Signalling Relays: Presented by P.Shakila Ios5

Signalling Relays
Presented
by
P.Shakila Ios5
8/21/2020 S19 Relays and cables 1

RELAYS & CABLES
INTRODUCTION :
The orthodox mechanical signalling system was replaced

with Electrical signalling.
Two essential components are widely used in all the

Electrical signalling systems. They are "Relays" & Cables ".

RELAY CABLE

What is a Relay ?
A relay is an electromagnetic device used to convey

information from one circuit to another circuit through a
set of contacts i.e. front or back contacts.
 Switching device used for remote control and succession
control of various electrical equipment.
 Capable of protecting the controlled equipment from cross
feeding and overloading
 Cater for speedy operations.
 Most of the relays in present day signaling are
electromagnetic devices,
 But even the electronic components like diode/transistors/
Integrated Chips etc are also used as relays
Principle-Electromagnetic relays

Advantages of Relays
 Relays can switch AC and DC, transistors can only

switch DC.
 Relays can switch high voltages, transistors cannot.
 Relays are a better choice for switching large currents
(> 5A).
 Relays can switch many contacts at once.

Disadvantages of Relays
 Relays are bulkier than transistors for switching small

currents.
 Relays cannot switch rapidly whereas transistors can switch
many times per second.
 Relays use more power due to the current flowing through
their coil.
 Relays require more current than many chips can provide,
so a low power transistor may be needed to switch the
current for the relay's coil.

Classification of Relays:
1 Based on their application,

 Line relays
 Track Relays
 Lamp Proving Relays
 Timer Relays
 Flasher Relays
 Contactor Relays
 Biased Relays

LINE RELAY TRACK RELAY

LAMP CHECKING RELAY
TIMER RELAY

BIASED RELAY
CONTACTOR RELAY

Classification of Relays:
2 Based on type of contact material used

Metal to Metal contact Relays
Metal to Carbon contact Relays
3 Based on polarity requirement

Polar Relay
Neutral Relay

Classification of Signaling Relays
4. According to their importance in ensuring train

safety
a) Vital relays : relays directly used for
traffic control like signal, point, track
detection etc.
b) Non-vital relays : relays used for controlling aids
like warning buzzers, indications etc.

5. According to special provisions to ensure reliability

of their contacts
a) Proved type : Relays for which proving of
normalization is necessary after every
operation (metal-to-metal contact relay).
b) Non-proved type : Relays for which above
requirement is not necessary as their contacts have
at least one non-fusible contact (Metal to carbon
contact relays).

6. Based on the source of feed

a) DC relays
i) DC neutral relays : are not affected by the polarity of
DC supply and close same set of contacts on
energization.
ii) Polar relays : are sensitive to polarity of DC supply and
close different sets of contacts depending upon the
polarity of the DC supply.

b) AC relays : AC induction motor track relays are used at some

places in DC electrified area.
c) Electronic relays- DC relays with electronic components in
them.
7. Relays can also be classified basing on their level of immunity to
external AC voltages :
a) AC immunized- Relays
b) Non immunized Relays

SYMBOLS AND NOMENCLATURE OF
RELAYS AND WIRING PRACTICE:
The power signalling systems on our railways follow

two practices:
(1) The British Railway practice and

(2) The Continental or German practice.
These two systems have an individual language of

symbols and nomenclature .However they have a few
common elements also

MEANING OF LETTERS USED IN SYMBOLS
AND NOMENCLATURE
Letter Description
A Approach, automatic
B Block, Bolt
C Checking or proving
D Clear (green)Decoding
E Light: heat (externally applied)
F Fog
G Ground, gate, signal aspect
H Caution (yellow)
I Indicator
J Time (delayed action)
K Indicating or detecting
L Locking, left,
M
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MEANING OF LETTERS USED IN SYMBOLS
AND NOMENCLATURE
Letter Description
N Normal (push button or key)
O Retarder
P Repeater
Q Treadle or bar
R Reverse, right, red
S Stick
T Track circuit
U Route
V Train stop
W Point
X Audible indicator
Y Slotting
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Z Zone, AnyS19special
Relays and cables
term defined 19
Symbols for british practise
S.No. Symbol Description
1 N Switch / Knob Contact in Normal Position
2 R Switch / Knob Contact in Reverse Position
R1 R2
3 Relay Coil (Name of Relay is written inside the rectangle)
Closed Contact when Relay is in Energised condition

4 (Front Contact)
Closed Contact when Relay is in de-energised condition

5
(Back Contact)
6 Slow to release Relay
7 Slow to pickup Relay
R1 R3
8 Double Coil Relay
R2 R4
9 A C Immunised Relay
10 Time Element Relay front Contact (Energised Condition)
11 Time Element Relay front Contact (de-Energised Condition)

12 Flasher Relay contacts
R2 R4
9 A C Immunised Relay
Symbols for british practise
10 Time Element Relay front Contact (Energised Condition)
11 Time Element Relay front Contact (de-Energised Condition)
12 Flasher Relay contacts
N
(3-Position Polar Relay) (Dependant type)
13 R NORMAL / REVERSE Contacts
(3-Position Polar Relay) (independant type)

14 N NORMAL Contacts (Energisation on NORMAL side)

15 R REVERSE Contacts (Energisation on REVERSE side)

16 D De-Energised Contacts
N
(2-Position Polar Relay) (Dependant type)
17 R NORMAL / REVERSE Contacts
N
18
NORMAL Contacts
R (2-Position Polar Relay) (independant type)

19
REVERSE Contacts

British relays and Nomenclatures
Sr No Name Description
1 TSR Track stick relay
2 UCR Route checking relay
3 ASR Approach stick relay
4 WLR Point lock relay
5 WNR Point normal (operation ) control relay
6 WRR Point reverse (operation ) control relay
7 NWKR Normal point ( position ) indication relay
8 RWKR Reverse point ( position ) indication relay
9 TRSR Track right stick relay
10 TLSR Track left stick relay
11 SMCR Station master’s control relay
12 UYR1,UYR2 Sequential route release relays
CIRCUIT IN BRITISH PRACTICE

Symbols used in Siemens Practice
S.No. Symbol Description
1 Neutral Relay
2 Interlocked Relay Reverse Coil

(Top Relay)
3 Interlocked Relay Normal Coil

(Bottom Relay)
4 Track Relay
5 Track Repeater Relay
6 Block Relay in Automatic Territory
7 T Time Element Relay
8 Indicates that a Neutral relay is normally energized
9 Indicates that a Neutral relay is normally de energized

Indicates that an Interlocked relay is normally latched
10
(Normal coil)
Indicates that an Interlocked Relay is normally de
11 (Reverse Coil)
latched
12 Make Contact
13 Break Contact
Make contact of a Neutral Relay that is normally picked up

14 (Front Contact)
Break contact of a Neutral Relay that is normally picked up
15 (Back Contact)
16 Make contact of a Neutral Relay that is normally drop

(Back Contact)
Break contact of a Neutral Relay that is normally drop,

17 (Front Contact)
Make contact of a Interlocked Relay that is normally latched,

18 (Front Contact)
Break contact of a Interlocked Relay that is normally delatched
19 (Back Contact)
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Make contactof a Interlocked Relay that is normally delatched 24
(Back Contact)
Break contact of a Interlocked Relay that is normally delatchedt
21
Siemens Interlocked Relay Symbols

Nomenclature of Siemens Relays
RELAY NOMENLATURES
GNR Signal button relay
GNCR Signal button checking relay
SH-GNR Shunt signal button relay.

CO-GGNR Common button relay for calling-on
signals
EGGNR/ERNR Common button relay to replace any
signal at 'ON"
UNR Route Button relay.

RELAY NOMENLATURES
UNR Route Button relay.
UNCR Route button checking relay
EUYNR Emergency sub-route release button
relay.
EUYZ Emergency sub-route release
operation counter.
EUUYNR Emergency ( full ) route release
button relay.
EUUYZ Emergency (full ) route release
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operation counter
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EUUYNCR Emergency (full ) route release button

RELAY NOMENLATURES
EUYR Emergency route release relay
( common for sub route and full route cancellation)
WNR Point button relay.
WNCR Point button checking relay
WWNR Common point button relay.
(when point zone track circuits are up)
EWNR Emergency Common point button relay
(when point zone track circuit is down)
EWZ
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and cables counter 28
WLR Point locking relay

WJR Point time delay relay
WR Point contractor relay (heavy duty contractor relay)
CHYNR Crank handle slot release button relay.
CHYRNR Crank handle slot return button relay
CHKLR Crank handle key lock relay.

Siemens Circuits
CCT-1(SHT- 5) CCT-5(SHT-7)
S12 GNPR S3 GNPR

S12 GN
S12 EGNR
LL1 UNPR LL2 UNPR 2 /3T UNPR
S12 GNR
5B Z1UR1

Terms connected with Relays
1. Non-fusible contacts: A pair of contacts in which one contact

element comprises of non-fusible material, which presents
practically no risk of welding of contacts.
2. Carbon contacts: 'carbon' in the expression 'carbon - to-
metal contacts' is used as a general term covering graphite
and compounds and mixture of carbon and metals.
3. Metal contacts: 'Metal' in the expression 'metal to metal
contacts' is used as a general term covering the use of silver,
silver cadmium oxide, tungsten, platinum or any other
suitable material to an approved specification.

4. Front contact: That contact which is made with 'arm contact'

when the relay is energized.
5. Back contact: That contact which is made with 'arm contact'
when the relay is de-energized.
6. Arm contact: That contact which is movable part of the pair of
contacts and is made with front contacts when the relay is
energized and with back contact when the relay is de-
energized.
7. Arm: The movable part of the pair of contacts.

• Dependent contact – a movable arm contact connects to a FC

when relay is energized and the same arm contact connects
to a back contact when the relay is de-energized (4F/B)
• Independent contact – the condition in which the movable
arm contact connects to either a front or a back contact and
not to the both (2F,2F/2B)
• Pick up value – the value of current just enough to close all
front contacts under specified conditions

DEPENDENT CONTACTS
Front contact
Arm contact
Back contact

INDEPENDENT CONTACTS
Front contact
Back contact

10. Contact element: Contact piece, which is secured to a

contact spring.
11. Wiping (self-cleaning) contacts: Contacts designed to have
certain relative motion, during the interval from the instant
of touching until completion of the crossing motion.
12. Contact follow: That distance which the movable arm
contact travels after touching the front or back contact.
13. Contact bounce: means the uncontrolled making and
breaking of the contact after it has closed first.

 Drop away/Release value - the value of current at which all

front contacts just open
 Operate – all front contacts just made
 Full operate – the condition when armature has completed its
maximum travel
 Release – all front contacts just broken
 Full Release – when armature returns back fully to stop postion
 Percentage release = drop away/pick up x 100

Operate Time (of )

(a) Back Contact: Means the time interval from the instant of
application of the current to the coil until breaking of the back
contact, which is the last to break.
(b) Front contact: Means time interval from the instant of application
of the current to the coil until closing of the front contact which is
the last to close and the contact bounce has ceased.
Release Time (of).
(a) Front Contact: Means the time interval from the instant of
removal of energy to the coil until breaking of the front contact,
which is the last to break.
(b) Back contact: Means the time interval from the instant of
removal
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the coil
Relays anduntil
cables closing of the back contact
38
which is the last to close and the contact bounce has ceased.
CHARACTERISTICS OF ELECTRO-
MAGNETIC RELAY:
 The following are the important characteristics of

electro-magnetic relays. Basing on these
characteristics components and designs features of
relays are decided .
 Force of attraction
 Effect of air gap.
 Effect of Hysteresis
 Transient condition.

CHARACTERISTICS OF
ELECTRO-MAGNETIC RELAY:
Force of attraction:
In any electro-magnetic system, the force of attraction is
given by.
F  B2 a
Where: B - is the flux density and a - is the cross sectional
area of the particular part of the magnetic circuit.
Effect of air gap:
If the air gap is not available, then the residual magnetism
fluxes might cause the armature to be retained when the
supply is disconnected. For this reason, residual pins are
provided to ensure a definite minimum air gap in the
energised position.
CHARACTERISTICS OF
Effect of Hysteresis:
Hysteresis is the property by which the flux produced lags behind the
current. To overcome the effect of Hysteresis the relay core is made
of material having high permeability and low retentivity
This reduces the difference between pick up value and Drop away
value. By selecting good quality core material, Percentage release
and sensitivity of the relay will be improve.
Transient Condition:
When the voltage is applied or disconnected from the coils, it takes
some little time before the current become steady. These are known
as transient conditions” and are important so far as track relays are
concerned as they effect the release time of the track relay

CHARACTERISTICS OF
 To reduce releasing time to a minimum value
 The relay iron should have low Hysteresis loss and low
retentivity.
 The degree of over energization of the relay should be
restricted
 Connecting a suitable external resistance in series with the
relay to keep L/R ratio low.

CHARACTERISTICS OF
 Use relay with minimum contacts, as they require lesser
current which keeps inductance value low
 Train working safety is ensured only if the track relay of

shortest length track circuit is released before a light
engine running at a highest permitted speed clears it.
Otherwise, the track circuit occupation may go
undetected. To avoid this, a special provision has to be
made in signal control circuits, wherever necessary.

ELECTROMAGNETIC RELAY

Q-SERIES RELAYS
Presented
By
P.Shakila IOS5
6/4/2020 S19 Relaya and cables 45

Plug-in type DC Neutral Line
Relays ( Non –Proved type )
The Plug-in type DC Neutral Line Relays which suit to

the BR specifications and used over Indian Railways are
known as Q-series relays.
No separate IRS specification issued for these relays

.But they confirm to IRS spec no. S23 and S34 ( for
testing procedures).
They are known as non –proved type because unlike

proved type relays their last deenergised state need not
be proved when ever they are reenergized ,
Transparent Adjustment
card Operating
cover Base
arm
Pusher
spring
Heel
piece
Handle
Armature
Non-magnetic Electromagnet
6/4/2020 residual pin S19 Relaya and cables 47
Constructional Features of the q-series
Dc neutral relay
Standard common plug board with coding pin

arrangement is used to prevent a wrong relay being
plugged.
Each relay is provided with 5 coding pins and

accordingly 5 holes (out of 10 i.e. A,B,C,D,E,F,G,H,J,K) are
drilled in the plug board. These are known as code
numbers.
No electrical connection establishes between relay and

plug board until code pins engage correctly. Six more
code pin positions exist (L,M,N,X,Y,Z) which are used for
special relays.

Constructional Features of the
q-series Dc neutral relay
Connectors, which are positively locked in to the plug

board and can be with drawn by a special tool to permit
easy disconnection.
Means for terminating permanent wiring to plug board

on the connectors both by crimping & soldering.
Registration device with specified coding

combination in order to prevent a wrong relay being
plugged.

Constructional Features of the
q-series Dc neutral relay
No electrical connection possible between plug board and

the relay base until code pins have correctly engaged
Fixed contact positioned by adjustment cards and moving

contact positioned by operating arm drive by the armature.
Provision of helical spring to provide definite back contact

pressure and aid in return torque.
Provided with Non-proved (metal to carbon contacts) and

all are independent contacts only.

Constructional Features (coding pins)
QN1 12F/4B ABCDE
QN1 8F/8B ABCDF
QNA1 12F/4B ABDFH
QNA1 8F/8B ABDGH
QLI ABDEG
QBA1 12F/4B ABFGH

Constructional Features (coding pins)
QBA1 8F/8B  ACDEH
QS3 (12V, 1000  CDEKX

ohms)
QT2  DEFJX
QTA2  FGHKX

Constructional Features
Conform to IRS: S 23 & S 34, besides relevant BRS

specification
Plug-socket type of inter-connection between relay

and plug board
Retaining clip to hold relay firmly to ensure firm

electrical connections.
All contacts are independent and non-proved type
Permanent wiring on plug board is terminated after

proper crimping and soldering of wires on the
connectors
Connectors are positively locked in plug board and at

the same time they can easily be withdrawn with the
help of a special tool in case of need
Fixed contacts are positioned by adjustment cards

and moving contacts are positioned by the operating
arm driven by the armature.

 A non-magnetic residual/stop pin on the face of

armature helps to reduce the effect of
hysteresis/residual magnetism
 A helical pusher spring helps to restore relay to full

released condition and helps back contacts make
properly when relay is de-energized
 All moving arm contacts are silver contacts and all

fixed front and back contacts are of silver impregnated
graphite (non-fusing).

D C B A
Front contacts 1 1
2 2
A1A2, A3A4 3 3
4 4
B1B2, B3B4 5 5 Interchangeable

6 6
7 7
contacts
C1C2, C3C4 8 8
R2 R1 B5B6, B7B8
D1D2, D3D4 R4 R3
C5C6, C7C8
X Y Z
Back contacts A B
L M N
C D
E F G H
A5A6, A7A8 J K
D5D6, D7D8
FIG : 4.3
Standard Contact Arrangements
Q-series relays are provided with a maximum of 16

numbers of independent contacts.
The standard contact configurations for various types
of relays are:
Line Relays – 12F/4B, 8F/8B, 8F/4B, 6F/6B
6F/2B, 4F/4B
Track Relays – 2F/1B, 2F/2B
ECRs (Lamp Checking Relays) – 3F/3B, 4F/4B
* All the front and back contacts are “independent”.
FC - “metal-to-carbon”, BC - “metal-to-carbon”.

Contact Configurations

TYPES OF Q-SERIES RELAYS
 QN1
 QNN1
 QNA1
 QNA1K
 QS3
 QSA3
 QB1
 QBCA1
 QSPA1
 QSRA1
 QL1
 QJ1

QN1 Relay
This is the fundamental Q series relay.
All other relays of the Q series have been developed

around the QN1 in order to standardize the components.
Iron circuits and contact stacks are mounted on a molded

base of extremely stable non-hygroscopic thermosetting
plastic (A thermo set material cannot be melted and re-
molded).
Rated life of a relay is 1000000 cycles

QN1 Relay
Contact springs are made of wear,corrosion &

fatigue resistant phosphor bronze which extend
beyond the base.
Armature pivots on a phosphor bronze plate

riveted to the heel piece.
 The magnetic circuit consisting of L shaped heel

piece, electromagnet (core & coil) and armature
are fixed to the thermosetting base below the
contact stacks

QN1 Relay

Applications and Contact Configuration
QN1 Relays
Contact Configuration – 12F/4B, 8F/8B, 8F/4B,

6F/6B, 4F/4B
Applications – All circuits in non-electrified

sections and internal circuits in electrified
sections

QN1 – Technical Data
 Rated voltage : 24
 Pick up voltage : 19.2 Volts
 Coil resistance : 400 Ω
 Drop away voltage : 3.6 V
 Pick up time : 150 millisecond
 Drop away time : 20 millisecond
 Operating current : 60 mA
 Spec : BRS 930A, IRS: S 23 & S 34

QN1K Relay

QNN1 – DC Twin Neutral Line Relay
 Conforms to BRS 960
 It is a combination of two neutral relays with a

common heel piece and a common base.
 The two relays are independent and can be used for

two different unrelated purposes.
 Affects saving of space when requirement of number

of contacts is less.
 Equal number of contacts either 4F/4B or 6F/2B on

both the relays

QNN1
QNN1 – DC Twin Neutral Line Relay
 Rated/normal working voltage : 24
 Application : all circuits in non electrified

sections and internal circuits in AC electrified
sections especially when number of contacts
required is less and/or space constraint is
there.

QNA1-AC Immunized DC Neutral
Line Relay
 The relay is same as QN1 relay except that a

copper slug is provided in this relay at the
armature end of the core to achieve immunity
against AC voltages.
 When AC current passes through relay coil, the flux

set up through air gap and armature is also linked
with copper slugs. This induces eddy currents in
copper slug the flux generated by which opposes
the flux which caused the eddy currents in slug.

QNA1 – Technical Data
 Pick up time : 220 millisecond
 Drop away time : 70 millisecond
 Operating current : 115-120 mA
 AC Immunity level : 120 V AC 1- Phase 50 Hz

QNA1 RELAY

Applications and Contact
Configurationof QNA1 Relays
 Contact Configuration – 12F/4B, 8F/8B,

6F/6B, 4F/4B
 Applications – All external circuits in

electrified sections

Provisions of Spec – IRS: S60-78
for AC Immunity Requirements
 The relay shall not make by sudden application of

1000V 50 Hz AC
 Relay not to break its back contact when1000Vrms

is applied gradually or abruptly.
 Maximum P.U transfer and release transfer time not

more than 200 m Seconds when relays energized
with 80% rated voltage.

QN1 QNA1
Pick up voltage – 19.2 V Pick up voltage – 19.2 V
Drop away voltage – 3.6 V Drop away voltage – 3.6 V
Coil resistance – 400 Ω Coil resistance – 208Ω
Operating current – 60 mA Operating current – 115

mA
Pick up time – 150 msec Pick up time – 220msec
Drop away time – 20 msec Drop away time – 70 msec
Suitable for internal ciruits Suitable for external

of RE area circuits of RE area

DC Neutral Sensitive Line Relay QS3
 It is a sensitive relay designed to work on low voltage and

current.
 Conforms to BRS 930
 It was introduced with a drive to replace shelf type relays
 Contacts are silver impregnated graphite to silver
Technical Data of QS3 Relays
 Working voltage : 12V

 Coil resistance : 1000 Ohms
 Contact configuration : 4F/4B
 Operating current : 12mA
 Pick up voltage : 7.5-9.35 V
 Min drop away voltage : 3.75 V
QS3 Relay

Applications of QS3 Relays
 Its application in most of the zonal railways started with

the drive to do away with shelf type relays from axle
counter circuits for safety reasons.
 Accordingly 12 Volt version is being used as evaluator

relay (EVR) and supervisory relay (SUPR) in analog axle
counters to suit output of axle counter cards.
 24V as well as 12V versions are being used for inner

distant, distant and IB circuit applications in non-
electrified sections where voltage drop becomes
critical.
DC Neutral Sensitive AC Immunized
Line Relay QSA3
 Conforms to BRS 931A

 Contacts are silver impregnated graphite to silver
 It is primarily for use over long supply lines
 A copper slug at the armature end of the core provides AC
immunity.
Technical Data & Applications of QSA3
Relays
 Working voltage : 12V / 24V

 Coil resistance : 1000 Ohms
 Contact configuration : 4F/4B
 Operating current : 12mA / 24mA
 Application : 24V as well as 12V versions are being used for
inner distant, distant and IB circuit applications in electrified
sections where voltage drop becomes critical.
DC Biased Neutral Line Relay QB3
 This relay is sensitive to the polarity of the DC supply and

operates only when rated DC supply of correct polarity is
applied across its coil.
 The armature does not get attracted even when a supply

20 times its rated voltage is applied in reverse polarity.
 This biasing feature is attained through a permanent

magnet fixed on the core.

 Neither electromagnetic coil flux nor permanent

magnet can hold the armature in attracted position
on their own.
 The armature gets attracted and remains attracted

only when both the fluxes act together to get added
up.
Technical Data & Applications –
QB3 Relays
 Rated voltage and current – 12V DC, 60mA

 Coil resistance – 200 ohms
 Contact configuration – 4F/2B
 Pick up current – 45 mA
 Pick up/drop away time – 380/20 millisec.
Applications of QB3
 Being biased, two relays can be worked on a single pair of

conductors - thus saving a pair of conductors.
 These are used in Podanur make single line block
instruments as code receiving and checking relays.
 The instrument contains 36 relays, 3 of which are QB3 type.
These are named CRR(N), CRR(R) and TCKR (Transmission
Code Checking Relays).
 These instruments are able to work on a single pair of
conductors because of these relays.
QBA1- Q series Biased & AC Immunized Relay
To make the relay AC immunized, copper slug is

provided at its armature end adjacent to the
permanent magnet.
Coil resistance – 200 ohms

Working voltage – 24V DC
AC Immunity – 1000V AC
Pick up/drop away voltage – 19.2/3.6 V
Application – this also affects saving of one pair of

conductors and is used in Daido single line block
instruments (NR, BLR).

QBA1 Relay

QBA1 Relay

QBCA1 Relay
Biased AC immunized relay with heavy duty front

contacts
It has 2 heavy duty front contacts and 4 normal rating

current rating back contacts.
Heavy duty front contacts are rated for 30 Amps.
Magnet pieces are held close to the heavy duty

contacts and they blow or disperse the electric arc
before it has a chance to grow and burn.

QBCA1 Relays
Immune to 1000V AC
The armature does not get attracted even when a supply

20 times its rated voltage is applied in reverse polarity.
Conforms to BRS 943 & 966
Two extension springs behind the base are joined with

front contacts and their springs so that 2 wires can be
connected for sharing heavy load currents through these
contacts.

QBCA1 Relays
Contacts are silver impregnated graphite to silver
Minimum front contact pressure is 56 gms as against 28

gms for other similar metal-to-carbon relays.
Two natural magnet pieces called magnetic called Blow

out magnets are fixed on a bracket by the side of front
contact elements .Spark quenching by these magnets
during operation makes it possible for them to carry
heavy currents

QBCA1 Relays
Rated voltage and current – 24V DC, 120mA

Contact configuration – 2F(heavy duty)/4B
Application – The relay is designed primarily for

control of point machines in AC electrified sections.

QBCA1 Relays
Rated voltage and current – 24V DC, 120mA
Contact configuration – 2F(heavy duty)/4B
Application – The relay is designed primarily for

control of point machines in AC electrified sections.

QBCA1 Relay features :
1) Permanent Magnet
2) Copper slug
3) Blow out magnets
QBCA1 Relay HD
Contacts
QBCA1 Relay HD Contacts

QSPA1-Slow to Pick up Relay
Conforms to BRS 933A

Magnetic shunt at the armature end makes
the relay slow to pick up.
The flux passes through the shunt initially
and the relay picks up once the magnetic
shunt saturates.
Copper slug at heel piece end provides AC
immunity.

QSPA1 RELAY

Slow to Pick up Relays

Application, Technical Data-QSPA1
Used as TPRs in RE areas to avoid unsafe situations in

cases of OHE snappings.
 Pick up time – 540-600 millisecond

 Release time – 140-200 millisecond
 Working voltage -24v DC
 AC immunity level – 1000 v AC

QSRA1-Slow to Release Relay
Conforms to BRS 934A

Magnetic shunt at the heel piece end makes the
relay slow to release.
Saturated magnetic shunt helps to maintain the
flux for a while as supply to the coil is cut off.
Copper slug at heel piece end provides AC
immunity.

QSRA1 RELAY
Slow to Release Relays

Application, Technical Data QSRA!
Used as HPRs, DPRs in RE areas to make them

insensitive to momentary supply fluctuations and
momentary track relay dropping, ECRs, button
failure/point failure/signal failure indication relays
etc
 DA time – 260 millisecond

 Working voltage -24v DC
 AC immunity level – 1000 v AC

QL1-Magnetic Latch Relay
A permanent magnet at the heel piece end keeps it latched in

the operated position.
No residual pin – requires power supply for releasing the relay
Reverse/operating coil – 150 ohms (to operate)

 and normal/release coil – 680 ohms (to release).
The two coils are wound on the same core but in the
opposite directions. Feed to the operating coil is cut by the
back contact of repeater relay.
 Feed to normal coil is cut off internally with the help of a

front contact as prolonged feed may demagnetize the
permanent magnet.
QL1
QL1-Magnetic Latch Relay

Applications of QL1 Relay
TCFR, TGTR, TAR and TOLAR relays in Podanur

make push button block instruments
Working voltage --- 24 v DC
In point circuits to prove correspondence

Available in 11F/4B and 8F/6B configurations

QJ1 Relay Constructional Details
It contains a heating element (TH) and a DC neutral relay

( JSR) which combine together and operate an external relay
after a preset time.
 Heating coil is wound over a bimetallic strip of invar (an

alloy containing 64% iron and 36% nickel) at top and brass
at bottom.
 Invar has the lowest thermal expansion of any known metal

or alloy from room temperature up to 230°C
QJ1 Relay Operating
Principle
 When heated, brass expands more as compared to invar

and the bimetallic strip bends upward as one end of the
strip is fixed.
 This movement causes a set of contact to make (hot

contact) after a predetermined time.
 Closing of hot contact causes internal neutral relay (JSR)

to pick up, which in turn cuts off the feed to the heating
coil.
QJ1 Relay Operating Principle
 .There by supply to TH coil is stopped. After some time, the

heating element cools off and its arm closes with the cold
contact. This cold contact in series with a 'JSR' front contact
extends feed to an external relay (JR).
 The complete cycle of making a hot contact and then a cold

contact ensures that the thermal contacts are normalized before
each operation. This in turn results in the time delay being equal
for all operations.
 In this relay, the time lapse during the 'cool off’ of the heating
element is thrice the time lapse during its heating.
QJ1-Relay

QJ1-Relay

QJ1-Relay
A1
TPR 1 JSR
TH
* BD
TH(HOT)
JSR
* NOT REQUIRED WHERE THERE
IS NO APPROACH TRACK
JSR
TH(COLD) JSR
JR
NEUTRAL RELAY
Electronic Timer Relay

Siemens Relays
Presented
By
P.Shakila IOS5

K50 Relays
DC Neutral Line Relays
Metal-to-Metal Contacts
Proved Type

K-50 Proved Type Relays
These are metal to metal contact miniature plug in

type relays .
Manufactured by M/s Siemens
As metal contacts are used they may get welded
during operation due to sparking
Hence to avoid any unsafe operation , these relays
are made proved type.
 Proved Type – Before using its operated contact to
control a function it is ensured that the relay was in
released condition earlier.
IRS Spec. S46/74


Relay construction
As seen in the diagram, the contact springs are

stacked below the yoke which extends beneath the
core.
 The armature when de-energized rests against
stop stirrup.
 A contact bar with pins on it is rigidly screwed to
an extension of the armature.
 A pusher spring provided between the armature
extension and the stop stirrup is compressed when
the armature is attracted and helps during its release
when the relay is de-energized.

1 CONTACT BAR 7 HEEL PIECE
2 PRESSING AWAY SPRING 8.PLACE FOR RELAY TYPE MARKING
3STOP STIRRUP 9.SPRING SUPPORT

4 ARMATURE 10.CONTACT SPRING
5 RESIDUAL PIN 11.CONTACT RIVET

6 MAGNETIC CORE 12.CONTACT PIN
Pusher Armature Magnetic
spring core
Contact
bar
Contac
t pin
Contact Spring
rivet Contact spring support
General Characteristics of K-50 Relays
Plug-in, Proved type DC Miniature Relays

 Independent Type of contacts (Max 8 Nos )
 PU Time : 25- 60 m sec; Drop away time : 7 – 15 m sec.
 (For AC immunized relays : 200 m sec / 50 m sec)
 60V Operation (Range : 50-110V)
 Contact resistance – 0.05 Ohm
 Guide pins to prevent inverse plugging
 Code pins to prevent plugging of wrong type
 Contact current rating : 3 A Continuous, 5 A for 30 sec (SW)
General Characteristics of K-50 Relays
Relays are available in form of groups (Mini, Minor,

Major ).
Metal to metal contact resistance is very less hence
more number of contacts can be used in one circuit.
To reduce arcing –1)Series double break double make
contacts are used, and 2) the elliptical shape of the
contact element and cylindrical shape of contact pins
provides less contact area.3)Wiping action of contacts
also called as self cleaning.
 Standard contact arrangement –
 Front 2 3 4 6 5 4
 Back 2 3 2 2 3 4

Classification:
Relays are classified as:

A type, B type and E type on the basis of
thickness of residual pin/separating pin.
(a) K50-A type: (0.35 mm residual pin
thickness).
Non ACI Neutral, Interlocking Relays.
(b) K50-B type: (0.15mm residual pin
thickness).
ACI Neutral and UECR
(c) K50-E type: (0.45mm thickness).
ON ECR and OFF ECR

Construction, General Requirements
If a back contact remains closed accidentally,

none of the front contacts shall close even at a
supply voltage of 1.5 times the rated voltage.
If a front contact remains closed accidentally, all

other front contacts must open and none of the
back contacts should close.

K50 Neutral Relay Mini-groups
Two K50A relays with eight contacts each are fixed one
below the other on a frame fitted into a back plate.
Contact springs and coil ends of relays are connected

separately by wiring to two spring blocks with springs
extending behind.
These springs get joined with corresponding smug fitting

spring terminals on two amphenol blocks fixed on a base
plate when plugged.

K50 Neutral Relay Mini-groups
External wiring is soldered on the terminals behind the base

plate.
Two thick pins each on the blocks of group back plate enter
into corresponding holes on base blocks and ensure correct
alignment.
They also prevent relay group being plugged upside down.

Mini group Relay-
View showing coils & contacts

CLASSIFICATION OF MINI GROUPS
MINI GROUP
NEUTRAL AC IMMUNISED INTERLOCKED ECR”S
BOTH 6F/2B ONECR

6F/2B IMMUNISED
5F/3B 5F/3B OFF ECR
ONLY TOP 4F/4B
4F/4B IMMUNISED UECR
Group Coding in Mini groups :
Two code pins are provided, one at the top and one at the
bottom screwed onto the base plate .
These code pins have 8 different positions( Four at the top

and four at the bottom ) .They enter into corresponding
holes in the back plate of the relay group when a proper
group is plugged in to the base.
These code pins ensure that only a group with a similar

contact configuration can be plugged in a base.
Three different codes can be found for the three contact

arrangements of these groups.
Code pins positions for different relay
groups :
 (a) Neutral:
 5F/3B (1260 ohms)
1&6
 4F/4B (1260 ohms)
1&7
 6F/2B (1840 ohms)
1&5
 (b) Inter Locked:
 4F/4B (615 ohms)
3&7
 5F/3B (615 ohms)
6/4/2020 3&6 S19 Relaya and cables 134
 6F/2B (615 ohms)

Code pin hole
Guide pin
Relay base for

Mini group
Guide pin
Code pin hole
Coil resistance:
Neutral relays: 5F/3B and 4F/4B: 1260 ohms,

6F/2B: 1840 ohms,
Interlocked relays: All contact configurations: 615 Ohms.
(More current is required for the operation of interlocked relay
to overcome friction of latch pieces).
Lamp checking relays: 64.1 ohms. (UECR, ON / OFF

ECR).

AC immunized Relays:
Uses copper slug for AC immunization

A Brass strip is provided on contact bar to reduce the
release time. This acts as counter weight on the
armature.
Immunized to 450 V AC
Coil resistance 1840 ohms. (All contact combinations)
PU time: 200 msec. DA time: 50 msec.


INTERLOCKED RELAYS
Two neutral K-50 relays are latched mechanically to

form an interlocked relay. Top coil is called Reverse coil
and bottom coil is called as Normal coil.
Latch pieces are provided on the contact bar of a top

relay and on the armature extension of a bottom relay.
A guide bracket is provided to keep the relay in

alignment. Front contact of the R coil is proved in the
pick up circuit of the N coil externally so that the supply
is automatically cut off.
This helps to save power. Hence this is called as

Economizer contact. S19 Relaya and cables
6/4/2020 140
UTLISATION OF INTERLOCKED RELAY
a) Work As A Memory Device To Detect The Last

Operation,because It Remains Picked Up In The Last
Operated Position.
b) It Is Also Used To Achieve Direct Interlocking Between
Two Conflicting Function Such As …..
1.SHUNT AND MAIN SIGNAL PROVIDED ON THE

SAME POST Ie SH-G(R/N)R
2.Direction Determining Relay Used To Lock Two

Conflicting Signals. Zu(r/N)r

INTERLOCKED RELAY:

Contacts
Max no. of contacts is 8 in Neutral and Interlocked relays a

In ECR there are 6 contacts only.
Total terminations: 8 X 2 Contact + 2 X 2 Coil
terminations=20 for one k50 relay.
For a mini group 40 terminations are required
For 4 mini group relays will mean 160 terminations, hence a
160 way tag block is used for terminations and.
For 5 numbers of mini groups can be accommodated in one
200 way tag block.

Standard Contact configuration:
Neutral and Inter Locked 6F/2B, 5F/3B,
4F/4B
ECRs (ON/OFF) 3F/3B.
UECR 5F/1B.
Contact current rating is : 5 A
continuous and 3A switching.

Neutral and Interlocked relay
4F/4B configuration

4F/4B configuration

5F/3B configuration

5F/3B configuration

6F/2B configuration

6F/2B configuration

TERMINATION DETAILS
Contact nos. Rear view - Termination details

Left column Right column
(Bottom relay) (Top relay)
11 94 (c) 93 92 (c) 91
12 84 - - 83 82 - - 81
13 74 - - 73 72 - - 71
14 64 - - 63 62 - - 61
15 54 - - 53 52 - - 51
05 44 - - 43 42 - - 41
04 34 - - 33 32 - - 31
03 24 - - 23 22 - - 21
02 14 - - 13 12 - - 11
01 04 -Sp- 03 02 -Sp- 01
TYPES OF MINI GROUP (LINE) RELAYS &
CONTACT CONFIGURATION
Control Relays Lamp Proving Relays

Neutral Interlocked ECRs
Non ACI Both One Both On Off Route
ACI Non- ACI, ACI
ACI One
Non-
ACI
6F/2B 5F/3B 6F/2B 5F/3B 5F/3B 3F/3B 3F/3B 5F/1B
5F/3B 5F/3B
4F/4B 4F/4B

ECRs
ON ASPECT ECR

OFF ASPECT ECRS

UECR

COMPARISON OF K-50 & Q-STYLE RELAYS
Item K-50 Q-Style

Contacts Metal to metal Metal to Carbon
Operation 60V 24V
Current 33 mA – 50 mA 60 mA
Configuration 6F/2B,5F/3B,4F/4B 12F/4B,8F/8B
Coil-R 1840/1260 Ohm 400 Ohm
PU Time 25-60 m sec 150 m sec
DA Time 7-15 m sec 20 m sec
Contact R 0.05 Ohm 0.2 Ohm
Contact rating 5A/3A 2A/3A

Tag block
 100 way(96)- panel wiring

 160 way -4 nos of mini group
 200 way –one major group, 2 minor
group,5 nos of mini group
Lamp checking relays
Presented
by
P.Shakila IOS5

Lamp Checking Relays
Lamp proving Relays are current sensing D.C. line relays
They operate by power drawn from the A.C. signal lamp

circuits
A current transformer is usually connected in series with the

signal lamp circuit.
The output of this current transformer is fed to a bridge
rectifier, which in turn feeds the lamp checking relay.

Purpose of ECRs
To provide a cascading arrangement.

 To provide a Red lamp protection arrangement
 Controlling the signal in accordance with the aspect
displayed on signal in advance.
 (To provide a signal aspects indication at the
operating place.

Methods adopted for repeating the
signal aspects
Using a series resistance usually known

as potential drop method
Using a current transformer method.

BX110 HR 110/12 V
1000
HECR HG
D1-D4
HR
110/12 V
RGKE
RG
NX110
A)Potential drop method 1

When the signal lamp is lit a potential about 10 V is obtained
and this is used for light up the indication lamp connected
across the resistor. The draw back of this method is greater
drop in voltage for indication purpos

BX110 HR 110/12 V
1000
HECR HG
D1-D4
HR
110/12 V
RGKE
RG
NX110
A)Potential drop method 2
In the second method the voltage drop across the

variable resistor is rectified and the out put voltage
is utilised to operate a ECR relay. When the lamp
fuses, the current through the resistance decreases
and therefore the ECR relay drops.

(B) Current transformer method
In this method a current transformer is connected in series

with either the primary or the secondary of the signal
transformer. The output of this current transformer is rectified
and connected to ECR relay . Again in this three different
methods are followed basing on the type of transformers
used
i) 'I' type current transformer.
ii) ‘L' type current transformer.
iii) 'H' type current transformer.

Comparision of ECR relays
'I' type ‘L' type 'H' type

Usage For giving direct To energise lamp To energise lamp
indications at checking relay in checking relay in the
cabins the ECR unit at ECR unit at signal
cabin or relay room and also for checking
main filament in
Triple pole lamps
Where connected In series with the In series with the In series with the
primary of the primary of the secondary of the
signal transformer signal transformer signal transformer
Current range 0.3A on the 0.3 Amp on the 2.5 Amp on the
primary primary secondary side
Voltage drop across 7 volts 9V across 9V
the load ( ECR or a
indication lamp )
Voltage ratio
8/21/2020 10V/7V S19 Relays0.5V/9V
and cables 0.3V/9V 169
Primary/ Secondary
ECR RELAY

Siemen’s ECRs
 The Siemen’s ECR relays are supplied as mini groups. The mini
group comprises of a current transformer, bridge rectifier and a
neutral relay of K. 50 ‘E’ type.
 There are three types of Siemen’s ECR relays
 ON aspect ECR, OFF aspect ECR and UECR.
 The ON aspect ECR de-energises when the main filament of a
signal lamp is fused and the auxiliary filament is intact, so as to
draw the cabin man’s attention . This helps early detection and
replacement of lamp and there by avoiding the possibility blank
signal. This consideration is not necessary for the OFF aspect.

RECR Unit
When both filaments of the signal lamp are lit, the primary voltage
of the current transformer is about 3.4V at 300 mA current. The
relay gets a D.C. voltage of over 7V and picks up. When the main
filament of signal lamp is fused, the primary circuit current falls to
about 100 mA. The relay voltage drops to less than 2V, well below
its drop away value. The relay drops.
Since the drop away value of this relay is above 4.5V, it drops even
when the auxiliary filament of signal lamp is fused and main
filament
8/21/2020
above is lit. S19 Relays and cables 173
DECR Unit
When both filaments of the signal lamp are lit, the primary voltage of this unit
transformer is about 12.5V at 300 MA current. At that time the relay gets a
DC voltage of about 9.6V.
When main filament is fused, the primary current falls to about 50 MA. The
relay gets a voltage of over 5V which is more than its D.A. value. Hence the
relay does not drop.
When both the filaments fuse, the no load current of signal transformer, which
is less than 15 MA makes the relay to drop.
Sl.no Description ON ECR OFF ECR
.
1 Current transformer 1:3 1:1
voltage ratio
2 Amphenol terminal 1-91 1-92
no’s of relay coil
3 Relay coil Resistance 64.1 64.1
4 Std contact 3F/3B 3F/3B

configuration
5 PU voltage/current App.5 App 9
V/<340 m A v/<340 m A
6 DA voltage/current App.4V/125 App 4V/125
8/21/2020 mcables
S19 Relays and A mA 175
SIEMENS UECR Unit
The primary of the current transformer is connected

in series with the signal lamp circuit.
Its secondary voltage is rectified by D1-D4 and

smoothened by condenser C1. This voltage is
applied to the ECR relay in series with an SCR.
The SCR switches on when its gate current is > 5

MA. Also, SCR has a constant voltage drop across it
irrespective of current through it.

UECR Unit

UECR CIRCUIT
CT- Current Transformer

D1- D4- Bridge Rectifier
D5- To make relay slow to release
C1- Condenser -100 Mfd. Filtration of rectified PC
C2- Condenser - 0.1 Mfd
R1- Resistance = 33 K Ohms
R2- Resistance = 3.9 K Ohms to limit gate current
8/21/2020
R3- S19 Relays
Resistance = 10 Ohms to limit circuit and cables
current 178
UECR = K-50. 'B' Type relay
Polarised
Relay
DC Polarized Relay
 It makes different contacts for different polarities of DC

supply connected to it.
 It works on the principle that the poles of
electromagne8ts change with the direction of current.
 Application –It is used in token block instruments to
check line polarity when block handle is turned at the
other end of the section.

Operating principle of DC Polarized Relay
 In this relay, a steel strap is polarized by a permanent

magnet placed behind it and is hinged between the poles of
an electromagnet.
 A movable contact spring called 'arm' is attached to the

strap in the front.
 This Arm makes with one of the two fixed contacts on either
side when the relay is energized with alternate supply
polarities.

Polarised relay

Polarised relay

Polarised relay
Reverse
contact

Polarised relay
Norma
l
contact

Operating characteristics:
a. Rated pick up value = 21 MA

b. Resistance = 77 ohms
c. Drop away value = Not less
than 50% of pick up value.
d. AC Immunization = 10 V AC
Permitted over energisation =25ma as per SEM para
22.9.10.2
Current carrying capacity of a contact -
continuous = 1 Amp
for 30 sec = 2 Amp
f. Contact resistance = 0.25 ohms

SIEMENS THERMO
FLASHER UNIT

Principle of operation of
Thermo Flasher unit
 The thermo flasher unit is used to generate a flashing

supply to give flashing indications on the panel
 An oscillating mercury column enclosed in a U-shaped
glass tube gives the periodical flashing of about 60
impulses per minute.
 The movement of mercury column is caused by hydrogen
gas in an interconnected glass chamber. In the lower
portion of the gas chamber, a heating element is placed.

Principle of operation of
Thermo Flasher unit
 When current is passed through the filament of heater, gas

expands and exerts pressure on the mercury column in one limb.
With depression of the column in one limb, the contact of the
heating element 'g/a' breaks.
 The mercury column then returns to its original position by force

of gravity. Now, the heating circuit is closed again. This
procedure gets repeated and swings the mercury column
continuously till the external feeding circuit is opened. This
opens and closes the contacts b/a, c/a, d/a, e/a & f/a, alternatively,
which can be used for the required indication controls

Flasher Relay

Flasher Relay

Thermo Flasher unit

Parameters of Thermo Flasher unit
1. Coil (heating circuit input)12V D.C/A.C or 110V/220V AC

(With built in transformer).
2. Approx. power input 9W @ 12V and
during heating impulse 20W @ 110/220V.
3. Flashing frequency 60/ minute.
4.Current on contact - 6A @ 12V, 2A @ 110V & 1A @ 220V.

Track relays
Presented
by
P.Shakila IOS5
PLUG IN TYPE TRACK
RELAYS
1)Characteristics of relay
2)QT2
3) QTA2
4) QBAT
Factors that effect the sensitivity of
relay :
a) Force of attraction
b) Effect of Air gap
c) Effect of Hysteresis
d) Transient condition
Force of attraction:
In any electro-magnetic system, the force of attraction is

given by.
F  B2 a
Where: B - is the flux density and a - is the cross sectional
area of the particular part of the magnetic circuit.
But B is proportional to Current .So F α I2 .
This feature has got more effect on Track relay , because even
a small change in current will have a great effect on the
working of the relay
Effect of air gap:
 The difference between Pickup current and drop away

currents of the relay should be as small as possible to ensure
good shunting characteristics .
 This can be achieved by maintaining a small air gap
between core and armature
 If the air gap is not available, then the residual magnetism
fluxes might cause the armature to be retained when the
supply is disconnected.
 For this reason, residual pins are provided to ensure a
definite minimum air gap in the energised position.
Effect of Hysteresis
 Hysteresis is the property by which the flux

produced lags behind the current. High hysteresis loss
will increase PU time & DA time
 To overcome the effect of Hysteresis the relay core
is made of material having high permeability and low
retentivity (i.e, low Hysteresis loss)
 This reduces the difference between pick up value
and Drop away value. By selecting good quality core
material, Percentage release and sensitivity of the relay
will be improve.
Transient Condition
 The relay coil has certain amount of inductance which

produces back emf during energising and de-energising of
the relay.
 This causes a transition in the relay current from reaching
its maximum or minimum values . Due to this transition the
pickup time and drop away time of relay are effected.
 Transient conditions” are important so far as track relays
are concerned as they effect the release time of the track
relay
How the percentage release &
sensitivity of TR are improved
To reduce releasing time to a minimum value

• The relay iron should have low Hysteresis loss and low retentivity.
• The degree of over energization of the relay should be restricted
• Connecting a suitable external resistance in series with the relay
to keep L/R ratio low.
• Use relay with minimum contacts, as they require lesser current
which keeps inductance value low
• Train working safety is ensured only if the track relay of shortest
length track circuit is released before a light engine running at a
highest permitted speed clears it. Otherwise, the track circuit
occupation may go undetected. To avoid this, a special provision
has to be made in signal control circuits, wherever necessary.
QT2 Style Track Relay
• Similar in construction to line relay.
• Coil resistance: 4 Ohms and 9 ohms.
• 4 ohms relay is used for longer length track circuits and 9
ohms relay for shorter length track circuits.
• 2F/1B is to reduce load on armature, hence sensitive and can
operate at low voltages.
• Back contact is used for cross protection to prevent the
repeater relay from picking up in case of false feed.
• Maximum permissible excitation is 300% of the rated PU value.
(Pusher spring allows higher excitation than shelf type).
Minimum excitation is 125% of p.u.v
• % Release must not be less than 68%.
• Use: As TR in Non RE areas.
• 9 ohms relay: PU current: 103mA- 117mA, PU voltage: 1.5V.
• 4 ohm relay P U voltage: 0.3V to 0.5V.
QTA2: AC immunized track
relay.
• In this relay, a copper slug is provided on the core at its armature

end to make it immune to A.C.
• In all other respects, it is similar to QT2 relay in construction.
• Its coil resistance is 9 ohms, which can ensure A.C. immunity of
not less than 50V.
• 20 ohms coil QTA2 relays are also available.
• Due to the provision of copper slug, the relay requires more DC
operating power and it takes more time for its pick up and
release.
QTA2: AC immunized
track relay.
• Only QSPA1 relay is permitted to be used as TPR with this

track relay.
• This is because an unsafe condition shall not be created
during the catanery short circuit conditions, when A.C.
voltage drop in a track circuit rail increases manifold, the TR
may pick up under train and remain so for over 250 m sec.
• The circuit breaker in the traction power substation takes
about 300 m sec. to trip.
• In this context, QSPA1 relay’s use as TPR is safer as it takes a
longer time to pick up.
QTA2 AC immunized track relay.
• A/C Immunity level 50V AC rms.

• Contacts --- 2F/1B.
• Being sensitive relay its DC PU value should not
change by a larger extent hence the limitation on
the AC immunity, same as in shelf type.
• Max length of Track circuit is 450mtrs. (Rail voltage
drop is 10V /90mtrs of track circuit).
• QSPA1 only is to be used as repeater relay with
QTA2.
• 9 ohm relay: PU volts: 1.0 to 1.4V, PU current:
120mA to 140 mA.
QTA2 AC immunized track relay.
QBAT: Biased AC immunized Track
Relay
• This is a track relay with an improved immunity level of 80V

A.C. by the provision of a biasing permanent magnet on its
core along with its copper slug.
• This biasing by initially polarizing the core strengthens its
electro-magnetic flux created in the correct direction by coil
current.
• This takes more AC voltage to disturb the DC working flux.
• This relay also requires QSPA1 relay as its TPR for the same
reasons specified in the case of QTA2 relay.
• Construction same as QBCA1 excepting for contacts.
• Permanent M agnet is for biasing and also contributes to
raising AC immunity level.
• Copper slug for AC Immunity.
QBAT: Biased AC immunized Track
Relay.
• Contact configuration: 2F/2B.

• PU volts: 1.1 to 1.75V,
• PU current: 140mA to 175 mA.
• AC Immunity level : 80V,
• Coil resistance: 9 ohms.
• Max length of track circuit: 720mtrs and can be extended
to 750mtrs by using a choke at relay end and feed
end
• Maximum excitation: 235% of P.U.V only because of the
flux of P.M.
QBAT RELAY
QBAT
M Biasing magnet
L Copper sleeve
Signalling cables
Presented
by
P.shakila IOS5

SIGNALLING CABLES
PVC insulated PVC sheathed and armoured signalling

cables to specification IRS S63 shall be used for signalling
circuits.
The conductors used shall be of copper and of approved

size.

SIGNAL CABLE LAYING PRACTICE

TYPES OF SIGNALLING CABLES
1. INDOOR CABLES
2. OUT DOOR CABLES
3. POWER SUPPLY CABLES

OUT DOOR
INDOOR CABLE CABLE
POWER CABLE

INDOOR CABLES
1. Indoor cables are without armor wire

2. All the PVC insulated conductors are bunched and kept in thin
PVC insulation tubes
3. Available in 60C,40C,24C,20C &16Core cables
S. Dia. of the Size of core Used
No conductor
1 0.6 mm 60C,40,24C & Used for relay wiring
20C
2 1 mm 60C,40,24C & Copper single stand used for high current
16C circuits such as signal lamp circuit, point
operation circuit, gate circuits, etc.,
3 0.4mm Flexible wires Copper single stand wire used for
single indication lamps and panel wiring.
stand
4 16 stands Flexible wires Used for Q- Series relay wiring.
8/21/2020 0.2mm S19 Relays and cables 219
Indoor cable conductors can be numbered according to color
code as shown below:
1 2 3 4 5 6 7 8 9 10
Yellow with
Blue Red Grey Green Brown Black White Pink Violet
Red dots

OUT DOOR CABLES (IRS . S63)
1. These conductors used are copper conductors having equal

diameter with PVC insulation.
2. All the PVC insulated conductors are bunched and kept in PVC
insulation tube.
3. On the circumference of this tube, Galvanized iron rectangular or
circular cross section wires called armor is provided to give the
mechanical strength to protect the cable from damages.
4. On the armor PVC insulated thick tube is provided to give the more
mechanical strength and good insulation resistance in addition to
preventing the water entering inside the cable.
5. Sizes of conductors: 1.5 sq.mm., 2.5 sq.mm. and 4 sq.mm.
6. Cables available in 2C, 4C, 6C, 8C, 9C, 12C, 18C, 20C, 24C and 30C.
OUT DOOR CABLES (IRS . S63)
7. Conductors bunched in the form of layers.

8. Numbering is started from outer most layers of conductors and
each layer numbering starts from Blue color, then Gray and layer
end with Yellow.
Core Color Layers
2C Red and Black
4C Blue, Black, Red and Yellow
12C Blue, Grey and Yellow Outer layer (9 conductors)
Blue, Red and Yellow Inner layer (3 conductors)
30C Blue, Grey and Yellow Outer layer (16 conductors)
Blue, Grey and Yellow Second layer (10 conductors)
Blue, Black, Red and Yellow Last layer (4 conductors)
SCREENED CABLE
PAPER
OUTER METALLIC INSULATION
CORE ARMOUR SHEATH SHEATH
UN SCREENED CABLE
CORE
INNER
OUTER
ARMOUR
8/21/2020 S19 Relays andSHEATH
cables 223
SHEATH
Outer 1 2 3 4 5 6 7 8 9 10
Layer Blue Grey Grey Grey Grey Grey Grey Grey Grey Yellow
Inner 10 11 12
Layer Blue Red Yellow
30 1st Layer (Outer 1 2 - 15 16

most Layer) Blue Grey Yellow
CORE 17 18 - 25 26
: Outer Layer
Blue Grey Yellow
8/21/2020 3rd Layer (Inner 27 S19 Relays
28 and cables29 30 224
Layer) Blue Black Red Yellow
12 CORE CABLE
Outer 1 2 3 4 5 6 7 8 9 10
Layer Blue Grey Grey Grey Grey Grey Grey Grey Grey Yellow
Inner 10 11 12
Layer Blue Red Yellow

30 CORE CABLE
1st Layer (Outer 1 2 - 15 16

most Layer) Blue Grey Yellow
17 18 - 25 26
Outer Layer
Blue Grey Yellow
3rd Layer (Inner 27 28 29 30
Layer) Blue Black Red Yellow

POWER SUPPLY CABLES
1. PVC insulated screened and armored cable to IRS. S35/1970.

2. Any metallic sheathed armored cable having a cable reduction
factor of not more than 0.4 at a field strength of 87.5 to 450
v/km
3. Paper insulated lead sheathed and armored IRS. E 17/1959.
4. Conductors are alluminium & copper.

POWER SUPPLY CABLES
Dia. (sq.mm) Core
70 (Alluminium) Single strands 3 & 3½
25 (Alluminium) Multi strands (7) 2, 3, 3½ & 4
10 (Alluminium) Single strands 2
8 (Copper) Single strands 2
6 (Copper) Single strands 2
Cable Numbering: 01 24 (4) or 02 18 (4) or 03 24 (6)

First two no’s indicates - S. No.
Second two no’s indicates – Core
In brackets indicates – Spare; M- main; T- tail; P- power cable
LAYING OF SIGNALLING CABLES
 All signalling circuits are transferred to underground

cables.
 Only un screened cable should be used.
 Screened cable already existing to be continued.
 The main cables shall ordinarily be PVC insulated and
armored cable to IRS S – 63.
 Insulation resistance of each core shall not be less than 5
Mega ohms/km at 50 degrees.

LAYING OF SIGNALLING CABLES
PLANNING:
1. Determine number of conductors required.
2. Adequate spare conductors min. of 10% of the total conductors
used shall be provided in each cable
3. No spare conductors are required if the total number of
conductors used is three or less.
4. After deciding the size and the no. of conductors , a foot survey
along the track should be taken, as far as possible, to avoid water
mains, oil pipes, drain/sewage pipes, water columns etc.,
5. Before starting the trench work approval shall be taken from
P.WAY/ELECTRICAL departments.

TRENCH
 Width of cable trench 0.46 Mtrs.

 The cable laid parallel to the track normally be buried at a depth
of 1 Mtrs. from ground level.
 In theft prone area depth of 1.2 Mtrs. with anchoring at every 10
Mtrs.
 Out side the station limits, the cable should generally be laid not
less than 8 to 10 Mtrs. from the centre of the track.
 With in station limits, the cable shall preferably be dug at a
distance not less than 5.5 Mtrs. from the centre of the track in RE
area.
TRENCH
 With in station limits, the cable shall preferably be dug at a

distance not less than 3 Mtrs. from the centre of the track in
non- RE area.
 When signalling and main telecom cables are laid in the same
trench, a distance of 100 mm is to be maintained between
them.
 When signalling cables and LT or HT power cables are laid in the
same trench, they must be separated by a row of bricks
between them.

TRENCH
 The bottom of the cable trench shall be levelled and sharp

materials, if any, shall be got rid of. In case of soft ground, the
cable shall be laid at the levelled bottom. In case, the ground is
rocky, the cable shall be laid on a layer of sand of 50mm thickness
deposited at the bottom of the trench.
 In both the above cases, the cable shall be covered with a layer of
sand or "Sifted" earth of 100 mm thickness as a protection and
provide bricks on the layer and filled.

While cross the track
 The cable crosses the track right angles.

 The cable does not cross the track under points and
crossings and
 The cable laid in concrete or GI or PVC pipes or suitable ducts
or in any other approved type.
 While crossing track 1 Mtrs. below the rail flange.
 Cables are to be laid with in 1Mtrs. from sleeper end, digging
beyond 0.5 Mtrs. shall be done in the presence of an official
from engineering department.

While cross the track
 When cable have to cross a metallic bridge, they should be

placed inside a metallic trough which may be fitted, as an anti
theft measure, with sealing compound. Adequate cable length
to the extent of 2 to 3 Mtrs. shall be made available at the
approaches of bridges.
 Cable markers shall be provided at suitable internal at diversion
points.
 At each end of the main cable an extra loop length of 6 to 8
Mtrs. Should be kept.
 For recognizing deferent cables in case of faults etc., the cable
shall be laid in an order from track side.
8/21/2020
Telecom cable. Signal cable.
S19 RelaysPower
and cables cable. 235
ADDITIONAL PRECATIONS IN RE-AREA
1.AT OHE STRUCTURE:-

 Cable depth does not exceed 0.5 Mtrs., cable trench
should be 1 Mtrs. away from the OHE mast.
 Cable depth exceeds 0.5 Mtrs., a minimum distance of
3 Mtrs. between the cable and the nearest edge of the
OHE mast.
 If it is difficult to maintain these distances, the cable
shall be laid in concrete / HDPE / Ducts / any approved
means for a distance of 3 Mtrs. on either side of the
mast. Where so laid, the distance between the cable
and the mast may be reduced to 0.5 Mtrs.
2.Sub Station and Feeding posts

 As far as possible, the cable shall be laid on the
side of the track opposite to the Feeding post.
 The cable shall be at least 1 Mtrs. away from any
metallic part of the OHE and other equipment at
the Sub station which is fixed on the ground and at
least 1 Mtrs. away from the Substation earthing.
 In addition, the cable shall be laid in concrete or
heavy duty HDPE or split RCC pipes or other
approved means for a length of 300 Mtrs. on either
side of Feeding post.
3. SWITCHING STATIONS
 The cable shall be laid at least 1 Mtrs. away from
any metallic body of the station, which is fixed in the
ground, and at least 5 Mtrs. from the station earthing.
 The distance of 5 Mtrs. can be reduced to 1 Mtrs.
provided the cable are laid in concrete pipes or
heavy duty HDPE or ducts or any other approved
means.
4. Where are independent earth is provided for an OHE

structure i.e., where the mast is connected to a
separate earth instead of being connected to the rail,
the cable shall be laid at
8/21/2020
least 1 Mtrs. away from the
S19 Relays and cables 238
earth.
INSTALLATION
Testing cable before laying :

1. Visual inspection of cable.
2. Cable shall be tested for insulation and continuity.
3. The insulation resistance of new cable shall not be
less than 200 mega ohms per km. at 20 degree
centigrade.

INSTALLATION
Paying out the cable:

1. The cable drum shall be mounted on cable wheels.
2. The drum on the wheel shall be brought to one end of the trench
and laid in the trench.
3. The drum on wheel shall then be rolled along the road or track.
4. Wheel are not available, the drum shall be mounted on axle at
one end of the trench and cable payed out.
5. Cable should be carried by adequate number of men ensuring that
the cable is not damaged and no kink is formed.

Testing Of Cables for Faults
The common faults which develop on

conductors of multi-core signaling cables are:
i) Earth
ii) Short-Circuit
iii) Open -Circuit.

Earth fault
Earth fault develops in a conductor due to

defective insulation, which allows the current,
carried by the conductor to leak to the earth
directly or indirectly instead of going to the
apparatus to which the conductor is connected

Short circuit occurs when a connection or short
develops due to defective insulation between two or
more conductors where no connection should exist.

Open circuit: It develops if a break occurs in a
conductor.

Method of Testing with a Megger
Megger used for testing signaling cables is of 500 Volts

DC. For telecom cables is of 110 Volts DC.
 All the above mentioned common faults which

develop on conductors of multi-core signaling cables can
be detected by testing with a megger.

To Test for an Earth fault:
If the conductor to be tested in the use, both ends must first be
disconnected from the circuit of which it forms part.
One end is then connected to the megger terminal marked for
line. The next step is to connect the other megger terminal E
(EARTH) to a good earth.
Then rotate the megger handle about 80 RPM and while doing
this observe where the pointer comes to rest on the scale.
 If the pointer rests at ZERO, there is a full earth fault in the
conductor.

To Test for an Earth fault:
If it rests at INF (INFINITY), it indicates that the insulation of the

conductor is O.K.
 When the megger handle is rotated a voltage is generated
which tries to pass a current through the conductor. No current
will flow, however, if the insulation is in order as the circuit is
not complete. An earth fault, however, will complete the circuit
and a current will then pass through the circuit

To test for a short circuit.
The conductors if in use, must first be disconnected.

Then connect them to and rotate the megger handle.
 It will megger be obvious from the diagram that, if
there is no connection between the conductors, no
current can flow, and the pointer will come to rest at
INFINITY.
If, however, the conductors are in contact, a circuit is
formed, and the current will cause the needle to indicate
ZERO.

To Test for an Open Circuit:
This test can be made in two different ways. One is made

by using an earth return, and the other is made by using
another conductor known to be o.k. When using an earth
return, first connect one end of the conductor to the
megger terminal L. Then connect the other megger
terminal to good earth. The far end of the conductor
should also be connected to a good earth If a second
conductor is used to make the test, connect up In both
cases, if the conductor under test is unbroken, a circuit is
formed, and, when the megger is operated, the pointer
will indicate ZERO. Should, however, the conductor be
broken the pointer will indicate INIFINITY.
1 SHORT 1
E L
2 2
E
E L
BREAK WIRE
OR
OPEN CIRCUIT
E L
BREAK WIRE
OR
OPEN CIRCUIT

Testing of cable insulation
Insulation Resistance tests should be made in such a

manner that safe operation of trains is not affected.
While conducting the tests, it should be ensured that
no unsafe conditions are set up by the application of
test equipment.
All conductors in signaling cables must be tested for

their insulation in dry weather every year preferably
during the same part of the year.

The insulation Resistance Tests should be made when

conductors, cables and insulated parts are clean and
dry.
In addition to regular testing of the cable in dry

weather, random tests in wet weather may also be
carried out where considered necessary. Spare cores
may be tested for insulation once a year during
monsoon periods to check.

The conductors of the cables possess appreciable electrostatic

capacity and may accumulate electrostatic charge. The cable
conductors should be shorted or earthed to completely discharge
any accumulated charge:
(i) Before connecting the insulation tester while commencing the
test and
(ii) before the Insulation tester is disconnected when the test is
completed.
This is in the interest of safety of personnel and protection of
equipment.

A 500V insulation tester should be used for insulation testing.

The insulation resistance should therefore be recorded after the
test voltage has been applied for one minute or so when the
indicator of the insulation meter shows a steady reading.
Any metallic sheath or metal work of any rack or apparatus
case should be bonded to earth during test.

Procedure: Disconnect all cores of a cable at

both ends. The disconnection may be made
through links of ARA terminals if provided.
Connect one terminal of the insulation tester to
the conductor under test and other terminal to all
the other conductors being bunched together and
connected to earth.

Procedure: Connect one terminal of the insulation

tester to the conductor under test and other terminal
to all the other conductors being bunched together and
connected to earth.
Similarly, test remaining conductors of the cable one by
one
Insulation resistance so measured should not be less
than 20 mega ohms irrespective of the length of cables.
In such cases where it is less than 20 mega ohms, the
periodicity of testing should be increased to twice a
year.

Procedure If the insulation value is found to be less than

10 mega ohms, the cause should be investigated and
immediate steps taken to repair or replace the cable to
prevent any malfunctioning of the equipment and
circuits. The conductors, which are showing below 05
mega ohms, should be identified and till the defects are
rectified, these conductors shall not be used for any
circuit. Such defective conductors shall be provided with
distinctive markings at both the ends of termination for
ease of identity during normal maintenance

Earth leak indicators & Earth leak protectors.
The use of these devices may also be
considered for modern signalling installations
such as Route Relay, Interlocking, Panel
Interlocking & Centralised traffic Control
systems.

Proforma for Cable Testing
____________ Railway
Station ___________________
CABLE INSULATION RESISTANCE TEST SHEET
Main/Tail* Cable
1. Location: From . . . . . . . . . . . . . . . . To . . . . .. . . . . . .
....
2. Cores: .
3. Size: .
4. Grade 250/440/650/110OV
5. Length:
6. Type: Unscreened/Screened
7. Insulation: PVC/Paper *
8. Date of installation/Commissioning . . . .
9. Name of the manufacturer: . . . . . . . . . . .
* Strike out whichever is not applicable.
- - - - - - -
- - - - - -
Core No. Date of Test
or Designation and whether
wet, damp or dry.
- - - - - - -
- - - - - -
Temperature:
Remarks:
Signature
These instructions are to be followed in addition to those contained in paras 614 to 618, 623 to 625, and
963/964 of the Signal Engineering Manual (Given in Annexure ‘A’)

TESTING OF SIGNALLING CABLES
Various faults develop in cable are

a) Earth faults
b) Open circuit fault and
c) Contact fault
Methods of testing generally the following methods are
used for testing of cables.
a) Megger method
b) Volt meter method
c) Testing lamp method
Among the above megger method prefers for signalling
cable testing meggering requires
a) 500 V insulation tester.
b) good earthing arrangement and
8/21/2020 c) communication S19arrangement.
Relays and cables 260
Difference between Screened and Un
Screened Cable
s. Screened cable Unscreened cable

no
1 IRS specification S-35/93 IRS specification S-63/07
2 It is PVC insulated metal It is a PVC insulated armoured
sheathed armoured cable cable
3 Cable screening factor 0.4 No screeining factor
4 Manufacturing cost more Manufacturing cost less
5 No more use in future In future installation only to be
Installation used Unscreened cable

CABLE SCREENING FACTOR
If any conductor lies in the magnetic field of the main source,
it reduces the induced voltage of the S&T conductor. This
property has been taken advantage of in the manufacturing of
cables.
While the cable cores are individually insulated and provided
with insulated sheathing to make them compact, one more
metallic sheathing is provided over this. The entire cores and
metallic sheath are then covered by an insulated overall
sheathing. This metallic sheathing can be in the form of an
aluminium extruded pipes or strips of Aluminium covering the
cores. These type of cables are called screened Cables.

In considering the screening effect of a cable sheath one must

distinguish between the voltage of the core to the sheath and
voltage of the core to the earth. If the metallic sheath is
insulated from earth, identical voltages are induced in the
sheath and core. The voltage between them is zero. At the
same time, the metallic sheath does nothing to reduce the
voltage between core and earth.
It is, for this purpose, earthing of cables sheath at frequent
intervals is insisted upon for providing an effective screening.

To reduce the voltage in the core, the sheath must have a current
flow, the field of which opposes the field induced by the current in
the catenary. For it to carry such a current, the cable sheath to be a
part of a circuit that is completed through the earth. A.C sheath that
insulates from earth or earthed at one place only, no screening effect
on the Voltage between core and earth.
The induced voltage in the core reduces considerably by using

screened cables. The extent by which the induced voltage is reduced
is called as "Screening Factor“.

• Metal sheathed cables were used (with earthed

sheaths) which provided screening effect due to
induced currents in them.
Screening Factor = Voltage induced in a screened
cable/ Voltage induced in an unscreened cable
typical value for a signaling cable – 0.4

Why un screened cable only used?
1. If screened cable is used cable screened factor
should be 1 instead of 0.4.
2. Screened factor can’t be maintained in India.
3. To maintain screening factor 1, earth resistance
required almost negligible ( less than 1 ohms ). So,
it may not possible in India.


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Signalling Relays

8/21/2020 S19 Relays and cables 1

The orthodox mechanical signalling system was replaced

Two essential components are widely used in all the

8/21/2020 S19 Relays and cables 2

8/21/2020 S19 Relays and cables 3

A relay is an electromagnetic device used to convey

8/21/2020 S19 Relays and cables 5

 Relays can switch AC and DC, transistors can only

8/21/2020 S19 Relays and cables 6

 Relays are bulkier than transistors for switching small

8/21/2020 S19 Relays and cables 7

1 Based on their application,

8/21/2020 S19 Relays and cables 8

8/21/2020 S19 Relays and cables 9

8/21/2020 S19 Relays and cables 10

8/21/2020 S19 Relays and cables 11

2 Based on type of contact material used

3 Based on polarity requirement

8/21/2020 S19 Relays and cables 12

4. According to their importance in ensuring train

8/21/2020 S19 Relays and cables 13

5. According to special provisions to ensure reliability

8/21/2020 S19 Relays and cables 14

6. Based on the source of feed

8/21/2020 S19 Relays and cables 15

b) AC relays : AC induction motor track relays are used at some

8/21/2020 S19 Relays and cables 16

The power signalling systems on our railways follow

(1) The British Railway practice and

These two systems have an individual language of

8/21/2020 S19 Relays and cables 17

1 N Switch / Knob Contact in Normal Position

2 R Switch / Knob Contact in Reverse Position

Closed Contact when Relay is in Energised condition

Closed Contact when Relay is in de-energised condition

6 Slow to release Relay

7 Slow to pickup Relay

10 Time Element Relay front Contact (Energised Condition)

11 Time Element Relay front Contact (de-Energised Condition)

11 Time Element Relay front Contact (de-Energised Condition)

12 Flasher Relay contacts

(3-Position Polar Relay) (independant type)

(3-Position Polar Relay) (independant type)

(3-Position Polar Relay) (independant type)

R (2-Position Polar Relay) (independant type)

8/21/2020 S19 Relays and cables 21

8/21/2020 S19 Relays and cables 23

2 Interlocked Relay Reverse Coil

3 Interlocked Relay Normal Coil

5 Track Repeater Relay

6 Block Relay in Automatic Territory

7 T Time Element Relay

8 Indicates that a Neutral relay is normally energized

9 Indicates that a Neutral relay is normally de energized

Make contact of a Neutral Relay that is normally picked up

16 Make contact of a Neutral Relay that is normally drop

Break contact of a Neutral Relay that is normally drop,

Make contact of a Interlocked Relay that is normally latched,