GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

Maintenance Instructions for

LED Signals

CAMTECH/S/PROJ/2019-20/SP5A
March 2020

Maharajpur, Gwalior (M.P.) - 474005

 Contents
Maintenance Instructions for LED SIGNAL .. 1
1. Introduction .................................... 1
2. Advantages ..................................... 2
3. Specifications ................................. 3
4. Important parameters ...................... 5
5. Measurement of voltage .................. 8
6. Measurement of Current ................. 9
7. Earthing, Fuse & MOV ................. 11
8. Maintenance ................................. 13
9. Testing ......................................... 17
9.1 Route Signal .................................. 17
9.2 Main Signal ................................... 19
9.3 Insulation resistance test ................ 20
 9.4 Check for lamp, CR and
Correspondence of ECR & Fuse
terminal block. .............................. 21
9.5 Check for Lamp, CR and
correspondence of ECR ................ 22
10. General Precautions ...................... 25
11. Monsoon precautions .................... 27
12. Do's & Don'ts ............................... 29
 CAMTECH/S/PROJ/2019-20/SP5A 1

Maintenance Instructions for

LED SIGNAL
1. Introduction
This is surface mounted Light Emitting Diode
(LED) based signal lighting unit with
transparent cover of UV painted in matte
(dull) finish, to prevent reflection of sunlight
or headlight of loco. LED based signal
lighting unit is the replacement of the hitherto
used signal lamp.

LED signal has two components - LED

aspect and current regulator. LED aspects
suitably fits into light unit frame in the
existing CLS housing and the current
regulator replaces the CLS transformer. LED
based signal units work at 110 Volt ± 20% on
both AC and DC supply.

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2. Advantages
LED signal unit offers the following
advantages.
 Life of LED signal is about 1,00,000
hours.
 Provides comprehensive protection against
lightening and/or surge voltages.
 Provides higher noise immunity and
failure free operation.
 Focusing is not required.
 Power consumption is reduced to about
50%.
 Requires very low maintenance.

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3. Specifications
Old Specifications

RDSO/SPN/153/2011 Revision: 4.1 (Draft) -

For Main and Secondary Signal Lighting
Units.

RDSO/SPN/199/2010 Revision: 1.0 - For

Integrated Signal Lighting Units.

New Specifications
RDSO Spec. No. RDSO/SPN/199/2010 Rev.
1.0 - For Main colour light signals (Integrated
Signal Lighting Units)

RDSO Spec. No. RDSO/SPN/153/2018 Rev.

5.0 (Draft) - For Subsidiary colour light
signals (Shunt, Route Calling-On)

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(i) Main Signal Wiring Diagram as per

RDSO/SPN/153/2011 Revision: 4.1

(ii) Main Signal Wiring Diagram as per

RDSO/SPN/199/2010 Revision: 1.0

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4. Important parameters
 The minimum visibility distance of Main
signal LED signal lighting Units shall be
600 m. in clear daylight with peak sunrays
at rated voltage.

 The minimum visibility distance of

Direction type Route Indicator with three
lit LED signal lighting units shall be 400
m. in clear daylight with peak sun rays at
rated voltage

 The minimum visibility distance of LED

signal lighting units, other than Main and
Route signal lighting units, shall be 200 m
in clear daylight with peak sunrays at
rated voltage.
Maint. Instructions for LED Signals March '20
 Parameter Main Calling- Route Shunt
Signal on Signal Lighting Lighting
unit unit
Rated voltage at 110V 110V AC 110V AC 110V AC
Input terminals AC ± 20% ± 20% ± 20%
of Current +25 %
Regulator
Operating parameters

Current at rated 140 150 mA 25 mA 55 mA

voltage per unit mA +10%, ± 5%(rms) ± 5%(rms)
at Input +10%, -20%
CAMTECH/S/PROJ/2019-20/SP5A

terminals of -20% (rms)

Current (rms)
Regulator *
Colour Red Yellow Lunar Lunar
6

,Yellow White White

Maint. Instructions for LED Signals March '20

Green
CAMTECH/S/PROJ/2019-20/SP5A 7

In blanking mode, a Main Signal Lighting

Unit shall extinguish when input current
drawn by the current regulator falls outside
specified limits of rated input current or
illumination falls to a value which is not less
than 40% of nominal illumination due to a
failure or any other reason. In such case,
current regulator should not draw input
current more than 30 mA at maximum rated
voltage.

In non-blanking mode, a Main Signal

Lighting Unit shall remain lit when input
current drawn by the current regulator falls
outside specified limits of rated input current
or illumination falls to a value which is less
than 40% of nominal illumination due to a
failure or any other reason. In such case, input
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current drawn by current regulator shall be

limited to less than 40 mA to ensure dropping
of ECR. Limit on input current shall apply
when illumination has deteriorated to a value,
which is not less than 40% of nominal
illumination.

As per RDSO guidelines, for RED aspect,

Non – Blanking mode should be selected in
Current Regulator & for Green Aspect, the
Blanking mode should be selected. For
Yellow aspect, it should be selected based on
installation.

5. Measurement of voltage
Measure the rated voltage at Input Terminals
of Main LED Signal Lighting unit or in
location box.

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(i) Main Signals

Specified range in rms @ 50 Hz –
82.5 V to 137.5 V AC
For use in tunnels in Metro Railway
Kolkata
Specified range in rms @ 50 Hz –
88 V to132 V AC

(ii) Subsidiary Signals

(Route, Calling –on & Shunt)
Specified range in rms @ 50 Hz –
88 V to 132 V AC

6. Measurement of Current
Measure the current at rated voltage per unit
at CT Rack or LED Lamp Proving Relay coil
terminal.
(i) Main Signals
Specified range in RMS @ 50 Hz –
110 to 150 mA
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For Main Signals of High Speed lines

(165 Kmph)
Specified range in RMS @ 50 Hz –
60 to 100 mA

For Main Signals in tunnels in Metro

Railway Kolkata
Specified range in RMS @ 50 Hz –
112 to 154 mA

(ii) Shunt Signals

Specified range in RMS @ 50 Hz –
52.25 to 57.75 mA
(iii) Route Signals
Specified range in RMS @ 50 Hz –
23.75 to 26.25 mA
(iv) Calling-On Signals
Specified range in RMS @ 50 Hz –
120 – 165 mA

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7. Earthing, Fuse & MOV

Sr. Item Specified
No. value/range
1 Signal unit earthing <10 Ohms
2 MOV connected to
MOV I/P terminals of
aspect.
(i) Integrated type 175 Volts
LED Signal units
as per RDSO
Spec. 199/2010
Rev. 1.0
(ii) Subsidiary LED 200 Volts
Signal units as per
RDSO Spec.
153/2018 Rev.5
(Draft),
3 Fuse provided in fuse
terminal block.

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Sr. Item Specified
No. value/range
(i) Integrated type 400 mA
LED Signal units
as per RDSO
Spec. 199/2010
Rev. 1.0,
(ii) Subsidiary LED 630 mA
Signal units as per
RDSO Spec.
153/2018 Rev. 5
(Draft),
4 Glass fuse inside the
LED Signal Lamp is of
the rating
(i) Main Signal NIL
(ii) Shunt Signal 250 mA
(iii) Route signal 250 mA
(iv) Calling-On Signal 630 mA

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8. Maintenance
(a) Clean the LED signal lighting units, all
terminals and current regulator
periodically with soft cloth.

(b) Check that all terminals in CT racks,

junction box, LED signal lighting unit,
CR and fuse terminal block are tight and
clean.

(c) Check fixing of protective caps on the

input supply terminals of CR and
protective covers on the jumpers
selection where applicable. Otherwise it
may be the cause of false operation.

(d) Ensure that interconnecting cable

between CR and LED/Signal lighting
Unit is properly connected and tight.
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(Not applicable for Integrated type LED
lighting units).

(e) Ensure that mounting screws of LED

Signal Lighting Unit, CR and fuse
terminal block are properly fixed.
Note:
LED Signal Unit should be mounted on 4
holes provided in existing signal unit. (In
case of replacement in existing signal
unit, Outer lens, Inner lens, CLS
transformer, MECR, Bulb holder & Bulb
should be removed.)

(f) Tighten all terminals in CT rack, junction

Box, LED Signal Lighting Unit, Current
Regulator, Route Signals, Shunt Signals
and Calling-On Signal periodically or as
per instructions given by the railways.

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(g) Ensure that mounting bolts/screws have
been tightened for LED signal lighting
unit and current regulator unit once in a
six month or as instructed by railways.

(h) Ensure that LED signal does not vibrate

during the running of trains.

(i) Ensure that the all LEDs of LED signal

lighting unit are properly lit.

(j) The connections in the location boxes

should be cleaned for removing oxidation,
rusting etc. regularly.

(k) After any check opening/refitting CRC

spray should be provided.

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(l) The LED signal lighting unit clear lens
should be cleaned once in a six month to
remove the dust with anti-static soft cloth
or as per instruction given by the
railways.

(m) Ensure that the AC supply used for

lightening the LED Signal Lighting units
is pure sine wave (i.e.50Hz±2 Hz).

(n) Check periodically and ensure that signal

housing door is kept shut and locked
properly.

(o) Safety validation test as per the pre-

commissioning check list may be
conducted once in a year.

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9. Testing
The following testing should be carried out as
per schedule of maintenance (Monthly) or as
per the instructions issued by the Railways:
9.1 Route Signal
The signal is cleared for diversion and all
the five route LED lighting units are lit
in parallel. Ensure that ECR is pick up
with five route LED signal lighting units
lit. (UECR PU - 90 mA, DA- 60 mA)
On removal of one route LED unit
– UECR should remain pick up.
(As current = 4X 25mA =100mA)
On removal of 2nd route LED unit
– UECR should remain pick up.
(As current = 3X 25mA =75mA)
On removal of 3rd route LED unit
– UECR should drop.
(As current = 2X 25mA =50mA
which is less than DA value =60 mA)
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Note:
As per RDSO Spec. No. STS/E/Relays/AC lit
LED Signal/09-2002 Amdt. 1. The pick up
current of AC LED UECR is 90 mA when
connected in LED lamp circuit.
If on clearing the signal for diversion, only
three route LED lighting units are lit then
the UECR shall not pick up as the three
lamps will draw a current of 25mA X 3 = 75
mA only.

UECR shall pick up

only when minimum
4 route LED lighting
units are lit on
clearing the signal
for diversion. In this

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case the current drawn shall be 25 mA X 4 =
100 mA which is more than the PU value.

9.2 Main Signal

(a) Ensure that cascading of the signals
is working properly.

(b) Ensure that current regulator draw

proper current while LED signal
lighting unit is lit and the concerned
ECR is picked up.

(c) Ensure that most respective aspect is

in non-blanking mode and other
aspects are in blanking mode.

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(d) Check correspondence of ECR for
main signals by disconnecting the
interconnecting cable.

9.3 Insulation resistance test

Check the insulation resistance as given
below after every six months or as per
instructions issued by the Railways:

 Check that insulation resistance for

LED signal lighting unit, current
regulator and health monitor unit with
500 Volt megger between the body
and the current carrying terminals
shall not be less than 100 M Ohms.

 Check that the insulation resistance of

cable conductor connected for lighting

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 CAMTECH/S/PROJ/2019-20/SP5A 21
the LED signal lighting unit shall not
be less than 100 M Ohms.
9.4 Check for lamp, CR and Correspondence
of ECR & Fuse terminal block.

(a) After taking (i) Aspect at site

off signal extinguishes and more
remove the restrictive aspect lights
fuse in the (In case of RED aspect
Fuse signal in rear goes to
terminal danger)
block. (ii) Fuse blown
indication appears on
terminal block.
(iii) ECR of the aspect
drops
(b) Restore the (i) Aspect at site lights
fuse in fuse normal
terminal (ii) ECR of the aspect
block picks up

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9.5 Check for Lamp, CR and correspondence
of ECR
(a) After taking OFF an (i) Aspect at the
aspect disconnect site
interconnecting cable extinguishes
between CR and LED and more
Signal Lighting Unit
restrictive
from LED Signal
lighting Unit (In case
aspect lights
there are two Inter (In case of Red
connecting cables aspect, signal
between CR and LED in rear goes to
Signal Lighting Unit– danger.)
Disconnect the Cable (ii) ECR of aspect
other than optical drops.
sensing cable. The
cable with 2 pin
connector is optical
sensing cable.)
(b) Reconnect (i) Aspect at site
disconnected cable lights normal
and take off the (ii) ECR of the
aspect again aspect Picks up
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(c) Disconnect the (i) In case CR is
optical sensing configured for
cable (i.e. 2 pin Non-blanking
round cell mode. Aspect
connector) from at site lights
LED signal lighting with
unit. deteriorated
illumination
with input
current of CR
restricted to <
40 mA.
(ii) In blanking
mode Aspect
at site
Extinguishes
with input
current
restricted to <
30 mA.
(iii) More
restrictive
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aspect lights
(In case of
Red aspect,
signal in rear
goes to
danger.
(iv) ECR of the
aspect drops

(d) Reconnect (i) Aspect at site

disconnected cable lights normal.
(ii) ECR of the
aspect picks
up

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10. General Precautions
1. LED signal lighting units shall only be
used with LED ECRs as per RDSO
specification STS/E/Relays/AC Lit LED
Signal/09-2002 as applicable.

2. LED signal lighting unit should be stored

in suitable cover provided with
thermocol packing on the inner side
surface.

3. True RMS Meter must be used for

measurement of current and voltage in
the input supply.

4. As per Pre-commisioning Check List,

LED Signal Lighting unit should be kept
in Burn in test for 168 hours before
putting in to use.
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CAMTECH/S/PROJ/2019-20/SP5A 26
5. Individual ECR is provided for every
signal aspect

6. Every Aspect has Individual return path.

7. Ensure that all connections are proper

and tight.

8. Ensure MOV is connected to MOV I/P

terminals of aspect

9. 400mA fuse should be used in fuse

terminal block. Don’t use fuse rating
more than 400ma for integrated signals.

10. 630mA fuse should be used in fuse

terminal block. Don’t use fuse rating
more than 630ma for Main signals.

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 CAMTECH/S/PROJ/2019-20/SP5A 27
11. Monsoon precautions
Ref.: Annexure to letter no.
2015/SIG/SF/Monsoon Precautions dtd.
12.05.2016.

(a). All signal units shall be examined to

check the possibility of water
seepage/leakage inside the Signal Units.

(b). Signal units have to be sealed with

proper gasket to prevent seepage of
moisture/water. All signal unit lamps
should be completely sealed including
any holes to prevent moisture ingress.

(c). Additionally a plastic cover wherever

required shall be provided and on the
back of the Signal units, in case,
leakage/seepage persists.
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CAMTECH/S/PROJ/2019-20/SP5A 28

(d). After the first showers, the signal units

have to be re-examined and action to be
taken to avoid water seepage/leakage.

(e). Any mechanical discrepancies/damages

in the signal units should be attended to
ensure that the unit cover fits properly on
the body and the locking arrangement is
proper and watertight.

(f). Strengthening of foundations of signal

posts/location boxes should be done
wherever required.

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 CAMTECH/S/PROJ/2019-20/SP5A 29
12. Do's & Don'ts
Do’s

 Select Blanking / Non-blanking mode in

Current Regulator as desired. (ONLY for
YELLOW aspects)

 All terminals in CT racks, junction box,

LED signal lighting unit, are tight and
clean.

 Connect only110V AC supply to the

units, as these are AC lit units.

 Polycarbonate cover of LED signal

lighting unit may be cleaned with soft
cloth periodically.

 Ensure that protective caps are replaced

once terminations and selections are
made.

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 Ensure MOV is connected between input
terminals of MOV connector
 Ensure of fixing of protective caps on the
input supply terminals of Aspect

 Ensure fixing of protective covers on the

jumpers selection where applicable

 Before Commissioning, follow the steps

provided in Pre-commissioning checklist

Don'ts

 Don’t leave loose connectors or wires at

LED Signal lighting units. This may
cause false operations.

 Don’t use fuse more than the specified

ratting, always use rated fuse.

 Don’t carry units by its cables.

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 Do not give 110 V DC supply to the

units.

 Do not wipe LED signals with moist OR

dusty cloth.

 Do not try to open the unit as it is sealed

for environmental protection.

 Do not use fuse other than 400 mA in the

circuit

 Do not ignore selection of protection

mode. (Blanking / Non-blanking), in case
of YELLOW aspects.



Maint. Instructions for LED Signals March '20

 गु णव ा नी त
“आर. डी. एस. ओ.” लखनऊ म हम सतत सुधार और
ाहक मू यांकन ा त करने हे तु गुणव ा बंध
णा लय को आव धक समी ा के मा यम से रे ल म
या ी एवं माल यातायात क बढ़ती आव यकताओं,
मांग और अपे ाओं को पूरा करने के लए गुणव ा
बंध णाल क यावहा रक आव यकताओं और
अनवरत सुधार को पूरा करने के समपण, गुणव ा
उ दे य को नधा रत करके अनुसध
ं ान, अ भक प
और मानक म उ कृ टता के मा यम से वैधा नक
और नयामक अपे ाओं का अनुपालन करते हु ए
सु र त, आधु नक और कफ़ायती रे ल ौधो गक
वक सत करने हेतु सेवाओं को बनाए रखने और
अ यतन पारदश मानक हेतु तब ध ह । इसे
संगठन के अंदर संसू चत एवं लागू कया गया ह तथा
सभी संबि धत इ छुक प कार को भी उपल ध
कराया गया ह ।“
 Quality Policy
“We at RDSO Lucknow are committed to
maintain and update transparent standards of
services to develop safe, modern and cost
effective railway technology complying with
statutory and regulatory requirements,
through excellence in research, designs and
standards by setting quality objectives,
commitment to satisfy applicable
requirements and continual improvements of
the quality management system to cater to
growing needs, demand and expectations of
passenger and freight traffic on the railways
through periodic review of quality
management systems to achieve continual
improvement and customer appreciation. It is
communicated and applied within the
organization and making it available to all the
relevant interested parties.”
 INDIAN RAILWAYS
Centre for Advanced Maintenance Technology
Maharajpur, Gwalior (M.P.) Pin Code – 474 005