SM-6800N - Ansaldo STS
Contents
1. 5 5 5 3 4 Hints on Troubleshooting LED Signals sidad 5 5 Part EisS La ore A A SEA ARA ande 6 1 RAIL Team and Technical Support 7 1 SM 6800N Original June 2007 ili Table of Contents UNION SWITCH amp SIGNAL Figure 1 1 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 5 1 Figure 5 2 Table 3 1 Table 5 1 Table 5 2 Table 5 3 Table 6 1 List of Figures The Components of the US amp S LED Signal System 1 1 EED System ar e ia 2 1 2 ta SiG EE E AEE ETA E AAT 2 1 gt The LEDI2 Gard u E a A mus aquqa A 2 2 Driver Protection PCB N4620520X iii 2 3 Constant Current Regulator N34801301 2 4 Typical Existing Signaling System Block Diagram eseeeeeeeeeeeeereeesererirrrssssrrerernees 2 5 US amp S LED Signal System Block Diagram 2 5 LED Signal Driver Pinout Drawing cra 3 2 Standard Configuration Regulator Sharing nn nnnnnnnnnnnnnns 3 5 Common Return Configuration with Failover to Red 3 7 Standard Configuration Regulator Sharing Double Break 3 9 Pins on the Constant Current Regulator ie 5 1 LED Prote2. EEE En EEEE 3 4 3 3 1 Standard Configuration with Regulator Sharing 3 4 3 3 2 Common Return Configuration With Failover to Red 3 6 3 3 3 Standard Configuration e i ai dae raa i nE aE E EEA 3 8 3 3 4 Multiple MicroLoks at a Single Location 3 8 Application Logic Programming 4 1 4 1 Board D eGlarati fiu u iaia aia 4 1 42 Example Declaration ui idad Es 4 1 43 PCB System Bits uuu bale aaa i alle 4 1 49 1 N AA d e u 2 aa IR aa 4 1 A 3 2 A a inci RE ai RARA TANTA NA IERI 4 2 4 3 3 Example Usage of Board System Bits dial ila 4 2 4 4 Sample Application Program 4 2 4 5 Application Programming Notes tdt 4 6 45 14 Flashing aloni 4 6 LED Signal System Troubleshooting ses 5 1 5 1 Typical System Measurements id lele riti a aa 5 1 5 1 1 Constant Current Regulator ua ts e 5 1 51 2 LEDO di 5 2 5 1 3 Driver Protection Board 5 2 5 4 O PE D A TELE 5 2 5 1 5 Replacing LED Protection Board sesion 5 2 9 2 LED Faut Detecti n Light QU irrita 5 3 5 3 Troubleshooting Notes lella ant 5 4 5 3 1 Field Testing Open Signal Detection 5 4 5 3 2 Operation without the Constant Current Regulator Connected 5 5 5 3 3 Failure to Provide Field Side Power to LED12 Board
3. T LED i N 2 GREEN LED Driver LED Signal LED Protection PCB LED PCB Li f USGA RED T 19 US amp S LED Signal LED Protection PCB LED PCB EARTH le WEN vi USGA RED AMBER US amp S LED Signal YELLOW LED Protection PCB LED PCB EARTH N12 wawam GREEN uscad 4 RED H CYAN EARTH EARTH Figure 3 1 LED Signal Driver Pinout Drawing SM 6800N Original June 2007 UNION SWITCH amp SIGNAL LED System Installation The following is a list of wiring specific requirements notes for the US amp S LED Signal System For all applications the use of the lightning surge protection components of the LED signal system is required US amp S recommends the use of twisted pair wiring two to three turns per foot to minimize possible noise This should be done wherever possible on all I O wiring US amp S recommends the physical separation of clean and noise generating wiring Ideally all outputs are gathered in one bundle inputs are gathered in another bundle and power wiring is gathered in a third bundle Each of these bundles is physically separated from each other 6 preferred and all bundles are physically separated from other house wiring It is particularly important to maintain this physical separatio
4. 12 Signal Driver PCB is designed to vitally drive the US amp S LED signals and only those signals It must not be used to drive incandescent signals or other non US amp S LED signals Figure 2 3 The LED12 Card 2 2 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL System Description 23 Driver Protection PCB The Driver Protection PCB N4620520X Figure 2 4 is an entrance panel mounted board It is used in combination with US amp S lightning arrestors to provide a high level of surge protection for the Signal Driver board The Driver Protection PCB N46205201 which is mounted in the house is designed to terminate house wiring on the left hand side of the board and field wiring on the right hand side of the board An optional version of the Driver Protection PCB N46205202 allows terminating the house wiring on the right hand side of the board and field wiring on the left hand side of the board Both versions of the board use the same components and allow the components to be viewed for inspection when mounted in the house EL de A L Lis HOUSE 30 FIELD 3 FIELD 38 WIRING 60 WIRING METTE WIRING d my yu DRIVER BOARD PROTECTION PCB DRIVER BOARD PROTECTION PCB N46205201 N4620502 HOUSE WIRING ON LEFT SIDE OF BOARD HOUSE WIRING ON RIGHT SIDE OF BOARD Figure 2 4 Driver Protection PCB N4620520X SM 6800N Original June 2007 2 3 LED System Description UNION SWITCH amp S
5. D signal cannot be checked for operation energized by applying battery voltage directly to its terminals A constant current regulator or equivalent current source is required to light the signal Also an ohmmeter across the terminals of the signal will not provide an indication of the signals integrity e The LED signal has five terminals which are clearly marked three require a field connection two have no external connection Ensure that the connections are made to the proper terminals e The LED signal field terminals have a polarity that must be observed where incandescent signals typically do not A signal hooked up with reversed polarity will not operate and could eventually damage the signal e When used in combination with the Vital Output LED12 PCB an OFF state US amp S LED signal will have a load voltage of approximately 2 5V This voltage level is normal and is present because OFF state diagnostics are being performed by the control system e The diagnostic and light out detection functions of the Vital Output LED12 PCB do not use external check pulses For both ON and OFF state LED signals a check pulse will never be seen at the load e Slide wire resistors are not required for use with the LED signals and should never be installed Also the LED signal cannot be dimmed by switching in a series resistance as can typically be done with an incandescent signal SM 6800N Original June 2007 5 5 LED Signal Sys
6. IGNAL 2 4 Constant Current Regulator CAUTION The constant current regulator is designed to be installed on a standard DIN rail When installed with other regulators there should be at least a 1 2 separation between the regulators The Constant Current Regulator PN N34801301 Figure 2 5 provides a constant 350mA regulated current output for driving the LED signals The output of the regulator includes both open and short circuit protection Note Only US amp S Constant Current Regulators are to be used with the US amp S LEDs A regulator is required for each ON LED signal in a system however a regulator can be shared between signals that will never be on at the same time The power consumption of the constant current regulator is With the Regulator Powered and the LED signal ON 16 5W With the Regulator Powered and the LED signal OFF 1 6W Figure 2 5 Constant Current Regulator N34801301 2 4 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL System Description 2 5 Detailed System Description The US amp S LED Signal System is a unique concept in railroad LED signaling Some LED equipment has been designed to perform like incandescent bulbs so they can be powered by existing incandescent lamp drivers The US amp S LED Signal operates from an external constant current source This design allows for accurate monitoring of the operational state of the LED devices in the signal Figure 2 6 illustrates
7. ST_SIG ADJUSTABLE ENABLE 1 TYPE LAMP16 ADJUSTABLE 18 WATT MODE 1 OUTPUT EAGE EAYE EARE SPARE EBGE EBYE EBRE Refer to SM 6800D for detailed information on the Lamp 16 definition Notice that this lamp board uses Lamp Out instead of Signal Good The Lamp Out bit is set when the lamp is believed to be bad based on the tests performed by the Microlok II executive So it status is inverted as compared to Signal Good el LAMP OUT EAG_LO EAY_LO EAR LO SPARE EBG_LO EBY_LO EBR_LO BOARD VIO ADJUSTABLE ENABLE 1 TYPE IN8 OUT8 OUTPUT ELR_OUT WLR_OUT INPUT WTR_IN COMM LINK PEERLINK ADJUSTABLE ENABLE 1 PROTOCOL MII PEER ADJUSTABLE PORT 4 ADJUSTABLE POINT POINT 1 ADJUSTABLE BAUD 19200 ADJUSTABLE STOPBITS 1 ADJUSTABLE PARITY NONE SM 6800N Original June 2007 4 3 UNION SWITCH amp SIGNAL Application Logic Programming ADJUSTABLE KEY ON DELAY 0 ADJUSTABLE KEY OFF DELAY 0 ADJUSTABLE GRANT DELAY 250 MSEC ADJUSTABLE MII ADDRESS 10 ADJUSTABLE ENABLE 1 STATION NAME MLK CNTRL POINT ADJUSTABLE PEER ADDRESS 20 ADJUSTABLE TIME STAMP 1 ADJUSTABLE ACK TIMEOUT 2400 MSEC ADJUSTABLE HEARTBEAT INTERVAL 2400 MSEC ADJUSTABLE INDICATION UPDATE CYCLE 2 ADJUSTABLE STALE DATA TIMEOUT 6000 MSEC ADJUSTABLE CLOCK MASTER 0 INPUT WHR_IN WDR_IN WFYR_IN WTR_SIN WBKR_IN OUTPUT WHR_OUT WDR_OUT WFYR_OUT WYLR_OUT WYYR_OUT WTR_OUT WBKR_OUT WMK_O
8. ST_TRACK TDIN TO ALARM 2 Delay kill for 3 seconds to prevent surge on power supply ASSIGN KILL_SP TO KILL Tf unit is running in limited mode Auto Reset after 10 minutes ASSIGN ERROR RESTRICTED TO CPS_SP ASSIGN CPS_SP TO CPS RESET CPS ENABLE must be set for the VCOR to pick EN_ADJ_L and EN_ADJ_R must be set for the user to change the track length ASSIGN ONE TO CPS ENABLE EN_ADJ_L EN_ADJ_R Because the Lamp 16 defines a Lamp Out bit instead of a Signal Good Light On Relays are built in application logic As shown the EARLOR functions the same as the WARLOR defined in the LED 12 definition ASSIGN EAR_LO EAST_SIG ENABLED CPS STATUS TO EARLOR ASSIGN EAY_LO EAST_SIG ENABLED CPS STATUS TO EAYLOR ASSIGN EAG_LO EAST_SIG ENABLED CPS STATUS TO EAGLOR ASSIGN EBR_LO EAST_SIG ENABLED CPS STATUS TO EBRLOR ASSIGN EBY_LO EAST_SIG ENABLED CPS STATUS TO EBYLOR ASSIGN EBG_LO EAST_SIG ENABLED CPS STATUS TO EBGLOR Green lamp good unit can display green ASSIGN EDR EAGLOR TO EDRP Signal can display FY ASSIGN EFYR EDR EAGLOR EAYLOR TO EFYRP Signal can display green ASSIGN WDR WAGLOR TO WDRP Signal can display FY ASSIGN WFYR WDR WAGLOR WAYLOR TO WEYRP WEST_SIG NV PB is an executive bit that is true when the user presses the Lamp Reset button on the front of the LED 12 The executive will ensure t
9. T SPARE SPARE SPARE SPARE SPARE SPARE E_R_OUT E_S_OUT E_T_OUT E_U_OUT E_V_OUT E_W_OUT INPUT E_D_IN E_E_IN E_F_IN E_G_IN E_H_IN E_I_IN E_J_IN E_K_IN E_L_IN E_M_IN E_N_IN E_O_IN E_P_IN E_Q_IN E_R_IN E_S_IN E_T_IN E_U_IN E_V_IN E_W_IN ADJUSTABLE LENGTH 9 ADJUSTABLE ENABLE 1 TRACKB EN_ADJ_L TRACK NAME WEST_TRACK OUTPUT SPARE INPUT SPARE ADJUSTABLE LENGTH 9 FIXED ENABLE 0 4 2 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL Application Logic Programming BOARD WEST _SIG ADJUSTABLE ENABLE 1 TYPE LED12 In this example the LED 12 is used for the West Bound signal aspects Not all aspects need to be defined only those that are used If you wish to skip an output location label it SPARE In this example outputs 1 3 and 5 7 are used Output 4 is not used and labeled as a SPARE All 12 outputs can be listed but are not required if they are not used E OUTPUT WAGE WAYE WARE SPARE WBGE WBYE WBRE The LED 12 uses the Signal Good executive bit This bit is set when the lamp is believed to be in a useable condition based on the tests performed by the Microlok II executive The Signal Good bits are listed in the same order as the aspect bits WAGLOR is the Signal Good bit for WAGE because these bits appear in the first position in the board definition SIGNAL GOOD WAGLOR WAYLOR WARLOR SPARE WBGLOR WBYLOR WBRLOR BOARD EA
10. UNION SWITCH amp SIGNAL S Union Switch amp Signal Inc an Ansaldo Signal company 1000 Technology Drive Pittsburgh PA 15219 e 645 Russell Street Batesburg SC 29006 SM 6800N MicroLok Il LED Signal System with the US amp S LED12 PCB US amp S Part No N4620440X E Installation m Operation m Maintenance Copyright 2007 Original Union Switch amp Signal Inc June 2007 UNION SWITCH amp SIGNAL Proprietary Notice This document and its contents are the property of Union Switch amp Signal Inc hereinafter US amp S This document has been furnished to you on the following conditions no right or license under any patents or any other proprietary right in respect of this document or its content is given or waived in supplying this document This document or its content are not to be used or treated in any manner inconsistent with the rights of US amp S or to its detriment and are not to be copied reproduced disclosed to others or disposed of except with the prior written consent of US amp S Important Notice US amp S constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it is impossible t
11. UT ADJUSTABLE MII NV ADDRESS 11 ADJUSTABLE ENABLE 1 STATION NAME CRS_LIGHT ADJUSTABLE PEER ADDRESS 12 ADJUSTABLE TIME STAMP 1 ADJUSTABLE ACK TIMEOUT 400 MSEC ADJUSTABLE HEARTBEAT INTERVAL 400 MSEC ADJUSTABLE INDICATION UPDATE CYCLE 2 ADJUSTABLE STALE DATA TIMEOUT 1 SEC ADJUSTABLE CLOCK MASTER 0 NV OUTPUT WAE_OUT Master West Approach Energy EAE_OUT Master East Approach Engery NV INPUT WAE_IN Master West Approach Energy IN EAE_IN Master East Approach Enerpy IN BOOLEAN BITS CONFIGURATION SYSTEM ADJUSTABLE DEBUG_PORT_ADDRESS 1 ADJUSTABLE DEBUG_PORT_BAUDRATE 9600 ADJUSTABLE LOGIC_TIMEOUT 2000 MSEC ADJUSTABLE DELAY_RESET 0 MSEC APPLICATION VERSION 1 LOGIC BEGIN This statement prevents this application from running in a card file it has not been configured for ASSIGN CONFIGURE ERROR TO KILL_SP The Microlok II CPU can sound two audible tones Below is an example of how this can be used to make the application software more user friendly NV ASSIGN CONFIGURE ERROR TO ALARM 1 4 4 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL Application Logic Programming NV ASSIGN MTRX WEST_TRACK SLEEPIN MTRX WEST_TRACK TDIN TO TD_W_BEEP TER NV ASSIGN MTRX EAST_TRACK SLEEPIN MTRX EAST_TRACK TDIN TO TD_E_BEEP TER NV ASSIGN TD_W_BEEP TER MTRX WEST_TRACK SLEEPIN MTRX WEST_TRACK TDIN TD_E_BEEP TER MTRX EAST_TRACK SLEEPIN MTRX EA
12. a typical existing signaling system where a software controlled switch is used to apply and remove a voltage source battery from the signal load Figure 2 7 illustrates the US amp S LED Signal System This system differs from the typical existing system in that the signal load is powered by an external regulated current source rather than a voltage source which is applied and removed from the signal load via a software controlled switch INCANDESCENT OR LED SIGNAL WITH INTERNAL DC TO DC CONVERTER POWER SUPPLY AND REGULATOR I SOFTWARE CONTROLLED SWITCH BATTERY 9 8 16 2V Figure 2 6 Typical Existing Signaling System Block Diagram US amp S 350mA CONSTANT a a Usi lla SOFTWARE CONTROLLED SWITCH US amp S LED SIGNAL BATTERY 9 8 16 2V Figure 2 7 US amp S LED Signal System Block Diagram SM 6800N Original June 2007 2 5 LED System Description 2 6 UNION SWITCH amp SIGNAL SM 6800N Original June 2007 UNION SWITCH amp SIGNAL LED System Installation 3 LED System Installation 3 1 Mechanical Installation The LED12 board is installed as part of the MicroLok II system the Constant Current Regulator is DIN rail mounted in the house and the Driver Board Protection PCB is mounted on the AAR terminals at the entrance rack 3 2 System Wiring 3 2 1 LED12 PCB Upper Connector and Add
13. across the driver protection board field terminals will be the same or slightly less due to resistance in the wiring than the readings taken at the LED12 Vital Output Board outputs shown in Table 5 2 Any readings outside of the stated ranges indicate a possible faulty driver protection board 5 1 4 LED Signal The expected voltage readings taken across the LED Signal field wiring terminals will be the same or slightly less due to resistance in the wiring than the readings taken at the LED12 Vital Output Board outputs shown in Table 5 2 Any readings outside of the stated ranges indicate a possible faulty LED signal 5 1 5 Replacing LED Protection Board Inspect the components for signs of stress or damage If present replace the board with a spare and return the faulty board to US amp S for repair Figure 5 2 illustrates the proper orientation of the protection board on the back of the LED signal 5 2 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL LED Signal System Troubleshooting Figure 5 2 LED Protection Board Orientation LED Signal 5 2 LED Fault Detection Light Out The LED signal system follows the AREMA Guidelines for LED signals The system repeatedly monitors the status signals connected to the LED12 board On state signals are monitored for open and short circuits between each signal s leads Off state signals are monitored for continuity of the leads to the signal and short circuits between each signal
14. allation N UNION SWITCH amp SIGNAL 3 9 89d 031 HIBINY aqi 89d 037 89d 031 MOTI3A Od uono loiq CIT 89d uono loid CIT Od uono lojq 18AUG Od uono loid CIT umoys jou 0 1 TISYAAW I I WNOIS G31 I I I I gd 21037 oonum aqal avaH k 3SNOH Nols TWNOIS _ aq 2 LNO Livd Joqe nBay 1u uno 1uelsuoO cla Figure 3 4 Standard Configuration Regulator Sharing Double Break SM 6800N Original June 2007 LED System Installation 3 10 UNION SWITCH amp SIGNAL SM 6800N Original June 2007 UNION SWITCH amp SIGNAL Application Logic Programming 4 Application Logic Programming 41 Board Declaration This section contains the information on how to declare a board in a MicroLok II Application Program 4 2 Example Declaration BOARD Board Name ADJUSTABLE ENABLE 1 TYPE LED12 OUTPUT SIGNAL OUTPUT 1 SIGNAL OUTPUT 2 SIGNAL OUTPUT 3 SIGNAL OUTPUT 4 SIGNAL OUTPUT 5 SIGNAL OUTPUT 6 SIGNAL OUTPUT 7 SIGNAL OUTPUT 8 SIGNAL OUTPUT 9 SIGNAL OUTPUT 10 SIGNAL OUTPUT 11 SIGNAL OUTPUT 12 SIGNAL GOOD SIGNAL GOOD 1 SIGNAL GOOD 2 SIGNAL GOOD 3 SIGNAL GOOD 4 SIGNAL GOOD 5 SIGNAL GOOD 6 SIGNAL GOOD 7 SIGNAL GOOD 8 SIGNAL GOOD 9 SIGNAL GOOD 10 SIGNAL GOOD 11 SIGNAL GOOD 12 As for other vital I O boards unused outputs must be declared as SPARE if a higher numbered output is used Unused outp
15. and set the SIGNAL GOOD bits for all signals connected to the LED12 board Retesting of the signals will commence immediately and in one second the fault status of all signals and their SIGNAL GOOD bits will be updated The Retest LEDs system bit has a slow pick of three seconds is edge triggered and has a slow drop of 10 seconds The application bit must be set 1 for three seconds before the application will process the system bit The Retest LEDs must be cleared 0 before the application will recognize another set 1 After the Retest LEDs system bit is set 1 no transitions of the bit will be processed for 10 seconds This prevents logic from repeatedly clearing the fault status 4 3 3 Example Usage of Board System Bits ASSIGN BoardName LED12 NV PB to BoardName LED12 Retest LEDs 4 4 Sample Application Program Example program is an intermediate with a DC track and Vital Peer link on one side and a Microtrax Coded Track Circuit on the other side using an LED 12 and a Lamp 16 lamp driver in a Microlok II Card File Both the Lamp 16 and LED 12 are shown to illustrate the differences in using this boards el INTERFACE LOCAL Track board maybe disabled for trouble shooting purposes This board is required for the program to perform any useful function BOARD MTRX ADJUSTABLE ENABLE 1 TYPE TRX TRACK TRACKA EN_ADJ_R TRACK NAME EAST_TRACK OUTPUT E_D_OUT E_E_OUT E_F_OUT SPARE E_H OUT E_I_OUT E_J_OUT E_K_OU
16. ction Board Orientation LED Signal 5 3 List of Tables Maximum Signal Distance from the Signal House esseeeeeeieeeeeeeererrrrrnesssrrrrrrresseee 3 1 Valid Constant Current Regulator Readings sseeseeeseeeeseerrrrressssrrrinrrrssssrrtrnnrnnssesreena 5 1 Valid LED12 Vital Output Readings ds ida 5 2 Fault Clearing logie uu ny o as eu cnn Oy eel a 5 4 Part Numbers for the US amp S LED Signal System Components 6 1 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL Introduction 1 Introduction The Union Switch and Signal US amp S LED Signal System consists of the LED signals in four distinct colors PN N4620440X complete with the LED Protection Board PN N46205001 a Constant Current Regulator PN N34801301 an LED12 Signal Driver Printed Circuit Board PCB PN N17066101 and a Driver Protection PCB PN N4620520X The LED12 Signal Driver PCB controls the US amp S LED signals CAUTION The LED12 Signal Driver PCB is designed to vitally drive the US amp S LED signals and only those signals It must not be used to drive incandescent signals or other non US amp S LED signals Each LED signal contains several high intensity LEDs which operate on a constant current provided by the constant current regulator The LED12 PCB provides vital control of the signals turning them on and off as needed and monitors their condition The Driver Protection PCB is in series with the signal and pr
17. etc will reduce the maximum distances allowed SM 6800N Original June 2007 3 1 LED System Installation UNION SWITCH amp SIGNAL PCB 48 pin Top Connector Pin Outs Top Connector Address Select Jumpers E SEL 1 E32 White q lt E30 Brown Constant Current Ho o le C30 Red ot i E28 Yellow mA oF de C28 Green o q 0 4 fl 7 A28 Blue a E26 Black GND 1 Regulator pod a 7 A30 Orange Biz VOOR N34800101 IN 1 To Board Addressing Circuits Software Controlled Switches Protection PCB LED Driver FIELD WIRING I I san SIGNAL HEAD SIGNAL HOUSE LED Signal LED Protection PCB LED PCB BATT OUT BATT LED 1 e Relay 3 ali 1 IN_ 2 y N12 3 BATT 4 1 BATT 2 Either Out 2 or 4 can be used for input gt LED 2 e IN 3 LED 3 E4 L OUT IN 4 LED 4 C4 IN 5 LED 5 E6 e CD W RED LED Protection PCB LED PCB IN 6 L iN D LED AMBER YELLOW LED Protection PCB LED PCB LED 6 C6 IN 7 LED 7 C10 gt to PCB IN 8 LED 8 IN 9 LED 9 A16 7 gt gt Nn R IN 10 LED 10 A18 x gt N 1 LED 12 E22 gt A14 IN 12 S SI f 1 A12 IN 11 LED 11 A20 ty gt I 1 USGA BLUE F USGA 4 RED N12 L EARTH Protection PCB
18. hat this bit is not set if the button is stuck the executive also filters the button so that the bit will not set if the button is momentarily pressed WEST_SIG Reset LEDs is the executive bit that when set will clear all of the LO latches for the board Retest LEDs could be assigned in different ways for example an office control could be used SM 6800N Original June 2007 4 5 UNION SWITCH amp SIGNAL Application Logic Programming ASSIGN WEST_SIG NV PB TO WEST_SIG Retest LEDs NV ASSIGN WEST_SIG Retest LEDs TO LED 8 END LOGIC END PROGRAM 4 5 Application Programming Notes 4 5 1 Flashing To overcome the long turn on time of an incandescent lamp application programs frequently flashed the signal with a 60 40 duty cycle 60 of the time on 40 off resulting in the signal appearing to be 50 on and 50 off Because the LED signals turn on and off almost instantaneously a 50 50 duty cycle will provide the 50 50 visible flashing 4 6 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL LED Signal System Troubleshooting 5 LED Signal System Troubleshooting 5 1 Typical System Measurements This section provides a list of voltage and or current measurement for a good system and for a faulty system Measurements are taken with a meter using the MicroLok II Development System 5 1 1 Constant Current Regulator Table 5 1 summarizes the expected measurements that can be observed from a functional constant curre
19. iting five seconds or setting and clearing the Retest LED board application bit Setting and clearing the Retest LED board application bit Waiting five seconds or setting and clearing the Retest LED board application bit Waiting five seconds or setting and clearing the Retest LED board application bit By requiring the logic bit to be set we are preventing a signal that has failed in the ON state and tests good in the OFF state from being upgraded by the application logic This may done by assigning NV PB the LED12 board s application bit associated with the NON VITAL front panel pushbutton to the RetestLED board Following AREMA guidelines a signal that is detected as faulty in the On state will continue to be considered faulty in the Off state This prevents an application from inadvertently flashing a signal when it downgrades a faulty on signal To clear the fault condition for a signal detected as faulty while in the on state the repaired signal either has to be turned on or the application logic must set and then clear the Retest LEDs board application bit This is typically done by mapping the non vital pushbutton on the front of the LED12 board to the retest bit Adding the following line to the LOGIC section of an application program will do this mapping ASSIGN LED12boardname NV PB to LED12boardname Retest LEDs With this line in the application the maintainer must press the non vital front panel pushbutt
20. ity LEDs in series which are powered by a constant current source Because the signals are designed to operate with an external constant current source no DC DC converters or other active electronics are included The signal system only includes LEDs and other passive components for diagnostics and surge protection When combined with the vital output LED12 Signal Driver PCB the system can provide true light out detection LED PROTECTION BOARD GROUND STUD FRONT BACK Figure 2 2 The LED Signal SM 6800N Original June 2007 2 1 LED System Description UNION SWITCH amp SIGNAL 2 2 The LED12 PCB The LED12 Signal Driver PCB N17066101 Figure 2 3 provides 12 vital outputs to control the LED signals These outputs are controlled by high side software controlled switches which connect and disconnect the output of the constant current regulators for the LED signals The LED12 PCB performs diagnostic and light out detection functions without the use of external check pulses In addition it provides a continuous continuity check of the LEDs The LED12 PCB has a non vital pushbutton on the front panel to set the state of the board s system bit refer to Section 4 3 1 The LED12 PCB is designed to be installed in the standard MicroLok II cardfile The LED12 PCB can light all of the LED signals at once if necessary provided there is a current regulator for each of the LED signals Section 2 4 CAUTION The LED
21. ls provided that only one signal is ON at any given time VCOR contacts are used on the B12 power supplied to the LED12 PCB and the constant current regulator s so that under a system reset condition all signals will be dark The maximum allowable length for the field wiring can be found in Table 3 1 3 4 SM 6800N Original June 2007 LED System Installation UNION SWITCH amp SIGNALIIS LIVE 894 037 Od uono loxd CIT 1N0 11vg WNOIS G31 JojeinBey 1ueunO Juejsuoo LIVE 1NO 11vg 10 2 1698 Juano UEISUOO Liva 1NO 11vg dod uonsaioig IAA L YOOA 89d 037 89d uono loiq CIT J0 e nS8y Juano Juejsuoo umoys you O T3stuqqv TWNOIS 031 god z1g31 SNIHIA k qual N GavaH I ASNOH i TYN IS TYN IS gt cla 3 5 Regulator Sharing ion t Figure 3 2 Standard Configura SM 6800N Original June 2007 LED System Installation UNION SWITCH amp SIGNAL 3 3 2 Common Return Configuration With Failover to Red Figure 3 3 illustrates the common return configuration for the LED signaling system components three signals shown when using a shared regulator and failover to red This configuration is supported with the following limitations e Only one signal can be on at a given time since the regulator is being shared e The resistance of the common return leg must be kept as low as possible within the 3 ohm limit a
22. n from high current noise generating wiring All field wiring should be configured to minimize cross talk between wires Cables and wires should be kept as short as possible to minimize induced line noise Case house wiring layouts should also be arranged to minimize noise Battery leads should be as short as possible and must be isolated as much as possible from noisy wiring The US amp S Common Mode Filter N4515521001 is recommended for use on the battery lines to the MicroLok II and all battery powered LED signal system components including battery broken by relay contacts This filter needs to be located as close as possible to the equipment to maximize its effectiveness Note that on MicroLok II systems that include LAMP16 PCBs in addition to LED12 PCBs power to the LAMP16 PCB and incandescent signals must NOT be filtered Using the filter in this instance can cause check pulse problems Additional loads such as local indicators cannot be connected across the signal leads of the LED signal Multiple signals cannot be wired in series or parallel 1 e color position lights must be separately wired to individual constant current sources The outputs of multiple constant current sources should not be connected in parallel or series Fuses are not needed recommended on the signal outputs the US amp S constant current regulator output includes short circuit protection and no damage will occur to the system if an output is inadvertentl
23. nt regulator operating off of a 9 8 to 16 2 volt source Any readings outside the stated ranges indicate a possible faulty regulator Table 5 1 Valid Constant Current Regulator Readings Voltage at output with no load connected _ 5 Mpa V 52V pin 4 referenced to pin1 Voltage at output with resistive load V 0 35 R 10 where connected pin 4 referenced to pin1 R lt 1400hms Voltage at output with a known good LED Signal connected signal ON condition pin 4 29V lt V lt 50V referenced to pin1 Current output With valid load signal ON 350MA 10 condition pin 4 See Figure 5 1 B12 LED OUTPUT CONSTANT CURRENT REGULATOR MODULE Figure 5 1 Pins on the Constant Current Regulator SM 6800N Original June 2007 5 1 LED Signal System Troubleshooting UNION SWITCH amp SIGNAL 5 1 2 LED12 Board Table 5 2 summarizes the expected measurements that can be observed on the LED12 Vital Output Board output that is functioning properly with a good LED signal load These measurements are taken with a meter at the signal output on the MicroLok II CPU front panel or with the MicroLok II Maintenance Tool Any readings outside of the stated ranges indicate a possible faulty system module Table 5 2 Valid LED12 Vital Output Readings 29V lt V lt 48V V lt OV V should be negative Output OFF 4 pis lt lt 0A 5 1 3 Driver Protection Board The expected voltage readings taken
24. o take into account every eventuality that may arise with technical equipment in service Please consult your local US amp S sales representative in the event of any irregularities with our product We expressly disclaim liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved US amp S spare parts be used as replacements SM 6800N Original June 2007 Revision History UNION SWITCH amp SIGNAL Revision History s Nature of Revision June 2007 Imitialisswe ii SM 6800N Original June 2007 UNION SWITCH amp SIGNAL 1 2 6 7 Table of Contents Introduction artiste ant detal icon ae iaia eil 1 1 System Description ida 2 1 ZA LED SiO MS een isuu 2 1 22 The LED 12 PCB reali la aa 2 2 2 3 Driver Protection PCB iii cad alec nesta aaa a ated an tete sha 2 3 2 4 GonstantGurrentRegulatol allea 2 4 2 5 Detailed System Description api 2 5 LED System Installation sise 3 1 3 1 Mechanical Installation u un un dalla lidia la aa lite dant pi nasua nuqa 3 1 3 2 SAMI cesta ec qasashina ees tt 3 1 3 2 1 LED12 PCB Upper Connector and Address Selection 3 1 3 2 2 Signal and Protection Board Wiring 3 1 3 3 Example Wiring Diagrams
25. on for three seconds Once recognized as being actuated the MicroLok II will set the status of all signals connected to that LED12 to be good and begin retesting One second later all signals will be updated to their current status good or faulty When the non vital front panel pushbutton is pressed an event will be logged The MicroLok I must detect the button to have been released before it will respond to a second pushing This would prevent a stuck non vital pushbutton from continuously clearing the signals status After a faulty signal has been replaced and recognized by the MicroLok II an event will be logged and the SIGNAL GOOD bit for the signal will be set 1 If all of the signals connected to a LED12 board are good the front panel red LED will be off 5 3 Troubleshooting Notes 5 3 1 Field Testing Open Signal Detection When field testing a system for detecting open signals special attention should be made to how the open wiring condition is created If the maintainer attempts to open a circuit by removing a ring 5 4 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL LED Signal System Troubleshooting terminal from a tall ARR stud many makes and breaks will usually occur This can cause the MicroLok II system to log Shift Test events and possibly a Shift Test Critical Error This occurs because the signal s output is unstable during the LED12 board circuit diagnostics The maintainer can choose to ign
26. ore the logged events or break the circuit in a quicker manner 5 3 2 Operation without the Constant Current Regulator Connected During the initial system installation it was necessary that all required constant current regulators be powered and connected to the LED12 board If there is an attempt to turn on a signal that is not connected to a constant current regulator a Critical Error will be detected and the MicroLok II System will reset The MicroLok II event log will record an UNDEFINED state error in the ON state 5 3 3 Failure to Provide Field Side Power to LED12 Board The LED12 Board is designed to allow the signals to be powered from an isolated power source While this is rarely needed it does require that connections from the battery through the VCO relay be made to each LED12 board If this connection is not made the MicroLok II will detect a Critical Error and the MicroLok II system will reset The MicroLok II event log will record an ADC signature failure This is caused by the system attempting to read signals from un powered circuitry 5 3 4 Hints on Troubleshooting LED Signals e Because of the constant current regulator the electrical readings taken at the LED signal load will be different from typical signals Where the load voltage of an ON state incandescent signal is typically at battery level 1 e 12V or lower due to line drop the load voltage of a ON state US amp S LED signal is typically around 35V e The LE
27. ovides surge protection for the signal The components of the system are ordered separately and installed as a system based on the specific application of the signals All of the components of the system are shown in Figure 1 1 FIELD 3 HOUSE WIRING 61 WIRING E LED Signal Complete The LED 12 Signal The Driver Constant Current with LED Protection PCB Driver Board Protection Board Regulator Figure 1 1 The Components of the US amp S LED Signal System SM 6800N Original June 2007 1 1 Introduction UNION SWITCH amp SIGNAL 1 2 SM 6800N Original June 2007 UNION SWITCH amp SIGNAL System Description 2 System Description This section contains a brief description of the LED System components and their function in relation to the overall system A block diagram of the LED System is shown in Figure 2 1 I FIELD I WAYSIDE WIRING SIGNAL HEAD G96 BUS to CPU VCOR Contact Constant Current LED Driver Regulator PCB LED Driver 4 N34801301 N17066101 PCB Protection Board Output N4620520x Battery 7 7 LED Signal Protection Board N46205001 LED Signal N4620440x Figure 2 1 LED System 2 1 LED Signals The LED signals Figure 2 2 are available in red amber yellow cyan green and lunar white in 6 3 8 diameter PN N4620480X These signals include high intens
28. ress Selection The pinouts and addresses for the LED board are presented in Figure 3 1 Note Even though the LED12 PCB will light up to 12 LED signals at once the figures in this manual show in most cases only three LED signals for illustration purposes only and are not meant to imply that the LED12 PCB should be limited to lighting only three LED signals at once Nor should it be inferred that the LED signals be all located in the same signal head 3 2 2 Signal and Protection Board Wiring Table 3 1 summarizes the maximum distance a signal can be located from the signal house based on the wire gauge selected for the application As noted in the table the distances already include the series resistance of all the lightning surge protection circuitry However the series resistance of additional components such as house wiring relay contacts and terminal connections will reduce the maximum distance for a signal they will need to be included in the 3 ohm limit for each leg Table 3 1 Maximum Signal Distance from the Signal House Wire Gauge Maximum signal distance w Ohmsper1000ft wire length for each leg E o E ARDE e ere son ete dC 4 o tion Note 1 Distances are based on maximum line resistance of 3 ohms per leg 6 ohms total Note2 Distances include series resistance of all lightning surge protection circuits Note3 Additional series resistance of house wiring relay contacts terminal connections
29. rn Configurati SM 6800N Original June 2007 LED System Installation UNION SWITCH amp SIGNAL 3 3 3 Standard Configuration Regulator Sharing Double Break As a variation on the standard configuration shown in Figure 3 2 a relay contact can also be added to the return of the signals as shown in Figure 3 4 VCOR 2 to provide a double break both power and ground to the signals under a reset condition The maximum allowable length for the field wiring can be found in Table 3 1 3 3 4 Multiple MicroLoks at a Single Location In locations where there are two or more MicroLok II cardfiles that are each driving US amp S LED signals there are specific application requirements to ensure that when one or more MicroLok II are under reset conditions the aspects return to a known safe state e All relay contacts corresponding to a single MicroLok II cardfile LED signal system shall be energized by the CPS in that system Do not use the CPS from another cardfile to energize relays or share a single CPS between all of the cardfiles This is necessary as all the cardfiles in the location will likely not reset at the same time e Do not share the constant current regulators between signals driven by separate cardfiles e Make use of the double break scheme as shown in Figure 3 4 This will prevent signals from lighting due to output shorts between the I O of the separate cardfiles 3 8 SM 6800N Original June 2007 LED System Inst
30. rning this product Contact the RAIL Team in the United States at 1 800 652 7276 or by e mail at railteam switch com SM 6800N Original June 2007 7 1 Technical Support UNION SWITCH amp SIGNAL 7 2 SM 6800N Original June 2007
31. s described in Table 3 1 The heaviest gauge wire possible should be used for this return Three VCOR contacts are used to implement failover to red for a signal head e VCOR I The back contact connects the constant current regulator output directly to the RED signal when the system is in reset causing it to light During normal operation the front contact will connect the constant current regulator output to the driver board so that all signals can be powered under application control e VCOR 2 The back contact connects the RED signal directly to the constant current regulators output when the system is in reset causing it to light During normal operation the front contact will connect the RED aspect to the driver board and the state of the RED aspect will be under application control e VCOR 3 This contact removes B12 from the LED12 board Note how the power to the regulators is not broken by a relay contact the contacts are on the output of the regulator The maximum allowable length for the field wiring can be found in Table 3 1 3 6 SM 6800N Original June 2007 LED System Installation UNION SWITCH amp SIGNAL LN 11va 1NO 11V4 Od uono lo1d 3A 894 037 89d uono loid CIT 10 e n6ay Juang JUEISUOD umoys jou 0 1 11S4qav I I TWNOIS G37 dod ZL031 onam Sd J av3H I ASNOH 4 TWNOIS TWNOIS cla 3 7 lover to Red ion with Fai Figure 3 3 Common Retu
32. s leads Faulty on or off state signals are detected in one second Flashing signals can take up to two seconds to detect since the system is separately monitoring the on and off states Once a signal has been determined to be faulty the MicroLok II system will log a warning and clear the faulty signal s SIGNAL GOOD application bit 0 The LED12 front panel LED corresponding to the faulty signal will begin flashing This flashing pattern is several quick on pulses followed by a longer off period This distinguishes a faulty signal from a normally flashing signal When any of the 12 LED 12 outputs detects a faulty signal the red LED at the bottom of the front panel will also turn on This LED quickly draws the maintainer s attention to boards with faulty signals Note Note that the SIGNAL GOOD bit is set 1 state when its attached signal is detected as good A LAMP16 board s LIGHT OUT bit is set 1 state when its attached signal is detected to be faulty Replacing a faulty signal will be automatically detected and the faulty condition cleared in one second except in the condition of a faulty On signal The fault clearing logic used on the LED 12 board is shown on Table 5 3 SM 6800N Original June 2007 5 3 LED Signal System Troubleshooting UNION SWITCH amp SIGNAL Table 5 3 Fault Clearing Logic Output state when After repairing the signal fault was Current output state signal the fault will be detected cleared by Wa
33. tem Troubleshooting UNION SWITCH amp SIGNAL 5 6 The LED12 PCB will detect shorts between signals that cause an incorrect signal state If the return leads of any two or more signals are shorted together the system will not indicate an error because this is a legal wiring option If the controlled lead of two or more signals are shorted together the system will not indicate an error if all of the signals are in the same state all on or all off If a wiring short causes an off state signal to turn on then a critical error will occur and the MicroLok II system will reset SM 6800N Original June 2007 UNION SWITCH amp SIGNAL Parts List 6 Parts List This section provides the part numbers for all system components Table 6 1 Part Numbers for the US amp S LED Signal System Components N46204402 LED Signal Cyan Green 6 3 8 includes LED Protection bu N46205001 LED Signal Amber Yellow 6 3 8 includes LED Protection Board N46205001 LED Signal Lunar White 6 3 8 N46204404 includes LED Protection Board N46205001 N46204403 SM 6800N Original June 2007 6 1 Parts List 6 2 UNION SWITCH amp SIGNAL SM 6800N Original June 2007 UNION SWITCH amp SIGNAL Technical Support 7 RAIL Team and Technical Support The Rapid Action Information Link Team RAIL Team is a group of experienced product and application engineers ready to assist you to resolve any technical issues conce
34. uts above the highest number used output do not have to be declared 43 PCB System Bits This section describes two bits unique to the LED12 PCB the NV PB bit and the Retest LEDs bit 4 3 1 NV PB The LED12 PCB has a non vital pushbutton on the front panel Pressing this button sets the state of the board s system bit NV PB The MicroLok II must detect the button to have been released before it will respond to a second set This non vital input can be used in the application to trigger logic An example is presented in Section 4 4 Application logic should be written to always examine the SIGNAL GOOD system bit and to turn OFF a signal that has been detected by the MicroLok II diagnostics to be faulty Failure to do so may result in a signal that could appear as partially illuminated or intermittent which could cause problems This is similar to the way the LAMP OUT system bit must be used for lamps driven by the LAMP16 board Refer to US amp S Service Manual SM 6800D Appendix B Note that the polarity of the SIGNAL GOOD system bit is SET when the MicroLok II diagnostics determine the signal to be working properly and CLEAR when they determine the signal to be faulty This is the opposite of the polarity for the LAMP OUT system bit used for LAMP16 signals SM 6800N Original June 2007 4 1 UNION SWITCH amp SIGNAL Application Logic Programming 4 3 2 Retest LEDs Setting this application bit 1 will clear the fault status
35. y shorted to ground Fuses can be installed on the system battery connections to the system as required These fuses can be installed in the circuit between VCOR 1 and terminal B12 Slide wire resistors are not required for use with the LED signals and should never be installed Also the LED signals cannot be dimmed by switching in a series resistance as can typically be done with an incandescent signal The LED signal has five terminals which are clearly marked three require a field connection two have no external connection Ensure that the connections are made to the proper terminals The LED signal field terminals have a polarity that must be observed where incandescent signals typically do not A signal hooked up with reversed polarity will not operate and could eventually damage the signal SM 6800N Original June 2007 3 3 LED System Installation UNION SWITCH amp SIGNAL 333 Example Wiring Diagrams 3 3 1 Standard Configuration with Regulator Sharing Figure 3 2 illustrates the standard configuration for the LED signal system components with regulator sharing three signals shown The constant current regulator can only power one LED signal at a time If multiple LED signals will never be on at the same time these LED signals can share the same constant current regulator Because the constant current regulator is only in use when a signal is the ON state a single constant current regulator can be shared between multiple signa
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