EBI Track 200 TI21 Audio Frequency Track Circuit

Transcription

1 EBI Track 200 TI21 Audio Frequency Track Circuit Technical Manual M125401A4 Scope: This manual covers non-electrified and double rail traction return applications. Single rail traction return applications are covered separately.

2 Amendment Record Issue Date From To Details 0p1 1 First release ECR12490 July Digital Rx added. Ref to Single Rail Application Manual added. ECR6- February refers. 2 3 Update to close issues arising from Digital Rx Safety Case. ECR6- October refers. 3 4 General update to reflect current practice. ECR October 2011 Bombardier Transportation Estover Close Estover Plymouth PL6 7PU Tel : Fax : enquiries@uk.transport.bombardier.com This document and its contents are the property of Bombardier Inc. or its subsidiaries. This document contains confidential proprietary information. The reproduction, distribution, utilisation or the communication of this document or any part thereof, without express authorisation is strictly prohibited. Offenders will be held liable for the payment of damages. (ii) M125401A4

3 2011 Bombardier Inc. or its subsidiaries. All rights reserved. M125401A4 (iii)

4 FOREWORD This manual describes the operation and application of the Bombardier EBI Track 200 TI21 Audio Frequency track circuit equipment. Companion reference documents are: Single Rail Manual M A4. Application Notes These are referenced in section 1.6. SAFETY CONSIDERATIONS If there is concern that the parameters specified in this handbook cannot be met for a particular intended installation, please contact the manufacturer. It may still be possible to apply EBI Track 200 by specifying alternative combinations of operating parameters by providing the manufacturer with full information regarding the intended installation, who may be able to specify modification to the parameters. Some extreme combinations may require additional safety and monitoring measures, of which the manufacturer will advise. Note that any deviations from this manual must be approved by the relevant rail authority before putting into service. If deviations from this manual are proposed, it is a condition that the manufacturer has a representative in attendance (for which it reserves the right to make a call-out charge to the operator). In no other circumstances but those described above will the manufacturer accept liability for any adverse consequences arising from the operation of the EBI Track 200 Track Circuit. MODIFICATION STATES The equipment label on each item of EBI Track 200 equipment contains a panel of numbers that is used to indicate the modification status or MOD STRIKE number (1,2,3,etc.) of that item of equipment. The modification panel, identified as M/S, for an unmodified piece of equipment is depicted below: S/N Y/M 1995 M/S: All 10 numbers are unmarked which indicates that the unit has not been modified and is at MOD STRIKE ZERO status. An item of equipment which has been subject to modification number one, it has the number 1 'struck out', this may be done either by scratching/stamping a diagonal line across the number 1 square or by deleting the number one with a black permanent marker pen. At each additional modification, the next number in sequence will be 'struck out', the last struck out number gives the MOD STRIKE status, e.g. if numbers 1,2,3,4,5 and 6 are struck out, that item of equipment would be at MOD STRIKE 6 status (iv) M125401A4

5 TECHNICAL ENQUIRIES Please send to ABBREVIATIONS The abbreviations listed below are commonly used in this handbook. A, amps Ampere ac, AC Alternating Current BRB British Rail Board CMD Condition Monitoring Display dc, DC Direct Current EBI Track 200 TI21 EBI Track 200 TI21 Audio Frequency Track Circuit ETU End Termination Unit IRJ Insulated Rail Joint LMU(Tx) Line matching Unit, Transmitter End LMU(TU) Line matching Unit, TU/ETU End RX, Rx Receiver SPETU Surge protected ETU. In this manual, the term ETU also applies to SPETU TCU Track Coupling Unit TI21, TI 21 Audio Frequency Track Circuit Style TI21 (former brand name) TTM TI21 Track Circuit Meter TX, Tx Transmitter TU Tuning Unit V Volt M125401A4 (v)

6 Contents Page no. 1. INTRODUCTION EQUIPMENT TRACK CIRCUIT AND TI UNIT TECHNICAL DATA TRACK CIRCUIT DESIGNER S GUIDE SETTING-UP AND COMMISSIONING PROCEDURE MAINTENANCE EQUIPMENT ORDERING INFORMATION MISCELLANEOUS INFORMATION AND DRAWINGS TI21 TX/RX EQUIPMENT RECORD CARD A. APPENDIX A, TECHNICAL DATA FOR SUPERSEDED PARTS... A-1 B. APPENDIX B, MANUAL CHANGE HISTORY... B-1 (vi) M125401A4

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8 Section 1 Introduction Contents 1. INTRODUCTION Safety Requirements Competence of Staff General Track Circuit Separation General Track Circuit Electrical Separation Joint Use Of End Termination Units Traction Return Current And Equipotential Bonding Single Rail Track Circuits Using Track Coupling Units Additional Reference Material... 7 M125401A4 1-1

9 Section 1 Introduction 1. INTRODUCTION 1.1 SAFETY REQUIREMENTS Competence of Staff The EBI Track 200 TI21 Audio Frequency Track Circuit must be installed and operated within the parameters specified in this handbook. Safety related applications conditions are given at the beginning of section 4. Specific Safety Requirements are given in: o Section 2.6 o Section 4.1 o Section o Section o Section 5.2 o Section 5.3 o Section 5.4 o Section 5.6 o Section o Section 6.3 o Section 6.6 Bombardier recommend that staff responsible for commissioning and maintenance of EBI Track 200 track circuits are able to demonstrate their competence as follows: EBI Track 200 training course certificate Manual handling course certificate Staff working on operational LMUs must be competent to work on voltages higher than 50V since voltages on LMU connections can reach 140V under fault conditions. It is further recommended that access to set-up keys is restricted to trained personnel. 1.2 GENERAL The TI Track Circuit Style 21 is of the jointless type designed for AC or DC electrified areas where high levels of interference (arising principally from 50 Hz harmonics) may be present. The equipment is classified as universal since it meets the onerous immunity requirements of all traction systems and the needs of all known track circuits. EBI Track 200 TI21 track circuits employ eight audio frequencies in the range of 1549 Hz to 2593 Hz, the nominal frequencies are usually referred to by letter, i.e. frequencies A, B, C, D, E, F, G and H. The equipment for the eight nominal frequencies are used as four pairs - A/B, C/D, E/F, and G/H. One pair is used per track and the frequencies are alternated, e.g. 'frequency A' track circuit, then 'frequency B' track circuit, then 'frequency A' track circuit, and so on. Further details of frequency allocation are given in section A block diagram of a basic track circuit is shown in Figure 1.2. Track Circuit Frequency F1 Track Circuit Frequency F2 50m to 1100m Track Circuit Frequency F1 20m 20m Tuning Unit F1 Tuning Unit F2 Tuning Unit F2 Tuning Unit F1 Transmitter F1 Power Supply 24VDC Receiver F2 Transmitter F2 Power Supply 24VDC Receiver F1 110 / 220 VAC Track Relay 110 / 220 VAC Track Relay 1-2 M125401A4

10 Section 1 Introduction Basic Track Circuit (1435mm gauge) Fig. 1.2 Standard BR miniature line relays or their equivalent are directly operated by the receiver. It is not necessary to use low powered, high percentage release relays with small contact stacks, or AC immune relays. The TI receiver has an inbuilt delayed pick-up response that obviates the need for "slow to pick-up" relays. The transmitters and receivers are arranged for standard BR relay rack mounting. The track circuit may be configured so as to cater for all types of traction current return systems. 1.3 TRACK CIRCUIT SEPARATION General The track circuit is of the 'jointless' type, electrical separation of adjacent track circuits is accomplished by tuning the inductance of 20 metres of track, using two track tuning units. The ideal properties of a separation joint are as follows: (1) That it embodies a minimum crossover length where one circuit begins and another one ends; (2) That a minimum signal is fed in the reverse direction through the joint. (3) That failure of any element of the joint is detected Track Circuit Electrical Separation Joint The electrical properties of the separation joint will be discussed with reference to the circuit diagram drawing (Figure 1.3.2a) which is a diagram of an electrical separation joint comprising two tuning units. CL Track Circuit Frequency 'A' Track Circuit Frequency 'B' Overlap Shunting Zone (Between 2m & 10m Depending on Ballast Conditions) 20 metres for 1435 (nominal) Track Gauge T1 T1 LA C1A 1 To Receiver (or Transmitter if in Low Power Mode) LB C1B 1 To Receiver (or Transmitter if in Low Power Mode) C2A TRA Earth Screen C2B TRB Earth Screen To Transmitter (for Normal Power Mode) To Transmitter (for Normal Power Mode) 5 5 T2 T2 Electrical Separation Joint Fig a M125401A4 1-3

11 Section 1 Introduction Each electrical separation joint is associated with two track circuit frequencies, the diagram shows one 'A' frequency track circuit and one 'B' frequency track circuit. 'A' for transmission to or from the left, 'B' for transmission to or from the right. Depending on application the joint may be associated with (i) one transmitter and one receiver, (ii) two transmitters or (iii) two receivers. Each track tuning unit presents a low impedance to one of the frequencies present in the joint, e.g. tuning unit frequency 'A' will present a low impedance, via L A and C 2A to the 'B' frequency signal, whilst tuning unit frequency 'B' via L B and C 2B presents a low impedance to the 'A' frequency signal, so the transmission of the frequencies is terminated at the low impedances. The inductance of the rails between the two track tuning units is tuned to a high impedance for both the frequencies present by means of the net capacitive reactances in the tuning units. The track tuning unit frequency 'B' tunes the rails to 'B' frequency whilst the tuning unit frequency 'A' tunes the rails to 'A' frequency to give directional tuning, with consequent directional transmission or reception. The following equivalent circuit diagrams (Figure 1.3.2b) show the directional tuning effect. Track Tuning Unit Frequency 'A' Track Tuning Unit Frequency 'B' Output Impedance (approx. 1Ω) Signal provided by Transmitter Inductance provided by 20m of rail Loss provided by 20m of rail Frequency 'A' Equivalent Electrical Circuit Track Tuning Unit Frequency 'A' Track Tuning Unit Frequency 'B' Loss provided by 20m of rail Inductance provided by 20m of rail Output Impedance (approx. 1Ω) Signal provided by Transmitter Frequency 'B' Equivalent Electrical Circuit Equivalent Circuits Fig b The voltages appearing in the direction of transmission or reception depend in part upon the losses in the tuned circuits, most of which will be in the rails themselves. The voltage appearing across the low impedance, L A, C 2A or L B, C 2B (Fig a) will be determined by the losses in these components alone. For a particular frequency, there is a ratio between the voltage across the tuning unit of that frequency and the voltage across its companion tuning unit; the ratios for each frequency and for various TX/RX arrangements are given in Table 6.1.2H. The low impedance circuits in the tuning units also serve the very important function of shorting the rail-to-rail traction harmonic voltages at the track circuit frequencies. Thus the track circuit frequency component of rail-to-rail traction voltage is kept low enough to avoid swamping the receiver as swamping the receiver can de-energise the relay when the track circuit is clear. The transmitter output and the receiver input provide a low impedance load to the track circuit which is necessary for correct tuning of the tuned area. On the tuning unit, receivers are always connected to terminals 1 and 2. For normal power mode (track circuit lengths of 200 to 1100 metres) the transmitter is connected to terminals 4 and 5, whilst for low power mode (track circuits of 50 to 250 metres long) the transmitter is connected to terminals 1 and 2. Within the tuned area there exists an overlap zone. This is a region where both track circuits will be de-energised by a shunt. The specified shunt value will de-energise both track circuits at the centre of the tuned area, and the shunt value required to drop each track circuit will reduce to zero as the shunt position moves away from that track circuit s pole tuning unit. 1-4 M125401A4

12 Section 1 Introduction The length of the overlap zone will depend upon several factors including the drop shunt set for each of the track circuits, ballast conditions and the shunt value. It will generally be between 2m and 10m. The typical variation in the shunt value required to drop the track circuit within the separation joint is indicated in Figure 1.3.2c. Shunt Value 1.0 Ω The shunt resistance required in the tuned area falls as the shunt position is moved further into the separation joint from the circuit concerned. The graphs show the relative shunt value required compared to 1Ω at the feed or receive tuning unit track terminations for a 1435mm gauge track. 1.0 Ω Track Circuit TC1 TC1 TC2 Track Circuit TC2 0.3 Ω 0.3 Ω TC2 TC1 0 5m 10m 15m 20m Shunt Value within Separation Joint Fig c NOTE: It has been found that the effect of the EBI Track 200 signal coupling into concrete steel reinforcing or DC stray current gathering systems can have a significant effect on overlaps. The specific effect on any individual tuned area is dependant on positioning of the tuned area with respect to the concrete decking, and overlaps may be biased toward one end or the other of the tuned area. There will however always be an overlap area where both track circuits are dropped by a zero ohm shunt, and the overlap will normally include the centre of the tuned area Use Of End Termination Units The End Termination Unit is a self-contained tuned circuit for applications where the track circuit isolation using the electrical separation joint is not required. Such applications are: (a) (b) end feed, or end receive, adjacent to insulated rail joints or, centre feed arrangements. The End Termination Unit employs the same housing as the standard tuning unit, and also the same terminations: Output to track on T1 and T2; Input from transmitter on terminals 4 and 5 for normal power; Output to receiver on terminals 1 and 2; Terminal 3 is the earth screen. For low power mode the transmitter output is connected to terminals 1 and 2. A surge protected version of the ETU (SPETU) exists for use railways usinjg the DC 3 rd rail system where high voltage transients can be generated by shorts between the 3 rd rail and the running rail. This product, and its applications, are fully described in the Single Rail Manual, M A4. M125401A4 1-5

13 Section 1 Introduction 1.4 TRACTION RETURN CURRENT AND EQUIPOTENTIAL BONDING Traction bonding is the practice of connecting the running rails to the traction substation and to each other to provide a return path for the traction current. It also includes the connection of exposed metal structures that are part of the traction supply system to the running rail for safety reasons. The EBI Track 200 track circuit has been designed to give safe and reliable operation in both AC and DC electrified territory, and with all known types of locomotive. EBI Track 200 can be used in both single and multiple track territory with traction current return arrangements as recommended below. AC: DC: EBI Track 200 can be used with either single or double rail traction return arrangements, although double rail traction return is recommended to minimise the effects of traction interference and optimise availability. Double rail traction return is preferred in DC electrified areas due to the higher currents found in the lower voltage systems. Examples of traction return bonding are given in Section SINGLE RAIL TRACK CIRCUITS USING TRACK COUPLING UNITS In some areas, where the track layout is complicated and adjacent tracks are in close proximity, it may not be physically possible to position TUs or ETUs at the trackside because of the limited space available. Using the track circuit in single rail mode may solve this problem. This single rail operation is achieved by using Track Coupling Units (TCUs) instead of Tuning Units. The tuned area is replaced by an insulated block joint in one running rail. The track circuit functions like the conventional AC track Circuit, i.e. you can have only one Receiver per track circuit and since the traction bonding is done through transverse bonding, the traction return current flows only through one rail and thus reducing the number of Impedance Bonds required. The TCUs are located in the apparatus cases or equipment room, and are connected to the track using 2.5mm 2 twisted pair cables. The total cable length between the track and the two TCUs can be up to 200 metres (See section ). A typical single rail track circuit is depicted in Figure 1.5. Full details of the Single Rail application are given in the Single Rail Manual, M A M125401A4

14 Section 1 Introduction Track Circuit Frequency F1 Track Circuit Frequency F2 Track Circuit Frequency F1 1 metre max. 1 metre max. IRJ IRJ Track Coupling Unit F1 Track Coupling Unit F2 Track Coupling Unit F2 Track Coupling Unit F1 Transmitter F1 Receiver F2 Track Relay Transmitter F2 Receiver F1 Track Relay Power Supply Unit 24VDC Power Supply Unit 24VDC 220 VAC 220VAC Basic Track Circuit with Track Coupling Units Fig ADDITIONAL REFERENCE MATERIAL The following application notes are available to provide additional information on specialist topics. IS A4 TR A4 IS A4 IS A4 IS A4 IS A4 M A4 M A4 M6/6/ M6/6/ TI21 Track Circuits, Guidance Notes for Traction Bonding EBI Track 200 TI21 Track Coupling Unit Circuit Review. Contains rationale for earthing strategy Operation With Concrete Slab Track With Steel Reinforcing Or Iron Lined Tunnels EBI Track 200 TI21, Summary of Fusing and Surge arrestor Arrangements Application Note: Maximum Transmitter and Receiver Feed Lengths When Using LMUs Information Sheet EBI Track Track Circuit Condition Monitoring EBI Track 200 Audio Frequency Track Circuit Style Single Rail Application EBI Track Audio Frequency Track Circuit, PC Application Users Manual, Customer Version. TTM Operating Instructions SIT Operating Instructions M125401A4 1-7

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16 Section 2 Equipment Contents 2. EQUIPMENT Transmitter Receiver Tuning Unit (TU) and End Termination Unit (ETU) Track Coupling Unit (TCU) Line Matching Unit (LMU) Power Supplies v dc Power Supply B / 3000 Impedance Bond Test Equipment TI21 Test Meter (TTM) Rocoil Current Transducer TI21 Shunt Box Sleeper Insulation Tester (SIT)... 7 M125401A4 2-1

17 Section 2 Equipment 2. EQUIPMENT 2.1 TRANSMITTER A block diagram of the transmitter is shown in Figure 2.1. The carrier is produced by direct digital synthesis (DDS). This entails sampling the level of a digital representation of a sine wave, stored in a PROM, at the appropriate rate to produce an output of the required frequency. The sample rate is changed between that appropriate for the low sideband and that for the high sideband at a frequency of 4.8Hz, thus producing the correct modulation of the output carrier. 'MOD' Input Interface circuitry OSC. 1 (32MHz) USB Step Size 18 ACC Modulation Rate Sideband Select Lookup PROM 8 Delta-Sigma D to A Converter Analog Power Regulator / Gate H-Bridge Output Stage Output Filter To Tuning Unit LSB Step Size ACC OSC. 2 (4MHz) Within ASIC Transmitter Block Diagram Fig. 2.1 The MOD input on the front panel allows the internal 4.8Hz modulation to be overridden. If MOD is tied to N24 then the output will be continuously at the Low Sideband, if it is tied to B24, then the output will be continuously at the High Sideband. Separate crystal oscillators and divider chains are used to generate the correct sampling rate for each the low and high sidebands, this is so that drift in one oscillator will only affect the frequency of one sideband. This would produce an output which does not correspond to any valid EBI Track 200 signal, so could not become a potential source of false feed to another track circuit. It is important, in order to provide good output regulation and avoid unacceptable increases in output power, that a good quality sine wave is produced by the DDS signal generator. One potential danger in this respect is that certain data or address lines, if failed permanently low or high, could result in the PROM output being closer to a square wave at the carrier frequency, and cause large output increases. It is not possible to avoid this failure mechanism completely, but it is possible to ensure that, if such a failure happens, it will only affect one sideband in this way, and probably corrupt the other sideband to make the overall output invalid. To avoid the possibility of the output changing to something approaching a square wave at the carrier frequency, at least for both sidebands, both the PROM address and data lines are inverted for the upper sideband. Tests have shown that no data or address line failing low or high causes an increase in overall energy to the track, and in many cases makes the track easier to shunt. Samples read out of the PROM are converted into analogue levels using a Delta-Sigma, or one bit, D to A converter, and then fed to the power regulator, which compensates for variation in the unit s supply voltage (B24). The Delta-Sigma converter does not use a voltage reference, its output switches between the supply rail and ground at a high frequency, and is filtered to produce the analogue output required. The regulator output is gated by a circuit which will not pass the signal if the converter supply voltage is more than a small percentage away from its 2-2 M125401A4

18 Section 2 Equipment correct value. In this way the failure mode of an increase in amplitude into the regulator, causing an increase in overall output power, is avoided. In addition to the transmitter function, the unit contains Health Monitoring circuitry which enables the operation of the unit to be monitored. Output is by means of three Green / Red / Yellow LEDs on the front panel. A green LED indicates OK, red indicates a fault and yellow has a special meaning as defined below. The LEDs are grouped as follows: Top LED: External power supply turns red if the input supply is too high or low. Centre LED: Internal functionality turns red if the sideband frequencies, the modulation frequency or the output pulse widths are out of specification, or the output drive stage stops switching. Bottom LED: External load condition turns red if the load current on the output is too high. This indicates that either the external output wiring is short circuit, or that the output stage is short circuit. Transmitters are frequency dependant, i.e. there is a Transmitter for each TI frequency, i.e. A, B, C, D, E, F, G and H 2.2 RECEIVER A block diagram of the receiver is shown in Figure 2.2. The signal from the track tuning unit is fed to the Front-End block which incorporates an input transformer to isolate the receiver circuit from the tuning unit. The signal is converted to digital format (ADC block) and then filtered by the DSP stage to recover the two sidebands. The sidebands are then demodulated and evaluated to ensure that upper asnd lower sideband signals are present in anti-phase to each other and above the detection threshold (supplied by the Auto-Set block). If the evaluation is true continuously for more than two seconds, the track clear indication output is set to TRUE. Receiver Block Diagram Fig. 2.2 Key Features A common Receiver unit is assigned to one of the eight EBI Track 200 frequencies by means of the configuration key. The Auto-Set feature simplifies the track set-up procedure and front end circuit by eliminating the requirement for sensitivity-setting straps. Condition monitoring and diagnostic information is available via a four character display and as isolated serial data on a 9-way D-type connector. The Track Clear output is an isolated relay drive signal. M125401A4 2-3

19 Section 2 Equipment 2.3 TUNING UNIT (TU) AND END TERMINATION UNIT (ETU) A Tuning Unit is used to couple energy into a track circuit which is terminated by an electrical separation joint (tuned area). Tuning units are frequency specific, i.e. there is a TU for each of the EBI Track 200 operating frequencies, i.e. A, B, C, D, E, F, G and H. The design utilises only passive components, no power is required for a TU at the trackside. An End Termination Unit is used to couple energy into a track where there is no tuned area, it achieves this by emulating the characteristics of a tuned area. ETUs are generally used in the following situations: Centre-fed applications At the end of a EBI Track 200 track circuit which adjoins a non-ti track circuit At the end of a EBI Track 200 track circuit which adjoins non-track circuited territory At the end of a EBI Track 200 track circuit which adjoins another EBI Track 200 track circuit where there is insufficient room for a tuned area (so insulated block joints are used), such as in points or crossings At the end of a EBI Track 200 track circuit which adjoins another EBI Track 200 track circuit, but of a different frequency pair (insulated block joints must be used) TUs and ETUs are frequency dependant, i.e. there is a TU and an ETU for each TI frequency, i.e. A, B, C, D, E, F, G and H. A Surge Protected End Termination Unit (SPETU) has been developed for applications where fault conditions could impose traction voltages across the running rails which would then cause damage to an unprotected ETU. Such fault conditions can be produced by third rail DC traction systems when a short circuit fault develops between the third rail and one of the running rails. The SPETU is identical in function to a standard ETU as described above except that it contains 10A fuses in series with its rail terminals and a surge arrestor in parallel.. SPETUs are frequency dependant, i.e. there is an SPETU for each frequency, i.e. A, B, C, D, E, F, G and H. SPETUs and their application are fully described in the Single Rail Manual, M A4 2.4 TRACK COUPLING UNIT (TCU) The Track Coupling Unit is used to couple energy into a track where: it is not convenient to mount units on or beside the rails and the maximum track circuit lengths do not exceed 200m and the Transmit end TCU-to-rail distance plus the Receive end TCU-to-rail distance is not more than 200m. These conditions typically arise in siding and depot areas. TCUs are frequency specific, i.e. there is a TCU for each of the EBI Track 200 operating frequencies A, B, C, D, E, F, G and H. TCUs and their application are fully described in the Single Rail Manual, M A4 2.5 LINE MATCHING UNIT (LMU) The Line Matching Unit allows the distance between the TX and its TU / ETU to be extended to up to 500 metres; the maximum track circuit length is restricted to 970m. The LMU consists of two units : Line Matching Unit (TX) - fitted next to its associated EBI Track 200 transmitter, 2-4 M125401A4

20 Section 2 Equipment Line Matching Unit (TU) - fitted adjacent to the associated tuning unit. LMUs are not frequency dependant, i.e. the same LMU(Tx) or LMU(TU) can be used with any of the EBI Track 200 operating frequencies A to H. 2.6 POWER SUPPLIES SAFETY REQUIREMENT The requirements on power supply loading in section must be observed to guarantee safe operation of EBI Track 200 track circuits V DC POWER SUPPLY The Power Supply is specially designed to be compatible with EBI Track 200 Transmitters and Receivers and AC input voltages of 110V 50 or 60Hz. It has the same physical dimensions, and occupies 2½ relay spaces when rack mounted. Two versions are available, one for 110V AC, and one for 220V AC. The power supply will run two transmitters or a combination of transmitters and receivers drawing a maximum load current of 4.4A. It s output is in the range of 22.5V DC to 30.5V DC. One power supply unit should not be arranged to feed a transmitter and receiver of the same frequency. A strap adjustment is provided to ensure adequate regulation for two ranges of load: (1) 0.25 Amps to 2.2 Amps. (2) 2.2 Amps to 4.4 Amps. A 3 Amp anti-surge fuse must be used on the AC input to the power supply to prevent nuisance blowing due to inrush current at switch on. A suitable fuse is specified in section 7. The circuit for the power supply is shown in Figure Green LED1 Red (not used) WAGO 5mm Pluggable 8-Way. Male Panel Mount T5 T0 T85 T95 T105 T115 E P BK BN RD OR YW BL GN BK T5 T0 T85 t21 BN GY RD T115 OR GN VI YW BL T95 T105 SCN t0 t19 T1 WH WAGO 5mm Pluggable 8-Way. Female Cable to Male Straight PCB WH GY VI GN GN BK YW D4 10A D1 10A 10A D3 V1 130V D2 10A C1a 10000uF C1b 10000uF R1 3K3 2.5W C1c 10000uF D5 1A WAGO 7.5mm Pluggable 9-Way. Male 90Deg PCB 1 2 B N A A 9 TAP COM P1 P2 V2 275V Power Supply Circuit Diagram Fig M125401A4 2-5

21 Section 2 Equipment Note: A green LED indication is provided to show that the 24V DC output is energised. It does not indicate that the DC output is within specification since it turns on when the output is above 5V. 2.7 B / 3000 IMPEDANCE BOND The B3 4000A impedance bond is a ferrite-cored, tuned impedance bond. The B3 4000A is designed to operate at up to 4000A traction return current in AC and DC electrified areas; where the areas are fitted with EBI Track 200 traction immune track circuits. The basic bond can be fitted with one of eight tuning modules (capacitor boxes) so that it can be re-tuned to any of the eight EBI Track 200 operating frequencies. L C Impedance Bond Equivalent Circuit Fig. 2.7 A variant of this impedance bond, the B3 3000A, utilises a different arrangement for terminating the tuning module to the bond coil. This version is intended for the UK market only. 2.8 TEST EQUIPMENT TI21 Test Meter (TTM) The TI21 Test Meter is designed to measure voltage levels within the individual EBI Track 200 frequency bands. It enables readings of track circuit parameters to be taken without corruption from other track circuit signals or interference at non-ebi track 200 frequencies, e.g. 50 Hz traction return currents. In particular it permits the voltage on a "zero" tuning unit to be measured at one particular frequency without any disconnections being necessary. Its use is recommended for use when working on EBI Track 200 track circuits so as to obtain accurate measurements with minimum disruption of adjacent track circuits, see section 5. Operating instructions for the TTM are given in M6/6/ Rocoil Current Transducer TI21 Shunt Box The Rocoil current transducer is designed to connect to the TTM to provide a means of measuring rail currents non-intrusively. The TTM / Rocoil combination is a versatile aid to diagnosing track faults. A description of the Rocoil s controls is given in section 3.10 and sections 5 and 6 provide further details on its application. The TI21 Shunt Box is designed for applying accurate shunt resistance values across the track during setting-up and testing, as described in sections 5 & 6. The shunt box provides shunt value settings from 0 Ω to 9.9Ω, selectable in steps of 0.1Ω. 2-6 M125401A4

22 Section 2 Equipment Sleeper Insulation Tester (SIT) The unit consists of an aluminium die cast box, two rotary switches for shunt value selection and two insulated, crocodile clip terminated cables for connecting the Shunt Box to the rails. The internal wiring is arranged so that switch contact resistance is kept reasonably constant. Because the internal resistors are of a high rating, the shunt box can remain connected to the rails during shunt testing of EBI Track 200 track circuits. The Sleeper Insulation Tester (SIT) is designed to detect leakage of EBI Track 200 track circuit signals into the sleepers. It provides the operator with an audible and visual indication of leakage level. The SIT allows a specific EBI Track 200 frequency to be checked without interference from any other EBI Track 200 track circuits or any other frequency. The SIT also has an AC detection mode that can be used to detect any AC signal up to approx. 3 khz; this mode is useful to detect high levels of harmonic leakage in DC 3rd rail, electrified areas. Note that the visual indication is not available to the operator in this mode. M125401A4 2-7

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24 Section 3 EBI Track 200 Technical Data Contents 3. EBI TRACK 200 TECHNICAL DATA General System Specification Minimum And Maximum Track Circuit Lengths Transmitter Receiver Tuning Unit (TU) and End Termination Unit (ETU) Track Coupling Unit (TCU) EBI Track 200 Power Supply Line Matching Unit (LMU) TX Line Matching Unit ( LMU(TX) ) TU / ETU Line MatchIng Unit ( LMU(TU] ) B3 Bonds for use in AC or DC Electrified Areas TI21 Test Meter (TTM) Rocoil Current Transducer Sleeper Insulation Tester (SIT) Shunt Box M125401A4 3-1

25 Section 3 EBI Track 200 Technical Data 3. EBI TRACK 200 TECHNICAL DATA 3.1 GENERAL System Specification System Specification Table Parameter Value Comments Power Supply 220 V (nominal) 50Hz or 60Hz AC 110 V (nominal) 50 Hz or 60 Hz AC 24V (nominal) DC Battery Uses 24V DC Power Supply 220 V version Uses 24V DC Power Supply 110 V version No Power Supply required Balllast Conductance 0.5 Siemens/km maximum Ballast conductance above 0.5 Siemen/km may promote nuisance dropping of the track relay, or Ballast Conductance Change Ballast conductance must not fall to less than one fifth of its value at the time of track circuit set up unsafe set-up conditions. It is very unlikely that the ballast condition will change from one extreme to the other between maintenance checks of the track circuit. If ballast is renewed, then the track must be reset. Train Shunt 0.5Ω or less in main part of track circuit This is the worst case shunt presented by a train. 0.15Ω or less throughout tuned area Temperature Range -30ºC to +70ºC Operating Track mounted units (TU / ETU) can tolerate a minimum temperature of -40 C. Humidity Resistance 0% to 100% Relative Humidity Tuned Area Length 1.0m gauge 22m ±0.5m Tuned area length depends on the rail gauge. For 1.067m gauge 22m ±0.5m rail gauges other than those shown, please 1.220m gauge 21m ±0.5m contact Bombardier Transportation for details m gauge 20m ±0.5m (Standard gauge) 1.674m gauge 19m ±0.5m ETU / IRJ Position Up to 3m ETU rail connections must be placed within 3m of the IRJ defining the end of the track circuit. In the event of staggered joints, this distance refers to the joint nearest the ETU. Note that some rail authorities may have more restrictive conditions. IRJ Stagger Determination of Circuit Extremity Relays Track Feed Voltage 0.8V to 1.8V 4.8V to 8.2V Track Circuit Frequencies Defined by centre of the Tuned Area ±5m or position of IRJs Standard Neutral Line Relay from BR930 series or equivalent non-welding safety relay. Nominal Actual A B C D E F G H Rail authorities may control the amount of permissible stagger in order to avoid an excessive length of dead section.. An overlap of 2m to 10m will exist in tuned areas, see section If BR 930 style relays or other non-welding safety relays are not used, then a contact proving arrangement which guarantees detection of welded contacts by the control system must be used. Low Power Normal Power Dependent on frequency and ballast condition A to D are the primary frequencies E to F are the secondary frequencies Hz Hz Track Connection 1 mω per connection Resistance Track Connection TU or ETU 25A minimum Current Capability TCU 5A minimum 3-2 M125401A4

26 Section 3 EBI Track 200 Technical Data Parameter Value Comments EBI Track 200 track circuits comply with European Directive 89/336/EEC. Electromagnetic Compatibility Maximum Number of Receivers in a Track Circuit Handling and Storage To achieve compliance, the E terminal on the transmitters, receivers and power supply must be connected to earth. 3 Complex crossings may require more than 3 receivers in a track circuit. In this case, consult Bombardier Transportation for guidance. There are no special handling requirements Storage temperature limits: -30ºC to +70ºC M125401A4 3-3

27 Section 3 EBI Track 200 Technical Data Minimum And Maximum Track Circuit Lengths Minimum And Maximum Track Circuit Lengths Table MODE TX-to-Track Distance (m) (see NOTE 5) No Impedance Bonds Track Circuit Length (m) (see NOTE 2) One Impedance Bond Two Impedance Bonds Comments Normal Power End fed < to to to 970 Centre fed < to 1000 (each half) 300 to 900 (each half) 300 to 850 (each half) See sub-section End fed With LMUs 30 to to to to 860 See NOTE 1 Low Power End fed < to to to 250 See sub-section See NOTE 4 End fed With LMUs Using Track Coupling Units Using ETUs 30 to to to m total Tx + Rx cables As double rail Single Rail 50 to 250 See NOTE to 200 N/A N/A 20 to 1100 See NOTE 6 N/A N/A See NOTE 1 & NOTE 4 See manual M A4 See manual M A4 NOTE 1: This is the preferred method for extending TX-to-TU distance, see sub-section NOTE 2: (A) End fed distances are from the centre point of the TX tuned area to the centre point of the RX tuned area. (B) Centre-fed distances are for each half of the track circuit measured between the TX ETU and the centre point of the receive tuned area. NOTE 3: To avoid loss of broken rail detection, only two impedance bonds are only allowed in a low power track circuit where they provide traction continuity across IRJs at either end of the track circuit. In this situation it is allowable to use a third bond for traction return to the sub-station, or the traction return conductor may be connected to the centre tap of one of the bonds at the TC joints. In either case only one connection should be taken to the traction return system or for cross-bonding. NOTE 4: If ETUs (with IRJs) are fitted at both ends of a low power track circuit, the minimum track circuit length may be reduced to 20 metres. NOTE 5: Tx to track distances assume 2.5mm 2 cable. The maximum Rx-to-track distance is500m (also in 2.5mm 2 cable). See section for further information. NOTE 6: The maximum length of single rail circuits may be limited by traction requirements. 3-4 M125401A4

28 Section 3 EBI Track 200 Technical Data 3.2 TRANSMITTER Supply Voltage Range: Vibration and Shock Resistance Current consumption with TU/ETU On Normal Power: Current consumption with TU/ETU On Low Power: Current consumption with TCU: 22.5V DC to 30.5V DC Complies with EN Outside the track. 2.2A maximum (clear track) over full supply range 0.25A maximum (clear track) over full supply range 0.5A maximum (clear track) over full supply range. Supply Fuse 3A slow blow (see section 7 for part number) Output power: Normal Power Mode 40W to track (maximum) Low Power Mode 3W to track (maximum) Single Rail with TCUs 3W to track (maximum) Output stabilisation over maximum variation of supply: ±5% Health Monitoring Displays: Modulation rate: Connector Unit size : Mounting: Weight: Red/Green LED External Supply Red/Green LED Internal parameters Red/Green LED External Load Green In specification Red Out of specification 4.8Hz Plug-in 9-way WAGO connector. 140 mm H x 142 mm W x 194 mm L (2½ BR relay spaces) Screw fixings arranged for standard BR relay centres (Ensure that there is at least 10 mm horizontal spacing and 35 mm vertical spacing between units for air circulation). If the unit is fitted in an enclosure, allow 50mm between the connector and the enclosure door for wiring. Rear panel fixing dimensions are identical to the front panel. 3kg M125401A4 3-5

29 Section 3 EBI Track 200 Technical Data EBI Track 200 Transmitter Outline: M5 RIVET BUSHES. MAXIMUM PROJECTION OF SCREW INTERNALLY 15mm CRS CRS CRS B24 N24 MOD O/P1 O/P CRS CRS Connector Allocation Position 9-Way Connector Legend Function 1 B24 Supply positive 2 N24 Supply negative 3 Mod Modulation input 4 Not used 5 OP1 Output 6 Earth Earth terminal symbol 7 OP2 Output 8 Not used 9 Not used 3-6 M125401A4

30 Section 3 EBI Track 200 Technical Data 3.3 RECEIVER Supply Voltage Range: Vibration and Shock Resistance Current Consumption: Relay Output: 22.5V DC to 30.5V DC Complies with EN Outside the track. 0.3A maximum with relay energised 42V DC at 50mA maximum (2.1W, suitable for driving a BR 930 series 50V relay). Alternatively, a 20.5V DC output version is available (2.1W, suitable for driving a BR 930 series 24V relay). Time Delay to operate output relay: Pick 2 seconds ± 0.5 seconds Maximum Input sensitivity: Maximum Input Signal: Frequency Configuration Condition Monitoring Display and Control Buttons Condition Monitoring Interface 15mA 4 x threshold level or 500mA whichever is lower. Defined by removable key User-interface for frequency configuration and automatic set up when the set-up key is inserted. Readouts of track circuit quantities: o Clear track current o Threshold current o PSU voltage o Relay state o Relay drive voltage and current o Internal temperature o Frequency, Mod state and Serial No 9-way D type connector enabling RS232 or RS485 interface with proprietary monitoring systems. The maximum length of the serial cable is 30m. Fault Relay Contact Rating 220V DC / 1A. Connector Unit Size Mounting Receiver Unit Mounting Plate Weight Receiver Unit Plug-in 9-way WAGO connector. 211mm x 140mm x 142mm with mounting plate. Clip-on fixing with integral latch at rear. Front mounting is not possible. Screw fixing arranged for standard BR relay centres (Ensure that there is at least 35mm vertical spacing between units for air circulation, horizontal spacing is not critical). If the unit is fitted in an enclosure, allow 50mm between the connector and the enclosure door for wiring. Note that a rear connector mounting plate is available for installations where analogue units were frontmounted. 1.3 kg M125401A4 3-7

31 Section 3 EBI Track 200 Technical Data EBI Track 200 Receiver Outline: 211 Rear View of Receiver only. 181 Front view of Receiver only. 71 EBI Track 200 TI21 Receiver Next 134 OK B24 N24 TP1 Back IP C IP 1 IP 2 RL RL E M5 EXTRUDED & TAPPED HOLES. USE SUPPLIED M5x12mm PAN HEAD POZI/SLOT COMBI HEAD SCREWS. EBI Track 200 TI21 Receiver Next B OK Back N24 TP1 IP C IP 1 IP 2 RL RL E Mating Connector Optional Convertor Adapter to Enable Use of Fanning Strip or Spade Crimps Right Angle Straight 3-8 M125401A4

32 Section 3 EBI Track 200 Technical Data 9-Way Main Connector Allocation Position Legend Function 1 Top B24 24V supply positive 2 N24 24V supply negative 3 TP1 Access to 1Ω 4 IP C Signal input 5 IP 1 Signal input and access to 1Ω 6 IP 2 Alternative signal input via 100Ω (not normally used on mainline applications) 7 RL+ Relay drive 8 RL- Relay drive 9 Bottom E Connected to case 9-Way Condition Monitoring Connector Allocation Pin Function Comments 1 RS485 or RS232 select Link to pin 9 for RS485 2 RS232 Tx or RS485 Z 3 RS232 Rx or RS485 A 4 Relay common Fault Relay contact 220V/1A: open = fault. 5 Isolated 0V 6 RS485 Y 7 RS485 B 8 Normally open relay contact Fault Relay contact 220V/1A: open = fault. 9 Isolated 5V supply M125401A4 3-9

33 Section 3 EBI Track 200 Technical Data 3.4 TUNING UNIT (TU) AND END TERMINATION UNIT (ETU) Vibration and Shock Resistance Size overall: Maximum rail to rail volts: Mounting: Weight: Complies with EN On sleeper. 375 mm H x 407 mm W x 114 mm L 110V AC /160V DC Lineside Stake or Sleeper 7.5Kg Note: Cables are supplied fitted with crimp terminations but each cable requires a rail termination kit for fixing at the rail end, see Fig 8.5. A Surge Protected version (SPETU) exists for use in single rail applications, see M A4. EBI Track 200 Tuning Unit / ETU Outline: T1 T2 Terminal Allocation M10 Terminals 2 BA Terminal Block Rail connection 1 RX or TX Low Power (not polarity sensitive) (not polarity sensitive) Rail connection 2 RX or TX Low Power (not polarity sensitive) (not polarity sensitive) 3 Earth terminal 4 TX Normal Power (not polarity sensitive) 5 TX Normal Power (not polarity sensitive) 6 Not connected 3.5 TRACK COUPLING UNIT (TCU) 3-10 M125401A4

34 Section 3 EBI Track 200 Technical Data 3.6 EBI TRACK V DC POWER SUPPLY For TCU details see Single Rail Applications Manual, M A4. Vibration and Shock Resistance Input Nominal V AC version Input tappings Input variation Input frequency Output voltage Output current Output ripple maximum Complies with EN Outside the track 110VAC 50Hz V AC version 220VAC 50Hz Peak inrush current at power up See below ±7% of selected tappings 50/60Hz Power factor 0.97 Connectors Unit size Mounting Weight 22.5 VDC to 30.5VDC smoothed 0.25A to 2.2A or 2.2A to 4.4A (Range set by output tappings) 3V peak-to-peak at full load current 50A. Note that an anti-surge 3 amp fuse must be used in series with the PSU input RH: Plug-in 9-way WAGO connector LH: Plug-in 8-way WAGO connector 144 mm H x 146 mm W x 210 mm L (2½ BR relay spaces) Screw fixings arranged for standard BR relay centres (ensure that there is at least 10 mm horizontal spacing and 35 mm vertical spacing between units for air circulation). Rear panel fixing dimensions are identical to the front panel 5kg 220V Variant Input tappings: V Input Voltage Input Connections between: 190 V T0 & T V T10 & T V T0 & T V T10 & T V T0 & T V T10 & T V Variant Input tappings: V Input Voltage Input Connections between: 85V T0 & T85 90V T5 & T85 95 V T0 & T V T5 & T V T0 & T V T5 & T V T0 & T V T5 & T115 M125401A4 3-11

35 Section 3 EBI Track 200 Technical Data Power Supply Outline: M5 RIVET BUSHES. MAXIMUM PROJECTION OF SCREW INTERNALLY 15mm CRS CRS 68 DC ON CRS T5 T0 T85 T95 T105 T115 B24 N24 2.2A-4.4A A TAP COM M6 EARTH TERMINAL (Transformer Screen & Chassis) CRS CRS Note: 110V variant shown. 220V variant identical except input terminals are labelled T10, T0, T190, T210 & T230 instead of T5, T0, T85, T95, T105 & T115. LH 8-way Connector Allocation EBI Track 200 Position Legend Function 8 Top T5 (T10) 7 T0 (T0) 6 T85 (T190) 5 T95 (T210) 4 T105 (T230) 3 T115 Voltage adjustment tappings 2 Not used 1 Bottom Earth Symbol Earth terminal RH 9-way Connector Allocation EBI Track 200 Position Legend Function 1 Top B24 24v supply positive output 2 B24 24v supply positive output 3 B24 24v supply positive output 4 N24 24V supply negative output 5 N24 24V supply negative output 6 N24 24V supply negative output A Output current adjustment A tappings 9 Bottom TAP COM 3-12 M125401A4

36 Section 3 EBI Track 200 Technical Data 3.7 LINE MATCHING UNIT (LMU) TX Line Matching Unit ( LMU(TX) ) Vibration and Shock Resistance Connector Unit size: Mounting: Weight: Complies with EN Outside the track. Plug-in 9-way WAGO connector 140 mm H x 142 mm W x 208 mm L (2½ BR relay spaces) Screw fixing arranged for standard BR relay centres (Ensure that there is at least 10 mm horizontal spacing and 35 mm vertical spacing between units for air circulation). If the unit is fitted in an enclosure, allow 50mm between the connector and the enclosure door for wiring. Rear panel fixing dimensions are identical to the front panel. 2.1 Kg EBI Track 200 LMU(Tx) Outline: M5 RIVET BUSHES. MAXIMUM PROJECTION OF SCREW INTERNALLY 15mm CRS CRS 68 TX CRS TU Line Matching Unit (Tx) M6 EARTH TERMINAL (CHASSIS) CRS CRS EBI Track 200 Position Legend Function 9 Top Tx Connects to TX (not polarity sensitive) 8 Not used 7 Tx Connects to TX (not polarity sensitive) 6 Not used 5 Not used 4 TU Connects to TU/ETU (not polarity sensitive) 3 Not used 2 TU Connects to TU/ETU (not polarity sensitive) 1 Bottom Earth Symbol Earth terminal M125401A4 3-13

37 Section 3 EBI Track 200 Technical Data TU / ETU Line MatchIng Unit ( LMU(TU) ) Vibration and Shock Resistance Unit size: Complies with EN On sleeper. 75 mm H x 127 mm W x 190 mm L Mounting: Screw fixing to backplate, see Fig 8.8 Weight: 2.04 kg including backplate and cover plate Sketch of LMU(TU) with lid removed to show position of Terminal Block & Terminal Identities. Ouput Cable Gland ( to TU ) TU TX E Input Cable Gland (from Tx ) LMU (TU) 2BA Terminal Block Position Legend Function Position Legend Function LH Column RH Column 1 Top TU Connect to TU/ETU 4 Top Not connected 2 (not polarity sensitive) 5 TX Connect to TX 3 E Earth terminal (connects to case) 6 (not polarity sensitive) 3-14 M125401A4

38 Section 3 EBI Track 200 Technical Data 3.8 B3 BONDS FOR USE IN AC OR DC ELECTRIFIED AREAS B3 Bond variants: B B Vibration and Shock Resistance Unit size (Both variants): Resonated Impedance: Meets BR863 temperature rise limits Capacitor box terminated on busbars outside of main casting Exceeds BR863 temperature rise limits Capacitor box terminated within main casting Complies with EN On sleeper. 158 mm H x 640 W mm x 459 mm D 12 Ω minimum. Note: A capacitor box matching the frequency of the track circuit must be fitted to the bond Traction Resistance: DC: < 25 µω. Each end to centre tap AC: < 3 mω Each end to centre tap Traction Current Rating: B B Per Rail Per Bond Per Rail Per Bond Continuous 1500A DC 3000A DC 2000A DC 4000A DC Two Hour 2250A DC 4500A DC 3000A DC 6000A DC Four Minute 4500A DC 9000A DC 6000A DC 12000A DC 100msec 25kA 50kA 25kA 50kA 20msec 50kA 100kA 50kA 100kA Out of Balance Current rating: Terminations: Tuning Capacitors (both variants) Weight: Track circuit signal voltage attenuation no greater than 5% at the appropriate carrier frequency for an out of balance current of 450A compared to level with no traction current. Clearance holes for M16 bolts. Freq Value µf A ±1.5% B ±1.5% C ±1.5% D ±1.5% E ±1.5% F ±1.5% G ±1.5% H ±1.5% 71 Kg 3.9 TI21 TEST METER (TTM) Refer to the Operating Instructions - M6/6/ M125401A4 3-15

39 Section 3 EBI Track 200 Technical Data 3.10 ROCOIL CURRENT TRANSDUCER Sensitivity Ranges: Current Rating: Batteries: Indicators: Output Connections: Control / Range Switch: 10A/Volt (with 50Hz blocking filter) 1A/Volt (with 50Hz blocking filter) 1A/Volt (without 50Hz blocking filter) 65A peak on 10A/V range 6.5A peak on 1A/V range 2 x PP3 Battery life > 40 hours Power LED Indicates steady red when unit powered on Flashes when battery voltage low. Overload LED Indicates red for 2 sec after switch on. Indicates red if current input is overrange. 2 x 4mm sockets OFF, 10A, 1A, 1A (unfiltered) 3.11 SLEEPER INSULATION TESTER (SIT) Refer to the Operating Instructions M6/6/ SHUNT BOX Resistance Values: 0 to 9.9Ω in 0.1Ω steps -5% +5% +25mΩ Power Rating: 15W (continuous use on EBI Track 200) Cable Length: Dimensions: Weight: 1m (each lead) 171mm wide (excluding cable glands) x 120mm deep x 160mm height (including handle) 1.67kg 3-16 M125401A4

40 Section 4 Track Circuit Designer s Guide Contents 4 TRACK CIRCUIT DESIGNER S GUIDE Safety Related Application Conditions Design Installation And Operation Preventative Measures against Bypass Paths Track Circuit Layout Design Overview Frequency Allocation Double Rail Track Circuits End Fed Arrangement Centre Fed Arrangement Jointed Double Rail Operation Low Power Operation Minimum Separation Of Units Of The Same Frequency Adjoining Other Types Of Track Circuit Or Adjoining Non-Track Circuited Lines Single Rail Track Circuits Using End Termination Units Using Track Coupling Units Adjoining Other Types Of Track Circuit Or Adjoining Non-Track Circuited Lines Changing Between Single And Double Rail Track Circuits In Electrified Areas Increasing Feed Lengths / Centralised Operation Increasing The Tx-To-TU / ETU Distance By Using Line Matching Units Increasing The Tx-To-TU / ETU Distance By Using Cable With Larger Cross Sectional Area Points & Crossings Shunting Considerations Generic Crossing Arrangements Electrical Bonding Of Metallic Structures To The Rails Non Standard And Exceptional Situations Track Circuit Interrupters and Treadles Cut Sections Inserting an Extra Track Circuit Track Circuits with steelwork in the bed of the track INSTALLATION REQUIREMENTS Overview Transmitter and Receiver Mounting Rail Connections Tuning Units (TUs) And End Termination Units (ETUs) Track Coupling Units (TCUs) Cables Rail Bonding Jointed Rail Traction Return Current Bonding Bonding For IRJ Failure Detection Check Rails Lightning Protection (This does not apply to single rail circuits using TCUs) Power Supply Unit Considerations Power Supply Unit Loading Rules V Battery Supplies Power Supply Location EMC Compliance Fusing - TX, RX and PSU TX and RX B Power Supply Input BX110 or BX220 Circuits: Torque Settings for EBI Track M125401A4 4-1 Issue 4: Otober 2011

41 Section 4 Track Circuit Designer s Guide 4 TRACK CIRCUIT DESIGNER S GUIDE 4.1 SAFETY RELATED APPLICATION CONDITIONS SAFETY REQUIREMENT The following requirements on design, installation and operation must be observed to guarantee safe operation of EBI Track 200 track circuits Design The following design rules must be observed for applications of EBI Track 200 to be adequately safe: The Track Circuit Layout Design section of this manual must be strictly observed. The track relay must be a BR930 style or other non-welding safety relay. AC immune relays are not required provided the relay is housed in the same equipment cabinet as its receiver. Abutting tracks must not be of the same frequency. Tuned Zone length must be in accordance with section Relay contacts (for example in track circuit interrupters, treadles and cut sections) must not be incorporated into the B24/N24 feeds to transmitters or receivers. This rule ensures that the logging capabilities of the EBI Track 200 are maintained Installation And Operation The following application rules must be observed for applications of EBI Track 200 to be adequately safe: The Installation and Set Up and Maintenance sections of this manual must be strictly observed. Any Insulated Rail Joints (not protected by the presence of a diagonal bond) must be subject to regular maintenance checks to ensure their integrity (section Test R). Rail insulation must be subject to regular maintenance to reduce the likelihood of nuisance failures. EBI Track 200 equipment conforms to the European EMC directive. Other equipment located in the vicinity should be checked for compatibility with EBI Track 200 equipment. If the track bed incorporates steelwork, an assessment of the impact of the steelwork on the track circuit behaviour must be made, see section Preventative Measures against Bypass Paths The following application rules are used to mitigate the risk of bypass paths arising between transmitters and receivers. Transmitters and receivers of the same frequency must be fed from separate power supplies, except where battery supplies are used to feed TCU circuits. All B24 and N24 lines must be earth-free. PSU, transmitter, receiver and LMU (Tx) cases must be earthed. Transmitter and receiver to trackside feed cables of the same frequency must be separated as described in section Surge arrestors used with TUs/ETUs must have their centre terminal earthed. Surge arrestors must be regularly tested to ensure that they have not become short circuit to earth (see test Q in section 6.2.2). 4-2 M125401A4 Issue 4: Otober 2011

42 Section 4 Track Circuit Designer s Guide 4.2 TRACK CIRCUIT LAYOUT DESIGN Overview Frequency Allocation In designing a complete track circuit scheme, the designer has to consider the following issues: The most applicable and cost-effective track configurations. For example, the use of double rail configuration through points and crossing should be considered as a more efficient alternative to single rail. Suitable equipment location and signal feed arrangements. Frequency allocation. Points and crossings: shunting performance and traction bonding requirements. Interface to non-track circuited lines or other types of track circuit. Considerations where impedance bonds are sited. Site conditions and construction. The uncertainty in definition of the end of a track circuit using tuned zones must be considered where position information is critical to signalling. EBI Track 200 is designed and has been approved to operate within a set of environmental and physical conditions which are defined in this manual. A number of options allow considerable flexibility for the designer in parameters such as track length, signal cable lengths and equipment positioning. Should either environmental conditions or the basic track circuit limiting conditions required for a specific application be beyond those specified within this manual, please contact Bombardier Transportation for further advice. The following sections define the design issues and options in more detail, particularly where there are interactive or conflicting requirements. Correct allocation of frequencies is critical in jointless applications as tuning units only operate with the correct paired frequencies for which they were designed. Jointed applications offer more flexibility to the designer when it comes to frequency allocation; however it is recommended that the same rules are followed where possible in order to simplify the overall application design. There are eight nominal frequencies of equipment used as four pairs - A/B, C/D, E/F, and G/H. One pair is used per track and the frequencies are alternated, e.g. 'A' track circuit, then 'B' track circuit, then again 'A' track circuit, and so on. Normally, the two frequency pairs A/B and C/D are considered as the primary frequencies for double track lines, while E/F and G/H are used only for situations where there are more than two tracks. This approach results in the following rules to control the risk of induction into parallel track circuits: Areas of multiple parallel lines, e.g. station areas, three lines should separate the use of the same frequencies Where parallel lines are spaced vertically, frequencies must be chosen so that no two track circuits of the same frequency are vertically adjacent for any distance exceeding 20m unless the separation is greater than 10m. Lateral separation of frequencies as shown in Table and Fig should be used to ensure that no two track circuits of the same frequency are laterally adjacent. M125401A4 4-3 Issue 4: Otober 2011

43 Section 4 Track Circuit Designer s Guide Track Frequency Letter 1 A B 2 C D 3 E F 4 G H Nominal Frequency 1699 Hz 2296 Hz 1996 Hz 2593 Hz 1549 Hz 2146 Hz 1848 Hz 2445 Hz Table Actual Frequency 1682 Hz to 1716 Hz 2279 Hz to 2313 Hz 1979 Hz to 2013 Hz 2576 Hz to 2610 Hz 1532 Hz to 1566 Hz 2129 Hz to 2163 Hz 1831 Hz to 1865 Hz 2428 Hz to 2462 Hz fa fb fa fb fa fb fa fb fa fc fd fc fd fc fd fc fd fc fe ff fe ff fe ff fe ff fe fg fh fg fh fg fh fg fh fg fa fb fa fb fa fb fa fb fa indicates limit of track circuit Double Rail Track Circuits End Fed Arrangement Frequency Allocation Example Figure EBI Track 200 is primarily intended for operation as a double rail track circuit, allowing balanced double rail traction current return in either AC or DC electrified areas. Under these conditions all traction return current paths, and any equipotential bonds for safety reasons, are connected to the rails via the centre tap of an impedance bond. In normal plain line track the use of tuned areas means that continuously welded rail is possible. In non-electrified territory EBI Track 200 is often used specifically to allow the use of continuously welded rail. Double rail configuration should also be considered as the most efficient method of track circuiting points and crossings. Sections to describe the equipment configurations required for basic double rail track circuit operation. Maximum and minimum track circuit lengths are given in Table A low power option is available for short track circuits, see section Typical points and crossings arrangements are discussed in section The standard configuration for double rail EBI Track 200 applications uses tuned areas for track circuit separation and Tuning Units for coupling the Transmitter and Receiver to the track. This basic configuration is termed End Fed. A typical end fed arrangement is shown in Figure M125401A4 Issue 4: Otober 2011

44 Section 4 Track Circuit Designer s Guide F1 Track Circuit 20m 20m Tuning Unit F2 Tuning Unit F1 Tuning Unit F1 Tuning Unit F2 Transmitter F1 Receiver F1 Track Relay Power Supply Power Supply Lineside Cubicle Lineside Cubicle Standard End Fed Track Configuration (1435mm gauge) Figure Centre Fed Arrangement For transmitters operating in normal power mode, ensure that no receiver of an identical frequency is closer than 200 metres (see section ). In order to economise on equipment on long plain track runs, a Centre Fed configuration is available. This uses an ETU to transmit the signal into the rails in both directions, and tuned areas (or ETUs) with receivers of the same frequency at either extremity. The two halves of the track circuit function completely independently and may be used as two separate track circuits providing the coarse overlap (see Fig b) does not cause any problem. If both halves are required to work as one track circuit then an extra line circuit must be provided to link the two track relays. It is not necessary for the two sections to be the same length which can be an advantage when planning trackside equipment case locations. Fig a.shows s typical centre fed track circuit arrangement. F1 Track Circuit 20m 20m Tuning Unit F2 Tuning Unit F1 F1a End Termination Unit F1 F1b Tuning Unit F1 Tuning Unit F2 Receiver F1 F1a Track Relay Transmitter F1 Receiver F1 F1b Track Relay Power Supply Power Supply Power Supply Lineside Cubicle Lineside Cubicle Centre Fed Track Configuration (1435mm gauge) Lineside Cubicle Figure a M125401A4 4-5 Issue 4: Otober 2011

45 Section 4 Track Circuit Designer s Guide 30m 30m 5m 5m Track Circuit F1a End Termination Unit Track Circuit F1b F1b never shunted F1b may be shunted F1b always shunted F1a always shunted F1a may be shunted F1a never shunted Overlap Zone at Centre Fed Position (1435mm gauge) Figure b Jointed Double Rail Operation There are various situations where it is not convenient to terminate a double rail track circuit with a tuned area, either at one or both ends. These situations include locations where: The 20m length of a tuned area will not fit into the signalling requirements. Precise definition of the track circuit boundary is required. EBI Track 200 abuts a track circuit of a different type. Two EBI Track 200 track circuits of non-paired frequencies abut. In these circumstances Insulated Rail Joints are normally used to provide track circuit separation. End Termination Units are used to feed and/or terminate the track circuit at one or both ends, depending on requirements. Double rail traction current continuity is provided by the use of B3 impedance bonds (for EBI Track 200 track circuits) fitted either side of the block joints, their centre taps being connected. When EBI Track 200 track circuits adjoin those of a different kind, then an impedance bond suitable for the adjoining track should be used. Figure shows a typical arrangement for jointed double rail operation. F1 Track Circuit Insulated Rail Joint End Termination Unit F2 B3 BOND B3 BOND End Termination Unit F1 End Termination Unit F1 B3 BOND B3 BOND End Termination Unit F2 Transmitter F1 Receiver F1 Track Relay Power Supply Power Supply Lineside Cubicle Lineside Cubicle Jointed Double Rail Operation Figure ETU / B3 Bond Connections Where ETUs are installed close to B3 Bonds, it is recommended that the ETU to track connection is made to the capacitor connection stud on the B3 Bond. This has the advantage of providing detection of loss of a B3 Bond sidelead connection. 4-6 M125401A4 Issue 4: Otober 2011

46 Section 4 Track Circuit Designer s Guide ETU / IRJ Position ETU rail connections must be placed within 3m of the IRJ defining the end of the track circuit. In the event of staggered joints, this distance refers to the joint nearest the ETU. Note that some rail authorities may have more restrictive conditions. IRJ Stagger Rail authorities may control the amount of permissible stagger in order to avoid an excessive length of dead section Low Power Operation Low power operation is used on short track circuits in the range of 50 to 250 metres long, and facilitates easy adjustment of the receiver by the use of reduced rail voltages. Normal Power circuits are permitted for track circuits in the range over 200 metres long In design, it is recommended that track circuits below 250m are specified as Low Power and the overlap between the lengths for low and normal power of 200m 250m is used to deal with specific site conditions during commissioning. Low power operation is available simply by driving a transmitter into tuning unit terminals 1 and 2 (normally the receiver terminals) instead of terminals 4 and 5. This connection gives a track drive voltage of approximately 25% of the normal without any other significant alteration to the functional performance of the track circuit. For transmitters operating in low power mode, ensure that no receiver of an identical frequency is closer than 50 metres (see section ). A special engraved insulated label is available for fitting to terminals 4 and 5 of the transmitter and receiver tuning units as a reminder that the track circuit is connected in low power mode (see section 7 for the part number of this label). It is recommended that track circuit identity labelling in the equipment cabinet or equipment room should include the legend Low Power. WARNING LOW POWER T.C. CONNECT Tx CABLES TO 1 & Minimum Separation Of Units Of The Same Frequency Low Power Label: 510/5222DA4 Figure For transmitters operating in normal power mode, ensure that NO receiver of an identical frequency (of a different track circuit) is closer than 200 metres on the same track. For transmitters operating in low power mode, ensure that NO receiver of an identical frequency (of a different track circuit) is closer than 50 metres on the same track. These minimum lengths are specified to ensure that, in the event that a tuning unit becomes disconnected or open circuit, a transmitter cannot falsely feed another receiver on the same line. They ensure that there is sufficient margin of safety provided by the impedance of the intervening rails. This precaution is in addition to the protection provided by the fact that the loss of a tuning unit will be detected because the associated track circuit will de-energise. The following sketches show typical layouts which can be used to maintain minimum separation of units of the same frequency. M125401A4 4-7 Issue 4: Otober 2011

47 Section 4 Track Circuit Designer s Guide Normal Power 200m m Low Power 50m min. Normal Power 200m m TC 1 fa TC 2 fb TC 3 fa TC 4 fb TC 5 fa TX NP RX TX NP RX TX TX RX RX LP NP Adjacent TC4 has TX & RX positions transposed so that TC4 RX is not within 200m of the same frequency normal power TX of TC2 TX/RX transposition to prevent a RX being within 200m of same frequency normal power TX Figure a Normal Power 200m m Low Power 200m - 250m Low Power 50m min. Normal Power 200m m TC 1 fa TC 2 fb TC 3 fa TC 4 fb TC 5 fa TX NP RX TC2 must also be at least 200m long to maintain separation between normal power fa TX of TC1 & RX of TC3 TX LP RX TX LP Adjacent TC2 has to be converted to low power because its TX is within 200m of same frequency RX of TC4. RX Use of second low power TX where transposition shown in Fig a is not possible TX NP RX Figure b Adjoining Other Types Of Track Circuit Or Adjoining Non-Track Circuited Lines Where double rail EBI Track 200 track circuits have to adjoin non track circuited line, the easiest solution is to use a Tuning Unit and a cable strap as shown in Figure a. This solution avoids having to insert insulated block joints and, in electrified areas, includes a low cost traction bond across the rails. The spacing of the cable strap from the Tuning Unit depends on the rail gauge: 1.0m gauge 21.5m ±0.5m 1.067m gauge 21m ±0.5m 1.220m gauge 20m ±0.5m 1.453m gauge 18.5m ±0.5m 1.674m gauge 18m ±0.5m 18.5m Track Circuit Frequency F1 Tuning Unit Frequency F1 Track Circuit length measured from centre of remote Tuned Area to this position 19/1.53 (35mm²) Copper Cable (Or traction rated in electrified areas) No Track Circuit Equipment 10m EBI Track 200 adjoining non-track circuited areas without the use of insulated block joints (1435mm gauge) Figure a If two EBI Track 200 track circuits of non-paired frequencies have to be joined, and double rail track circuit operation and traction return are to be maintained, then the arrangement 4-8 M125401A4 Issue 4: Otober 2011

48 Section 4 Track Circuit Designer s Guide shown in Figure b should be adopted. Each bond is resonated to the frequency of the track circuit it is in by means of the appropriate tuning module. Failure of either block joint should be detected by the loads reflected across the impedance bonds by autotransformer action in each direction. These should be sufficient to drop both track circuits. Rail connections to be within 3m of the IRJ 3m 3m IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 B3 Bond B3 Bond End Termination Unit Frequency F2 Track Circuit Frequency F2 NOTE: IRJ Frequencies F1 and F2 can be any non-paired TI frequencies, but must not be the same. EBI Track 200 adjoining a non-paired frequency Double rail track circuits and traction return Figure b Where EBI Track 200 track circuits have to abut track circuits of a type other than EBI Track 200, care must be taken to confirm that there is no possibility of the EBI Track 200 carrier signal energising the receiver of the adjoining track circuit, or vice versa, especially in the presence of block joint failures if these are not detectable. Certain types of track circuit use similar carrier frequencies and modulation schemes, so careful design of the interface is essential. There is also a danger that one EBI Track 200 track may feed through an intervening non-ebi Track 200 track to falsely energise another EBI Track 200 track if there is a multiple failure of IRJs. In many instances an EBI Track 200 impedance bond installed on the EBI Track 200 track close to the IRJs will detect their failure by shunting the adjacent non- EBI Track 200 track. Otherwise the type of non- EBI Track 200 track to be used must be chosen to avoid this danger. Bombardier Transportation will be pleased to advise further on solutions to this problem. Figures c and d give suggested arrangements for double rail EBI Track 200 track circuits adjoining both double and single rail track circuits of different types. Rail connections must be within 3m of the IRJ IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 B3 Bond Other T.C. Bond Other T.C. Tx / Rx Other Double Rail Track Circuit EBI Track 200 adjoining a double rail track circuit of a type other than EBI Track 200 IRJ Figure c M125401A4 4-9 Issue 4: Otober 2011

49 Section 4 Track Circuit Designer s Guide Rail connections must be within 3m of the IRJ IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 B3 Bond Other T.C. Tx / Rx Other Single Rail Track Circuit EBI Track 200 adjoining a single rail track circuit of a type other than EBI Track 200 IRJ c Figure d Single Rail Track Circuits Due to its traction current immunity, EBI Track 200 is also suitable for operation as a single rail track circuit, allowing imbalanced traction current return in either AC or DC electrified areas. Under these conditions all traction return current paths, and any equipotential bonds for safety reasons, are connected to the rail allocated as the traction return or common rail. The other rail is used solely for track circuiting purposes, and is periodically isolated with insulated rail joints for this purpose. Impedance bonds are not used. In many cases insulated rail joints are positioned in both rails, and the common rail is swapped from one side to the other by means of a traction bond connected diagonally across the joints (See Figure ). In this way failure of an insulated block joint is always detected by the bond presenting a dead short across one of the two track circuits associated with the joint. It must be noted that broken rail detection cannot be guaranteed for the traction return (or common) rail when EBI Track 200 is used in single rail mode, and that certain other conditions apply in order to guarantee shunt detection under fault conditions (i.e. in the presence of a broken rail). These conditions are given in the single rail manual M A4. Sections to describe the equipment configurations required for basic single rail track circuit operation M125401A4 Issue 4: Otober 2011

50 Section 4 Track Circuit Designer s Guide Using End Termination Units The use of End Termination Units (ETUs) allows track circuits in an End Fed configuration with lengths of between 50m and 250m in low power mode, or 200m to 1100m in normal power mode. There are restrictions to the number of traction return connections that can be made within any single track circuit, and there are more restrictive length limits if overhead line equipment gantries are connected directly to the rail (see section 4.2.8). Only one traction return or track cross bond connection is allowed within any single track circuit. This does not include the diagonal traction bond across double insulated block joints, if used. F1 Track Circuit End Termination Unit F2 End Termination Unit F1 End Termination Unit F1 End Termination Unit F2 Transmitter F1 Receiver F1 Track Relay Power Supply Power Supply Lineside Cubicle Lineside Cubicle Standard Single Rail End Fed Configuration Figure Using Track Coupling Units Track Coupling Units (TCUs) provide a lower cost method of implementing single rail track circuits which has the advantage of not requiring equipment immediately beside the track. For details, see Single Rail Applications Manual, M A Adjoining Other Types Of Track Circuit Or Adjoining Non-Track Circuited Lines Where single rail EBI Track 200 track circuits have to adjoin non track circuited line insulated block joints are normally used as shown in Figure a. The block joint avoids the EBI Track 200 signal travelling in the wrong direction, into the non-track circuited area. Less than 3m IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 OR No Track Circuit Equipment NOTE: IRJ If precautions are required to protect against the consequences of IRJ failure, then a possible solution would be to fit a bond as indicated by the dotted lines. Any bond fitted must be traction rated in electrified areas. Single Rail EBI Track 200 Track Circuit Adjoining Non Track Circuited Areas Figure a M125401A Issue 4: Otober 2011

51 Section 4 Track Circuit Designer s Guide If two single rail EBI Track 200 track circuits of non-paired frequencies have to be joined, then the arrangement shown in Figure b should be adopted. Failure of either block joint is detected by the diagonal bond presenting a short circuit across one of the track circuits. Less than 3m Less than 3m IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 End Termination Unit Frequency F2 Track Circuit Frequency F2 NOTE: IRJ Frequencies F1 and F2 can be any non-paired TI frequencies, but must not be the same. Bond must be traction current rated in electrified areas. EBI Track 200 Single Rail Track Circuit Adjoining Non Paired Frequency EBI Track 200 Track Circuit Figure b Where EBI Track 200 track circuits have to abut track circuits of a type other than EBI Track 200, care must be taken to confirm that there is no possibility of the EBI Track 200 carrier signal energising the receiver of the adjoining track circuit, or vice versa, especially in the presence of block joint failures if these are not detectable. Certain types of track circuit use similar carrier frequencies and modulation schemes, so careful design of the interface is essential. There is also a danger that one EBI Track 200 track may feed through an intervening non- EBI Track 200 track to falsely energise another EBI Track 200 track if there is a multiple failure of IRJs. Normally a cable bond installed diagonally across the IRJs will detect their failure by shunting either the EBI Track 200 or the adjacent non-ebi Track 200 track. Otherwise the type of EBI Track 200 track to be used must be chosen to avoid this danger. Bombardier Transportation will be pleased to advise further on solutions to this problem. Figures c gives a suggested arrangement for single rail EBI Track 200 track circuits adjoining single rail track circuits of a different type. Note that the second IRJ and transposition bond may not be required for certain track circuit types; therefore it is recommended that local railway authority rules are consulted. Less than 3m IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 Other T.C. Tx / Rx Other Single Rail Track Circuit NOTE: IRJ Bond must be traction current rated in electrified areas. EBI Track 200 Single Rail Track Circuit Adjoining Single Rail Track Circuit Of Another Type Figure c Changing Between Single And Double Rail Track Circuits In Electrified Areas In some schemes there is a need to change between double and single rail track circuits. An example of this is schemes where plain line tracks are double rail, but single rail track circuits and traction return is used in points and crossings areas. In these circumstances it is important that the transition between the two traction return styles is done correctly, otherwise imbalanced traction currents in the double rail area can saturate impedance bonds and cause track circuit unreliability M125401A4 Issue 4: Otober 2011

52 Section 4 Track Circuit Designer s Guide Figure shows how an impedance bond is used to make the transition between single and double rail track circuits without causing traction current imbalance. Rail connections to be within 3m of the IRJ IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 B3 Bond End Termination Unit Frequency F2 Track Circuit Frequency F2 NOTE: IRJ Normally frequencies F1 and F2 would continue the paired sequence if the transition is in the normal route in points, or be non-paired frequencies if the transition is in the reverse route. Transition From Double To Single Rail EBI Track 200 Track Circuit Figure Increasing Feed Lengths / Centralised Operation The normal method of connection between the Transmitter or Receiver and the Tuning Unit (TU) or End Termination Unit (ETU) is using 2.5mm 2 (50/0.25mm) twisted pair wire. Under these conditions the loop resistance of the wire in the transmitter circuit must be limited to 0.5Ω maximum, which limits the length to 30m. Because of the impact on the source impedance of the TU/ETU, increasing the Tx to TU/ETU feed cable resistance above the nominal 0.5Ω is not normally recommended.. Longer feed lengths for the transmitter may be possible depending on cable type, track circuit length and rail authority regulations. The loop resistance of the wire in the receiver circuit is much less critical, and feed lengths of up to 500m can be used without special precautions. On some installations, the required distance between the Transmitter and its associated TU or ETU exceeds the distance allowed by the normal equipment arrangement. In such cases the Tx-to-TU / ETU distance may be increased by adopting one of two methods, given in order of preference. (1) Use Line Matching Units to increase the Tx-to-TU / ETU distance to up to 500m.. (2) Use a cable with a larger cross sectional area to maintain a loop resistance of no greater than 0.5Ω The following sections provide more detail on each of these methods Increasing The Tx-To-TU / ETU Distance By Using Line Matching Units The maximum length of the Transmitter to TU / ETU cable can be extended up to 500m by fitting Line Matching Units between the Transmitter and TU / ETU without any special precautions other than a reduction in the maximum track length to 970m. Longer feed lengths for both transmitter and receiver may be possible depending on cable type, track circuit length and rail authority regulations, please consult Application Note IS A4 for details. The LMU consists of two units: Line Matching Unit (TX) - fitted next to its associated EBI Track 200 transmitter. Line Matching Unit (TU) - fitted adjacent to the associated TU / ETU. The general equipment layout for the use of LMUs is shown in Figure M125401A Issue 4: Otober 2011

53 Section 4 Track Circuit Designer s Guide F1 Track Circuit Tuned Area Tuned Area Tuning Unit F2 Tuning Unit F1 LMU (TU) Tuning Unit F1 Tuning Unit F2 Up to 500m Up to 500m Power Supply Transmitter F1 LMU (Tx) Track Relay Receiver F1 Power Supply Equipment Room Standard Remote Fed Track Configuration With LMUs Figure Ref Application Rules for LMUs 1 Since the normal maximum distance between LMUs is limited to 500m, induced voltages from OHLE are kept to safe levels and there is no need for restrictions on running parallel to OHLE. Additional restrictions relating to induced voltages may be required if longer lengths are used. 2 Because of the long feed length and high voltage, 50/0.25 twisted pair or screened twisted pair cable shall be used between the LMU units in order to minimise cross-talk. See also rules regarding runs in the same troughing or cable hangers in section LMU(Tx) or LMU (TU) may be positioned up to a total (for both units) of 5m from the Tx or TU/ETU that they connect to. This rule permits flexibility where there are space constraints on mounting the LMUs. Table : Application Rules for LMUs Increasing The Tx-To-TU / ETU Distance By Using Cable With Larger Cross Sectional Area This method is intended for relatively small increases in distance; if this requirement exists, then a cable with cross sectional area greater than the standard 2.5mm 2 should be used. The cable size should be chosen to maintain the total loop resistance in the Tx-to TU / ETU circuit of 0.5Ω or less. The Rx-to-TU / ETU cable length is unaffected M125401A4 Issue 4: Otober 2011

54 Section 4 Track Circuit Designer s Guide Points & Crossings Shunting Considerations Generic Crossing Arrangements EBI Track 200 may be used through points and crossings, but consideration must be given to obtaining acceptable shunting throughout the track circuit. In electrified areas, since cross bonding has to be used at IRJs to enable traction current continuity, consideration must be given to the consequent feed around paths that these bonds may create. No more than 3 receivers should be used in a track circuit. If a complex crossover requires more than this, please consult Bombardier Transportation for guidance. ETU / IRJ Position ETU rail connections must be placed within 3m of the IRJ defining the end of the track circuit. In the event of staggered joints, this distance refers to the joint nearest the ETU. Note that some rail authorities may have more restrictive conditions. Points and crossings can be divided into three generic types which are described below. If further assistance is needed for a specific application, please contact Bombardier Transportation. It should be noted that the double rail, jointless configuration generally provides the most cost-effective solution. (1) Single Turnout of Less than 20 metres 1 The following sketch shows a typical EBI Track 200 arrangement at a single turnout of less than 20 m length. Bonding is arranged for full double rail track circuit operation and traction return. TRACK CIRCUIT 1 TU Frequency 2 TU Frequency 1 [A] TU Frequency 1 TU Frequency 2 Tx F1 < 20 m Rx F1 B3 Bond B3 Bond Rx ETU Frequency 3 Points With Turnout Less Than 20 metres Long - Double Rail Operation Figure a In this application, the bond [A] fitted at the IRJs ensures that a train is detected within the turnout, it may also carry traction current and must be rated accordingly. Note that failure of bond [A] will cause a loss of shunt detection in the turnout. The turnout stub may be terminated with a tuned area if it is desired to make the stub termination jointless. In single rail territory block joints replace the tuned area and back to back bonds, as shown in Figure b. In this arrangement bond [A] should carry little or no traction current, this would not be the case if the common rail were swapped. 1 Note that the maximum permitted spur length may vary between rail authorities. M125401A Issue 4: Otober 2011

55 Section 4 Track Circuit Designer s Guide TRACK CIRCUIT 1 ETU Frequency 2 ETU Frequency 1 [A] ETU Frequency 1 ETU Frequency 2 Tx F1 < 20 m Rx F1 Rx ETU Frequency 3 Points With Turnout Less Than 20 metres Long - Single Rail Operation Figure b For locations where plain track is double rail and points and crossings change to single rail, see Section 4.2.5, Changing between single and double rail track circuits in electrified areas (2) Single Turnout Longer Than 20 Metres Where the turnout is more than 20m long then it must be terminated with its own receiver. The same variations for double and single rail operation apply to this arrangement, Figure c shows a typical arrangement for longer turnouts with double rail operation. TRACK CIRCUIT 1 TU Frequency 2 TU Frequency 1 TU Frequency 1 TU Frequency 2 Note: Contacts of Track Relays for RX1 & Rx2 are wired in series to control a single track occupancy indicator. Tx F1 Rx1 F1 Rx2 F1 TU Frequency 1 TU Frequency 3 Points With Turnout More Than 20 metres Long - Double Rail Operation Figure c 4-16 M125401A4 Issue 4: Otober 2011

56 Section 4 Track Circuit Designer s Guide Figure d shows a typical arrangement for longer turnouts with single rail operation. TRACK CIRCUIT 1 ETU Frequency 2 ETU Frequency 1 ETU Frequency 1 ETU Frequency 2 Note: Contacts of Track Relays for RX1 & Rx2 are wired in series to control a single track occupancy indicator. Tx F1 Rx1 F1 Rx2 F1 ETU Frequency 1 ETU Frequency 3 Points With Turnout More Than 20 metres Long - Single Rail Operation Figure d In this application, the contacts of the track relays for each receiver in the track circuit are wired in series to control a single indication for track occupancy. The bond in the turnout ensures that a train is detected within the turnout by one of the receivers. (3) Simple Crossover Arranging track circuiting in crossovers can give rise to complex problems of meeting traction return bonding requirements, yet not building in track circuit signal run-round paths which could lead to false feeding of a receiver when a train is present in the section. Figure e shows a typical EBI Track 200 arrangement at a simple crossover, where double rail traction return is used throughout. Since there is generally insufficient room to place impedance bonds within the crossover, two impedance bonds sited in the main routes are used to provide a traction connection between the roads. Rx F1 Tx F2 Rx F2 Tx F1 Track Circuit Frequency 1 TU Freq. 1 TU Freq. 2 B3 Bond Track Circuit Frequency 2 TU Freq. 2 TU Freq. 1 Track Circuit Frequency 1 NOTE: If either turnout length is greater than 20m then that section must be terminated with an ETU and Receiver Track Circuit Frequency 3 TU Freq. 3 TU Freq. 4 Track Circuit Frequency 4 B3 Bond TU Freq. 4 ETU Freq. 3 Track Circuit Frequency 3 Tx F3 Rx F4 Double Rail Generic Crossover Arrangement Fig e M125401A Issue 4: Otober 2011 Tx F4 Rx F3

57 Section 4 Track Circuit Designer s Guide Figure f shows a typical EBI Track 200 arrangement at a simple crossover, where double rail traction return is used in the plain line sections, but single line traction return is used in points and crossings. Impedance bonds are used to convert from double to single rail return on entering the crossing area at all four positions. A single cable bond between the common rails of the two crossing point tracks gives a cross bonding connection. Rx F1 Tx F2 Rx F2 Tx F1 Track Circuit Frequency 1 ETU Freq. 1 B ETU Freq. 2 Track Circuit Frequency 2 ETU Freq. 2 B ETU Freq. 1 Track Circuit Frequency 1 NOTE: If either turnout length is greater than 20m then that section must be terminated with an ETU and Receiver Track Circuit Frequency 3 ETU Freq. 3 B ETU Freq. 4 Track Circuit Frequency 4 ETU Freq. 4 B ETU Freq. 3 Track Circuit Frequency 3 Tx F3 Rx F4 Tx F4 Rx F3 Single Rail GenericCrossover Arrangement Fig f These applications are basically the same as the less than 20 m application, longer crossovers could employ the longer than 20 m application using the arrangements shown in Fig c or d. IMPORTANT Where two receivers are used, the Tx to Rx paths for each route must be either greater than 250m (ie normal power) or less than 250m (ie low power). This is ensures that neither the longest path is run with insufficient current nor that the shortest path is run with too much Electrical Bonding Of Metallic Structures To The Rails It is important that the electrical bonding of metallic structures, such as OHL gantries, switchgear, bridge metalwork, metal fences, etc. is performed according to the requirements of the electrification engineer of the railway authority. This will normally mean compliance with a specification produced by that authority or with a national standard. In Europe the applicable standard will be the national version of EN In DC traction systems the running rails are not generally connected to earth, this being to avoid cathodic corrosion problems in buried metalwork near the track. This practice eases the potential problem of run-round or false feed paths for the track circuit signals being formed via earth connections, however traction current return bonding practices must be taken into account when designing track layouts. Due to the difficulty of providing a good earth at every gantry location, and the much reduced degree of cathodic corrosion caused by AC systems, these systems tend to have the rails closely coupled to earth, and often use them directly for equipotential bonding of gantries and other metalwork close to the track. This practice can lead to the formation of run-round or false feed paths for the track circuit signals M125401A4 Issue 4: Otober 2011

58 Section 4 Track Circuit Designer s Guide The preferred solution to this problem is the use of a buried earth cable or overhead earth wire system. In this case an earth cable is either buried alongside the track or carried on the catenary system. All metalwork which must be earthed is connected to this cable, and the cable in turn is connected to the running rails via the centre taps of impedance bonds at suitable regular intervals. In this way the track circuit signals remain balanced within the rails of each track circuit, the rail potentials (at track circuit frequencies) remain equal and balanced about ground, and no run-round or false feed paths are set up. In order to safely implement this system a few application rules must be followed: The maximum distance between impedance bonds will normally be specified by the traction engineer for the railway authority, a typical maximum distance is 1500m. There must not be more than one connection to the buried earth cable within any single track circuit. If traction return conductors are provided, but no booster transformers, then the return conductor will normally provide the connections between the gantries and the rails (via impedance bonds), and no earth cable or direct gantry to rail bond will be required. Where booster transformers are fitted the voltage on the traction return cable will vary, and an earth cable is again required. Under the right conditions it is possible to use EBI Track 200 in areas where gantries are directly connected to the rails. This will normally involve restrictions in the maximum length of the track circuits, and possibly the loss of broken rail detection in the earthed rail. Please consult Bombardier Transportation for advice on such applications. A fuller discussion of traction bonding solutions is given in the Guidance Notes for Traction Bonding, IS A Non Standard And Exceptional Situations Track Circuit Interrupters and Treadles Track circuit interrupters are provided so that if they are activated, for example at catch (or trap) points when a train passes over the points whilst they are in the normal (trap) position, the track circuit protecting the points is set to the occupied state. Treadles are often provided at level crossings for strike in/out detection and in some locations for leaf fall protection. In these cases the interrupter or treadle must be insulated from the rails on which it is mounted and a repeat relay provided. The preferred solution is to use the repeat relay contacts to cut the receiver output to the track relay. Note that because of restrictions on the cabling between the receiver and the track relay, the repeat relay must be in the same cabinet as the receiver. On electrified lines this repeat circuit must be designed so as to be immune from the interference caused by the traction system. See Figure Equipment Cabinet Location Power Supplly 50V INT. PR ET200 Receiver RL+ RL- INT. PR ET200 Rx Output to Relay Track Circuit Interrupter or Treadle Track Circuit Interrupter or Treadle Figure M125401A Issue 4: Otober 2011

59 Section 4 Track Circuit Designer s Guide Cut Sections An alternative to a centre fed track circuit for obtaining a longer track circuit is to use one track relay to cut the output of the next section s transmitter. This can be done as many times as required to meet the desired track circuit length. A typical cut section arrangement is shown in Figure Direction of Travel Operates as single track circuit with TRB acting as track relay for complete section TU Frequency 2 TU Frequency 1 Track Circuit Frequency F1 TU Frequency 1 TU Frequency 2 Track Circuit Frequency F2 TU Frequency 2 TU Frequency 1 T R A Rx Freq. 1 T R B Tx Rx T R A Tx Freq. 1 Freq. 2 Freq. 2 Cut sectioned Track Circuit Figure Inserting an Extra Track Circuit There is sometimes a requirement to install an extra track circuit in an established signalling system. In jointless territory using tuned areas the alternating frequency arrangement of adjacent track circuits must be maintained. In some circumstances the insertion of an extra track circuit can simply be achieved by converting an end fed into a centre fed track circuit, or a centre fed into two end fed tracks of the same frequency, separated by one of the paired frequency. If these options are not available, then it may be possible to insert block joints and use a track circuit from a different frequency pair, otherwise it may be necessary to change the frequencies of a number of tracks to maintain the correct sequence. In jointed areas, having inserted an additional pair of joints, the new track circuit should be selected from a different frequency pair to that currently on the line. This avoids the risk of false energisation of a track circuit in the event of an insulated rail joint failure Track Circuits with steelwork in the bed of the track If the bed of the track incorporates steelwork (e.g. steel reinforcing rods in concrete or metal bridge components) it may have an effect on the length of track circuit or tuned area. It may even preclude the use of tuned areas because of excessive loading of the tuned area rail inductance. Application note IS A4 provides further information on the types of track construction to be avoided. Please contact Bombardier Transportation for guidance, and please supply full details of the intended installation M125401A4 Issue 4: Otober 2011

60 Section 4 Track Circuit Designer s Guide 4.3 INSTALLATION REQUIREMENTS Overview This section provides the detailed information required to enable the correct installation of EBI Track 200 track circuits. WARNING The nominal voltage on the LMU terminals is 95V RMS. Under some circumstances this can be as high as 140V RMS, therefore before fitting or removing these units, power must be removed from the associated transmitter. personnel delegated to work on these units while in operation, must be suitably competent. In order to detect wiring errors in LMU circuits which could lead to overloading, commissioning tests shall be carried out as soon as practicable after power is switched on. Before handling heavy or bulky items, ensure that adequate lifting resources are available Transmitter and Receiver Mounting It is important to ensure that no signal from a transmitter feed cable can couple into a receiver feed cable where the receiver and transmitter are of the same frequency. This places requirements on the wiring between the various track circuit components, but does not impact the physical location of Transmitters and Receivers in equipment cabinets or control rooms. Therefore, there are no restrictions on the mounting of transmitters, receivers and LMU(Tx). Specifically, it is permitted to mount two receivers of the same, or different frequency on the same mounting plate Rail Connections Tuning Units (TUs) And End Termination Units (ETUs) Units are normally mounted on a post or stake at the side of the track. If required, LMUs may be used with this arrangement, which is referred to as stake-mounted. Details of this mounting arrangement are shown in Figures 8.7 to 8.9 in Section 8. Alternatively, Tuning Units and End Termination Units may be mounted between the rails on standard sleepers or between sleepers where continental tie-bar sleepers are used. These are referred to as track-mounted installations. Details of these mounting arrangements are shown in Figures 8.10 to 8.12 in Section 8. All electrical rail connections should be bonded to the rails using methods which ensure that the high current and low impedance requirements of Section 3.1 are met.. Cembre or Glenair Rail Bonds are recommended; details of these connections are shown in Figure 8.5 in section 8 Track connection cables from stake-mounted TUs and ETUs as far as the nearest rail are to be run in parallel and tied together. Ideally, cables from stake-mounted TUs/ETUs should be run over the ballast in a protective tube; if a protective tube is not employed, the long cable to the furthest rail should be tied to the nearest sleeper as shown in Figure 8.9a. M125401A Issue 4: Otober 2011

61 Section 4 Track Circuit Designer s Guide TU/ETU-to-rail cables tied together Stake mounted TU / ETU Stake Mounted Unit With Cables Tied Figure a IMPORTANT The length and size of the cables must be within the recommended values specified in table 4.3.3, as any variation may lead to degradation of system safety. The rail connections must be checked for security and that they do not exceed the resistance value given in sub-section 3.1. With track-mounted units, the unit to track cables should be arranged to cross as shown in Figure b. Sleeper mounted TU / ETU ETU-to-rail cables crossed and tied together Track Mounted Unit With Cables Crossed Figure b Track Coupling Units (TCUs) Cables For details see single Rail Applications Manual, M A4. Limitations on transmitter and receiver to TU/ETU feed lengths, and methods for increasing them, are given in section SAFETY REQUIREMENT It is important to ensure that no signal from a transmitter feed cable can couple into a receiver feed cable where the receiver and transmitter are of the same frequency. To achieve this each circuit must use a separate single twisted pair cable of the recommended type. Extensive lengths (ie longer than 50m) in the same troughing, or cable run, are not permitted. Where cable hangers are used, the spacing between cable runs must be greater than 200mm. If screened twisted pair cable pairs are used, then the spacing requirements may be waived. Twisted pair cables must have a pitch not exceeding 75mm or 120mm for screened cables M125401A4 Issue 4: Otober 2011

62 Section 4 Track Circuit Designer s Guide In case of doubt, please contact Bombardier Transportation. The recommended cables to be used on a EBI Track 200 track circuit installation are summarised in Figure and in Table 4.3.3: 0.75mm² copper (24/0.2mm) single-core 24V Supply 24V Supply 0.75mm² copper (24/0.2mm) single core With LMUs (OPTIONAL) LMUs allow increased feed length between TX & TU / ETU up to 500m. 2.5mm² copper (50/0.25mm) Twisted pair TX LMU (TX) Cable Termination Block TX Cable Termination Block 2.5mm² copper (50/0.25mm) Twisted pair Gain Straps 0.75mm² copper (24/0.2mm) Single core RX Cable Termination Block 0.75mm² copper (24/0.2mm) Single core 2.5mm² copper (50/0.25mm) Twisted pair Track Relay 2.5mm² copper (50/0.25mm) Twisted pair Junction Box LMU (TU/ETU) Junction Box 2.5mm² copper (50/0.25mm) Twisted pair 2.5mm² copper (50/0.25mm) Twisted pair Junction Box 2.5mm² copper (50/0.25mm) Twisted pair 2.5mm² copper (50/0.25mm) Twisted pair TU / ETU TU / ETU TU / ETU 35mm² copper (19/1.53mm) Single core. 35mm² copper (19/1.53mm) Single core. TX End RX End Cable Summary Figure Notes: For clarity, earthing cables are not shown on this diagram, see Table Trackside Junction Boxes are optional. For TCU arrangements, see Single Rail Applications Manual, M A4. M125401A Issue 4: Otober 2011

63 Section 4 Track Circuit Designer s Guide Equipment PSU to RX PSU to TX PSU current strap RX to Track Relay RX Gain Strap TX /RX to cable termination block inside location case TX to LMU(TX) LMU(TX) to cable termination block inside location case TX to TU/ETU or LMU (Tx) to LMU (TU) LMU (TU) to TU/ETU TU / ETU to RX Cross-sectional area 0.75 mm² (minimum) 2.5 mm² (minimum) 2.5 mm² (minimum) 2.5 mm² (minimum) Recommended Cable Types Table Cable Details Core material Construction Additional Information copper (24/0.2 or 7/0.37) single core PSU must be located in the same equipment cabinet as the Rx and Tx that it feeds. Cables must be less than 100m in length. Lengths over 10m must be run as twisted pairs The track relay must located in the same equipment cabinet as its Rx. copper (50/0.25) twisted pair If there are no units of the same frequency in the equipment case or REB, then single core cable may be used since there is no risk of crosstalk. Copper (50/0.25) copper (50/0.25) TU / ETU to Rail 35 mm² copper (19/1.53) Continuity bonding cables TX/RX/PSU/LMU earth terminals to earth TU / ETU terminal 3 to earth TU / ETU terminal 3 to LMU(TU) terminal E Surge Arrestor connection to earth Alternatively high flexibility multistrand cable may be used. 2-core twisted pair (in areas prone to severe electrical storms, eg tropical countries, it may be desirable to use 2-core with screen, earthed at one end only) 2-core twisted pair (in areas prone to severe electrical storms, eg tropical countries, it may be desirable to use 2-core twisted pair with screen, earthed at one end only) single-core No LMU: With LMU: up to 30m up to 500m If Tx and Rx cables carrying the same frequencies are run together, then 2-core twisted pair screened cables must be used (see 4.3.4). Screens shall be connected to earth at the Tx or Rx end. See Figures 8.1and 8.2 for earthing. Normally up to 500m See Figures 8.1 and 8.2 for earthing. Stake Mounted Long: 2.9±0.15m Short: 1.65±0.15m Sleeper Mounted Both: 1.2±0.15m Part numbers for cable sets are given in section mm² copper single-core Longer cables used to place TU/ETU in a position of safety to suit traction current 2.5 mm² (minimum) Stake Mounted TU/ETU Long: 4.8 ±0.15m Short: 3.0±0.15m ETU cables may be up to 15m. copper single-core 35mm 2 minimum (traction) 2.5mm 2 minimum (non-traction) Includes check rail bonding. copper (50/0.25) single-core, green/yellow This is the minimum cross-sectional area that should be used for earth cables on a EBI Track 200 installation. See Figures 8.1 and 8.2 for earthing M125401A4 Issue 4: Otober 2011

64 Section 4 Track Circuit Designer s Guide Rail Bonding Jointed Rail Traction Return Current Bonding Tuning units must be sited so that no catch points or expansion joints are located within the 20 metres between tuning units. If the track circuit is installed on conventional jointed track then it is likely that there may be rail joints within the track circuit boundary. It is important that good quality connections are used in order to achieve reliable operation. Within the tuned area, 19/1.53 copper cable,and a rail connection meeting the resistance requirement in Table must be used. Cembre or Glenair rail bonds are the recommended method of achieving rail connections. Traction return current bonding is primarily the responsibility of the traction supply engineers, but the requirements of EBI Track 200 must be considered. The bonding for traction return current must be applied so it does not compromise the safe operation of the train detection system, i.e. EBI Track 200. The full methodology of traction bonding is outside the scope of this manual, but some typical bonding configurations, suitable for EBI Track 200 operation, are shown in the following figure. Further information on traction bonding can be found in Guidance Notes for Traction Bonding, IS A4. Negative Return IRJs Negative Return Track Track Return rail (common) Impedance Bonds e.g. Type B3 Cross Bond Track Track Return rail (common) Double Rail Traction Current Return Single Rail Traction Current Return Note : Try to limit cross bonds to one per track circuit if possible. Rail break detection lost in common rail. IRJs IRJs Return rail (common) Track Return rail (common) Return rail (common) Track Impedance Bond e.g. Type B3 Double Rail to Single Rail Traction Current Return Single Rail to Single Rail Traction Current Return Examples of Typical Traction Current Return Bonding Figure M125401A Issue 4: Otober 2011

65 Section 4 Track Circuit Designer s Guide Bonding For IRJ Failure Detection Double Rail Boundaries At double rail track circuit boundaries, impedance bonds are used to carry the traction current around the IRJs as shown in Figure a. Rail connections must be within 3m of the IRJLess than 3m IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 B3 Bond B3 Bond End Termination Unit Frequency F2 Track Circuit Frequency F2 NOTE: IRJ Frequencies F1 and F2 can be any non-paired TI frequencies, but must not be the same. Figure a In order to provide IRJ failure detection, ETUs of frequency A, C, E or G must be paired with an ETU from the group B, D, F, H. For example, a frequency A ETU can be used with a frequency B, D, F or H ETU and still retain IRJ failure detection capability. Failure detection is achieved because, when an IRJ fails, the combination of the load from the Bond and the load from the zero in the paired ETU causes one, or both of the track circuits to drop. Single to Double Rail Boundaries At single to double rail track circuit boundaries, impedance bonds are used to carry the traction current around the IRJs as shown in Figure b. Rail connections must be within 3m of the IRJ IRJ Track Circuit Frequency F1 End Termination Unit Frequency F1 B3 Bond End Termination Unit Frequency F2 Track Circuit Frequency F2 NOTE: IRJ Normally frequencies F1 and F2 would continue the paired sequence if the transition is in the normal route in points, or be non-paired frequencies if the transition is in the reverse route. Figure b In the event of failure of the lower IRJ, the B3 Bond acts to present a low impedance across both track circuits thus causing them to indicate occupied. In the event of failure of the upper IRJ the combination of the load from the Bond and the load from the zero in the companion ETU causes one, or both of the track circuits to drop. Detection is achieved for all combinations of ETU frequencies, without restriction. Non-Electrified Boundaries At non-electrified boundaries, no impedance bonds are required. This track arrangement cannot detect the first block joint failure due to lack of bonding. Detection of failure of the second IRJ can be assured if ETUs of frequency A, C, E or G are paired with an ETU from the group B, D, F, H, except that the pairing of frequency C with frequency F must not be used. Single Rail Boundaries Single rail boundaries are dealt with in the Single Rail Manual, M A Check Rails Check rails must be bonded at both ends to the adjacent running rail. In addition, any joints must be bonded out and long check rails must be bonded every 60m 4-26 M125401A4 Issue 4: Otober 2011

66 Section 4 Track Circuit Designer s Guide If check rails span an IRJ, then the check rail must also contain an IRJ to prevent a bypass path Lightning Protection (This does not apply to single rail circuits using TCUs) In temperate climates it may be permissible to omit the earth connection on the TU / ETU, only judgement and experience of the local climatic conditions can be employed to make this decision. However, under all conditions, it is recommended that surge arrestors are fitted across the input terminals of the receiver and output terminals of the transmitter, or LMU(Tx). In order to ensure correct by-passing of the surge current it is essential that the centre tap of the arrestor is connected directly to a low impedance local earth. It should be noted that any traction currents are effectively isolated from this earth system by the tuning unit. Surge arrestor details are given on Figure 8.3 in Section 8. The input transformer in the receiver, the output transformer in the transmitter and the power supply transformer each include screens which are wired out to an earth terminal (E) on the front of the unit and, when connected to earth, these provide valuable rejection of common mode transients. The exposed metalwork of each unit is also connected to the E terminal. The E terminal on all receivers, transmitters, power supply units and LMU (TX) s must be connected to a low impedance local earth. It should be noted that any traction currents are effectively isolated from this earth system by the TU/ETU. Where intermediate equipment cubicles or junction boxes are used, and the cable between these intermediate locations and the Tx / Rx equipment location is protected from lightning, eg by cable ducts or troughing, optimum protection of assets is achieved by placing the Surge Arrestor in the intermediate cubicle closest to the rails as possible. For example if the Track Circuit feed to the TU/ETU is wired from a Relocatable Building to a Location Case the Surge Arrestor and Fuse must be fitted in the Location Case. Typical circuits are shown in Figure IS A4 summarises the surge arrestor arrangements for different circuit configurations. Surge Arrestor Types One arrestor arrangement is generically approved for use with EBI Track 200 TU / ETU installations: Littelfuse SL1026 For arrestors approved for single rail applications, see the Single Rail Manual, M A4. Recognition and installation information is illustrated in section 8, Figure 8.3 and part numbers are given in section 7. Users must check rail authority certification for approved types in their region Power Supply Unit Considerations SAFETY REQUIREMENT The following requirements on power supply loading must be observed to guarantee safe operation of EBI Track 200 track circuits Power Supply Unit Loading Rules Prohibited: For safety reasons, one power supply unit shall not be arranged to feed a transmitter and receiver of the same frequency. M125401A Issue 4: Otober 2011

67 Section 4 Track Circuit Designer s Guide Permitted: Table shows the permitted combinations of transmitters and receivers run from a single supply. No. of Receivers or Low Power Tx Table : No. of Normal Power Transmitters X 1 X 2 X 3 X 4 X 5 X 6 X X 7 X X 8 X X Permitted Combinations of Transmitters and Receivers V Battery Supplies Power Supply Location EMC Compliance Fusing - TX, RX and PSU TX and RX B24 Notes: No transmitter and receiver may be of the same frequency. If more than 2 track circuits are driven from one PSU, then the overall arrangement must be shown by the not to have a negative impact on scheme reliability. A strap adjustment is provided to ensure adequate regulation for two ranges of load: (1) 0.25 to 2.2 amps (2) 2.2 amps to 4.4 amps Where battery supplies are used in conjunction with rail authority approved charging systems, the maximum current available will be limited by the charger s output current rating. This rating should not be less than 4A. Combinations of transmitters and receivers may be used provided: The total current requirement is less than 70% of the nominal current output raying of the charger. No transmitter and receiver may be of the same frequency 2. Power supplies (including battery supplies) must be located within the same Relay Room, REB or Location Case as the transmitters and/or receivers that they feed. The power cables to Tx and/or Rx must not exceed 100m and lengths longer than 10m must be run as twisted pairs. EBI Track 200 Track Circuits comply with European Directive 2004/108/EC. However, to achieve compliance, the E terminal on the TX, RX and PSU must be connected to earth. The transmitter current consumption of 2.2A stated in Section 3.2 is a typical maximum value for transmitters operating in normal power mode, obtained when measured with a multimeter on the DC range. This is the DC average value of the current, and is valid for commissioning and maintenance tests and records. 2 The only exception to this rule requires the use of TCUs. TCU applications are covered in the single rail manual, M A M125401A4 Issue 4: Otober 2011

68 Section 4 Track Circuit Designer s Guide The actual supply current drawn by a transmitter also contains an AC component, which can be up to 2.0A. This component can only be accurately measured using a true RMS multimeter with a frequency response high enough to cover the EBI Track 200 operating frequency range (up to 2600Hz) on the AC range. In this mode, the meter will only measure the AC component. The total RMS value of the current, combining the AC and DC components, can approach 3.0A RMS. This being the case, it is important to fit fuses that are rated for continuous operation at 3.0A RMS rather than rated to rupture at this level. It is recommended that the following fuse type is used for fusing of EBI Track 200 Transmitter B24 and Receiver B24 : 3A anti-surge fuse such as a Cooper Bussmann MDA-3-R, Bombardier part number This fuse is also recommended for Power Supply fusing, see section An alternative fuse type for the Transmitter and Receiver is: 3A Joint Services Fuse to DEF Standard (NATO Reference System). available from Cooper Bussmann under their part number , the Bombardier part number Either fuse is compatible with the Entrelec M10/13TSF fuseholder (Entrelec part no , 13), IMPORTANT: If it is not possible to obtain these fuse types, always use a fuse that is rated for continuous operation at 3.0A RMS. Note that suitably rated circuit breakers can be used instead of fuses Power Supply Input BX110 or BX220 Circuits: A 3A anti-surge fuse is used to prevent nuisance blowing due to inrush current at switch on. A suitable fuse type is a Cooper Bussmann MDA-3-R, Bombardier part number The latest power supply, part number L , must be use this fuse. Note that suitably rated circuit breakers can be used instead of fuses. M125401A Issue 4: Otober 2011

69 Section 4 Track Circuit Designer s Guide Torque Settings for EBI Track 200 This sub-section outlines the torque settings to be used when making connections to EBI Track 200 equipment: Equipment REFERENCE FIXING SIZE TORQUE Nm Impedance Bond (see Figs 8.13, 8.14) Side leads connection at Bond (copper crimp) Side leads connection at Bond (aluminium crimp) Bond centre tap to cable (copper crimp) Bond centre tap to cable (aluminium crimp) Bond centre tap to Aluminium, plate Capacitor Module to bond housing Capacitor Module terminations to Bond Aluminium plate to Rail Lead connection (Copper or Aluminium crimp) Aluminium plate to Rail Lead connection (Copper or Aluminium crimp) Side leads or Rail Leads to Cembre or Glenair rail bonds M M16 90 M M16 90 M16 90 M6 7 M10 40 M16 90 M12 72 M12 72 Bond cover fixing M10 Tighten manually using best judgement Bond to concrete sleeper M16 expanding stud 110 to fix insert, 80 to secure Bond Bond to timber sleeper M16 or 5 / 8 inch coach screw with gimlet point 60 Bond to steel sleeper M12 blind bolt Jam nut Phillidas nut T1 & T2 M10 (see Fig 8.6) 40 TU / ETU Cembre or Glenair Rail Bonds M6 (see Fig 8.5) 10 Terminal block 2BA (as supplied) (see Fig 8.6) M125401A4 Issue 4: Otober 2011

70 Section 4 Track Circuit Designer s Guide Equipment REFERENCE FIXING SIZE TORQUE Nm TU/ETU to adapter plate/ or to stake M8 (as supplied) (see Figs 8.7, 8.8) 24 Adapter plate to concrete sleeper (if used) M16 safety stud anchor (see Fig ) 80 Adapter plate to wooden sleeper (if used) 5/8 Coach Screw (see Fig ) 60 Adapter plate to steel sleeper (if used) M20 Blind Bolt Jam nut Phillidas nut (see Fig ) TU protective cover (if used) M8 (see Fig ) 24 Mounting 2BA/M5 (as supplied) 6 TX / RX / PSU / LMU(TX) Terminals 4BA/M3.5 (as supplied) 1.5 Earth stud (where provided) M6 6 LMU(TU) Terminals 2BA 4.5 M125401A Issue 4: Otober 2011

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72 Section 5 Setting-up and Commissioning Procedure Contents 5. SETTING-UP AND COMMISSIONING PROCEDURE Introduction General Summary Of Setting-up And Commissioning Procedure Equipment Required Pre-requisites For Setting-up Limitations On Setting Up Conditions Limitations On Ambient Temperature Limitations On Ballast Conductance Track Circuits With TUs Or ETUs and EBI Track 200 Receivers Standard Procedure: Track Circuits with One Receiver Track Circuits With Two Or Three Receivers Track Circuit Records Checking the Accuracy of the Condition Monitoring Display Emergency Set-up Procedure Track Circuits With TUs Or ETUs and Analogue Receivers Standard Procedure: Track Circuits with One Receiver Track Circuits With Two Or Three Receivers Analogue Receiver Settings Nominal Track Circuit Lengths For Each Receiver Sensitivity Setting Receiver Input Wiring and Pick-Up Current for Each Sensitivity Setting Additional Commissioning Tests Crosstalk and Feed-through Checks IRJ Confirmation Checks Earth Connection Confirmation Checks M125401A4 5-1

73 Section 5 Setting-up Procedure 5. SETTING-UP AND COMMISSIONING PROCEDURE 5.1 INTRODUCTION General WARNING High voltages may be present at EBI Track 200 rail connections. Setting-up, maintenance and repair of an EBI Track 200 track circuit must be undertaken only by qualified and authorised personnel. Before setting-up, maintenance or repair is attempted, the effect of such actions on the operation of the system must be determined and the necessary authority obtained. If the track relay function is to be tested by imposing an external voltage on the relay coil then, to avoid damage to the receiver output circuit, the receiver s 9- way connector shall be disconnected. The nominal voltage on the LMU terminals is 95V RMS. Under some circumstances this can be as high as 140V RMS, therefore before fitting or removing these units, power must be removed from the associated transmitter. Personnel delegated to work on these units while in operation, shall be suitably competent. In order to detect wiring errors in LMU circuits which could lead to overloading, commissioning tests shall be carried out as soon as practicable after power is switched on. Observe all Safety Procedures that are in force for track possession, and for working on or near the track. Before handling heavy or bulky items, ensure that adequate lifting resources are available. No facilities are provided on the transmitter for adjustments. The receiver input signal will vary with track length and ballast condition. EBI Track 200 digital receivers have a readout of receiver input current provided on the receiver s display so that use of a current-measuring meter, or shunt, is not required. A 1Ω resistor is provided internally and wired to the front panel terminals, so that checking of the current measurement is possible. It is recommended that a record of track circuit characteristics is taken for future reference, as an aid to fault finding and as part of a routine maintenance programme. If such a record is required, then an appropriate selection of the tests listed in Section 6 may be carried out, as shown on the equipment record card in section 9. It is recommended that the tests are carried out during commissioning, setting-up and/or after any subsequent equipment changes. The prescribed settings ensure that the track will not drop when there is not a train present if the ballast conductance increases to its specified maximum value of 0.5 Siemens / km, nor will the drop shunt ever decrease below 0.5 ohms, if ballast conductance reduces Summary Of Setting-up And Commissioning Procedure Power up transmitter and receiver. Set a 1Ω drop shunt across the rails at the receiver TU or ETU rail connections. Replace the frequency key with a set-up key and perform the auto-set operation at the receiver. The auto-set operation locks the receiver current threshold into the receiver. After set-up, receiver currents above the threshold cause the receiver to indicate track clear, while currents below the threshold cause an indication of track occupied. 5-2 M125401A4

74 Section 5 Setting-up and Commissioning Procedure Equipment Required Pre-requisites For Setting-up Replace the set-up key with the frequency key and verify that the track drops with 0.7Ω drop shunt. Set-up any additional receivers in the track circuit, re-checking each when all have been set up. Set up each half of a centre-fed track as if it were a single track circuit. Carry out any additional commissioning tests required (see section 5.6). Record the track settings and measurements. Bombardier TI21 Track Meter (TTM). Bombardier Shunt Box. The following track circuit information is required before a track circuit can be set-up: Track circuit identification. Track circuit length and boundaries. Track circuit frequency. Quantity of receivers in track circuit. Before setting-up a track circuit. Ensure that the following conditions have been met: The EBI Track 200 equipment has been correctly installed with the correct frequency allocation. Required rail and traction bonding is correctly installed. The correct frequency key, and a set-up key, are available for the receiver. The equipment wiring has been verified as correct. There should be 2-way communications between the staff setting-up the track circuit. The correct test instruments are available and test leads. A Track Circuit Record Sheet is available. Currently installed rail and traction bonding meets requirements. M125401A4 5-3

75 Section 5 Setting-up Procedure 5.2 LIMITATIONS ON SETTING UP CONDITIONS SAFETY REQUIREMENT The following limitations on setting-up procedures must be observed to avoid erosion of the track circuit safety margin Limitations On Ambient Temperature In order to optimise availability whilst maintaining the highest levels of safety, EBI Track 200 track circuits should be set up at a time when the ambient temperature in which the trackside equipment (TUs and ETUs) are operating is within the range +10 C to +30 C. This ensures the optimum set up for operation over the ambient temperature range given in Section 3. If a track circuit has to be set-up when the trackside ambient temperature is outside the settingup temperature range, the following guidelines must be observed: Ambient temperature below +10 C If the temperature is below +10 C at the time that the track circuit is set-up, then it is possible that a large increase in ambient temperature at the trackside equipment could cause the receiver current to fall below the receiver threshold setting. As a result, the track circuit will show occupied. If this situation should occur, the problem will be rectified by repeating the setting-up procedure for the track circuit when the trackside ambient temperature has risen above +10 C. Ambient temperature above +30 C If the temperature is above +30 C at the time that the track circuit is set up, then it is possible that a large decrease in ambient temperature could significantly erode the track circuit safety margin. To avoid this possibility, any track circuit that is being set up when the trackside ambient temperature is above +30 C should be set up temporarily to have a drop shunt between 1.3 Ω and 1.7Ω. When the temperature has fallen below 30 C, the track circuit must be set up with the normal drop shunt limits of 0.8Ω to 1.2Ω Note: If the trackside ambient temperature is outside the +10 C to +30 C range during setting up, then record the actual temperature in the remarks column on the Track Circuit Record Card Limitations On Ballast Conductance There is an upper limit to the ballast conductance above which it becomes impossible to set up the track circuit without lowering the RX threshold to an unacceptable level. This effect is most noticeable for track circuit lengths of 800m and above. 5-4 M125401A4

76 Section 5 Setting-up and Commissioning Procedure 5.3 TRACK CIRCUITS WITH TUS OR ETUS AND EBI TRACK 200 RECEIVERS SAFETY REQUIREMENT The following setting up procedures must be completed before the track circuit is used in traffic, both after initial installation and after alterations to the track or equipment. IMPORTANT If connections to the test points on the 9-way WAGO connectors are required, then the 2mm test lead adaptors supplied with the set-up key must be used to prevent damage to the connector. If the track relay function is to be tested by imposing an external voltage on the relay coil then, to avoid damage to the receiver output circuit, the receiver s 9-way connector must be disconnected Standard Procedure: Track Circuits with One Receiver WARNING The correct frequency key must be used in the receiver High voltages may be present at EBI Track 200 rail connections. Observe all Safety Procedures that are in force for track possession and for working on or near the track. (1) At both the transmitter and receiver ends: (a) (b) (c) measure the actual value of the incoming 110V AC (or 220V AC ) supply using a TTM or suitable multimeter. Connect the incoming supply to the Power Supply Unit via the appropriate taps to match the measured input supply voltage (see section 3.6), set the output current strap on the power supply unit to match the current drain. For a current drain of 0.25A to 2.2A, link terminals A and TAP COM. For a current drain between 2.2A to 4.4A, link terminals A and TAP COM. Check that the power supply is giving out 24-26V DC. Adjust the input incoming supply taps if necessary. (2) Power up the transmitter. Power up the Receiver. The display will respond with KEY. Fit the correct frequency configuration key for the track circuit under test. The display will echo back the frequency and then display the relay state ( PICK or drop ). (3a) (3b) Using a TTM, or the condition monitoring display, confirm that Rx has a supply voltage within the range 22.5V to 30.5V. Confirm the track circuit has a Sideband imbalance ratio less than 1.6:1 for TU/ETU as follows. On the receiver: Press OK then NEXT until INOW Press OK then Next Until USB Press OK and note the value. Press BACK then NEXT until LSB Press OK and note the value Calculate and record sideband imbalance by dividing the larger value by the smaller value. (3c) Confirm that the clear track current is within the expected range for the length of the track circuit (see Table 5.3.1). If the clear track current is more than 20% below the expected level, this indicates that the track circuit is losing current. In this case the M125401A4 5-5

77 Section 5 Setting-up Procedure cause of the current loss must be determined and rectified otherwise the safety margin of the circuit can be eroded. Note: If the transmit circuit uses LMUs then losses in the LMUs reduce the expected clear track current by 10%. Table DISTANCE (metres) Clear Track Current Normal Power Low Power ma Min Max Min Max (4) Connect a shunt box across the rails at the receiver TU or ETU track connections. Fix the drop shunt at either 1.0Ω for a normal power track or 1.5Ω for a low power track. Check that clear track current is 40-60% less than the value without the shunt box connected. (5) Replace the frequency key with the set-up key. The display will respond with SET? Press the OK button to begin the automatic set-up process WARNING If the set up key left in place for more than 1 minute, then the set up function will time out and the threshold will be set to zero. (6) The condition monitoring display will show the legend WAIT, followed by PASS or FAIL. PASS indicates that set-up has been successful, and the new gain settings have been locked into the unit. FAIL indicates that set-up was unsuccessful because, for example, the wrong frequency key has been used, or the track current is too low. In this case, FAIL will cycle with the reason for failure shown as a code. The track circuit must be investigated, and faults corrected before set-up is attempted again. WARNING If the set up fails, then the threshold will be set to zero. The automatic set-up failure code consists of 4 letters which are designed to focus the fault investigation: M indicates that the modulation rate is in error, eg mod pin stuck on high sideband. S indicates that the sideband imbalance is too great (exceeds 100%) suggesting a TU fault. 5-6 M125401A4

78 Section 5 Setting-up and Commissioning Procedure H indicates that the input signal is too high suggesting the track should be moved to Low power. L indicates that the input signal is too low suggesting open circuits / poor connections. Typical examples of fault codes are given in Table Table 5.3.2: Typical Automatic Set-up Failure Codes Message Meaning of Code Field Examples L Input signal low. Over-long TC. Poorly set-up tuned area. Loose connections. H Input signal high TC too short. HL Input signal high and low Internal RX fault. S Sideband imbalance high Failed TU. SL Sideband imbalance high and Unlikely to occur signal low SH Sideband imbalance high and Unlikely to occur signal high SHL Sideband imbalance high, Internal RX fault. signal high and low M Mod rate incorrect Faulty TX. ML Mod rate incorrect and signal low Open circuit in TC. Wrong frequency TX or RX key. MH Mod rate incorrect and signal Unlikely to occur high MHL Mod rate incorrect and signal Internal RX fault. high and low MS Mod rate incorrect and sideband imbalance high MOD pin tied on TX or TX MOD fault. MSL Mod rate incorrect, sideband Incorrect frequency key used. imbalance high and signal low MSH Mod rate incorrect, sideband Unlikely to occur imbalance high and signal high MSHL All signals incorrect Internal RX fault. Thld Tol A-B mismatch between thresholds. High level traction interference signal present. Time Out - OK not pressed within 60 seconds. Key Wrte - Faulty key or process corrupted. WRNG - Set up key inserted before frequency key or incorrect frequency key inserted to finish the process. (7) Replace the set-up key with the frequency key. Check that clear track current is still 40-60% less than the value without the shunt box connected. Remove the shunt box and check that the current recovers to the value noted at the beginning of step 3. (8) Connect a shunt box, set to 0.7 ohms, across the rails at the transmit end TU / ETU track connections and check that the track circuit drops. (9) Record the clear track current and the threshold level on the track circuit record card. Note 1: See section for advice on using data from the Condition Monitoring display for use on the record sheet. Note 2: Where low power tracks are used, Low Power labels must be fixed to the Tx, Rx and TUs / ETUs M125401A4 5-7

79 Section 5 Setting-up Procedure Track Circuits With Two Or Three Receivers When setting up a track circuit which has two or three receivers being driven from the same transmitter, the following procedure should be adopted: (a) (b) (c) (d) Carry out step (1) above. Ensure that all receivers in the track circuit are connected. Carry out step (2) and (3) for all receivers in the track circuit. Set-up each receiver in turn as detailed in steps (4) to (6) above Track Circuit Records (e) Finally, Connect a shunt box, set to 0.7 ohms, across the rails at the transmit end TU / ETU track connections and check that all Rx drop. Track circuit record cards have traditionally recorded the sensitivity, or gain, setting of the analogue Receiver. It is important to note that, with Digital Receiver, this parameter is replaced by the threshold value read from the Condition Monitoring display using the Ith command. Similarly, the I/P signal for track clear can be read from the Condition Monitoring display using the Inow and then Av commands. All other recorded values are unchanged. Full details of the operation of the Condition Monitoring display are given in section Checking the Accuracy of the Condition Monitoring Display The measurements displayed by the Condition Monitoring Display are made by high integrity, duplicated circuitry. However, if there is difficulty in reading the display, eg if some of the LED segments have failed, measurement of key values can be made independently of the Condition Monitoring display using a calibrated TTM in the following way. PSU Voltage Sensitivity Setting I/P Signal Track Clear Relay O/P Voltage Measure the voltage across B24 and N24 using a TTM on the DC range. A 1Ω resistor is included in the input circuit between IP1 and TP1. The sensitivity setting locked into the unit at set-up can be checked by measuring the voltage across TP1 and IP1 (using a TTM set to the correct frequency) while the automatic set-up is in progress. Again, use the 1Ω resistor by measuring the voltage across TP1 and IP 1 using a TTM, when the track is clear. Measure the voltage across RL+ and RLusing a TTM on the DC range. Note: The 1Ω resistor has a protection circuit in series with it and TP1, thus any attempt to check the value of the 1Ω will return a resistance value much larger than 1Ω. 5-8 M125401A4

80 Section 5 Setting-up and Commissioning Procedure Emergency Set-up Procedure This procedure may be used when it is necessary to replace a failed receiver and there is no opportunity to take possession of the track to perform the drop shunt test. IMPORTANT: A full set-up in accordance with section or should be carried out as soon as practicable. (1) Note the threshold current value recorded on the track circuit record card. (2) Remove the failed receiver and replace with the new one. (3) Insert the original frequency key. Press the Next Key to display Inow, then the OK key to display AV, then OK again to display the value of average track current. (4) Using the 2mm test lead adaptors, attach a shunt box across the IPC and IP1 terminals, or at the equivalent point on the surge arrestor terminals. Then adjust the shunt so that the average track current reads the same as the threshold current value recorded on the test record card. (5) Leaving the shunt box in place, remove the frequency key and replace it with the set-up key. Press OK to carry out the automatic set-up process as described in steps (5) and (6). (6) On successful completion of the automatic set-up, replace the set-up key with the frequency key. Record the clear track current on the record card. The receiver is now operational. M125401A4 5-9

81 Section 5 Setting-up Procedure 5.4 TRACK CIRCUITS WITH TUS OR ETUS AND ANALOGUE RECEIVERS SAFETY REQUIREMENT The following setting up procedures must be completed before the track circuit is used in traffic, both after initial installation and after alterations to the track or equipment Standard Procedure: Track Circuits with One Receiver WARNING High voltages may be present at EBI Track 200 rail connections. Observe all Safety Procedures that are in force for track possession and for working on or near the track. (1) At both the transmitter and receiver ends: (a) and (b) measure the actual value of the incoming 110V AC (or 220V AC ) supply using a TTM or suitable multimeter. Connect the incoming supply to the Power Supply Unit Style 11 via the appropriate taps to match the measured input supply voltage (see sub-section 3.6), set the output current strap on the power supply unit to match the current drain. For a current drain of 0.25A to 2.2A, link terminals A and TAP COM. For a current drain between 2.2A to 4.4A, link terminals A and TAP COM. (2) Set the receiver sensitivity to the value given in Table , according to the track length and operating mode (normal or low power). (3) Connect a shunt box across the rails at the receiver TU or ETU track connections. (4) Adjust the sensitivity so that the track drops with a shunt of: (i) (ii) between 0.8Ω and 1.2Ω for a normal power track, between 1.3Ω to 1.7Ω for low power. Note 1: To lower the drop shunt, raise the sensitivity setting (eg 9 to 10) To raise the drop shunt, lower the sensitivity setting. (eg 12 to 11) Note 2: If the sensitivity setting has to be raised by more than 2 steps then this indicates that the track circuit is losing current. In this case the cause of the current loss must be determined and rectified otherwise the safety margin of the circuit can be eroded. (If the transmit circuit uses LMUs then this does not apply due to losses in the cable) Note 3: Where low power tracks are used, Low Power labels must be fixed to the Tx, Rx and TUs / ETUs. (5) Connect a shunt box, set to 0.7 ohms, across the rails at the transmit end TU / ETU track connections and check that the track circuit drops Track Circuits With Two Or Three Receivers When setting up a track circuit which has two or three receivers being driven from the same transmitter, the following procedure should be adopted: (a) (b) Carry out step (1) above. Ensure that all receivers in the track circuit are connected M125401A4

82 Section 5 Setting-up and Commissioning Procedure (c) (d) (e) Set-up each receiver in turn as detailed in steps (2) to (4) above. Return to the first receiver and check that the drop shunt is still correct; if not, then readjust the receiver sensitivity as detailed in step (4) above. Repeat step (d) for each of the other receivers in turn until a drop shunt within the specified range is achieved for each receiver in the track circuit. CAUTION If the sensitivity setting for any receiver in a multi-receiver track circuit has to be adjusted, then the drop shunt for each of the other receivers in the track circuit must be checked, and re-set if necessary. 5.5 ANALOGUE RECEIVER SETTINGS Nominal Track Circuit Lengths For Each Receiver Sensitivity Setting IMPORTANT The figures given in this sub-section apply only to standard gauge: 1435 mm End Fed Track Circuits Table is intended as a guide that can be used to set the initial RX sensitivity setting for various track circuit lengths; they have been calculated to give a 0.5 ohm shunt at both transmitter and receiver track connections with a worst case ballast condition of 0.5 mho/km. IMPORTANT: The actual sensitivity setting necessary for any track must be determined from practical shunting tests achieving a shunt value at the receiver tuning unit in the range 0.8Ω to 1.2Ω for normal power, and 1.3Ω to 1.7Ω for low power. These values allow for a reduction of ballast impedance due to, for example, a rain shower. Table DISTANCE (metres) Sensitivity Normal Power Low Power Step Min Max Min Max Example: A 680 metre end fed track circuit should have its receiver initially set to sensitivity step 11. M125401A4 5-11

83 Section 5 Setting-up Procedure Centre Fed Track Circuits Note: If a track circuit contains any impedance bonds then the sensitivity may need to be higher than that indicated. Before the track is cleared for traffic, a rail to rail shunt test must be made by the receiver TU / ETU rail connections. The sensitivity setting should be adjusted if necessary to give a shunt of 0.8Ω to 1.2Ω (normal power), or 1.3Ω to 1.7Ω (low power). Centre fed track circuits should be treated as two independent track circuits. Because of the extra loading effect of the second circuit, the sensivity setting may need to be increased by one step. Example: A centre fed track with receivers 500m and 700m from the transmitter should have the two receivers set initially to sensitivity steps 9 and 12 respectively. Before the track is cleared for traffic, a rail to rail shunt test must be made by the receiver tuning unit rail connections for each receiver. The sensitivity setting should be adjusted if necessary to give a shunt of 0.8Ω to 1.2Ω Receiver Input Wiring and Pick-Up Current for Each Sensitivity Setting Receiver sensitivity is set by adjustment of the turns ratio of the input transformer. This is achieved by connecting the input signal through one or more of the three primary windings of the transformer, and arranging the relative phases of the windings (if more than one is required) to either add or subtract their effect. This section describes the receiver input wiring arrangements required to obtain the desired pick-up current. The polarity of the signal from the TU is not important, therefore the terms Input 1 and Input 2 are interchangeable. In all cases one input (Input 2 in Table and Figure 5.5.2a) from the TU / ETU is terminated to one end of the 1Ω resistor in the receiver. A link from the other end of this resistor is taken to the required end of the appropriate input transformer winding, and other links (if required) and the other input from the TU / ETU are connected such that the required gain is selected. Table contains the required connections for up to 3 straps and the other TU / ETU input (Input 1) for each receiver gain setting. Table Pick-up Input Wiring Nominal Current Sensitivity (ma) Input 1 Strap 1 Strap 2 Strap H 1L L 3L 1H - 3H H 3L H 3L 1L - 3H L 9L 1H - 3L 3H - 9H L 9L 3H - 9H H 9L 1L - 3L 3H - 9H L 9L 1H - 9H H 9L H 9L 1L - 9H L 9L 1H - 3H 3L - 9H H 9L 3L - 9H H 9L 1L - 3H 3L - 9H Input 2 is connected to the lower end of the 1Ω resistor. Strap 1 is taken from the upper end of the 1Ω resistor to the position shown above. Inputs 1 & 2 are interchangeable. I.e. TU / ETU outputs are not polarity sensitive M125401A4

84 Section 5 Setting-up and Commissioning Procedure From TU / ETU to Input 1 1H 1L 3H 3L 9H STRAP 1 as shown in Table L 1 Ω From ETU to Input 2 Receiver Input Connections Figure 5.5.2a Notes: (1) STRAP 1 is always taken from top of 1Ω resistor and one output from the TU / ETU is always connected to bottom of 1Ω resistor. (2) INPUT 1 (the other output from TU / ETU ), STRAP 2 & STRAP 3 are connected to achieve the required sensitivity. (3) For convenience, INPUT 2 is usually connected to terminal 2 on TU / ETU & INPUT 1 connected to terminal 1 on TU / ETU - but it does not matter if these two connections are reversed. (4) Measuring the voltage across 1Ω resistor in mv gives same value as Rx input current in ma. The following sketch (Figure 5.5.2b) shows the strapping for three example sensitivities: M125401A4 5-13

85 Section 5 Setting-up Procedure INPUT 1 from TU or ETU STRAP 2 1H 1L (series aiding) INPUT 1 from TU or ETU STRAP 2 1H 1L (series aiding) INPUT 1 from TU or ETU STRAP 2 1H 1L (series opposing) STRAP 3 STRAP 1 from resistor 3H 3L 9H 9L (series aiding) (series aiding) STRAP 3 STRAP 1 from resistor 3H 3L 9H 9L (series opposing) (series aiding) STRAP 1 from resistor 3H 3L 9H 9L (series aiding) 1 Ω 1 Ω 1 Ω INPUT 2 from ETU INPUT 2 from ETU INPUT 2 from ETU Sensitivity Setting = 13 Sensitivity Setting = 7 Sensitivity Setting 3-1 = 2 Figure 5.5.2b Example Sensitivity Settings 5-14 M125401A4

86 Section 5 Setting-up and Commissioning Procedure 5.6 ADDITIONAL COMMISSIONING TESTS SAFETY REQUIREMENT It is a safety requirement that the tests defined in to are carried out Crosstalk and Feed-through Checks Carry out Test P in section to confirm that crosstalk and feed-through interference are controlled. Record the result of the test on the record card IRJ Confirmation Checks If the track circuit is bounded by insulated block joints, then carry out inspection and testing as detailed in section 6.2.2, Test R, to confirm that the IRJs are providing adequate insulation between sections. Record the result of the IRJ test on the record card Earth Connection Confirmation Checks Carry out earth continuity confirmation tests as detailed in Test Q in section M125401A4 5-15

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88 Section 6 Condition Monitoring, Maintenance and Disposal Contents 6. CONDITION MONITORING, MAINTENANCE AND DISPOSAL Condition Monitoring Powering Up and Key Operations Operation of Display and Control Buttons Operation of Display and Control buttons Under Error Conditions Remote Monitoring Recovery of Snapshots, Error Logs and Operating History from the Configuration Key Applications of Monitored Parameters Track Circuit Tests General Tests - Track Circuits with TCUs Routine Maintenance Fault Finding Track Circuits with TUs / ETUs Track Circuits with TCUs After Fault Clearance Disposal M125401A4 6-1

89 Section 6 Condition Monitoring, Maintenance and Disposal 6. CONDITION MONITORING, MAINTENANCE AND DISPOSAL 6.1 CONDITION MONITORING The EBI Track 200 TI21 Receiver incorporates three forms of condition monitoring to help the maintenance team achieve high reliability. For routine testing, a four character display can be used to show key track crcuit values. For fault investigation work, key track circuit values leading up to the most recent Track occupied indication are stored on the Configuration Key. These values can be read back via a PC to reveal track circuit activity. Continuous, remote monitoring is enabled via the Condition Monitoring Interface Connector. Further details of these three interfaces are given in the following sections. Condition Monitoring Display Control Buttons EBI Track 200 TI21 Receiver Next Frequency Key Main Connector OK B24 N24 TP1 Condition Monitoring Interface Latch Back IP C IP 1 IP 2 RL RL E Powering Up and Key Operations EBI Track 200 Front Panel Figure After power up, and during normal operation, the following displays may appear: Key? There is no frequency, or set-up key, inserted in the Receiver. A frequency key must be inserted so that the Receiver can configure its frequency. 200freq followed by PICK or drop where freq is the EBI Track frequency A H. This is the normal sequence after inserting a frequency key or powering up with a previously-set-up key in place: it indicates that the Receiver has configured its frequency and the unit is now displaying the track relay state. 6-2 M125401A4

90 Section 6 Condition Monitoring, Maintenance and Disposal WRNG A set-up key has been inserted before a frequency key. The set-up key must be removed and a frequency key inserted, so that the Receiver can configure its frequency. An incorrect frequency key has been inserted to finish the process. BadK The key is corrupted and must be replaced. 200freq followed by NewK where freq is the EBI Track frequency A H. A frequency key has been inserted for which the Rx does not have threshold data. A fresh auto-set procedure must be carried out (seee section 5.3) Operation of Display and Control Buttons The condition monitoring and the associated control buttons provide a simple user interface with the Digital Receiver. There are two operating modes: With the set up key in place, the receiver is in Set-up mode: o Pressing the OK button will initiate the set-up sequence as described in section 5.3. With the Frequency Key in place, the receiver is in Condition Monitoring mode. o In this mode, the control buttons are used to cycle through the condition monitoring displays, as explained below. o No alterations to operating characteristics can be made in this mode. In condition monitoring mode, The display allows the following parameters to be interrogated via the menu structure shown in Figure 6.1.2: Receiver output relay state ( PICK or drop ). Instantaneous track current ( I now ) readout in ma to three significant figures 1. Receiver threshold value 2 locked into the Receiver during the set up process ( I th ) readout in ma to three significant figures. Power supply voltage ( Vout ) readout in Volts Output drive voltage to the track relay ( Vout ) readout in Volts Output drive power to the relay ( Pout ) readout in Watts Internal temperature ( Temp ) readout in C. Receiver Status Stat Unit configuration data ( CFG ): o Unit frequency o Unit modification state o Unit serial number Operation of Display and Control buttons Under Error Conditions When the Receiver detects an error, the default Relay state display changes to cycle between ERR and KEY? if no key is inserted, ERR and NEWK? if a new, unregistered key is inserted, or ERR and PICK or drop if an operational error has occurred In this last case, pressing OK will route the display to the quantity causing the error. From this point, the standard menu navigation key presses apply so the user can check for disturbance of other parameters. Figure illustrates the complete menu navigation structure. 1 During measurement of track current, it is important to know that the display has not frozen. For this reason, the decimal point alternates between. and,.. If the point does not alternate, then the display has frozen and the unit should be replaced. Mod Strike 1 and earlier receivers had lower resolution, and used an alternating A and B prefix for this task. 2 After set-up, receiver currents above the threshold value will cause the receiver to indicate track clear, while currents below the threshold will cause an indication of track occupied. M125401A4 6-3

91 Section 6 Condition Monitoring, Maintenance and Disposal CM Display Menu Structure Figure M125401A4

92 Section 6 Condition Monitoring, Maintenance and Disposal Remote Monitoring Remote monitoring can be accomplished using the Condition Monitoring interface connector and the serial link protocol described in the following paragrapghs. Pin Function Comments 1 RS485 or RS232 select Linked to pin 9 for RS485 2 RS232 Tx or RS485 Z 3 RS232 Rx 4 Relay Common Fault Relay contact 220V/1A: open = fault. 5 Isolated 0V 6 RS485 Y 7 Do not connect 8 Normally Open relay contact Fault Relay contact 220V/1A: open = fault. 9 Isolated 5V supply Condition Monitoring Connector Details Table 6.1.4a SAFETY REQUIREMENTS: The maximum length of the serial cable is 30m. The serial cable must not be terminated so as to link RS232 connector shells at both ends because of the risk of connecting grounding systems at different potentials together. The RS485 configuration is recommended for daisy chain connections between monitored units since it uses twisted pair cable without a screen. For details on using the remote condition monitoring facility, refer to the application note: EBI Track 200 TI21 Digital Receiver Condition Monitoring Interface, IS A4. Recommended logger for use with EBI Track 200 is: SA380TX manufactured by MPEC Table 6.1.4b contains a list of the quantities that are available for remote monitoring. M125401A4 6-5

93 Section 6 Condition Monitoring, Maintenance and Disposal Channel Ref Display Label Description Display Serial Port 1 TEMP Temp Unit internal temperature 2 VPSU Vpsu External power supply voltage 3 FPGP FPGA boot ROM S/W part no. 4 FPGV FPGA boot ROM S/W version 5 ACMP ARM Condition Monitoring S/W part no. 6 ACMV ARM Condition Monitoring S/W version 7 ACMB ARM Condition Monitoring S/W build 8 ABLP ARM Bootloader S/W part no. 9 ABLV ARM Bootloader S/W version 10 ABLB ARM Bootloader S/W build 11 PIP1 PIC 1 S/W part no. 12 PIV1 PIC 1 S/W version 13 PIP2 PIC 2 S/W part no. 14 PIV2 PIC 2 S/W version 15 SERN S/N Receiver serial no. 16 MODS MS Receiver modification state 17 FREQ Freq Frequency code 18 KYID Key ID code 19 KYSN Key serial no. 20 EADD Address of last error log 21 STAT Stat Receiver status 22 FCON FPGA condition 23 FSTA FPGA status 24 ASSN Last auto-set key serial no. 25 RLST PICK/drop Output relay drive status 26 ITHR Ith Auto-set current threshold 27 VOUT Vout Output relay drive voltage 28 IOUT Iout Output relay drive current 29 ILSB LSB Lower side band input current 30 IUSB USB Upper side band input current 31 IAVE AV Average input current 32 SECS Seconds since 01/01/ LADD Logging buffer address. 34 LERC Last error code 35 FPFT FPGA firmware type 42 POUT Pout Output relay power 54 FPDY FPGA firmware date Data Available for Monitoring Table 6.1.4b 6-6 M125401A4

94 Section 6 Condition Monitoring, Maintenance and Disposal Recovery of Snapshots, Error Logs and Operating History from the Configuration Key The receiver continuously logs real time data to the configuration key so that following data is available via the condition monitoring interface: A snapshot of the operating conditions at the Rx (see Figure ) The error log (see Figure ) A readout of operating history, covering sufficient history, is available in case investigation of intermittent faults or other occurrences are required. These outputs may be recovered to a standard Laptop or Notebook computer using proprietary software available from Bombardier. This action only recovers logged data from the receiver, it is entirely non-destructive. Snapshot Data Figure Error Log Figure M125401A4 6-7