railway environment

The system operates in ambient temperature ranges of 40 to +70 degrees centigrade. This refers to the
temperature outside the card file but inside the relevant building enclosure
The system operates from 0 to 95% non-condensing humidity
The system meets the required EMI specification
The system meets the required vibration specification

PHYSICAL

The card file is 16.75 wide and it can be mounted in a standard 19 rack
Boards in the card file include a faceplate where status information will be displayed. A blank panel will be
available to cover empty slots
The system will accept power from an external battery in the range of 9.8VDC to 16.2VDC for an internal
conversion to the required voltages
The internal power converter will have a start-up voltage requirement of 11.5V DC to inhibit start-up when
the battery voltage is low
Nominal 24V input/output boards will have an input/output supply in the range of 19.6V DC to 32.4V DC

CARDFILE
The Microlok II card file is a G64/96 bus based card file that holds the CPU, Power Supply & Variety of I/O boards.
The card file will be a user configurable. The Microlok II card file is designed to house standard 6UX220 Euro card
plug-in printed circuit boards. The card file will have twenty slots.
Slots No. 1 to 15 & 20 are used to accommodate Non-Vital or Vital I/O boards.
Slot No. 16 & 17 are reserved for Power Supply board.
Slot No. 18 & 19 are reserved for CPU board.

CPU BOARD
The CPU board is controlled by a Motorola 68332 microprocessor, which operates at a speed of 21 MHz, and
includes 2K bytes of internal fast termination RAM. Most internal operations are 32 bits wide, while all outside bus
cycles are 16 or 8 bits wide. The executive and application software is stored in four flash EPROMs that provide up
to 8MB of memory. Flash EPROMs permit direct handling of the executive and application software using a PC
connected to the CPU board front panel serial port connector. Jumpers are provided on the board to enable or
disable the flash EPROMs for programming and to select the required programming voltage. The CPU board
contains the central controlling logic and diagnostic monitoring for the Microlok II system, and provides five serial
data ports. The CPU connector housing has an internal EEPROM that is used to store site-specific configuration
data. Even if the CPU board is replaced, the configuration data remains intact within the CPU connectors
EEPROM.
Ports 1 and 2 support an RS-485 hardware interface
Port 3 supports an RS-423 & RS 232 interface
Port 4 & 5 supports an RS-232 interface
It provides five serial ports, those are used to communicate with other MLK II and PC.
Four serial ports are terminated on the 48-pin connector.
Fifth serial port is extended on the front face panel of the CPU board.
A 250Hz. signal is generated from the CPU board if all diagnostic checks are passed and this signal is
externally connected to Power supply board to generate a Conditional Power Supply (CPS) to drive VCOR
relay.

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EEPROM is installed behind 48-pin connector in each CPU board

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CPU Function

Monitoring external inputs from vital input boards and non-vital input boards
Processing vital external inputs and executing logic defined in the application software
Driving vital output boards as required by the application program
Monitoring and controlling serial communication ports (links to other controllers)
Testing individual vital input and output channels for faults (in parallel with control of these channels) and
responding to detected faults
Monitoring system internal operation for faults and responding to detected faults
Controlling power to vital outputs through the card file power supply and an external VCOR (fail-safe
function)
Recording system faults and routine events in user-accessible memory
Responding to CPU board front panel switch inputs and operating the associated displays
Interacting with a laptop PC during system diagnostic operations, application logic programming, and
executive software upgrading
Four serial ports are terminated on the 48-pin connector.
Fifth serial port is extended on the front face panel of the CPU board.
A 250Hz. signal is generated from the CPU board if all diagnostic checks are passed and this signal is
externally connected to Power supply board to generate a Conditional Power Supply (CPS) to drive VCOR
relay.
EEPROM is installed behind 48-pin connector in each CPU board.

POWER SUPPLY BOARD

The power supply board is basically a DC-DC converter, which converts a 12V DC card file supply into three
different voltages +5V, +12V and 12V. It also has a conditional power supply circuitry driven by a 250Hz. Signal
generated from CPU board. The conditional power supply drives VCOR relay.
The Power supply board will have double width housed in the card file and it operates in the range of 9.5V to 16.5V
DC producing 5V at 3amps and +12V at 1amp that are needed for the operation of the card file circuitry. The power
supply will have a startup voltage requirement of 11.5V DC. This prevents the unit from attempting a recovery
when battery voltage is low. The power supply board performs the following functions:
Converts the external supply voltage (9.8V to 16.2V DC) to regulated +12V and +5 for outputs to the
system card file internal circuits
Supplies energy to the VCOR relay coil under the control of the CPU board The power supply board serves
a vital role in the fail-safe design of the Microlok II system. The regulated +12V and +5V power is
distributed to all system card file boards through the card file back plane bus.
It occupies slot 16-17 in the card file.
It provides regulated +12V, -12V and +5V power, which are distributed to all system card file boards
through the card file back plane bus. 12V supply from IPS/Battery chargers is wired to Power supply board
through connector.

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Non-Vital I /O Board
The Non-Vital I/O board is designed to receive non-vital inputs (controls) and generate non-vital outputs
(indications). The version of the NV.IN32.OUT32 board connects each of its 32 inputs and outputs to a 96-pin
connector mounted on the rear of the board. The board employs polyswitches to protect the output circuitry. A
polyswitch functions like an auto circuit breaker.When the over current trip point (about 0.75 amp) is exceeded, the
device switches to high impedance. The polyswitch returns to low impedance when the overload or short circuit
condition is removed. Inputs on the boards are activated from a positive voltage relative to battery ground over a
range of 6 to 30V DC. The non-vital I/O boards use latch ICs to buffer inputs and field effect transistors to drive
outputs.

The minimum ON threshold for a Non-Vital Input will be 4.5V DC for nominal 24V DC systems.
The maximum OFF threshold for a Non-Vital Input will be 2V DC for nominal 24V DC systems.
External wiring is achieved using 96-pin connector and one-in-two-out terminals.
A +ve panel input is read into non-vital I/O board.
A ve output is delivered out of non-vital I/O board.
N24 for input/output reference is separately wired to 96-pin connector.

Vital Output Board

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Outputs are controlled by high side software-controlled switches. Loads should Be connected from outputs to
battery negative. The high side switch is used to connect battery (+) to the output. Each output is protected with a
polyswitch, which acts like an auto circuit breaker. When the over current trip point is reached (approximately
0.75A), the polyswitch switches to a high impedance state. The switch resets to its low impedance state when the
additional load or short is removed. A short to battery (-) will trip the polyswitch and cause the VCOR relay to drop,
but will not cause any damage. A short to battery (+) will not cause any damage, but since this condition is
equivalent to a false output, the Microlok II CPU will cause the VCOR relay to drop.
Each Vital Output PCB is having 16 outputs.
Each output is assigned to the final relay which is driving the outdoor signalling gears such as HR, DR in
case of signal & WNR, WRR in case of points.
Since the output boards are driving outdoor gears, they are continuously monitored by the CPU and any
abnormal voltage present in the output will lead to system reset / shutdown to ensure safety.
External wiring is achieved using 48-pin connector & diode terminals.
16/0.2 mm wires are used for wiring between output boards (+ve end) and diode terminals.
All ve ends are looped using comb link.
Twisted pair wires are used for wiring between diode terminals and relay coils.
Tranzorb is provided across all relay coils that are driven by Microlok II to nullify the back emf generated by
relay coils.
Loads should be connected between Microlok II outputs and battery negative.
Each output card should have VCOR controlled B24 and N24 connections to switch the controlled outputs.

Vital Outputs
The Vital Outputs are designed primarily to interface with vital relays. In typical railway and transit applications,
most Vital relays are specified to use nominal 24V DC supply voltage.
The minimum voltage for a Vital Output in the ON state will be 95% of I/O supply battery for 24V DC
outputs.
The maximum voltage for a Vital Output in the OFF state will be such that a Vital relay will not remain
picked at the current produced. This voltage is 1.5V DC for a 24V DC output.
The output will be capable of driving a minimum output load of 100 mA f or the 24V DC outputs.

Vital Input Board

There are no power connections required through the upper connector. When wiring a vital input PCB to a relay
contact circuit contained in the same house of the Microlok II card file, the signal battery may be used as the energy
source to activate the inputs. Terminals designated (-) may be connected to battery N24 and B24 switched over
relay contacts. When wiring a vital input PCB to a relay contact circuit outside the Microlok II house, use the
isolated source that is part of the power supply. This is consistent with the practice of confining signal battery to the
case in which the Microlok II unit is housed.

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Vital input boards enable the Microlok II system to monitor the field gear status like signal aspect, point detection,
track status, LX status, CH status etc. The IN.16 (N17061002) input board connects each of its 16 isolated inputs to
a 48-pin connector mounted on the top rear of the card file slot.

External wiring is achieved using 48-pin connector and one-in-two-out terminals.

All inputs require a double cut wiring using twisted pair cables.
Each Vital Input PCB is having 16 Inputs.
Each input is assigned to the detection of outdoor gear status such as ECRs in case of
signal, WKR incase of points & TPR in case of Track.
Since the vital inputs are dealing with the detection of outdoor gears they normally configured
with double cutting arrangement.

Vital Inputs
Vital inputs, which are in most cases, derived from the battery supply must have the same range of inputs as the
supply battery. To ensure reliable operation, the Minimum ON thresholds (the levels above which an input must
read ON) were chosen to match the low ends of the battery ranges. The only criteria for selecting the Maximum
OFF thresholds (the levels below which an input must read OFF) are that they must be below the Minimum ON
threshold, yet high enough above 0V to reject induced noise. The system will have the ability to access Vital Inputs
even when the system is running with the Vital Outputs in an un-powered state. Since the most restrictive state for
the inputs has already been defined as the de-energized state, failed inputs can safely be set to this state. This
allows the system to react to the failed input without causing a Critical Error. This may cause the system to run in a
downgraded state due to the OFF input state, but will cause no safety-related failures. The failed input status is
available to the Application Logic such that the Application Developer may take other action as required by a
particular system in the case of a failed input.

The minimum ON threshold for inputs will be 19.6V DC for 24V DC inputs.
The maximum OFF threshold for inputs will be 9.0V DC for 24V DC inputs.

Control of inputs
A principle similar to that used for the output circuitry is employed in the input interface circuitry. De-energizing of
any input results in a more restrictive condition. All individual input interface circuits on a given board are forced to
the more restrictive state through the closed loop vital input monitors. The inputs are then read and verified that
they can, in fact, be forced to the more restrictive state. This is ensure that no interface circuit malfunction have
occurred that could place an input in a less restrictive state. See the Block diagram.

VITAL CUT-OFF RELAY

The vital cut-off relay (VCOR) contacts are used to control the power to all card file vital outputs. The VCOR is
controlled by the CPU board. The CPU board performs continuous diagnostics, to include monitoring of all vital
output and input channels at the point of interface with external circuits. This CPU responds to failure of a safety-

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critical diagnostic by commanding the CPS on the power supply board to remove the DC supply to the VCOR coil,
thereby opening the contacts that provide battery power to the vital output boards. This fail-safe function defaults
the interlocking equipment associated with the Microlok II system to the most restrictive state. PN-150B vital biased
relay is used for the VCOR. This relay consisting of low voltage silver-to-silver fronts and silver-to-silver backs
contacts. The vital cut-off relay (VCOR) is used by the Microlok II system to control the power of all vital outputs.
This relay is energized by the conditional output from the power supply board in the system card file. This relay
consists of silver-to-silver impregnated graphite front and silver-to-silver back contacts. It is mounted above the card
file in the Microlok II rack.
If the CPU board detects an error, it stops the 250Hz. signal, which removes the conditional power supply to the
VCOR relay and thereby VCOR drops. Thus the power to all vital output boards is removed, when there is an error
in the system and safety is ensured.

MICROLOK II SOFTWARE
The primary Microlok II software components are the executive software, which is actually the Microlok II operating
system software, as well as the application specific user-written software. Also included in the Microlok II software
architecture is self-checking diagnostics designed to support failsafe operational requirements. The following briefly
describes the major components of Microlok II software.

EXECUTIVE SOFTWARE
The US&S developed Executive software (Operating system) is standard for all Microlok II systems, and is
responsible for the overall vital monitoring and control of the system. Executive software functionality includes vital
input monitoring, decision making, and commands related to interlocking functions, monitoring vital input and output
channels for intended on/off states, processing user inputs received from laptop PC or the CPU board front panel,
continuous internal and external diagnostics, recording and playback of routine event and error codes,
management of serial data ports, and execution of the user developed application program software.

APPLICATION SOFTWARE
The Vital application program software contains the user-developed, application-specific logic for the particular
Microlok II system configuration. The user develops the unique application program using software using the same
US&S developed maintenance tools program used to input Executive software version upgrades. Additionally, sitespecific configuration data is stored in the Card file-mounted EEPROM, and can be loaded using the CPU board
front panel toggle switches and LED Displays. This data can be also loaded using the Maintenance tools program
on a laptop PC via connection to the CPU board front panel serial port, the PC based method allows a grater range
of configuration options.

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SYSTEM OPERATING MODES

The Microlok II controller is a complex combination of hardware and software. when the system can not function in
the Normal Operating Mode.Other system modes must be supported to allow access to those system functions that
are still operational even though the entire system is not functional at that time.Critical Errors in the Microlok II
system may be caused by persistent or transient faults. After a Critical Error has occurred, the Microlok II will be
reset and will perform complete system diagnostics.The most common persistent Critical Errors are related to vital
physical output processing. In order to attempt to provide some system functions in the presence of persistent
Critical Errors, the unit will discontinue the vital physical output functions and, if there are no other Critical Errors
encountered, continue to run in a downgraded mode. If Critical Errors continue to occur, all system application
processing will be discontinued.
The Microlok II system will be capable of operating in seven different modes.

NORMAL MODE
In this mode, all outputs and application processing are active. All other system functions are available at user
request. This will be the default mode for systems operations in the absence persistent of Critical Errors.

SELECTIVE SHUTDOWN MODE

This mode will be entered when persistent Critical Errors prohibit complete system operations. In this error mode,
all of the Vital Physical Outputs will be disabled. In this mode, other application processing, such as logic
processing, Serial Links, Vital Physical Inputs and Non-Vital I/O continues.

USER SELECTIVE SHUTDOWN MODE

In this mode all Vital Physical Outputs are disabled. This mode will be entered when identified as the operational
mode by the Application Logic and the unit would otherwise operate in the Normal Mode as identified above. In this
mode, other application processing, such as logic processing, Serial Links, Vital Physical Inputs and Non-Vital I/O
continues.

COMPLETE SHUTDOWN MODE

In this mode, no system I/O or logic processing will be performed and all vital outputs will be in the most restrictive
state. This mode will be entered when persistent Critical Errors prohibit system operations. When possible,
Diagnostic Interfaces will function.

RESET MENU MODE

In this mode, the unit remains in the initialisation routines. No system I/O or logic processing will be performed and
all vital outputs will be in the most restrictive state. This mode will be entered by a request from the System
Maintainer through the Integral User Interface.

CONFIGURATION MODE
This mode places the unit in a special non-operational mode where the unit remains in the initialisation routines to
allow for Application Configuration. No system I/O or logic processing will be performed and all vital outputs will be
in the most restrictive state in this mode. This mode will be entered by request from the Application Developer.

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BOOT MODE
This mode to allow the Generic System Software and/or the Application Image to be loaded into the system. No
other system activities will take place while in this mode. This mode will be entered by request from the Application
Developer.

SYSTEM SPECIFICATION

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SYSTEM OPERATING POWER

Power Characteristics

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Card File in MICROLOK II Rack

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Typical System Configuration

Diagram

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WIRING PRACTICES
RACKS

Dust proof metallic racks with protective arrangements are provided forcard file.
All the racks used are insulated from the ground by means of PVC bushes for suitable mounting bases.
Adequate moving space is to be maintained around all the racks in line with Railway Standards.

LADDERS

Cable ladders installed horizontally shall have sufficient space to facilitate cable pulling and
cleating/stapping.
It is isolated from racks and wall via rubber bush & hylum sheet.
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.
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.
Maximum distance between the supports is provided every 3 meters.
All surfaces are cleaned prior to bolting together.

CABLE RUNS

All the cable /wire run will have smooth surface.

Sharp bending will be avoided when coming to racks.
Cable entry holes in the Racks will have correct size rubber beedings.
Ladders will be used for Interconnection of cable runs.
PVC Troughs with cover will be used for Intra-connections.

CABLE SYSTEMS

Cable shall be separated into Power cable, Serial Communication cable, I/O cable and Panel cable.
Sufficient cable spare length shall be provided for equipment, which needs future adjustment.
Cable splicing will be avoided.
Cable insulation resistance must be 20 mega ohms.
Cable should be arranged properly for maintenance.

CLEAN WIRING
Wires carrying extremely small currents that are prone to EMI and other disturbance coupling caused by transient
conditions in adjacent wiring.

DIRTY WIRING
Wires regularly carrying large varying currents or currents that are subject to EMI or other disturbance caused
transient conditions which can couple with adjacent wiring. Dirty wiring will be separated as much as possible from
clean wiring.

INPUT & OUTPUT WIRING

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.
All output wiring from signalling power supply units to the Microlok II 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.

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POWER WIRING

The power supply wiring and equipment should be located close to the Microlok II and other electronic
equipment to minimize the length of low voltage power leads.
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.
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.
It will be of reasonable cross-sectional area to minimize noise coupling and avoid the power sag.
Cables & wires will be kept as short as possible from power supply to minimize induced noise.
Case/house wiring will also be arranged to minimize noise.
To avoid transient voltage, surge suppression device must be installed for Microlok II card file.

SERIAL LINK WIRING

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.
The cable shields must be earthed at one end only.
All cable shields located within the CPU board 48-Pin connector must be bonded together and attached to
the Microlok II chassis using a low impedance copper braid.

COLOUR CODING OF WIRES/CABLES

Blue/Grey sleeved shielded serial communication cable is used for serial communication wiring.
4/5 twisted pairs blue sleeved shielded serial communication cable is used for RS485 standard serial ports.
8 core grey sleeved shielded serial communication cable is used for RS232/423 standard serial ports.
Red/Black and Blue/Yellow colour wire is provided for power supply wiring.
(16/0.2) Blue/Black colour twisted pair wire is provided for Vital input circuits.
(16/0.16) Grey/Blue/Red colour wire is provided for Non-vital I/O circuits.
(16/0.2) Grey/Red/Black colour wire is provided for vital output circuits.

LABELLING
All cable ends are provided with proper identification Tags made of non deterioratingmaterial.

All the Terminals will have identification markers.

All the wires connected to the terminals will have proper PVC ferrules.
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.

TERMINATION

A perfect termination is gastight, therefore corrosion free and amounts to a cold weld of the parts being
connected.
Wires are to be terminated shall match with the correct size of the crimp contacts.
If these basic requirements are met, highly reliable connections with low contact resistance and high
resistance to corrosive attack are assured.
Conductors of cables are to be correctly identified and are to be connected to the correct terminals.
Conductors are to be securely held in terminals of fittings and are not subject to tension at the terminations.

SPARE CORE TERMINATION

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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.

SURGE PROTECTION PRACTICES

POWER PROTECTION
Power protection is much important in a signalling 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. Such levels must be handled properly
by staged protection. The staged protection refers to primary, secondary & tertiary levels and DC & Data line
equipment.

AC POWER PROTECTION
Primary AC line protection
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. Generally the IPS is connected to the AC service
entrance and provided OBO make surge arrestor as primary AC line protection device.

Secondary / Tertiary AC line protection

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. Tertiary protection is generally found within the equipment itself. OBOVF surge suppressor is provided for 230V AC circuit (Operator and Maintenance PC).

GROUNDING PROCEDURE
The first step in providing effective personnel and equipment protection is preparing a low impedance grounding
electrode or grounding electrode system at each equipment housing room. Once the low impedance earth ground
is established for a signal housing, the apparatus in the house should be connected to the earth ground as
described in the following sections.

EARTH PIPE
The Copper Clad earth electrode has been in use for grounding purpose. The details of Copper Clad earth
electrode is given below.

COPPER CLAD EARTH ELECTRODE

Modern maintenance free and durable earthings employ steel conductors which are copper clad pipe (Maintenance
Free Earthing) and utilize graphitic compounds and non corrosive salts as ground enhancing material (GEM)
which doe not lead to corrosion. Such earth pits would also not require the usual watering schedules to maintain the
earth resistance within limits. For installations where earths are not freely accessible for maintenance and
measurements. Where clusters of earth pits are required to keep the earth resistance as low as less than 1 ohm,
provision of maintenance free earth pits may be made during initial installations and whenever replacements takes
place Type, size and specification of earth electrode
Shall have 3000mm (10feet) , 17mm (3/4) copper bonded / copper clad stainless steel
Shall be corrosive resistant
Shall be molecularly bonded with copper to high strength steel cores

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Shall withstand minimum 20 KA discharge current for one year

Shall have a minimum life of 20 years
To achieve earth resistance 1 ohm, depending on the soil condition, two or more earth rods may be used in
the form of mesh.
The distance between tow earth earth pipes is maintained within 20 feet.

Composition of earth enhancement material and its specification

Shall have high conductivity, low water solubility and highly hygroscopic
Shall be non corrosive
Shall have resistivity of less than 4.7 ohm meter
Shall be stable between -60 to =60o C temperature
Shall be suitable for any kind of electrode and grounds (soil) of different sensitivity
Shall procedure compounds with conductive powder and decrease the earth resistance, mainly in those
areas with salts deficiency.
Shall not be explosive when comes in contact with another explosive gas or dust
Shall not releases toxic and irritating gases in any abnormal explosive gas or dust
Shall not cause burns when moist, irritation to eye, skin and mucous membrane
Shall be anti-allergic
Low lying close to the building or location box or equipment room is good for locating earth electrodes. The location
box can be close to any water bodies or water points. Earthing rods should not be fixed on high bank or made
upsoils.

ROOM EARTH BAR (REB)

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.
There shall be one REB for each of the following rooms:
Equipment Room and
Power supply room.
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 lea ds
shall however be bolted to the lugs.All terminations on the REB shall be by bolted lugs with spring washers. The
earth leads shall however be bolted to the lugs.

REB-REB BONDING CONDUCTORS

To minimize the effect of circulating earth loops, noise pick-up and to provide equi-potential 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. The bonding is done by bare stranded copper wire run along the
wall on insulators. If the bonding wire need 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.
Recommended Earth resistance value 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.

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EARTHING ARRANGEMENT

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PERIMETER EARTHING

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Merits of Electronic Interlocking (EI) over Route Relay Interlocking (RRI):

1. System can be tested at factory level using simulation panels.

2. Non- interlocking period is reduced.
3. Modular in design hence easy for maintenance, and requires less staff.
4. Expertise in Hardware & software for maintaining is not much needed at initial stage.
5. Requires less number of relays.
6. Less power supply, Less space as compared to existing EI / RRI.
7. Compatible to Centralized Traffic Control (CTC).
8. Designed according to CENELAC standards, Hence ensures safety.
9. Inbuilt functionality of Datalogger is available.
10. Self diagnostic feature is available, hence Error code / Alarm code messages will be
displayed on display cards.

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