1

LED Signal

Introduction
This is surface mounted light emitting diode (LED) based signal
lighting unit with transparent cover of U.V. stabilized polycorbonate
material preventing refraction of sunlight and head light of loco.

LED based signal lighting unit is the replacement of hitherto used

signal lamp. LED signal has two components- LED aspect and current
regulator. LED aspect is suitably fitted into frame in the existing CLS
housing and current regulator take place of the CLS transformer. LED
based signals work at 100 volts±20%.

Health monitoring device continuously monitors the health of LED

signal. LEDs have been developed which have a luminous efficacy
(lumens per watt) exceeding that of candescent lamps. However, the
relatively small lumen package that is produce by a single LED still
means that dozen, if not hundred of LEDs must be used together to
produce a modest amount of light. For LED signals, over 80 of LEDs
are kept together to create the high luminance signal face which is
required by the specifications.

Advantages
LED signal unit have the following advantages:
 Life of LED signal is 1 lakh hours.
 Provides comprehensive protection against lightening and/or
surge voltage
 Focussing is not required
 Less power consumption
 Requires minimum maintenance
 2
Brief Description

As per RDSO/SPN/153/2002 (Amend) LED signal consists of the

following:

 LED aspect unit

 It consists of a cluster of LEDs in series and parallel
combinations. LEDs in a signal aspect are arranged in more
than one array. So that in the event of failure of single LED
whole unit does not blank.
 LEDs in the arrays are interleaved so that effect of failure of
any array is spread out equally to maintain uniform visibility.
All aspects except route and shunt use two arrays for higher
noise immunity and also provide redundancy. LED in each
array are in electrically independent path so that failure of
any LED does not affect operation of other. The optical
sensors are provided for each aspect and output from optical
sensors is given to the current regulator unit for corrective
alarm action. If few LEDs in the signal unit are so arranged
as to ensure near visibility of five meters so that signal is
clearly visible to a driver stopping it the foot of the signal.

LED Lamp Unit

 Current regulator unit

 LED is a current driven device. Therefore LEDs clusters in a
LED signal lamp are fed by a constant current irrespective of
 3
input supply voltage by current regulator. It consists of solid
state variable resistance controlled by feed back from sensors
(current and voltage for each array and optical sensors) and
current regulator for each LED array solid state variable
resistance detects failure of 20 – 25 % LED and
 Limits the current to cause low current
 Boost the current to cause high alarm current.
 If optical sensors detects signal blank/dim, it reduces the
current to 30mA to generate alarm and cut off the aspect.
LED signal unit housing is made either of mild steel sheet or
of industrial grade plastic like ABS or fibre glass. The front
cover is made of CV stabilized ply carbonate dome. LED
signal unit is thermatically sealed in order to ensure that it is
able to withstand the environmental severity. The dimension
of LED signal unit as such that it can be fitted securely in the
existing CLS unit without any modification to them.

Current Regulator

Salient features of LED signal unit

 There is no phantom effect.
 LED lamp is pre focussed and do not need periodic focussing.
 LED signal lighting units suitably fits to adjust in the CLS units
available in RE and non RE areas.
 4
 Traffic hazards while bulbs are being replaced by maintenance
staff, is eliminated.
 LED signals use less energy.
 DC power feeding to signals thereby transformer are eliminated.
 Wide voltage variation in power feed is tolerated.
 LED signal unit is provided with a curve transparent cover of UV
stabilized Polly carbonate material with a minimum thickness of
2.5 mm ± 0.5mm.
 LED signal unit housing is made with industrial grade plastic like
ABS or fibre glass.
 The LED signal lighting units covers Main signal, Route
indicator, Calling on signal and Shunt signal.
 The LED signal lighting unit have a display areas as follows
 For main signal and calling on signal – 125 mm diameter
 For route indicator and shunt signal – 85 mm diameter
 LED signal lighting unit are AC and DC fed.
 LED signal lighting unit can generally be used with ECRs
 However it shall be possible to use signal lighting units with
convential “on” aspect metal to metal or metal to carbon ECRs.
(either than seimens ECRs) and “OFF” aspect siemens ECRs.
 The DC lit signal lighting unit have AC immunity of 300 volts, 50
Hz.
 Signal lighting unit have noise immunity of 60 volts ± 5%.
 The LED signal unit does not reflect sun light / head light of loco.

Failure indication unit

LED signal unit works in association with failure indication unit
located at the cabin/relay room. The failure indication unit monitors
the performances of the LED signal aspect. The following failure
conditions detected by current regulator unit are displayed to warm
impaired visibility of aspect 20-25% LED failure and low/high aspect
current (below 1.5mA/145mA above). No light/low visibility and
aspect current less than 30mA.
 5
Fundamental requirements
The LED lamps should satisfy the following functional requirement.
Sr. Description Specification
1. The colour coordinate of Red, Green Class “C” of
LED signal unit and Lunar BS:1376-1974
white aspect
Yellow aspect Class “B” of
BS:1376-1974

2. Visibility of each aspect 600 meters in

of LED signal unit clear day light
3. Visibility of route 200 meters in
indicator clear day light
4. The minimum Red aspect 50 lux
illumination of LED
signal units measured at Yellow and 100 lux
a distance of 1.5 meters Green aspect
in axial direction
5. LED signal lighting units Main and 125 mm diameter
display area Calling on
signals
Route and 85 meter diameter
shunt signal
6. ECR (DC) normal All LED 125 mA current
operate current signal units

AC models and DC LED models

LED signal unit AC models - It is suitable to fix in existing CLS unit
available in RE and non RE areas.
LED signal unit DC models – It is suitable for all new work in RE and
non RE areas.

The ECR used in this model is DC ECR which is common ECR for all
type of signals.
 Main signal – Red, Yellow and Green aspects
 6
 Calling on signal
 Route indicator
 Position light shunt signal
In case of DC models
 AC immunity more than 300 V AC, no cutting in relays in RE
area and even for 2nd distant signal.
 Common ECR for all types of signals helps in reducing number of
ECRs cost.

Operating parameters
Table
ECR for LED signal unit of AC models
 Universal plug in type tractive armature AC lamp proving relay is
used.
 Maximum pick up current – 90mA/AC 50 Hz
 Minimum release current – 60 mA/AC 50 Hz
This ECRs with stand for a continuos current 0 and 250mA /AC 50 Hz
 Contact configuration – 4F/4B identically in in A to D rows.
 Voltage drop across R1 and R2 is less than 10 V125 m/A AC
(normal working current).

DC ECR for LED signal unit of DC model

 Universal plug in type tractive armature DC lamp proving relay is
used.
 Maximum pick up current – 80mA/DC
 Minimum release current – 55 mA/DC
This ECRs with stand and continuos current 0 and 200mA /DC
 Contact configuration – 4F/4B identically in A to D rows.
 Voltage drop across R1 and R2 is less than 10 V100mA DC
(normal working current).
 7

General maintenance
 Tighten all nuts and screws and the terminals
 Ensure that LED signal unit is properly fixed on signal unit and
secure with nut and bolts or screws
 Properly clean the LED signal units, all terminals and current
regulating devices periodically with soft cloth
 Ensure that LED signal unit does not vibrate during running of
trains
 LED signal should be kept in suitable cover provided with
thermocol packing on the inner side surface.
 Ensure that the protection is provided on the current regulator
terminals to avoid external interference.

Do’s and Don’ts

Do’s
 Always sprays CRC spray after every tightening / opening of
terminals of aspects and current regulator
 Always provide proper rating fuse
 Monitor health monitor device on each visit
 Operate audio alarm and check acknowledge button.
 Keep shut the signal housing door properly
Don’ts
 Do not leave the three and two pin connectors loose
 Does not over tight the LED lead connector to the LED signal
unit
 Do not interchange any connections after current regulating
device
 Do not try to give direct supply to the signal unit
 8
 Do not try to open the cover for replacement of LED
 Do not try the drill the hole on the base of LED signal unit for
fixing of the existing signal unit