KCSR IP microwave project.ppt - railroads.dot.gov · 19700 Janelia Farm Boulevard, Ashburn, VA, 20147 (703)726−5651 PCN Date: 08/19/2011 Prev Job Num: Administrative Information

Confidential – Internal Use Only

Legacy Microwave to IP Microwave Conversion

6/11/13


• The Kansas City Southern Railway (KCSR) had a need to modernize an outdated microwave system in preparation for a PTC deployment

• Microwave system is made up of 48 sites than runs through 5 states

• Primarily paths run North/South from Kansas City to Beaumont and New Orleans

• Multi year project• Phase I included sites South of Shreveport• Phase II included sites North of Shreveport

Legacy to IP Microwave Conversion


Phase I Tower Locations

3


Phase II Tower Locations

4


Legacy Microwave Backbone

5

• T1’s were used for back feed on the legacy system

160 MHz160 MHz

160 MHz

T1 Back Feed

Kansas City Data CenterShreveport

T1 Back. Feed


• New system needed to be capable of handling PTC data transfer requirements

• New microwave radios needed to be implemented with failover capability in mind

• Tower infrastructure needed upgrading where for enhanced reliability

• Needed to be deployed with a minimal impact to the business

Key Objectives


• Sites needed to be surveyed• Had to determine what equipment would stay after the

upgrade• A one for one comparison, existing endpoint/channel

interface to IP interface, was performed on the entire network • Will the remaining legacy equipment work with the new

equipment being installed

Interface considerations


• There was legacy equipment that needed to remain post cutover not capable of communicating over IP

• Had to find an interface solution– Distributed Power (DP) repeaters– Wind speed indicators– Cameras– Base Communication Package (BCP) communication to backoffice.– Dispatch radios

Non IP Equipment


DP Repeaters • Relays communication between locomotives in a train consist

• CPU for two zones located at master end, limited equipment located at remote end, each end equipped with one multichannel transmitter and four independent receivers at 450 Mhz

• OLD – Used E&M channels via mux equipment. Mod/Dem for data transmission, E&M for PTT and Channel Selection

• NEW – Duplicated configuration using E&M interfaces on routers.

DATE:SCALE:

DRAWN BY:REV: 4/11/13 gm

APPROVED BY:

D R AWING NO.:

7/12/12NONE

XXX-XXXXWIRING DIAGRAM

Rich Mt and HoratioDP Repeater

gm

Kansas City Southern

DP MSTRMDF

Rich Mt Horatio

0/1/0

CISCO

10 Base T0/1/1

0/2/0

0/2/1

SB

DEM

M

3C55A1

3C6R5A7T

8

3C95A2

3C10R5A7R

3C10T

3C135A3

3C14T

3C175A4

3C18R5A6T

3C20R

3C12R

3C14R

3C195A5

SB

DEM

M

SB

DEM

M

SG/E

D

M

SG/E

3C8R

3C7

3C6T

3C12R

3C11

3C12T

3C16R

3C15

3C16T

3C20R

3C19

3C20T

3C18T

3C14T

3C10T

3C8T

SG

MOD

SB

SG

MOD

E

SB

SG

MOD

E

SB

SG

MOD

E

SB

E

3C17DEM

CH 1

CH 2

CH 3

CH 4

Zone B Rx 1

Ch Sel Bi t 0

Zone B Rx 2

Ch Sel Bi t 1

Zone B Rx 3

Zone B Tx 4

Zone B Rx 4

PTT

MOD

MDF

-48V

24

Bits 11 = Ch 1 452.925Bits 01 = Ch 2 452.950Bits 10 = Ch 3 457.925Bits 00 = Ch 4 457.950

1011

1516

23

78

45

12

18

19

SB

Signal is received at Horatio on the corrsponding ch. according to the chart. The signal is sent to Rich Mt. Master DP repeater. Repeater then selects TX freq via ch. select bits 0 & 1. See chart. Then master keys tx via M lead on ch 4. Signal goes out on mod of ch. 4

and is transmitted on the correct frequency.

3C6T

175A6R

5A8

3C18T

-48V

6B4R

Tx Key Return

Ch Select Return

SG3C8R

SG

+48V GND

K3

1

9

2/0/0 Chan 1 2/0/1 Chan 2 2/ 0/ 3 Chan 4

+

-

+

-

+

-

6

4

8

11

13

16

5.6K1

9

6

4

8

13

5.6K1

96

4

8

13

5.6K

16

+

-

-48V

yellow yellow Green

PTTFreq Dat a bit "0"

Normally Off

F-9

Act ive Positive Act ive PositiveAct ive Posit ive

11

Active Positive

Freq Dat a bit "1"

Active Positive

16

11

K2K1

External Circuit Boiard Notes:

T0 DP Repeater T0 DP Repeat er T0 DP Repeater

All relays shown in the picked positionUsed at remote (zone B) location only.

RX Ch 123 DB

BIT 0Ch Sel

23 DB

5A7T

F8 1 Amp

SG

23 DB

23 DB

RX Ch 2

BIT 1Ch Sel

RX Ch 4

TX Ch 4

Tx Key

RX Ch 3

-48V

5A6T

5A4

5A6T+48V

5A3

5A2

5A7R

5A5

Ch 4

5A6R

DP slave

Act ive Positive

L M

N O

P S

L

M

N

O

P

S

J1 DB-25 12 pairJ6B DB-25 12 pair

5A6R

6A7T GND +V

SG +48V

5A8T

5A8R

SG +48V

SG +48V

Relays needed for required hard ground.

5A1

3C16R

CISCO

0/1/0

0/1/1

0/2/0

0/2/1

3D44D4

4D5

4D6

4D7

4D8

(FB3)

3D5

3D6

3D7

3D8

6B4T

3D4

4B213B21

4B223B22

4B233B23

4B243B24

PROT

PROT

PROT

PROT

4D33D3

4D53D3

4D73D7

4D93D9


Wind Speed Monitor• OLD – Used a GDC

MUX channel on each end to transmit Asynchronous Data

• NEW – Now use a GDC ADT (Asynchronous Data Transport) module to convert to IP, bookend solution

APPROVED BY:SCALE: NONE

DRAWING NO.

BLOCK DIAGRAM

Kansas City SouthernDATE: DRAWN BY: RDO

XX-XXX-XXXX

Kansas City

Wind Speed Indicator

REV: 09/12/2012 RDO

Kansas City - Beaumont Bridge

Beaumont Bridge

01/25/2010

Console 4

RS-485

RS-232

RS-485 to RS-232

9600 Baud

4th Floor Comm Room

Young Model 05103Wind Monitor

Young Model 06201Wind Tracker

BBox ConverterRS-232 to RS-485 BBox Converter

Young Model 32400Serial Interface

RS-485

RS-2329600 Baud

MW Router

GDC ADT (SA)

Switch to Network

IP Network

GDC ADT (Shelf Mt)

Async N81

Async N81

P7

P1

P1

10.102.168.129 /28

NW B

NW B


Video Camera• OLD – Used an

Enerdyne Codex and a GDC MUX channel on each end to carry video and control signals

• NEW – Now use a Pelco 300T video transmitter and a Pelco 300R video receiver to transport video and control signals via IP, bookend solutionAPPROVED BY:

SCALE: NONE

DRAWING NO.

BLOCK DIAGRAM

Kansas City SouthernDATE: DRAWN BY: RDO

XX-XXX-XXXX

Kansas City 12th Street

CCTV Camera over SMW IP

REV:

Camera

Light

Kansas City - Beaumont Bridge

Beaumont Bridge

04/23/2009

Console 4

CID Desk

CCTV

Tower

PC

Box

MONITOR

CCTVMONITOR

Enclosure

300T

300R

10 Base T

VideoRS-422

KBD

Video

Video

Video

RS-422

DVR

Video

KBD

4800 Baud

4800 Baud

General Settings

Video Settings

Pelconet 300T Settings at Beaumont Bridge:

Frame Skip Ratio: 2

CID PC runs Client software with DVR

110 VAC

Control

Control

4th Floor Comm Room

LDR

KBD set for Camera 1KBD AUX 1 controls light.

Set date and time.

Video Stamp: Neches River Bridge and date/time.

Field Mode: Interlaced

MW Router

10 Base T

P8

Intraframe Distance: 0Video Quality: ManualData Rate 100KPreset Parameter Name: High Res (4CIF)

Network SettingsIP Address Subnet MaskDefault Gateway :Video Transmission: TCP port 80

Com 14800 N 8 1 (controls pan/tilt/zoom)

9/12/2012 RDO

Switch to Network


Centralized Traffic Control (CTC)• BCP located at the tower

sites communicate with WCP at signal locations

• Allows the centralized dispatch office the ability to control traffic flow remotely using signals

• Critical system that supports safe fluid train operations

12

160 MHz160 MHz

Dispatch Center

BCP BCP

WCP WCP


Centralized Traffic Control (CTC)

• OLD – Used a channel on the GDC MUX to a synchronous serial port on the BCP

• NEW – Now use a router serial interface to a PPP (point to point protocol) serial interface on the BCP

SCALE: NONEAPPROVED BY:

REV: 08/22/12 RDO

DRAWING NO.


CABLE DETAIL

DATE: D R AWN BY:

BCP Field LocationBCP WIRING DETAIL

gm

5

3

6

8

4

2

7

20

DB25M to RJ45

WHT

RED

BLK

YEL

BRN

GRN

ORG

BLU

XXX-XXX-XX

Safetran BCP

H3C / Hauwei

Tx D ata Out

R x Data In

RTSCTS

Not Used

Not Used

Not Used

Common

4

2

5

7

3

1

6

8

DB25M to RJ45 Jack Adapter

DB25M RJ45 JACK

J 1 Port

+12VDC

GND

J 2 Port

Serial Port

RS 232

Jack Adapter

Note:BCP RS232 port must be set to PPP Mcast

Use straight through cable

P/N : FA770 (Black Box)

5/8/2012

OR CiscoRouter


Dispatch radios• Use Motorola Quantar

analog dispatch radios at tower locations

• OLD ‐ Communicated over E&M channel to Avtec outposts located in central office

• NEW ‐ Avtec outposts were moved to tower locations to support Scout deployment and allow for disaster recovery

SCALE: NONEA PPROVED BY:

REV:

DRAWING NO.


CABLE DETAIL

DATE: D R AWN BY:

North MWOUTPOST WIRING DETAIL

RDO04/26/2012

8

6

9

14

7

3

12

15


WHT

RED

BLK

YEL

BRN

GRN

ORG

BLU

XXX-XXX-XX

AVTEC OUTPOST (IP to 4Wire)

4WIRE TONE CONTROL RADIODISPATCHER'S VHF

TO IP NETWORK

R AD IO GND

PTT COM

PTTCOR

R X LO

TX LO

TX HI

R X HI

4

2

5

7

3

1

6

8

} R AD IO R X AUDIO (0 bdm) } R AD IO TX AUDIO (0 bdm)


DB25M RJ45 JACK

R AD IO 1 PORT

ETHERNET

MDF

+12VDCEarth GND

GND

Typ ically Wht/Blu Pair Typ ica lly Wht/Grn Pair

P/N : FA770 (Black Box)


Frequency Coordination• ComSearch performed

frequency coordination• All links were analyzed• This is an example data

sheet from Plain Dealing, LA to Shreveport, LA

• Helps determine possible interference issues with outside entities and legacy paths

• Found interference issues with some legacy paths, temporarily decreased new transmitter power until cutover was complete

Microwave Path Data Sheet Page 23 of 23 COMSEARCH

19700 Janelia Farm Boulevard, Ashburn, VA, 20147 (703)726−5651 www.comsearch.com

PCN Date: 08/19/2011 Prev Job Num: Job Number 110819COMSTH02 RCN Number: 11081917

Administrative Information PLAIN DEALI LA SHREVEPORT LACity/County /Bossier Shreveport/CaddoStatus / License Basis Engineering Proposal / PRIMARY OPERATION Engineering Proposal / PRIMARY OPERATION Call Sign KJN89 KJN88 Licensee Code S0047P S0047P Licensee Name Kansas City Southern Railway Compan Kansas City Southern Railway Compan Radio Service / Station Class MG −− Microwave Industrial/Business Pool FXO −− Fixed

Site Information Latitude (NAD 83) 32 ° 56’ 1 6.0 " N 32 ° 32’ 27.0" N Longitude (NAD 83) 93 ° 43’ 5 5.0 " W 93 ° 50’ 10.0" W Ground Elevation (m/ft−AMSL) 142.30 / 466.9 62.20 / 204.1 Antenna Structure Registration # 1054953 1054958

Path Azimuth (°) 192.533 12.477 Path Length (km / miles) 45.091 / 28.018

Transmit Antenna A64130 A64130 Manufacturer ANDREW CORPORATION ANDREW CORPORATION Model P8−65D P8−65D Gain(dBi) / Beamwidth(°) / Tilt(°) 42.3 / 1.30 / −0.28 42.3 / 1.30 / −0.02 Centerline (m / ft − AGL) 89.92 / 295.0 68.58 / 225.0

Receive Antenna Same As Transmit Manufacturer Model Gain (dBi) / Beamwidth (°) Centerline (m / ft − AGL)

Diversity Receive Antenna A64130 A64130 Manufacturer ANDREW CORPORATION ANDREW CORPORATION Model P8−65D P8−65D Gain (dBi) / Beamwidth (°) 42.3 / 1.30 42.3 / 1.30 Centerline (m / ft − AGL) 76.20 / 250.0 59.44 / 195.0

Radio Information TEMZ47 TEMZ47 Manufacturer CERAGON NETWORKS CERAGON NETWORKS Model IP10−6−T10−64QAM−4 IP10−6−T10−64QAM−4 Model Description IDU T 64QAM IDU T 64QAM Emission Designator / Modulation 10M0D7W 64 QAM 10M0D7W 64 QAM Loading 1 CH DIG 44730.000 1 CH DIG 44730.000 Stability (%) 0.001 0.001

Nominal Coordinated Maximum Nominal Coordinated Maximum Power (dBm) 32.0 32.0 Received Level (dBm) −38.3 −38.3 EIRP (dBm) 67.4 68.4

Fixed Loss: Tx / Common (dB) 0.0 / 6.9 0.0 / 5.9 Free Space Loss (dB) 142.1

Transmit Frequencies (MHz) 6785.0000H(5) 6625.0000H(5)


T1 Interfaces • It was determined during 1 for 1 evaluation that legacy wireless T‐1 circuits needed to be maintained after cutover, supporting backup for leased T‐1 circuits

• The solution was to emulate T‐1 circuits across the ethernetnetwork

• This was accomplished using Cisco routers with T‐1 interfaces

• Main issue to overcome was determining the correct clocking environment for the T‐1s over multiple router hops

CISCO 2941 T1 Interface


DRAWING NO.

BLOCK DIAGRAM

Kansas City SouthernD A TE : 04/04/2012 DRAWN BY: R D O

XX-XXX-XXX

KC and Sport Cisco 2941TDM T1 Interface Detail

REV:

IP Network

Kansas City 11th Street Shreveport

GD C TMS

GD C TMS

GD C TMS

GD C TMS

Cisco 2941Lpbk1

Cisco 2941

Lpbk1

A

A

A

A

A Adapter Deta i l (Black Box PN FA770)

C EM RX

STD CAT5 Patch

STD CAT5 Patch

STD CAT5 Patch

STD CAT5 Patch

C EM TX

Router

TX D ATA ATMS ACC

TX D ATA BR X D ATA AR X D ATA B

T

T

R

R

RJ45 F DB25 M

142

42

5

1

163

T1 0/0C EM 0/0CLK Line

T1 0/0C EM 0/0CLK INT

T1 0/1C EM 0/1CLK Line

T1 0/1C EM 0/1CLK INT

ROUTER

C L OCK SOURCE

BLUORGREDGRN


PBX Tie Trunks

• Legacy tie trunks using T‐1 had to be supported with the Ethernet solution

• We used a Cisco call manager with T‐1 interfaces to convert the legacy T‐1 trunks to IP

• Analog sections of the MW network already had MPLS circuits and VOIP phones, now supported via IP microwave


DRAWING NO.

Kansas City SouthernDATE: 08/2 7/ 20 12 DRAWN BY: R D O

XX-XXX-XXX

SHREVEPORT

Interface Detail

REV:

IP Network

Shreveport

PBX T-1 1

Cisco ?

Cisco 2911

T1 0/0

T1 0/1

PBX T-1 2

Kansas City Call Manager

11th Street

12th Street

Cisco 4507

g 0/0

150B

12

4

B4

W

5

O

21

5 W

WO

BW

17

18

21

22

Cisco 2911 Voice Gateway

Blade 7Port 7


Equipment Racks• Rack layout drawings

were made before any physical work

• Different layouts required based on building type and equipment requirements

• Height to top of rack kept consistent for measurement of flex waveguide needed

• Provided for uniform installation

FUSE PANEL

SHELF

RFU RFU RFU RFU

H3C Router

ALARM UNIT

CABLE MGMT

Rep MW Rack Site Mux RackS'port MW Rack

N/W N/W S/E S/E2 21 1

IDU S/E

RFU RFU

MW Rack

21S/E S/E

BUILDING ALM

RF PANEL

RFU RFU

21N/W N/W

PATCH PANEL

FAN ASSY

CABLE MGMT

222324

192021

4546

43

PATCH PANEL

17

15

FUSE PANEL 46FUSE PANEL 46FUSE PANEL 46

IDU N/WIDU S/E

RF PANEL

CABLE MGMT

FAN ASSY

1718

RFU RFU RFU RFUN/W N/W S/E S/E

1 12 2

IDU N/WIDU S/E

RF PANEL

CABLE MGMT

FAN ASSY2021

15

22

31

IDU N/W

RF PANEL

CABLE MGMT

FAN ASSY

IDU N/W

RF PANEL

CABLE MGMT

FAN ASSY202122

31

18

16

14

222324

32

19

1618


• Researched radio manufactures to understand their interface options

• Technical considerations such as path reliability projections or bandwidth limitations and frequency limitations eliminated some vendors

• Selected Ceragon IP‐10 all indoor, 32 dbm TX, native Ethernet, 64QAM

IP Radios


• Phase I– General DataComm (“GDC”) multi‐plex units were being used for re‐

routing and T1 interfaces on the legacy microwave system– Chose to use Huawei AR 4549 routers recommended by GDC for the IP

routing

• Phase II– KCSR converted to Cisco core network devices before this phase began– Implemented Cisco 3925 routers instead of the Huawei routers in the

first phase– Utilize Cisco certified network engineers on staff

Network Routers


• Advertised in industry magazine to solicit vendors• Generators needed to work with current transfer switches

where possible• Sized for 25% capacity growth• Needed a minimum of 3 alarm contacts (generator run, loss of

AC power, fail to start)• Outdoor model (current indoor units overheated and were

starved for oxygen if building ventilation failed)• We had used Generac back up power systems in the past and

were happy with the units

Generators


GeneratorsNew Generac QT025A 25kWGenerators replaced


• A site package, containing all necessary equipment, hardware, and drawings was created and delivered to each location to assist technicians during the install and cutover

• All cabling, power connections, and grounding terminations were completed before equipment was put in service

• Racks were staged at field locations to minimize down time• Utilized diversity antennas during cutover

– One set of antennas used for the legacy radios, second set used for new radios

– Kept the legacy microwave in service until cutover complete

Installation


• Equipment configured and tested in lab environment

• Equipment racks were built in central office

Installation


Site Deployment• Ceragon IP‐10 radios• 1 + 1 HSB configuration


Antenna Configuration During Cutover

26

New Digital Path

Old Analog Path Old Analog Path

New Digital Path


Space Diverse Configuration Post Cutover

27

New Digital Path

Space Diversity Paths

New Digital PathMain Antennas

Diverse AntennasSpace Diversity Paths


Tower with space diverse antennas


IP Communications backbone ‐Microwave

• Replaced the T1 point to point back feed circuit with MPLS

• Added flexibility for routing traffic to multiple locations if needed

29

160 MHz 160 MHz 160 MHz

MP

LS B

ack Feed

Data Center Shreveport


Phase I Timeline

215Feb ‘10 Mar ‘10 May ‘10 June ’10 Sep ‘10 Jan ‘11Aug ‘09 Dec ‘09 Jan ‘10

Phase I kickoff

Get vendor quotes for microwave radios and network routers

Complete configuration of radios, routers and other support equipment

Site preparation for generators complete

Generator installs complete

Generators arrive

Microwave radios and network equipment arrive

Back feed circuits installed

Complete assembly of racks

2015????? ??????? ??????Feb ‘11 Mar ‘11 ??????

Start generator installs

Lab testing complete, equipment move to field locations

Field installations complete

Start cutover to IP radios

Cutover Complete

Old equipment removed from field locations

Phase I Complete


Phase II Timeline

215Aug ‘11 Sept ‘11 Dec ‘11 Jan ’12 Feb ‘12 March ‘12April ‘11 June ‘11 July ‘11

Phase II kickoff

RFP’s for generators, network routers and microwave radios goes out

Back feed circuits installed

Vendor selection of radios, routers and generators. Prepare sites for generators.

Microwave radios arrive

Network routers arrive

Start generator installs

Complete assembly of equipment racks

Generator installs complete

Project Complete 2015July ‘12 Aug ‘12 –

Jan ‘13 Jan ‘13 Mar ‘13 April ‘13April ‘12 May ‘12 June ‘12

Site preparation for generators complete. Generators arrive.

Complete configuration of microwave radios, routers and other support equipment

Lab testing complete. Equipment moved to field locations

Field installations complete

Waiting for completion of packet switch replacement project

Start cutover to IP radios

Cutover Complete

Old equipment removed from field locations


• Gained an understanding of Ethernet microwave radios– Reduced latency– Better bandwidth utilization– Scalable

• Realized that the data network had to be prepared so it could handle “communications” traffic

• Gained an understanding of dynamic routing (OSPF). Before this project we only used static routing in the network.

• Realized the importance of getting design help from data network engineers. Didn’t have adequate network engineering support on the first phase.

Lessons Learned


• Not all legacy equipment that had to say on‐site was IP capable and not all vendors offer IP solutions

• Had to design interfaces between some legacy equipment and new IP radios

• Had to learn new diagnostic and trouble shooting techniques• Network Engineering and Communication Engineering teams

have to work more closely together • New radios are IP devices on the network, have to become

more security aware

Lessons Learned

KCSR IP microwave project.ppt - railroads.dot.gov · 19700 Janelia Farm Boulevard, Ashburn, VA, 20147 (703)726−5651 PCN Date: 08/19/2011 Prev Job Num: Administrative Information

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