1

TEACHING NOTES

ON
REVERSER,
ALR & LLCC

SIGNAL & TELECOMMUNICATION TRAINING CENTRE, BYCULLA, MUMBAI

( I S O 9001-2000 CERTIFIED )
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CONTENTS PAGE NO.

REVERSER
1. Introduction 03
2. Main Parts of Reverser 03
3. Electrical Parameters 04
4. Function of various parts 04
5. Checks to be carried out before installation. 06
6. Performance Test 06
7. Trouble Shooting and Maintenance 07
8. DO’s and Don’ts 09

ARMS LIGHT REPEATER

1. Introduction purpose 10
2. Working Principle of Arm Repeater and Main parts. 10
3. Light Repeater, Main Parts, and working 11
4. Alarm circuit and working 12
5. Indoor and outdoor equipment 12
6. Maintenance and Testing 12
7. Trouble shooting 13

LEVER LOCK AND CIRCUIT CONTROLLER

1. Introduction and working of lever lock 14
2. Types of Lever Locks 14
3. Circuit Controllers 15
4. Force drop arrangement 15
5. Economizer contact 16
6. Checks for Maintenance 16
7. Trouble Shooting 19
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ELECTRICAL SIGNAL REVERSER

In Electro-Mechanical signaling territory an Electrical Signal reverser is

used to establish an electrical control over semaphore signal by one or more
controlling agencies where the transmission is mechanical. Reverse is one of
the methods to achieve slotting system.

Types of Reverser:

a) Cabin type
b) Post type
I) Post Type Style ”A”
II) Post type style “B”
In cabin type reverser the signal arm may be taken “OFF” by pulling signal
wire from out side even in absence of control (slot). To avoid this unsafe
working post type reverser was developed. Style “A” type has so many
demerits hence RDSO has standardized only post type style “B” reverser.

Main Parts of Style “B” reverse

i) Electro Magnet
ii) Armature
iii) Semaphore arm lever
iv) Operating arm lever
v) Spectacle crank
vi) Operating crank
vii) Coupling lever
viii) Support lever
ix) Lock pawl
x) Dash pot
xi) Terminal Block & Lighting Arrestor
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Electrical parameter:
Coil resistance 600 ohms
Min. operating voltage 7.5 volts
Normal working voltage 10 volts
Normal working current 16.5 ma

NOTE: There is no basic difference between “UQ” & “LQ” reversers. The
reverser fit for UQ signal can be made fit for LQ simply by turning the
spectacle crank & operating crank by 180 degree.

FUNCTIONS OF VARIOUS PARTS:

Electro Magnet: It is laminated core winding which gets energized through
the concerned controls.
Armature: Armature picking up does two things.
i) Sliding bar lifts up and so the lock pawl releases the spectacle lever for
operation.
ii) The ball bearing connected with support lever rests with armature lever
hence the spectacle and operating lever gets rigidly connected.
SEMAPHORE ARM LEVER: Normally this lever remains locked through lock
pawl. It is connected with spectacle crank on other side. Signal arm cannot
be operated due to this locking from out side interference.
OPERATING ARM LEVER: This lever can be freely operated without
operating the semaphore arm lever. Its operation operates the signal arm
only when it gets coupled with the arm lever.
SPCTACLE CRANK: Down rod of the semaphore signal arm is connected
with this crank. Arm can be taken OFF only when this crank operates & this it
self will operate when semaphore arm lever operates.
OPERATING CRANK: It is connected with pull wire of the transmission and
can be operated freely without operating the semaphore arm lever.
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COUPLING LEVER: This lever couples semaphore arm lever and operating
arm lever when the armature picks up. Under energized condition of
Reverser, pulling the signal lever not only operating crank and lever operates
buy t semaphore arm also operates lever through coupling lever.

SUPPORT LEVER: It is attached with coupling lever. The coupling lever

couples both the lever only when the armature lever restricts the movement of
this lever. The ball bearing of this lever eliminates the possibility of armature
lever pitting.

LOCK PAWL: Locks the semaphore lever is normal condition and allows the
movement of this lever only after energisation of electro magnet.

DASH POT: It consists of sliding cylinder, plunger nozzle, plunger and a

spring. It absorbs the shop offered to the system when the signal arm flies
back/comes to “ON”.

TERMINAL BLOCK: For electrical connections inside.

LIGHTENING ARRESTOR: It is used to avoid risk of damage due to

thundering & lightening because of overhead line used.

CONTACT ASSEMBLY: It is used to provide indications at panel & for

controlling other electrical circuits as per requirement it can be 2 ways or 3 or
6 way and is connected with spectacle lever through link and crank.

WORKING: To operate a signal, controlling agency releases its control first.

Now electromagnet gets energized, the armature lever attracted. In turn
sliding bar moves up the lock pawl releases semaphore arm lever.
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When signal lever is operated, the roller B of operating lever comes in contact
with CAM surface of coupling lever. Since armature lever holds the ball
bearing of support lever this can semaphore arm lever moves down.
Resulting spectacle crank moves towards down side, this movement gives
stoke to the down rod of signal arm an signal arm taken off.

As soon as current through coils ceases the armature drops so ball bearing
leaves it base.

Now coupling lever gets detached and the weight of the signal arm pulls the
operating lever due to gravity. For next operation it is necessary to put back
the signal lever to normal.

Checks to be carried out before installation:

i) Check oil level in the dash pot. It should be at least 35 mm above the
bottom of sliding cylinder.
ii) Check tightness of all nuts and bolts. All split pins are in position and
their ends are properly opened.
iii) Check the correctness of internal wiring.
iv) Ensure smooth working by lubricating and greasing the moving parts.
v) Check the proper connection of signal down rod to the semaphore
crank and the transmission wire with the operating crank.
vi) Check the alignment of arrow mark of the bridge with the marks on
operating and semaphore lever.
vii) Check that the armature houses properly on the core phase of the
electromagnet in normal position.
viii) Check that the clearance between lock pawl teeth and spectacle lever
gear is not more than 1mm.
ix) Check that in the normal position spectacle lever touches the bottom
surface of dash pot.
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PERFORMANCE TEST

1) Energize the electromagnet at 10 volts supply, operate the signal

lever and see that signal arm is taken “OFF”. Ensure that signal
arm does not return to “ON” due to any obstruction on the
transmission line.
2) Cut of the supply of electromagnet, signal should return to “ON”
smoothly.
3) Apply external force to lower the signal. It must not come to “OFF”
position.
4) Replace the signal lever to normal. Check that arrow on the
operating a semaphore lever aligns with arrows on bridge.
5) With releasing control, pull the signal lever. Signal does not resume
“OFF” position.
6) Replace the signal lever to normal. Ensure that any strain in
transmission line must not lower the signal and lock pawl has
logged the spectacle lever.

TROUBLE SHOOTING AND MAINTENANCE

1) To avoid unsafe effect of residual magnetism, change polarity of the coil at
every fortnight (every maintenance round).
2) Use grafted grease for smooth working of ball bearing.
3) Oil all moving parts with light grade oil once in 15 days for smooth
working.
4) Check Dashpot oil lever & oil condition once in a year.
5) Dashpot spring must be checked once in 15 days, replace if necessary.
6) Sliding bar should move freely so apply oil here.
7) There must not be any dust, oil or grease on armature & core.
8) For cleaning the contacts, armature & core use chamois leather.
9) Align arrow of bridge with levers arrow.
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FAILURES

I) SIGNAL FAILS TO OFF:

Probable cause:
a) Battery connection to coil terminal is break or loose or fuse blown out.
b) Weak batteries.
c) Grease, oil or dust on armature and/or on core.
d) Balling bearing jams and de-shaped.
e) Operating lever roller jams and de-shaped.
f) Lever & bridge connection is loose.
g) Tension in mechanical transmission is more causing armature lever
dropping form its normal position.
h) Down rod connection infringing each other movement.
i) Bride arrow not aligns with levers arrow.

II) SIGNAL DOES NOT RETURNS TO NORMAL AFTER:

Unsafe side collapse of feed in reverser coil.

PROBABLE CAUSE:
a) Residual magnetism
b) Foreign feed
c) Sliding bar jamming
iii) Signal taken ‘OFF” without releasing Unsafe side control

PROBABLE CAUSE:
a) Residual magnetism
b) Foreign feed
c) Slide bar jamming
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iv) A lowered signal returns to “ON” without safe side putting back
control to normal.
PROBABLE CAUSE:
a) Weak battery
b) Fuse or lightening arrestor blown out
c) Weak reverser coil

v) Reverser connection with signal post frequency looses: Safe side

PROBABLE CAUSE:
a) Oil level is not adequate in Dashpot.
b) Oil mud in sliding cylinder
c) Dashpot spring loose or cracked.

DO’S AND DON’T’S

DO’S
1) Change the coil polarity at every fortnight.
2) Maintain correct oil level in Dashpot.
3) In normal position bridge arrow align with levers arrow.
4) Tight all nut & bolts and open split pins properly.
5) Oil the sliding bar for its free movement.
6) Performance test periodically.
7) Locking and sealing of it.
DON’TS
1) Forget to change the polarity.
2) Stuck armature with foreign means.
3) Oil the ball bearing only graphite – grease it.
4) Clean armature or core with emery paper.
5) Over energize the electro magnet.
6) Forget to disconnect for any adjustment.
7) Forget locking & sealing.
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ARM AND LIGHT REPEATER

1. PURPOSE: If the Arm or light or both of a semaphore arm signal is not
visible to operating man from the place of operation due to any obstruction
like, tree, or any structure or curvature, in such case the arm and light of the
semaphore arm signal is repeated in the office of operating /controlling staff.
So that SM cabin man/switchman could know about position of semaphore
signal arm & light in night.
2. WORKING PRINCIPPLE OF ARM REPEATER: It works on the principle
of electromagnetic induction. When the arm of signal is at “ON” or OFF
position then depending upon the circuit controller contact the current flows
through the electromagnet coil and its is magnetized and the signal arm
position is shown by the small arm of arm repeater. When semaphore arm is
in other position then “ON” or “OFF” position then electromagnet coil is not
energized and the arm repeater shows wrong position of semaphore arm of
signal.
Main Parts
1. Dial
2. Small Arm showing 3 positions. “ON” “OFF” wrong
3. Indicator coil 300 ohms (3 to 5mA)
4. Permanent Magnet
5. Needle
6. Armature
7. Light repeater coil 150 + 150 ohms
In arm repeater, Arm position (For two aspects LQ)
(i) “ON” – when the signal arm is at +/- 50 from horizontal position.
(ii) “OFF”–when the signal arm is at 400– 600 below the horizontal position
(iii) “WRONG” – When the signal Arm is in any other position then the
above two position i.e. signal arm is in between 50 – 400 from the
horizontal position. When any open circuits failure.
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FOR MULTIPLE ASPECT SIGNALLING

(I) “ON” when the Arm is +/- 50 from the horizontal position.
(II) “OFF” when the arm is 400 – 900 from the horizontal position.
(III) WRONG – When the arm is in between 50 – 400 from horizontal
position and any open circuit fault.

3. LIGHT REPEATER: Light repeater is used to know that the

semaphore Arm signal lamp is lit or not. It is provided below the
Arm repeater. It is in the form of a “Pointer”. It shows two
positions. i.e. out, and “in”. The construction of pointer is such that
in normal position due to its weight it remains out side and indicates
that signal lamp is not lit to and when signal is lit it comes towards
In side and indicates that signal lamp is lit.

Main Parts
1. Dial with a pointer
2. Contact bell
3. Armature
4. A coil of 300 ohms (150 ohms + 150 ohms in series)
Current 8 to 10 mA
5. Bell circuit contact
WORKING- When signal lamp is burning, the thermostat contacts are
made and a current flows through less resistive path. Electromagnet coil
of repeater is energized and pointer moves toward ‘In’ and indicates that
signal lamp is in lit position. When signal lamp is extinguished then
thermostat contacts gets break and current flows though high resistive
path and current flowing in the repeater coil is reduced the pointer comes
towards out.
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4. ALARM CIRCUIT- There is day and night switch which is provide

on bottom side of the equipment this switch is connected in series
of the bell circuit during day. Switch is turned towards day and it
disconnects the bell circuit. During night it is turned toward night
and close the Bell circuit.
Bell coil resistance – 5 ohms
Voltage – 3 V DC
Current – 600mA
WORKING: In night when signal lamp is extinguished thermostat contact
breaks and pointer moves towards out and the strips above pointer makes
and completes the electrical circuit and buzzer stats to ring which
indicates that signal lamp is extinguished.
The arm and light repeater both are provided in a single unit itself it is
installed in office of signal operating / controlling body.
5. INDOOR UNIT: Arm and light repeater unit is called indoor unit.

OUTDOOR UNIT:
1. Thermostat Rod ( above the signal lamp) with bimetallic strip.
2. Circuit controller (4way).
6. MAINTENANCE:
1. Circuit Controller band should be neat and clean
2. Circuit controller should be filed with signal post strongly.
3. “ON” “OFF” “WRONG” ‘IN’ and out of the Arm light repeater should
correspond the signal Arm and light position.
4. Thermostat contact should be adjusted properly.
5. L. D. and fuse should be cleaned.
6. Earth should be proper (not more than 10 ohms earth resistance)
7. Battery terminal should be clean and tight.
8. There should be no loose connection.
9. Color and shape of Arm repeater should be accordingly to signal
Arm it repeaters.
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TESTING
1. Signal Arm at “ON” – (+) in on linen (-) to earth.
Signal arm at “OFF” – (+) to earth (-) on line.
2. When no current through Arm repeater coil Arm shows wrong
position.
4. When signal lamp lit, pointer should be towards “IN” and when
signal lamp not lit pointer should be towards out.
5. When light repeater is at OUT and day/night switch is at day, buzzer
should not ring. When switch kept at night then buzzer should ring.
TROUBLE SHOOTING
SL. TROUBLE SYMPTOMS REMEDY
1. L. D. Short Connection between line Check the reason of
circuit & earth short circuit. Remove it.
2. a. Break in line Arm repeater will indicate 1. Check the coil
wire “wrong” position. Light continuity and earth
b. Arm and light repeater will show “out” wire connection remove
repeater coil open indication. the fault
c. Open earth No current in line
d. Break in circuit
controller band.
3. Reverse polarity of No correspondence Check the battery.
battery between the signal arm and Change the polarity of
arm repeater position battery
4. Faulty Battery 1. Arm repeater will show Check the battery. If
“Wrong”. Light repeater will required replaces it.
show out position, No
current in circuit. Or less
current in circuit
5. Signal Arm in High resistance in OFF Check the controller
‘OFF” position but position circuit controller band .if required clean
Arm repeater in contact. and adjust it.
wrong position
6. High resistance in 1. Arm repeater OK but Clean the thermostats
thermostat contact light repeater in out position contact and adjust it.
or break
7. High resistance in Current will be less in circuit Check the reason for
over head line and arm light repeater will high resistance and
not work rectify it.
8 Loose connection Do Clean the terminal and
tight it.
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LEVER LOCK AND CIRCUIT CONTROLER

LEVER LOCK
FUNCTION:

Electric lever lock is an electro-mechanical lock used to provide an

electrical control on a mechanical lever.
WORKING:
A plunge (slide0 with notches cut in required locking positions of the lever
is connected to the lever tail through a down rod. A lock bolt operated by the
electromagnet (lever lock coil) when dropped inside the notch holds the lever
mechanically. The lever can be operated only when the lock coil is energized, its
armature is attracted and lock comes out of the notch on the lever slide. The coil
gets energized only when the conditions for operating the lever are safe.
SPECIAL FEATURES:
(1) An economical contact to cut off the feed to the cols at the end of the lever
operation to save power. This contact makes from ‘a’ to ‘E’ position of lever and
remains open (Break) in full ‘N’ and ‘R’ position of lever.
(2) A forced drop arrangement to ensure that the lever is locked after the de-
energisaton of the lock coil.
TYPES: (a) For S.W. lever framed (200 mm strokes)
TYPE COIL RESISTANCE WORKING VOLTAGE
S&F 7.5 + 7.5 Ohms 10 V D.C. coil in series
110 V A. C. coil in parallel
IRS 4.5 Ohms 10 V D. C. /110 V A. C.

(b) For D. w. lever frame (40 mm. stroke)

TYPE COIL RESISTANCE WORKING VOLTAGE
T2 150 ohm 10 V D. C.
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USES: Used for Track/Indication/Approach/back locking. Slot control, Gate

controls etc.

CIRCUIT CONTROLLER:

Circuit controller is a device by which electrical circuits can be made or broken at

different positions of levers according to the requirement. It has generally got
two sets of fixed contacts and corresponding number of rotating segments called
‘bands. The segments (bands) position can be adjusted in steps and locked in
that position. The linear motion of plunger is converted into circular motion
through a rack & pinion. Different bands used are NA, NB. RE. RE. AR. A.E.B, C
etc. (NB band is one, which makes from N to B position of lever and remains
break (open in all other position.)

FORCED DROP ARRANGEMENT

FUNCTION:

It is a mechanical arrangement adopted to ensure that the lock controlled by a

lector-magnet become effective (i.e. equipment gets locked) after the de-
energisation of the lock coil.

NEED:

Any lock controlled / operated by an electromagnet gets released

whenever the lock coil is energized and the lock becomes effective (equipment
gets locked) once the coil is de-energized.

But if due to residual magnetism or mechanical friction the armature of the

electromagnet remains stuck in energized position even after the supply to the
coil is cut off, then the lock will become permanently free and will not be effected
for further (further) operations which is unsafe.

To prevent this “forced drop arrangement” is employed.

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HOW ACHIEVED?

In lever lock, it is achieved by the provision of forced drop pin riveted to

the plunger and a triangular piece called “Ramp” riveted to lock dog.

In lever lock it the lock fails to drop inside the notch after the de-
energisation of lock coil, the forced drop pin strikes against the slope point of
ramp when lever is operated and forces the lock to droop inside the notch.

The effectiveness of forced drop arrangement should be tested

periodically in all locking position.

5. ECONOMISER CONTACT
One of the means to ensure supply to the electromagnet is available only
during the operation of lever. The arm of economizer contact droops in to the
depression of the plunger in Normal and Reverse position and contacts remain
open, cutting of supply of the coil. This arm is pushes out of the depression when
the lever is operated and the contact is make to complete the supply to the lever
lock. Thus the economize contact ensures that the supply is available to the coil
during the stroke of the lever ‘AE’ band is used in lieu of economizer contact.

CHECK LIST FOR MAINTENANCE AND SAFETY CHECKS TO BE CARRIED

OUT ON LEVER LOCK CIRCUIT CONTROLLER.

MONTHLY CHECKES BY Sis

1. There is no tapering on the locking face of the notches and that the notches
are cut perfectly square.

2. The forced drop pins are riveted properly as required and their effectiveness
checked for every locking position.

3. The economizer contacts are functioning properly.

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4. The various contact segments provided are cut to proper size as required and
they are securely fixed and adjusted properly. The segments do not make
contact in any position other then the one intended.

5. In the case of LLCC having insulator with serrations, contact segments are so
adjusted that the serrations properly mesh with the contact segment and in case
of LLCC having contact segment with fixing screws for securing the
segment on to the roller, the screw should be properly tightened to ensure that
the band is in position at all times.

6. The insulated separators are not broken and are secured in position.

7. There will be no possibility of the bands making unintended contacts through

the keepers, contact spring etc.

8. The keepers are kept in proper alignment and should never be bent to give
tension to the contacts.

9. While the finger contacts are kept properly tensioned, it must be ensured that
they do not get entangled with the LLCC rollers and get damaged.

10. The fiber insulation provided for holding the wires inside the metallic clamp
at the entrance to the LLCC are in position and that there is no possibility of the
wires leading to the LLCC and their insulations due to abrasion at the clamp
edges.
11. The insulation of the wires must be periodically checked to ensure that there
is no deterioration in the insulation.
12. The LLCC lock holding spring has sufficient tension to keep the lock dog in
the locking position, when the lever lock is not energized, and that the spring
tension is not less than 390 grams/cm as specified.
13.All split pins, including limiting split pins, are of proper size and are properly
split.
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14. All working parts are cleaned and oiled and work freely. All terminal screws
and looking screws are kept tight. It should be ensured that no metallic dust is
allowed to accumulate in the LLCC.
15. Voltage in excess of the rates voltage is not applied to the lever locks.
16. Every individual LLCC has the last date of overhauling painted on both of its
covers and that the covers are locked and sealed.
17. A record must be kept in every station/cabin having LLCC, indicating the
type of LLCC provided, giving details of the make, date of overhauling, the detail
of inspections done monthly and quarterly by the signal Inspectors. This record
shall be maintained in the prescribed register. The contact segments shall be
maintained at stations provided with LLCC for every individual LLCC, indicating
the details of the contact segment number, type of contact segments and the
circuit in which it is used duly indicating the relevant circuit diagram sheet in
which it appear. This record shall be available for inspection at all times.
18. That the functional test are carried out to ensure the correct operation of the
LLCC. It must further be ensure that operating staff as observe the check lock
indicating as required while operating the lever from normal to reverse or from
reverse to normal.
19. The fixing bracket is properly anchored to the wall or ground so that
operation of the lever locks and circuit controller does not transmit vibrations to
the adjacent LLCC and disturb the adjustment of their contact segment.
20. The LLCC is fixed securely to the brackets with its bolts an nuts tightened
properly.
21. LLCC should be checked to ensure that the slide is properly aligned and its
travel is smooth.
22. The functional test shall be carried out.

CHECKS TO BE CARRIED OUT BY ESMs:

ESMs during their maintenance rounds shall check the items listed at Sr.
No. 1to 15 and shall keep a record there of in their diary or a History card
maintained for this purpose.
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QUARTERLY CHECKS BY SI INCHARGE:

It should be ensured that in addition to the checks refer to the above the
following check should also be carried out.

TROUBLE SHOOTING
Failure Observation Action
1. Lock released 1. Lock armature not 1. Interchange the coil
without proper release due to residual connection
feed magnetism and force droop
mechanism not function
2. Armature mechanically
held up in energized position
2. Lock released 1. the circuit controller 1. RE-adjust
in unwanted bands wrongly adjusted
position of lever 2. False feed 2. Check for false feed
3. Lock not 1. Notch edge are not 1. Square the notch
effective at certain square
position 2. Feed continuously 2. Re adjust the band
available due to wrong
adjustment of C.C. band
3. Armature held in released 3. Clean the same
position due to residual flux
or mechanical parts
4. Force drop mechanism 4. Replace the mechanism
defective
4. Frequent fuse Circuit controller cross Readjust the band.
blowing off in the protection contact wrong
controlling circuit adjustment and shoring the
supply
5. Contacts of Contacts band slipping due Tighten the holding nut,
circuit controller to holding nut slack or remove the warn out bands
working in serrations on holders warn replace with now one
unwanted position out and not holding the
bands rigid
6.Circuit controller 1. The contact bands not 1.Clean the contacts
contacts open cleaned properly
circuit 2. Contact spring lost 2.Give tension at the
tension end of spring
3. Wrong adjustment of 3.Readjust bands
bans.
4. Lasting nut slack and 4.Tighten the same.
band slipping
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