KAVACH rollout and it’s implementation IR

Automatic Train Protection
System
(KAVACH)
HBL(Make)
KAV 15
A.V.GIRI, ITK 1,
KAVACH LAB

Automatic Train Protection System (KAVACH)
• KAVACH is an automated situational awareness system
that
provides Automated Train Protection as well as
Collision
Prevention capabilities for trains.
• Prevents Signal Passing At Danger (SPAD) and
enforces
automated speed restrictions wherever required
• Detects and automatically stops trains in situations of
head-on,
rear-end and side-ways collision
• Provides in-cab display of signaling to the loco pilot, making
train

Automatic Train Protection System(KAVACH)
• Stationary KAVACH is a ground-based
equipment.
• The stationary KAVACH is part of the automatic
train
protection system
• It is responsible for communicating the field status and
also
continuous updating of the end of authority for
safe
movement of KAVACH fitted trains.
• This equipment constitutes more than one
subsystem,
• which are interconnected through the
communication
network.
• The Stationary KAVACH includes the application
data

KAVACH – System Architecture

Automatic Train Protection System
The Train Collision Avoidance system
broadly
comprises of following components:
(i) Trackside equipment including
Stationary
KAVACH Unit
(ii) On-board
equipment.

Trackside Sub-system
The Trackside subsystem shall be composed of
(a). RFID tag
(b). Stationary KAVACH Unit
(c). Tower and Antennae

On-Board Sub-Systems (LKAVACH)
The On-board subsystem shall be composed of
• Loco KAVACH Vital Computer
• RFID reader
• Loco KAVACH Radio Unit
• Driver Machine Interface (DMI)
• Brake Interface Unit (BIU), where required

On-Board Sub-Systems (LKAVACH)

Kavach – Equipment List
Equipment in the Loco Track-side Equipment
RFID Tags
Station Equipment
Station KAVACH
Loco KAVACH
RFID Reader RF Communication tower
GPS antenna
RF & GPS antennae
Driver Machine Interface
(DMI)
Station Master Operation
cum Indication Panel
Brake Interface Unit (BIU) Power supply arrangement
Speedometer Interface,
along with pulse
generators
Relay rack
Remote Interface Unit
(Wherever needed)
Cab Interface Unit

KAVACH – System Components(HBL)
S
T
A
N
T
I
GPS
antenna
W
A
O
Y
- E
S
I
Stationary Vital
Computer
Radio Tower Radios
RFID Tags
D
L
O
C
O
Speedo
meter
Loco Vital
Computer
Driver Machine
Interface
RFID Reader Radios
Brake Interface Unit

Loco KAVACH architecture
KAV 16 A
6/16/2023
V Giri, ITK 1

Loco KAVACH Unit
• Loco KAVACH unit is the heart of the
KAVACH system in the loco.
• It interfaces with
– LP-OCIP (DMI) to facilitate
interaction by the loco pilot
with KAVACH
– Brake Interface Unit (BIU) to stop
the train when needed and

Loco KAVACH Unit (cont.)
– Other equipment like
• Radiomodems for communication
• GPS for time synchronization
• RFID reader for reading RFID tags on the tracks
• Speedometer(Pulse Generator) for sensing train
speed
• Cab selection keys

Loco Kavach Unit HBL
Peripheral Processing Card – 2no’s
Vital Computer card – 3 no’s
Voter Card – 2no’s
Integrated Data Logger (IDL) – 1no’s
GSM card – 1no’s
CAB-Input card – 2no’s
KAV 16 A
6/16/2023
V Giri, ITK 1

Peripheral Processing card (PPC)
• There are two PPC modules with one as hot-standby.
• This module interfaces with the peripherals like
GPS/GNSS, Radios, LC OCIP, ,RFID reader,
Speedometer.
• The 1-sec marker is generated by PPC using
GPS/GNSS.
• PPC handles the RF communication through the
Radio modems and transfers data received from
radio modems to VC over CAN Bus.
• PPC Interacts with the Loco Pilot through LPOCIP.
• PPC interfaces with RFID Reader for reading the RFID
tag data.
• PPC module processes the speed pulses read
through the pulse generator
KAV 16 A
6/16/2023
V Giri, ITK 1

CAB INPUT CARD
• There are two CAB input modules in
LKAVACH system with independent working
power supplies for each CAB input module.
• The CAB input module interfaces with the
inputs from the driver’s desk.
• The two CAB input modules work in hot
standby.
• The CAB input module supports 32 inputs.
S.NO LED Description
1
2
3
4
PWR
SCS
24V DC available
Field inputs scanning status
CAB-INPUT card address status
Scanner con
A
troller health status
ADC
HLT
KAV
16
6/16/2023
V Giri, ITK 1

Vital Computer
(VCC)
There are three vital computers in
loco
KAVACH.
The VC module acquires the data from
the PPC
module on CAN Bus, further processes
and the
decision is made.
The decision is sent on CAN Bus to the
Voter
module for voting to derive the final
decision.

Voter Card
• The decisions by all three vital computers are
processed in voter module and the final decision is
derived by implementing 2oo3 voting.
• The final derived decision is sent to the respective
modules i.e. to PP modules for communicating to the
RFID reader and radio modems, to BIU for braking
functions, LPOCIP for displaying the relevant
information to Loco pilot.
• There will be two voter modules working as hot-
standby.
KAV 16 A
6/16/2023
V Giri, ITK 1

Integrated Data logger (IDL)
• This module logs radio packets, system health,
error events and NMS packets of the system
received on CAN Bus.
• This module can support memory interfaces like
SD/MMC, USB, Data Flash, and EEPROM.
• This also supports the transfer of log data through
the USB interface.
• The IDL also supports to retrieve the log through a
laptop connected on Ethernet port of IDL
(USB-UNIVERSAL SEVERAL DATA) SD/(MMC-Secured Digital card./Microsoft Management Console)
KAV 16 A
6/16/2023
V Giri, ITK 1

GSM
• GSM module is used for acquiring the encryption
keys from the key management server.
• This module supports the transfer of critical log
over GSM to the NMS service.
• This module supports interface for two GSM
service providers and both can transmit data
simultaneously. The log is received on CAN Bus.
KAV 16 A
6/16/2023
V Giri, ITK 1

KAVACH rollout and it’s implementation IR

KAV 16 A
6/16/2023
V Giri, ITK 1

Power supply distribution in Loco
KAVACH

Connectors
KAV 16 A
6/16/2023
V Giri, ITK 1

The inputs for the Loco Kavach unit
are
§ Relay inputs from locomotive Relay panel
§ Speed pulses from Pulse Generator fitted on the axle of a
wheel
on a locomotive
§ RFID Tag data read from the RFID Tag encountered by
locomotive
§ Brake pipe pressures like Main Reservoir (MR), Brake-Pipe (BP)
Brake Cylinder (BC) of the locomotive brake system
§ Operations done by Loco Pilot on LP-OCIP
and
§ Radio data reception from Loco TCAS systems in the
vicinity
§ Keys from KMS Server through GSM interface
The outputs for the Loco Kavach unit
are
§ Radio data transmission to Loco Kavach systems in the vicinity
§ Radio data transmission to Stationary Kavach systems in the
vicinity
§ Brake command to the Brake Kavach Interface unit (BIU)
§ Display speed, signal aspect, text messages to Loco Pilot on LP-
OCIP

Cable connections for LP-OCIP
modules

KAVACH – RFID Tag Reader
• KAVACH-equipped loco has an RFID Tag
Reader fixed to the locomotive under-
frame, just behind the cattle-guard at
height of 450mm from Rail Level.
• The tag reader reads the RFID tags,
installed in pre-defined locations on the
tracks, as the loco passes over these
tags.
• The RFID tags contain pre-programmed
data, which lets the loco know the track
ID on which it is currently running and its
absolute location. Each tag also lets the

KAVACH – RFID Tag Reader (cont.)
• Loco KAVACH compares
this
information with the
information
sent by the station KAVACH
on
wireless communication,
to
determine if there is any
unusual
occurrence and act accordingly.
• RFID tags, already installed on
the
tracks, can be re-programmed
using
a portable RFID programmer.

KAVACH – RFID Tag Reader
RFID Reader
• Welding the mounting brackets on
either side of the locomotive
• Installing the RFID readers to each
of the mounting brackets, along
with their power supply boxes
• Connecting the cables between RFID
reader and loc KAVACH

RFID Reader connectivity
diagram

Pulse Generator
• Two pulse generators are installed on
two different axles of the locomotive.
• The signals from the two pulse
generators are conditioned in a
Speedometer Interface Unit and sent
to Loco KAVACH.
• Pulse generators are also designed
and manufactured by HBL
• HBL PGs are fixed on 2nd and 11th
wheel of Loco.

Speedometer connectivity
arrangement

KAVACH – Driver Machine Interface (DMI)
Also called as LP-OCIP (Loco Pilot Operation cum Indication Panel)
• Complies with IRDMI specification, to
provide a standard user interface to
KAVACH.
• 10.4” Color LCD Display, with 10 soft
keys.
• Allows Loco Pilot to define
– whether the loco is leading or
non-leading
– If the loco is operating as a light
engine or as part of a train
formation
• Allows the loco pilot to generate an
SoS message in an emergency
situation

Indications and switches on
DMI

SOS CONDITIONS
• Loco KAVACH shall have a provision to generate Manual
• Station KAVACH shall have provision to generate SOS
• SOS shall be received to all Loco KAVACH within a 3000 mts
radius of the vicinity
• SOS received Loco KAVACH can move with a speed of
30kmph after receiving SOS with EB Brake application by
pressing Cancel Button on DMI
• SOS shall be cleared by pressing CANCEL Button by the
source who is generating
• SOS shall be cleared in other Loco KAVACH moving away
from source 1500mts
• No communication from source for a period of 3 minutes

KAVACH – Loco Brake Interface Unit
• Indian Railways locomotives use three types
of braking systems.
– Indian Railways Air Brake (IRAB)
– CCB (computer controlled Braking) by
Knorr Bremse and
– E-70 by Faively Transport

KAVACH – Loco Brake Interface
Unit
• HBL manufactures and supplies IRAB Brake
Interface Unit for allowing KAVACH to control the
braking of locomotives equipped with IRAB braking
system.
• For locomotives with CCB or E-70 braking system,
brake interface units are procured from their OEMs
and installed along with KAVACH.

KAVACH – Loco Brake Interface
Unit

LOCO TCAS BIU unit Pneumatic Circuit

Installation activity in the locomotive
• Pulse Generator
– Fixing the speedometer interface box
(supplied by HBL) in the identified
location
– Installing two pulse generators on two
different axles of the loco & connecting
their cables to speedometer interface
box. Wheel no. 02 and wheel no. 11
• RF & GPS antennae
– Welding the antenna mounting brackets
on the roof top
– Drilling holes on the roof top to route the
RF cables to the machine room
– Installing the antennae on the mounting
brackets
– Connecting the cables to the antennae
and weather-proofing their entry holes

GPS Antenna
• GPS antenna is installed on top of the station
building and Loco.
• Accuracy of Time Pulse : 1PPS
• Used for time synchronization of KAVACH Ra
communication network
• Real time events logging
• Two GPS modems are used for redundancy
• Both GPS are active. Faulty one is detected and
isolated in 3 cycles.
• Automatic recovery of faulty GPS
.

Radio modem
• The Radio modems are installed in the loco KAVACH and Station
KAVACH unit.
• The communication between the Radio modems and the KAVACH
system is through RPS card.
• There are two serial communication ports available on the Radio
modem.
• One serial port is for Data communication and another serial port
is for Set-up of Radio modem.
• The connectivity of these serial ports to the modem

Radio
modem
Ø Working frequency : 406
- 470 MHz UHF Channel
Bandwidth : 25KHz
Ø Mode of operation :
Full-
Duplex
Ø Data rate : 19200bps
over
-the-air;
Ø Output Power : 10W
KAV 16 A
6/16/2023
V Giri, ITK 1

Radio
modem
• Power Supply: 10-30V (Medha : 24V)
• Communication Range : upto 20Km (depends on
terrain)
• Two radio modems are used for redundancy
• Both are active in alternative cycles. Faulty radio is
detected
and isolated in 1 minute.
• Automatic recovery of faulty
radio
KAV 16 A
6/16/2023
V Giri, ITK 1

Radios and Antennae connectivity
diagram

RFID Tag Fixing
Arrangement
• RFID Tags provided in block section at ~1
km
and in station yard for each signal and
signal
approach.
• Used for track identification,
correction of
location of train and train movement
direction
identification.
KAV 16 A
6/16/2023
V Giri, ITK 1

Tags
Placement
• Fixed at the center of PSC
Sleepers
• No holes are drilled in the
Sleepers. Fixing through
clamps
only
• Not more than 450mm
above the
top surface of PSC Sleeper at
center.
• Suitable for reliable
working at
train speed upto 200
KMPH
• able to work even
when
submerged in water up to rail
level
KAV 16 A
6/16/2023
V Giri, ITK 1

Station Kavach
architecture
KAV 16 A
6/16/2023
V Giri, ITK 1

KAVACH – Station KAVACH
• Station KAVACH is the core component of the
entire KAVACH system architecture.
• It manages the RF communication with
several locos.
• It receives inputs from the station
interlocking system, loco position and speed
through RF communication.
• Based on this information, Station KAVACH
determines Movement Authority for each
loco and communicates it to each loco
through RF communication.
• Station KAVACHs in all stations are networked
on an OFC cable to the Network Management
System.

Power
Supply
• Stationary KAVACH works on 110V DC IPS power supply.
• In Station KAVACH, IB-Hut KAVACH and LC gate KAVACH. This 110V DC
power supply is sourced from IPS power supply
• 110V DC is also provided in Location Box where Radio sub-system is
placed.
• Incoming 110V DC power supply is protected against short-circuit using
HRC Fuses and MCBs. Also, diode protection is provided to prevent
reverse polarity connection.
• Incoming 110V DC power supply is fed to EMI/EMC Filter before
connecting KAVACH sub -system
• 24V DC, primary supply for all sub-modules
• 5V DC for peripheral circuits on all cards and 5V for CAN Bus, system
communication.
• There will be two DPS sub-modules per system to increase the
availability of power supplies to all sub-modules of the system.

Power Supply (Cont.)
• Stationary KAVACH unit requires 24V DC and 5V DC
power
supplies for its functioning.
• The Digital Power supply module in the KAVACH
generates
required 24V DC and 5V DC power supplies from 110V
DC.
• There are two Digital Power Supply (DPS) modules in
the
KAVACH system
• In each sub-system and modules, the 24V power
supply is
provided with fuse protection against short-

• Redundant power supply channel to each module is
generated by providing two DPS modules i.e DPS1 and
DPS2.
• Each 24V DC channel can independently be switched
ON/OFF.

• Power monitor of each channel is also done to protect the
channel against overload.
• 5V_CAN1 and 5V_CAN2 are used to power system Bus CAN1
and CAN2 channels. ( Controlled area Network )
• 5V_ISO1 and 5V_ISO2 are used for powering all the RS232,
RS485 and GPIO input/output. (Recommended Standard 232)
• All the 24V and 5V power supply channels are isolated from
each other
KAVACH Unit

IB-Hut TCAS architecture
KAV 16 A
6/16/2023
V Giri, ITK 1

The position of the sub-modules in KAVACH main rack
from left-hand side are
Position from
Sub-module name
Left-Hand side
1
2
3
4
5
6
7
8
9
Peripheral Processing Card-1 (PPC1)
Peripheral Processing Card-2 (PPC2)
Vital Computer card-1 (VC1)
Voter-1 (VOTER1)
Voter-2 (VOTER2)
Integrated Data Logger (IDL)
Dua
K
lAV
G1
S
6
M (GSM) A
6/16/2023
V Giri, ITK 1

• The position of the sub-modules in FIU (sub-rack
from
left-hand side are
Position from
Sub-module name
Left-Hand side
1
2
3
4
5
6
FIU Scanner Card-1 (FSC1)
KAV 16 A
6/16/2023
V Giri, ITK 1

Feed to Station TCAS taken through Parallel contacts of TCAS Repeater Relays with
double cutting

FIU (Field Interface unit termination
Card)

 The 32 field inputs are given to two FSC cards to
increase the
availability of the field inputs to the KAVACH system,
All the FSC cards are inserted in a 19” 4U FSC sub-rack and the FSC sub-rack can
accommodate 12 FSC cards. With 12 FSC cards, the total field inputs per FSC sub-
rack will be
196

To accommodate 1024 field inputs, there will be 5 FSC sub-racks, each
accommodating 12 FSC
cards supporting to 960 inputs.
 6 th FSC sub-rack will accommodate 4 FSC cards with 64 field inputs support.
 With all 6 FSC sub-racks, the total field inputs will be (960 + 64 = 1024).
 The 6th FSC sub-rack also accommodates the FIU Interface card (FIC) which is
connected to
all FSC cards in the FSC sub-racks over CAN Bus.
 All the field inputs status that is scanned by FSC cards will be transferred to the
FIC card
over CAN Bus.
 From the FIC module, all the field inputs status is communicated to KAVACH sub-
unit over
CAN Bus or RS485 interface based on the location of the FIU sub-rack and the TCAS

FIU Scanner Card
• The FIU sub-rack provides the interface for Field-inputs
connected to KAVACH through the FIU Scanner card and FIU
Termination cards.
• The FIU sub-rack supports up to 4096 field-inputs.
• The 4096 field-inputs are divided into four groups,
• each group can support 1024 field-inputs.
• The 1024 field-inputs are further divided into 32 sub-groups
each sub-group supports up to 32 filed-inputs.
• There will be 32 FIU Scanner modules to read these 32 field
-inputs in each sub-group.
• The FIU Scanner can accept either front or back contact of
the relay in the RRI panel.

FIU Scanner Card(Cont.)
• Two FIU Scanner modules are used for the same set
of 32
field inputs to increase the availability of the field-
input
interface.
• Each field-input connected to FIU Scanner module is
scanned
and sent to the Vital Computer modules on System
Bus which
• The number of FIU Scanner modules required in
FIU sub-
system depends on a number of field inputs in the

Peripheral Processing Card (PPC)
• This module interfaces with the peripherals like
GPS/GNSS, Radios, SM-OCIP and Yard Viewer.
• The 1-sec marker is generated using GPS/GNSS.
• The RF communication is through the Radio
modems.
• Transfers data to VC over CAN Bus.
• Interacts with the Station Master through SM- OCIP.
• There are two PPC modules with one as hot-
standby.

Diagnostic LED on Peripheral Processing card (PPC)
S.No LED Description
1
2
PWR 24V DC Available
RDAC LED will glow when the Radio is active
3 RDRT LED will toggle for Radio packet
Reception & Transmission
4
5
HLT4
SPD
PIC 4 micro Controller health status
LED will always toggles for health of
speedometer circuit in PPC module.
Wheel dia
6
7
8
9
WHD
RGS Status of GPS
HLT3
HLT2
Pic 3 Micro controller health status
SM-OCIP micro-controller health status
10 HLT1 Radio micro-controller health status

There are two GPS systems available as sub-modules in Station TCAS unit.
The GPS sub-module is available on Peripheral Processing card (PPC) card
and interfaced through TTL level UARTs (Universal Asynchronous Rx/Tx)
and
the GPS antenna is connected to GPS sub-module.

Vital Computer Card
• This module acquires the data from the PPC
module on CAN Bus.
• This further processes and makes the decision.
• To implement 2oo3 design, there will be three
vital computers.
• The decision is sent on CAN Bus to the Voter
module for voting to derive the final output.

What Does Controller Area Network (CAN)
Mean?
A Controller Area Network (CAN) bus is a
communication
system made for vehicle intercommunication.
This bus allows many microcontrollers and different
types of
devices to communicate with each other in real time and
also without a host computer

Diagnostic LED on Vital Computer card (VCC)
S.No LED Description
1
2
PWR
HLT1
24V DC Available
LED toggling ON/OFF at the rate of 5Hz indicating
Core micro-controller is healthy
3 HLT2 LED toggling ON/OFF at the rate of 5Hz indicating
Bridge Master micro-controller is healthy

Voter Card
• The decisions by all three vital computer are
processed in this module
• the final decision is derived by implementing 2oo3
architecture.
• The final derived decision is sent on CAN Bus to
the destination.
• There will be two voter modules working in hot-
standby.

Diagnostic LED indications for VOTER
card
S.NO
1
LED Description
2
3
VTS
SYS
Voter Status
System Status
4 CMS
MNR
BMS
CNS
Communication status
Maintenance Required
Bus-Master Status
5
6
7 CAN-Bus Status
8 ACC Active CAN
9 TTM
HLT1
HLT2
Time Trigger Mark
10
11
CORE controller health status
BRIDGE controller health status

Integrated Data logger Card
• This module logs radio packets, system health, error events
and NMS packets of the system received on CAN Bus.
• This module can support memory interfaces like SD/MMC,
USB, Data Flash and EEPROM.
• This module has Ethernet interface through which modems
are interfaced to connect with neighbor stations and IB Hut.
• This also supports transfer of log data through USB
interface. The real- time yard status is updated on the yard
viewer.

Ethernet connectivity for
Laptop

Diagnostic LED indications for IDL
card
1
2
HLT1 LED toggling ON/OFF at the rate of 5Hz
indicating Core micro-controller is healthy
3 HLT2 LED toggling ON/OFF at the rate of 5Hz
indicating Bridge Master micro-controller is
healthy

GSM Card
• This module supports interface for two GSM
service providers and both can transmit data
simultaneously.
• The log is received on CAN Bus.
• Two GSM modems are used for redundancy
• Events and Faults logging in NMS through GSM
• To get Security Keys from KMS
• To send SMS for emergency/critical messages

Diagnostic LED indications for Dual-GSM card
S.NO LED Description
1 PWR 24V DC Available
2
3
G1S Data on Rx/Tx port of GSM1
HLT-1 GSM1 controller health status
4
5
G2S Data on Rx/Tx port of GSM2
HLT-2 GSM2 controller health status

KAVACH – RF Communication Tower
• RF Communication towers are located near
stations and IB huts.
• UHF communication being line-of sight, the
locations of RF communication towers are
decided after a detailed geographical survey
of a potential KAVACH territory.
• Typically, the towers are 40 meters tall and
are constructed as steel lattice structures.
Tower should be designed to meet the
requirements of zonal railway wrt local wind
speed and factor of safety.

KAVACH – RF Communication Tower
§ tower carries two sets of antennae, which are
connected to two radios.
§ The radios are installed in a Radio Tower Unit at a
height of 10m from the foot of the tower.
§ Fiber optic cables connect the radios to the Station
KAVACH located in the Relay Room.
• Station TCAS and Loco TCAS units communicates with
each other for every 2 seconds.
• Pair 1 : Station Tx - 456.8 MHz, Rx - 416.8 MHz
• Pair 2 : Station Tx - 466.8 MHz, Rx - 426.8 MHz
• Common Frequency, f0 - 441.8 MHz

GPS Antenna
• GPS antenna is installed on top of the station
building and connected to the station KAVACH.
• Accuracy of Time Pulse : 1PPS
• Used for time synchronization of TCAS Radio
communication network
• Real time events logging
• Two GPS modems are used for redundancy
• Both GPS are active. Faulty one is detected and
isolated in 3 cycles.
• Automatic recovery of faulty GPS
.

GPS Antenna
• There are two GPS systems available as sub-modules in Station
KAVACH unit.
• The GPS sub-module is available on Peripheral Processing card
(PPC) card and interfaced through TTL level UARTs
• GPS antenna is connected to GPS sub-module.

Radio
modem
• TCAS Radio Modem
Ø Working frequency : 406
-
470 MHz UHF Channel
Bandwidth : 25KHz
Ø Mode of operation :
Full-
Duplex
Ø Data rate : 19200bps
over
-the-air;
Ø Output Power : 10W
KAV 16 A
6/16/2023
V Giri, ITK 1

Station TCAS Radio communication
arrangement

Radio Modem communication for IB-Hut TCAS
unit

Ethernet connectivity for
modems

Transient
Protection
• In Station TCAS, all the field-inputs and outputs are protected
against transients in all sub-systems and modules.
• The field-inputs are interfaced to the FIU Scanner modules through
FIU Termination card.
• All the field inputs coming to the FIU Termination card have
transient protection diodes.
• The Radio RF cables like Rx & Tx are also protected against
transients using gas discharge transient protector unit kept in
series with Rx and Tx antenna from the Radio modem.
• The RS-232 interfaces from Peripheral Processing Card (PPC) which
connect to the Radio modems are also protected with TVS Diodes.
KAV 16 A
6/16/2023
V Giri, ITK 1

• RS-485 interfaces from Peripheral Processing Card
(PPC)
which connect to the Station Manager Operation Cum
Indication Panel (SM-OCIP) are also protected with TVS
Diodes.
• All these diodes are assembled on their respective cards
very
close to the connectors.
• A surge suppressor is connected between the antennae
and
the radio RF connector.
• An axial surge suppressor is placed close and connected
to
the radio.
• The surge suppressor is connected between the
LMR400
cable and LMR200 patch cable.
• The surge suppressor supports connectivity through N-male
Conne
• both LMR400 and LMR200 cables will have N-male connector.
KAV 16 A
6/16/2023
V Giri, ITK 1

Availability, Reliability, and
Redundancy
Availability, reliability, and redundancy, is achieved in
stationary TCAS
• All the peripheral devices are interfaced with
Peripheral
Processing Card (PPC), and there are two Peripheral
Processing Cards (PPC) one PPC card is active, and
another is available as the hot standby module
• There are two Radio modems, and both are active
to
increase the availability
• There are two GPS modules with a separate antenna
to
increase the availability
• There are three Vital Computer cards to implement
2oo3
desig
KAV 16 A
6/16/2023
V Giri, ITK 1

• There are two Voter cards for voting purpose. One
Voter
card is active, and another Voter card is available as a
hot standby.
• There are two GSM modules for
redundancy
• There are two Digital Power supply modules (DPS),
both
are active to maintain redundancy
• There are two FIU Scanner along with two
FIU
Termination cards both are active to
maintain
redundancy
• There are two isolated RS-485 interfaces to SM-
OCIP
module to maintain availability as redundant
communication channels
KAV 16 A
6/16/2023
V Giri, ITK 1

Relay rack
• KAVACH uses relay contacts of
existing interlocking system to
know the status of signaling gear
in the yard. Spare contacts may
not be available for these relays.
• Therefore, KAVACH uses its own
relay racks. Each relay rack is pre-
wired in the factory with 48 relays.

Relay rack
• The relay rack is installed in the KAVACH room,
next to the station KAVACH.
• Each relay coil is connected to one contact of each
relay in the interlocking relay panel. When the
relay in the interlocking panel picks up, the
corresponding relay in the KAVACH relay rack picks
up, and its contact status is read by KAVACH.

Remote Interface
Unit
• In some cases, status of signaling gear
beyond the station building needs to be
known to the station KAVACH.
– Example: LC gates, auto-signaling
section
• A Remote Interface Unit is installed close
to such signaling gear. Relay contacts of
those signaling gear are connected to the
RIU.

REMOTE INTERFACE UNIT(RIU)
 Power Supply Card (PS)– 2no’s
 Communication card (RIU COM)–2 no’s
 Field Scanner Card (FIU) – 2no’s
 Battery Charger EMI Filter- 2no’s
KAV 16 A
6/16/2023
V Giri, ITK 1

Remote Interface
Unit
• An optical fiber cable is used between RIU and
Station
KAVACHto communicate the status of these
signaling gear,
in the form of digital data.
• The optical fiber cable is usually laid as part of
KAVACH
contract execution.

Installation activity in the station
• RF Communication tower
– Soil survey in the identified location
– Foundation
– Erection of tower & its painting
– Installation of RF antennae (supplied by HBL) along
with cables and aviation lamp
– Installation of RTU (supplied by HBL)
– Earth pits and their connection
– Fencing

Station KAVACH
– Construction of room, if required
– Installation of Station KAVACH
and its earthing
– Installation of relay rack and
inter-connection
interlocking relay rack
to the
– Installation of GPS antenna on
building and connecting its cable
to Station KAVACH
Ø Installation of DC-DC Converter
& Distribution Board for power
supply arrangement between
existing IPS and Station KAVACH
– Installation of SMOCIP in station
master room and connecting its
cables to Station KAVACH

• Remote Interface Unit
– Installation of location box in the identified location and its
earthing
– Installation of RIU in the location box
– Wiring of field inputs to RIU
• Cabling
– OFC cable & power cable between station KAVACH & RF Tower,
through trenching
– OFC cable between RIU & Station KAVACH, through trenching
– Open-tray cabling for inter-connection between KAVACH Relay
Rack and Interlocking relay rack
– Open-try cabling between SMOCIP & Station KAVACH
– Open-tray cabling for power supply to Station KAVACH

KAVACH – Station KAVACH with RIUs

• Loco KAVACH
– Welding the mounting bracket in the
identified location
– Installing loco KAVACH unit on the
mounting bracket
– Opening the cable tray covers in the
machine room, by cutting through
weld joints
– Laying cables supplied by HBL &
closing the cable tray covers
KAV 16 A
6/16/2023
V Giri, ITK 1

Brake Interface Unit
• Welding the mounting bracket in the identified location
• Welding the copper piping to the pneumatic lines of the
loco braking system
• Installing the brake interface unit on the mounting
bracket
• Connecting the cables between KAVACH and BIU
DMI
• Welding or screw fixing of the mounting bracket on the
dashboard
• Installing the DMI and connecting its cables
KAV 16 A
6/16/2023
V Giri, ITK 1

DOs
1
2
3
Keep the TCAS system and location dust free
Maintain 77V-132V DC at the output of TCAS MCB
Check the system for blown fuse and proper fuse contact at regular
intervals
4
5
6
7
8
9
SM-OCIP LCD display is functioning properly
Ensure Proper connection of TCAS to NMS
Ensure that the system is firmly connected to Earth terminal
Clean the TCAS system with soft cloth / Brush to get rid of dust
Use the ESD footwear in case of Cards replacement or repair
Ensure that all cards mounting screws are tightened properly

1
2
Trouble shoot without proper system training.
Use Walkie – Talkie, Mobile Phone or any Radio Equipment near TCAS or
any of its subsystems.
3
4
5
6
7
Switch OFF any of the IPS / DC-DC converter modules when system is functioning.
Remove system modules / Fuse or connectors when TCAS is in operation.
Forcibly pickup or Remove relays related to TCAS.
Touch components on the PCBs or repair them.
Change configuration of the system using jumpers / Application data
without approval.
8
9
Disturb OFC cable / connector.
Use removable media (Pen drive, etc.,) in Event logger Module without approval.
10
11
Repair of cards is a highly technical job and is not possible at site.
Never practice any self-made guideline which are not recommended in manual.

KAVACH rollout and it’s implementation IR

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