THE ORANGE BOOK
Contents
1. XiMul pnhase J EE PSL1569 issue 1 Contents Introduction Welcome XL Multiphase panel layout XL signal head panel layout Operation Making adjustments Operation modes Calling hold all red from a signal head Resetting the system Decommissioning the system Incidents during operation Error indications Troubleshooting Fuse replacement Installation XL signal heads Checking whether a head can be used Upgrading earlier XL signal heads Setting up the heads and controller Phase set up examples vonna AONAN Further information Control panel rear connections Specifications Power requirements Warranty Disclaimers Environmental information pike 13 13 13 14 14 15 15 16 17 18 19 19 19 19 20 20 20 release 1 0g Y y y Y y y Introduction Welcome Thank you for choosing the XL Multiphase Controller which allows you to orchestrate up to eight wireless signal heads controlling a maximum of four separate traffic phases Using sophisticated radio links and integral failsafe measures the XL Multiphase system lets you quickly and safely install junction control without the complication of cables Although powered by advanced technology within outwardly the XL Multiphase Controller has a panel with a conventional appearance and logical layout This allows you to quickly apply settings and then to easily monitor every aspect of the system in operation The XL Multiphase Contr2. Early models with serial numbers starting with 5 cannot be upgraded Scroll and enter buttons Use to choose and confirm setup options pike signals Itd Installation The XL Multiphase Controller can control up to four phases of traffic either all via wireless links or with one phase directly con nected by cable and the remainder by wireless According to the junction layout the XL Multiphase Controller can be set to control each junction approach as a separate phase or alternatively combine both directions of a road within a single phase XL signal heads Checking whether a head can be used There are two ways to determine the suitability of an XL signal head Check the serial number Switch on and check the initial screen In the lower right corner of the XL signal head control panel is the e f this is the initial screen J serial number label It will take one of three forms then the XL head IS able to operate with the XL PIKE SIGNALS LIMITED PIKE SIGNALS LIMITED BIRMINGHAM B19 2RS MODEL XL869 Multiphase Controller MODEL XL A SERIAL NO 7xxxx SERIAL NO xxxxx TYPE APPROVED TO DoT SPEC TR 0111 A XLTO XL TYPE APPROVED TO DoT SPECIFICATION TR 0111 A TR2502 MULTIPHASE e lf this is the initial screen i then the XL head IS NOT X Old version Upgraded New version able to operate with the XL Must be upgraded Label marked by a Serial number 7xxxx Multiphase Controller until it before it can be handwr
3. 8 approaches 3 phases This example shows two approaches of a main road controlled This example shows two approaches of a main road controlled by one phase with opposed heads The side road approach is by two separate single approach phases The side road ap controlled by a single approach phase proach is controlled by a third single approach phase pike 9 Example 5 Crossroad control 4 approaches 2 phases This example shows a crossroad or staggered junction controlled by two phases two opposed heads USE UP amp DOMH KEYE rim i PHS S PHL PHE PHE FH Bi Pees we ME USE UF OG DOMH KEYE FHI FHe FHS PHY amp HE PHS PHS DB F N USE UP DOWN KES PHIGPHS PHS EHT amp PHL PHE PHS FHA Bi SS ae KEY BEE Eee LEE UF OE DOM REVS Finke ri PHS PHd PH PHE PH4 D Phase modes ieee oe e es y Two opposed 1 2 7 f heads Example 6 Crossroad control 4 approaches 4 phases This example shows a crossroad or staggered junction controlled by four separate single approach phases Note For 2 heads per approach DOWN REVS set up each phase as per example 2 HE PHA 5 PHL PHE PHS FHd Bi PRESS e KEY USE UP PHL PHE PHIL PHE PHS FHd Bi PRESS e KEY DHUH KEVS aePH4 5 USE UP amp DOMH KEYS PHiePHE PHS PHA 5 PHL PHE mae FH Pi PERESS HEY USE UP amp DOWH KEYS PHL FHE FHS FHee 5 PHL FHE FHS PHa B PRESS 6 KEY Phase
4. EU RoHS directive and similar initiatives through efficient product design that reduces unnecessary waste the use of recyclable materials throughout and a transfer to lead free components and solder EU directive 2002 96 EC on Waste Electrical and Elec tronic Equipment WEEE Pike Signals Limited is focused on developing a compliance program for the European Union EU Directive on Waste Electrical and Elec tronic Equipment Directive 2002 96 EC Under the EU WEEE Directive manufacturers of covered electronic equipment are obligated to take back such products at the end of their useful life Pike Signals Limited is committed to meeting or exceeding environmental standards in the production of all products and is engaged in a comprehensive company wide effort towards full compliance with the EU WEEE Directive Documentation by esa www ctxd com pike 0 8 4 6 b RADIO LINK UP TO 8 HEADS EASY SETUP BATTERY POWERED PORTABLE Pike Signals Limited Units 7 9 amp 11 Phoenix Business Park Avenue Road Aston Birmingham B7 4NU tel 44 0 121 359 4034 fax 44 0 121 333 3167 email enquiries pikesignals com www pikesignals com
5. button 12 pike Operation Making adjustments When the system is running continue to monitor the build up of traffic on each approach If regular patterns of significant traffic queues are emerging on particular approaches consider mak ing careful adjustments to alleviate the problem Timing adjustments can be made to a phase at any time The effects of timing changes will be incorporated during the next full cycle of operation for each phase Note Introduce timing changes in small steps and one at a time Observe the results before making any further changes Slow moving vehicles not clearing the works If there are large numbers of slow moving vehicles which have difficulty in clearing the works before the signals have changed in crease the ALL RED settings for the affected approach es by 5 seconds Vehicles taking more than one green period to clear the works If substantial queues begin to form and vehicles regularly take more than one green period to get through the works increase the MAXIMUM GREEN settings for the affected approach es by 5 seconds pike Operation modes The mode switch determines how the system operates MANUAL Phases respond to the control panel DEMAND buttons the microwave vehi cle detectors of the heads are ignored In this mode the ALL RED time settings for each phase are used the minimum green time is set at 12 seconds and the maximum green time is determined by th
6. lanes are cleared of obstructions with the exception of the signals heads their cones and related warning signs 2 Change the mode switch of the XL Multiphase Controller to HOLD ALL RED 3 Inturn go to each approach and face the signal head away from the traffic 4 When all signal heads have been faced away from traffic press and hold the ON OFF button on the XL Multiphase Con troller until all indicators extinguish Remove the signal heads from the carriageways 6 Carefully remove all cones then the signs all in accordance with the recommended procedures given in the guide Safety at street works and road works ISBN 0115519580 1 pike Incidents during operation In accordance with Highways Agency specification TR2502 the XL Multiphase Controller and all associated signal heads monitor themselves continually for faults or unexpected incidents during operation The system as a whole adheres to a defined set of responses for particular failures as discussed here Red signal failures If a red signal failure is detected on a signal head e The green signals on all other approaches phases will be suppressed In other words as any other phase begins its sequence the green signal that should immediately follow the red amber will be blanked The signal head with the failed red is the only one that will continue to show green during its active cycle All green times will be reduced to 12 seconds e O
7. NGLE waiting for control signals If the signal head does not display the above screen it Sala EOR MELE from the XL Multiphase Con may not be suitable for use See page 5 troller No signal lamps will be lit at this stage C USE UF E DOWH KEYS ben Yy A to yie n 4 Repeat for all other signal heads then go to step 4 FHL PHEePHE PHa e correct phase number PHI PHD PHZ Pha D irili continued on page 11 Brassica See pages 8 to 10 for N phase set up examples otes x Ensure that each XL signal head is capable of operating Use row for a single or 3 Press B to proceed with the XL Multiphase Controller See page 5 for details primary signal head Use row for a second signal head in a phase if used pike 7 about how to check If a signal head is directly connected to the XL Multiphase Controller by cable it will automatically become the primary signal head of phase 1 FH Phase set up examples Example 1 Carriageway 2 approaches 2 phases 2 heads Example 2 Carriageway 2 approaches 2 phases 4 heads This example shows a carriageway controlled by two single This example shows a carriageway controlled by two single approach phases each with one signal head approach phases each with nearside and offside signal heads Offside head Secondary bla Nearside head Primary Offside head Secondary 8 pike Example 3 T junction control 3 approaches 2 phases Example 4 T junction control
8. annot entertain any claims for labour or other ex penditure in connection therewith Items or components subject to another manufacturer s guarantee are subject to the terms of that guarantee only Any warranty given is void if seals on equipment are subsequent ly found to have been broken without prior permission by Pike Signals Limited Any item of equipment repaired by Pike Signals Limited is guar anteed from failure for three months from the date of repair pro vided that the item has been subjected to fair usage and regular maintenance Disclaimers Pike Signals Ltd reserves the right to change or alter product specifications without prior notice The information contained within this guide is subject to copyright and may not reproduced in part or in full without prior written permission by Pike Signals Ltd While every effort has been taken to ensure that this guide provides accurate information no liability shall be accepted for any errors or omissions It is a policy of Pike Signals Ltd to seek registered Design and or Patent Protection for its products 20 Environmental information EU directive 2002 95 EC on the Restriction of the use of certain hazardous substances in electrical and elec tronic equipment RoHS It is Pike Signal Limited s desire to meet customer requirements with respect to the RoHS initiative We are actively working to achieve the important objective of making our products compli ant with the
9. d The top indicator shows when a vehicle is detected by the microwave vehicle detector on either signal head Battery indicators for each phase The battery indicator will flash when there is roughly two hours of operational time remaining within a re imi mote signal head battery When the battery becomes too low for operation the signal head will switch off and the indicator on the XL Multiphase Controller will remain on If two heads are used within a phase the low battery state could signify low power at either or both signal heads the control panel on each XL signal head will provide further details When the primary signal head and the XL Multiphase Controller are cable connected they both use a common battery The common battery s low power state is signified by a hAkk message on the TIME display 16 Time display The four digit display at the bottom of the control panel shows a continual count of the elapsed time for the current signal of the active phase In error situations this display is used to provide alphanumeric status codes as follows Conn then EnF Connection configuration problem with remote XL signal heads Heads are either not configured as set up on the XL Multiphase Controller or are not available as expected StoP Operation has been stopped due to a serious fault Check the other panel indicators and the signal head displays to locate and remedy the fault bAEE The battery supplying the XL Mult
10. e operator s actions Note It is important to set the correct ALL RED time for each phase in order to prevent green signals being given too soon on opposing phases HOLD ALL RED All signal heads are forced to red and held until the mode is changed MANUAL VEHICLE HOLD ALL RED e TIME VEHICLE All enabled phases use their configured timings and respond to the micro wave vehicle detectors on each signal head This is the most efficient mode of operation and should be used in most situations unless there are special circumstances FIXED TIME All enabled phases use only their configured timings the mi crowave vehicle detectors of the heads are ig nored This is an inefficient mode of operation as it does not adapt to the prevailing traffic conditions 13 Calling hold all red from a signal head The multiphase system allows the hold all red mode to be invoked from any of the remote signal heads as well as via the main control panel This is a useful feature for e Occasional heavy plant crossings e When the works involve temporarily blocking the shuttle lane s or e When traffic needs to be stopped due to an accident or incident within the works area To call hold all red from a remote signal head 1 On the remote signal head press the all red call button e All signal heads will be returned to red and will stay at red until the state is overridden e The time display on the XL Mu
11. ht cross headed screws located in the corners of the control panel 3 Lift the control panel carefully out of the cradle Take care not to pull or snag the cables at the rear 4 Pull out each fuse and inspect it visually and with a meter if necessary If a fuse is blown replace it with an identically rated fuse Check all three fuses 5 Place the control panel back into its cradle and replace the eight screws Blade fuses 30 amp Controller power 30 amp Controller power 1 amp MVD see note 18 pike Further information Control panel rear connections Specifications e Type approved to Highways Agency specification TR2502 Approval number AP 14 703 A copy of the approval authorisation can be provided upon request e Manufactured in the United Kingdom in accordance with ISO 9001 Quality Assurance procedures Power requirements e Operating range 10 5Vdc to 14 5Vdc e System shuts down at 10 5Vdc to protect supply batteries e Use only deep cycle batteries with a minimum power rating of 105Ah pike 19 Warranty The XL Multiphase Controller is guaranteed against failure subject to fair wear and tear correct operation and return to our works carriage paid We undertake to repair or replace this equipment free of charge providing e t has been maintained in good condition and operated with due care and e Any failures are directly traceable to faulty material or work manship However we c
12. iphase Controller is run ning low roughly two hours operation or less remaining rrc Oo The system has entered hold all red mode due to a re quest from a remote signal head Press RUN to override Status indicator In normal operation the status indicator will show a constant green light or other states as follows Constant green System running correctly Constant red O System unconfigured not running Flashing green Attempting to locate a remote head that is regis tered to be available according to panel settings Setting state change made at the control panel but not yet transferred to the affected signal head s Note Alternate red and green flashes may be seen as attempts are made to send new settings to remote heads pike Flashing red Troubleshooting Green mimic indicator flashing A green conflict has been detected Reset or replace the corre sponding signal head as necessary See Resetting the system on page 14 Red mimic indicator flashing A red lamp failure has been detected Check and replace the affected signal lamp or head as necessary See Resetting the system on page 14 The Status indicator is flashing Flashing green Communications attempting to locate a remote head that is registered to be available according to the panel settings Flashing red Setting state change made at the control panel but not yet transferred to the affected signal head s Flashing red and green Atte
13. itten M or with or above Can be receives an upgrade used with the XL a sticker Can be used used with the XL Multiphase Controller with the XL Multiphase Multiphase Controller Upgrading earlier XL signal heads See note below Controller Most earlier versions of XL heads except those with 5xxxx serial numbers can be upgraded to operate with the XL Multiphase Controller The upgrade work must be carried out by a Pike certified engineer either on site or at Pike Signals Contact Pike Signals for details pike ol Setting up the heads and controller 1 Set up all signal heads cones and signs according to 2 For each approach measure the distance from each WAIT Highways Agency regulations HERE sign to the WAIT HERE sign furthest away Attach the supplied antenna to the XL Multiphase Controller and connect a fully charged battery Ensure that all signal head batteries are fully charged 6 pike 3 On each remote XL signal head a ve Switch on the signal head d marine oeeeatioe The screen will confirm your at the control panel THIS SIGHAL HEAD settings FHASE THO SIHGLE IF OK PRESS e KEY If correct press to proceed If a change is required use b ENSE SELECT OHE Press Yy to choose V A to make the change OF THE FOLLOWING hae TTEEZE as per step G OTH PHASE a a MUL TIPHASE Press Gi to proceed e HULTIFHASE OPERATION The head is now ready and Important a ale THO SI
14. ltiphase Controller will show Fre remote red call e The display panel on each head will show FL ACT IE To override the hold all red state 1 On the XL Multiphase Controller press the RUN button e The system will resume with the mode that was running prior to the hold all red 14 Resetting the system Certain failures within the XL multiphase system require the operator to cure acknowledge the failure and reset the system as a whole In such cases the system may be held within a special condition or remain operating in a reduced mode To reset the system after an error 1 Inspect the XL Multiphase Controller panel indicators to trace the problem Pages 15 16 and 17 provide descriptions 2 If the problem is traced to one or more signal heads visit each affected head and check the control panel s Depend ing on the fault e f possible rectify the problem and reset the signal head s or e Replace the signal head s and follow the set up instruc tions in step 3 shown on page 7 to select the correct phase number s 3 When all affected heads have been reset on the XL Multiphase Controller panel press the RUN button to restart operation Monitor the system operation until you are sure that it is operating correctly pike Decommissioning the system When the portable traffic signals are no longer reguired please fol 1 low this procedure to decommission their use Ensure that the shuttle
15. modes PH PH PH PH puma One head 1234 IS per approach pike Setting up continued from page 7 4 On the XL Multiphase Controller change the mode switch to HOLD ALL RED 5 Press the ON OFF but ton to power on the XL Multiphase Controller The controller retains all of the settings from its previous installation 6 For each phase that will be used a Press the PHASE ON OFF button to enable or disable the phase lt Ensure that all unused phases are disabled b Press the phase mode button to choose the appropriate mode OD One head per approach Two heads per approach CD Two opposed heads pike c Using the measurement taken earlier A CJ A from this phase s WAIT HERE sign to the WAIT HERE sign furthest away set the appropriate ALL RED time Om 50m 100m 150m 200m 250m 300m lt gt lt gt lt gt lt gt lt gt lt gt 15 20 25 seconds seconds seconds seconds seconds seconds Using the measurement taken earlier from this phase s WAIT HERE sign to the WAIT HERE sign furthest away set the appropriate MAXIMUM GREEN time Om 75m 135m 195m 300m lt gt lt gt lt gt lt gt 35 seconds 40 45 50 seconds seconds seconds Repeat for each active phase and then go to step 7 overleaf 11 7 Press the RUN button to begin operation 8 You can now switch to VEHICLE activated operation It is at this poin
16. mpts are being made to transfer new control panel settings to one or more signal heads pike Battery symbol flashing The indicated signal head has roughly two hours or less of operation remaining before it must shut down Check the control panel of the affected signal head and replace its battery Battery symbol on The indicated signal head has shut down due to insufficient bat tery power Change the battery of the affected signal head The mimic lights are not working on the controller The controller has probably entered power save mode after 20 minutes of operation Press the RUN button to restore the status illuminations if required Operation of the signal heads is not affected by the power save mode XL Multiphase Controller does not respond to ON OFF button A fuse may have blown within the controller See page 18 for details 17 Fuse replacement The XL Multiphase Controller has three fuses located on its right L hand side The control panel must be removed from its cradle in order to access the fuses All fuses are standard automotive blade types that are available at many outlets To change a fuse 1 Switch off the XL Multiphase Controller if it is still switched on all slave signals will show red until the controller is reinstated If traffic needs to be directed make im mediate provision of alternative controls while the XL Multiphase Controller is out of action 2 Remove the eig
17. n simulates the microwave vehicle de tector being triggered for that phase When pressed the chosen phase will change to green after all others have been set to red see page 12 Phase on off button Use this button to enable or disable this phase within the current set up see page 11 Low battery indicator Illuminates to warn that one or both of the remote heads on this phase are getting low on battery charge see page 16 Phase mode This section determines the number of heads and their function within this phase see page 11 pike signals Itd XL MULTIPHASE CONTROLLER ZAN PHASE 3 ve PHASE 4 oem L N SERIAL NUMBER ON OFF IN MANUAL VEHICLE TIME SECONDS a e ABA STATUS BIRMINGHAM 0121 359 4034 WWW PIKESIGNAL3 COM CE iss1 ON OFF button RUN button Mode switch Timer display Expansion Status indicator Press and Press to begin Selects the Counts the connector Displays green release to switch running the main operation elapsed time in Reserved for or red to indicate PIKE SIGNALS LIMITI on press and programmed mode for the seconds within future use the current status hold for two sequences system asa the current phase of operation see seconds to see page 12 whole see of operation When page 16 switch off see page 13 failures occur this page 11 displays trouble shooting codes see page 16 XL signal head pa
18. n the XL Multiphase Controller panel the mimic indicator representing the failed red signal will flash continuously If failed red signals are detected on more than one signal head e All signals will be immediately blanked and the controller will stop operation e On the XL Multiphase Controller panel the TIME display will show SkoF and the mimic indicators representing the failed red signals will flash See Resetting the system on page 14 Green signal conflicts If opposing phases show green signals simultaneously at any time e All signals will change directly to red no amber signal and all will remain at red See Resetting the system on page 14 e On the XL Multiphase Controller panel the TIME display will show SkoP and the mimic indicator representing the signal head that incorrectly presented a green signal will flash 15 Error indications The XL Multiphase Controller uses its various panel indicators to provide assistance in tracing and solving operational problems Mimic indicators for each phase In normal operation these displays mimic the currently active lamps of each signal head with a steady illumi nation of the appropriate lamp colour If a lamp fails or a green conflict is detected the relevant indicator s will flash to highlight the location of the problem The left three indicators of the mimic represent the primary signal head for a phase the right three indicators rep resent the secondary head if use
19. nel layout The control panel of each XL signal head is located either at the rear of the head or within the head s base unit All XL signal heads must be configured before the XL Multiphase Controller begins operation All configuration is achieved using the three blue buttons and the display screen Demand button Not used for multiphase operation Signal head mimic These indicators flash if an error occurs on a different head Demand indicator Not used for multiphase operation Power switch All red call button Can be used to place the multiphase system into Hold All Red mode Radio signal Flashes green when radio com munication is OK Flashes red to indicate a radio link problem Low battery Flashes red when battery is low Remains on when battery is too low to continue operation Major fault Flashes red if a major fault occurs Switch off and return for repair Display screen Indicates available options current settings and error messages SPECINICATION TR 0111 A Demand button Not used for multiphase operation Signal head mimic These indicators show the signals cur rently being given at this head Demand indicator Shows when the microwave vehicle detector of this signal head recognises an approaching vehicle Information label Models with se rial numbers less than 7xxxx must be upgraded for multiphase operation Upgraded models are handmarked with an M
20. oller is fully type approved to Highways Agency specification TR2502 and is manufactured in the UK in accordance with ISO 9001 Quality Assurance procedures Secure radio links The XL Multiphase Controller can maintain radio communication with up to eight remote signal heads located up to 500 metres away line of sight ER Direct connection The primary signal head can be optionally connected directly to the XL Multiphase Controller XL Multiphase Controller pike XL Multiphase panel layout The control panel of the XL Multiphase Controller is ar ranged logically for ease of set up and use General items are located in the lower section of the panel while controls specific to each phase are placed in four identical groups Signal head mimic These indicators show the signals currently being given at the head s for this phase left side pri mary head right side secondary head The top demand indicator shows when the microwave vehicle detector recognises an approaching vehicle see page 16 PHASE 1 DEMAND All red dial Sets the time in seconds that all signal heads must remain on red before the next phase can begin its amber green cycle see page 11 Maximum green dial Sets the time in seconds that this phase will show green during a normal cycle of operation see page 11 Demand button When the mode switch is set to MANUAL this butto
21. t that the XL Multiphase Control If traffic is tailing back significantly on one approach ler will begin to communicate with the remote XL signal heads a Change the mode switch to MANUAL MANUAL If any communication or configuration problems exist it is now that they will become apparent Errors are signalled on the XL Multiphase Controller panel in three main ways b Press the DEMAND button for that gt lt e Flashing indicators within each phase section of the approach phase control panel e Error codes shown on the numeric TIME display and or e Flash codes on the STATUS indicator Cc Then as the traffic starts to flow Operation will not begin and the signal heads will not be lit change the mode switch to VEHICLE until all communication and or configuration problems are solved See pages 14 15 and 16 for details about error indications and possible remedies DEMAND VEHICLE If traffic is evenly spread among the approaches When the XL Multiphase Controller is fully confident of a Change the mode switch straight to nn the system integrity the signal heads in each phase VEHICLE approach will in turn display amber and then red Important To preserve battery power after 20 minutes of normal operation the XL Multiphase Controller panel indicators will switch off The backlight for the RUN button and also the STATUS indicator will remain on and normal operation will continue To restore the indicators press the RUN
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