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AF-902/AF-904 Generation II Audio Frequency Track

1. 6 6 Entering AF 902 904 Front Panel Restricted Menu For Setup 6 13 Entering AF 902 904 Setup Using the Web Server Interface 6 13 Setting the Communications Address and Track Circuit ID 6 14 AF 902 904 350 or 500 MCM Tuning Instructions 6 14 Coupling Unit Nominal Capacitance Setting 6 16 AF 902 904 350 or 500 Calibration Procedure 6 16 Rail Current Settings 350 MCM 500 MCM and Cab Loop Circuits 6 18 Rail Current Settings Direct Injection Circuits 6 18 AF 902 904 Cab Loop Track Circuit 6 19 AF 902 904 Direct Injection Track Circuit 6 20 Key Preventive Maintenance Actions 8 7 Basic Troubleshooting 9 1 EVOUDIGSNOO NMO MERE T Tm 9 3 Tektronix Setup Procedure a Se ARE coo e 11 2 AF 902 904 Track Circuit 12 1 AF 902 904 Track Circuit 12 1 Track Circuit Cardfile Parts 12 1 Motherboard Direction Relays Parts 16
2. 06 4 2 12 AV E 4 AnsaldoSTS Functional Description 3 FUNCTIONAL DESCRIPTION 3 1 Introduction The TCS receives vital data from the Track MICROLOK II processes message speed and distance data adds local track circuit identification and formats a track message This message is then sent to the train via the transmitter end track coupling unit bond and rail The TCS monitors the track signal via the receiver end bond track coupling unit to detect the presence of a train in the track circuit The TCS reports track circuit track occupancy to the MICROLOK II Vital Interlocking Controller The data message sent to MICROLOK II also contains the status of the partner system health direction relay correspondence and local speed reductions The message to MICROLOK II is returned over the Ethernet or RS 485 data link Occupancy status 15 also sent to the MICORLOK II by a Vital Parallel Output line 3 2 Wayside to Train Message Processing 3 2 1 Message Data Processing When a signal is received from MICROLOK II the TCS extracts the data from the MICROLOK Serial Protocol or MICROLOK Peer Protocol message The TCS vitally processes the message data with past message data and local track data stored in its Electrically Erasable Programmable Read Only Memory EEPROM Each of the four TCS s in a cardfile has its own EEPROM The EEPROM data used in the processing includes the unique 12 bit Track I D num
3. WAIT AF 902 AF 904 Menu System Navigation Cancel Move from menu A to menu B by 10 0 5 10 0 WAIT depressing the Enter switch pwr AAAA WAIT WAIT 10 77 Move from menu B to menu A by depressing the Escape switch M T LT H pwr 10 Denied 10 Denied WAIT WAIT Move left right with the Mode Up and Mode Down switches P 5 Denied Denied A dashed line indicates the move will happen automatically when the task is completed Done User must execute a system reset by cycling power or depressing the front Move between stacked information menus with panel reset button the Mode UP and Mode Down switches User must accept the calibration Enter key or reject the calibration Escape key increase the value and ADJ Down to decrease the value Figure 4 2 Menu System Hierarchy 4 7 4 8 gt E 7 AnsaldoSTS User Interface 4 2 8 Configuration Menu This menu contains submenus that modify system parameters The Password Entry submenu allows the user to enter the password The Restricted submenu option contains other submenus that allow the user to modify critical system data 4 2 8 1 Password Entry This submenu option is used to enter and validate the restricted access password The 4 character password is entered one character at a time The active character flashes while i
4. Z N 2 NZ Serial and Network Communications TCS TCS TOS TCS POWER SUPPLY POWER SUPPLY To more AF 90x or Ethernet Switch d MICROLOXK II Local PC for web tool access Can get network address from Demo DHCP if present or will need to conmngurec be manually configured for Dono PNE network Address of AF90x hardware be obtained with discovery tool or manual input Can access all HW on network lt Figure 5 2 Non Redundant Peer Communications 5 3 Serial and Network Communications Local PC for web tool access Address of AF90x hardware can be obtained with a discovery tool or manual input Can access all No RS 485 Connections J3 AF 902 Digital FSK Track Circuit J4 V Van Optional Connection for Local PC for web tool access Address of AF90x hardware can be obtained with a discovery tool or manual input Can access all HW on 77 AnsaldoSTS HW on network gt gt network a a PRIMARY 9 BACKUP PRIMARY m BACKUP TCS oc TCS TCS oc TCS QU z z s 47 e e Nu DO LO ZN AN AN ZN Remote PC configured to monitor SNMP messages VW N Ethernet Switch A Ethernet Switch B ON LINE MICROLOK Il STANDBY MICROLOK II 7 N 2 2 N N e e MD gt Figure 5 3 Fully Redundant P
5. 6 11 6 6 4 Setup 6 12 6 7 AF 902 904 Track Circuit System Setup and 6 13 6 7 1 AF 902 904 350 or 500 MCM Track Circuit Tuning 6 14 6 7 2 Coupling Unit Tuning nennen 6 15 6 7 3 AF 902 904 350 or 500 MCM Rail Current Calibration 6 16 6 7 4 AF 902 904 Cab Loop Current Calibration 6 19 6 8 Test Documentation and Data 6 20 6 9 Example of a Record Keeping nennen 6 21 7T LIGHTNING PROTECTION RECOMMENDATIONS FOR AF 902 904 INSTALLATIONS 7 1 7 1 1 Primary AC Line 7 1 7 1 2 120VAC Isolated Ungrounded 7 1 7 1 3 Secondary AC Line 7 1 7 1 71 59 Gommupnicallon POLIS Eat 7 2 7 1 6 Microlok 1 Lightning Protection Considerations 7 2 8 PREVENTIVE MAINTENANCE ges Uu onon Sd 8 1 1 O Rm 8 1 8 2 Importance of Preventive Maintenance 8 1 9 2
6. 4 4 4 2 3 Restricted Access Menus 4 5 42 44 WAI E 4 5 4 2 5 Block Speed 4 5 4 2 6 Display Menu NTC 4 6 4 2 7 Events 4 6 4 2 8 Configuration 4 9 5 SERIAL AND NETWORK COMMUNICATIONS 5 1 6 INSTALLATION AND ADJUSTMENT 10 4 6 1 HINO FFRTTFTRTTm T ZTERwE 6 1 62 Recommended Test Equipment kalo AK kaa 6 1 Sellial Link u uuu 6 1 6 4 Vital Parallel Output 6 3 6 5 System Setup Procedure Using the Network Interface 6 3 sw Um m 6 3 CAPO 6 8 6 6 Detailed Calibration 6 9 6 6 1 Testing Codes and 6 10 6 6 2 Test Equipment and Tools 6 11 6 6 3 Transmit Power
7. 275mA for Cab loop to the Train Control and Communications Building TCCB Record l oop transmitter tap pwr for If location is a double crossover proceed to other cab loop CAB LOOP on Track Circuit Data Sheet Figure 6 6 e Check cab loop wiring to ensure proper connections AF 902 904 signal wire to 1 2 4 5 Cab loop wire to 7 8 10 11 Toggle ENTER for pwr Using a Spectrum Analyzer with a Current Probe attach ADJUST pwr xx to the same pwr Probe to Cab loop wire and monitor report loop current value set in step 3 Icabloop to TCCB Check that the ICabloop gt 250mA SM 1F2 0001 Rev 2 May 2011 6 19 A Installation and Adjustment AnsaldoSTS STEP AF 902 904 OPERATOR S ACTION TRACK COUPLING UNIT TECHNICIAN S ACTION Record Icabloop and pwr Cab Loop Circuit Sheet If calibration is denied by the AF 902 904 the display will show Denied If calibration is accepted the display returns to Set Up To exit press ESC and then press Enter when Sure is displayed Or press ESC to device calibration and return to Set Up Table 6 13 AF 902 904 Direct Injection Track Circuit Setup Proceed step by step with the calibration Proceed step by step with calibration procedure in Table procedure in Table 6 9 6 9 Exception Notes STEP 4 AND STEP 8 Check coupling unit wiring AF 902 904 signal wire to 1 2 4 5 Track Inject wire to 6
8. Introduction 7 AnsaldoSTS TRAFFIC INSULATED JOINTS SIGNAL RAIL TRACK A RETURN RAIL quM TRACK WIRES 6 AWG HRl MAX 300 FT MAX 300 FT MAX 6 000 FT TWO TWISTED PAIRS 14 AWG TRACK WIRES 6 AWG AF 90X TWO TWISTED PAIRS 14 AWG TRACK CIRCUIT Figure 1 10 Typical Track Cable Bond Application Direct Injection 1 5 4 2 350 or 500 MCM Bonds Signals and messages in the rails are transmitted to and received from the AF 902 904 cardfile via cabling type bonds known as or SOOMCM bonds The actual bond type that 15 used for an application depends on the current draw of the train motor Although similar only the 350 MCM bonds are addressed for the purpose of this discussion AF 902 904 track coupling units are tuned to the carrier frequency and provide impedance matching to from the track NOTE Within a limited range there may be several capacitance values that will provide good signal transfer The capacitance value that provides the best performance at the carrier frequency can usually be found by tuning at a frequency 400 Hz lower than the carrier frequency The 350 MCM Thousand Circular Mils bond consists of a few meters of 350 MCM cable connected between the two rails an S I or O shape with the end of the S I or O bonded to each rail See Figure 1 7 Figure 1 8 and Figure 1 9 One turn track loops are inside the
9. 2011 N 4 AnsaldoSTS Installation and Adjustment AF 902 CAB LOOP DATA SHEET Location Cable Length to Cab Loop Coupling Unit 65 1000 ft 20 305 m Ft m Track Circuit ID 1 4095 MLOK Address 1 127 Peer Address 1 65535 Calibration Procedure Frequency kHz 10 5 11 5 12 5 13 5 14 5 15 5 16 5 Transmitter Tap Setting m DO Primary Backup Backup Direction AF 902 Unit pwr Pulse Width 25 9596 CG CABLOOP 250mA lt I 300mA m Receiver Tap Setting Not Applicable Inspector Date Figure 6 6 AF 902 Cab Loop Data Sheet SM 1F2 0001 Rev 2 May 2011 6 23 5 Installation and Adjustment AnsaldoSTS AF 904 TRACK CIRCUIT DATA SHEET Location Track Circuit Length 65 1000 ft 30 305 m Feet Meters Cable Length to Nearest Bond 6000 ft max 1800 meters max Feet Meters Track Circuit ID 1 4095 MLOK Address 1 127 Peer Address 1 65535 Tuning Procedure ain 11 5 12 5 15 5 16 5 West to East East to West Coupling Unit Capacitance Transmitter Tap Setting Calibration Procedure East to West pwr Pulse Width 25 9596 RAILS Receiver Tap Setting Receiver Level Levl Vari Shunt Level Shnt Unshunted 151 17190 151 17190 2 _ DO Shnt Shunted lt 100 lt 100 Inspector C Date C W Figure 6 7 AF 904 Track Circuit Data Sheet 6 24 SM 1
10. 12 3 pO B Pur c REDE 12 3 Coupling Unts EC SRRT 12 3 Next Freguency IRR ETE A 1 Speed Chart representative A 1 Distance Chart representative distance 9 A 2 SM 1F2 0001 Rev 2 May 2011 m 74 AnsaldoSTS Introduction 1 GENERAL INFORMATION 1 1 Safety Summary Read and thoroughly understand this manual before attempting any of the procedures listed Pay particular attention to CAUTION and WARNING These headings may appear throughout this manual Caution statements indicate conditions that could cause damage to equipment Warning statements indicate conditions that could cause physical harm serious injury or loss of life Always observe standard precautions familiar to trained electrical technicians Always adhere to all safety regulations stipulated by the railroad 1 2 Introduction This service manual 15 for the AF 902 and AF 904 Generation II Digital Frequency Shift Keyed FSK Track Circuit Controller Systems The AF 902 system 15 a fully redundant track circuit controller with automatic fail over operation The AF 904 system 15 a non redundant track circuit controller When describing features common to both systems the term AF 902 904 is used The AF 902 and AF 904 Generation II Digital Frequency Shift Keyed FSK Track Circuit Controller Systems provide a plug in upgrade to the prior version of the AF 902 904 systems A new single module called
11. Table 12 5 Cardfile PCBs Parts List Part Number Track Circuit Controller System TCS N12361001 Power Supply N12360501 12 5 Coupling Units The coupling units associated with the AF 902 and AF 904 track circuits are listed Table 12 6 Table 12 6 Coupling Units Parts List Coupling Unit for inductively coupled locations 1 S O or I bonds See Figure 1 7 through Figure 1 9 N37500601 Coupling Unit x direct injection locations oe e g crossovers See Figure 1 10 N37500603 E RET a See Figure 2 4 N37500604 SM 1F2 0001 Rev 2 May 2011 12 3 N Parts List 77 AnsaldoSTS 77 AnsaldoSTS 12 4 SM 1F2 0001 Rev 2 2011 ay 77 AnsaldoSTS Jael Cs cl LL INSTALL IN SLOTS 1 3 5 7 9 11 13 15 17 amp 19 VIEW B SHOWING STACKING OF HARDWARE ON GROUND STUD FOR REF ONLY VIEW A SHOWING INSIDE OF BACK COVER IT 15 SHOP HEAD DIGITALFSK TRACK CIRCUIT UNION SWITCH amp SIGNAL IL zz ae P ij N SWITCH amp SIGNAL 79 RUSSELL ST BATESBURG SC 29006 P N N12200204 S N 320500278 REV 10 MADE IN USA 1F2 0186 00 SM 8051 Rev 6 0 March 2008 4 PLACES VIEW C SHOWING STACKING OF HARDWARE ON GROUND STUD Parts List MOTHERBOARD KEYING SCHEDULE INSTALL KEYING PEGS BOARD REF ITEM 265 INTO POSITION KEY 1B 2 5 6 8 E N123 60301 OR N1236100X KEY2B N 12360401 KEY 3
12. Verify that the inside of the track coupling unit is free from water and any moisture Check all 350 or 500 MCM bond connections for damage corrosion and tightness Check that all PVC tubing 1s properly secured against the 350 or 500 MCM cable EN D de Check all wayside components for any signs of physical damage such as cracks in loop PVC tubing etc Check all mounting hardware for tightness and to see if any of the hardware needs to be replaced 7 Remove any debris or foreign objects that may hinder the proper operation of the AF 902 904 track circuit system SM 1F2 0001 Rev 2 May 2011 8 9 lt Preventive Maintenance 7 AnsaldoSTS NOTE If any fault condition 15 observed during inspection it should be corrected immediately Inform your supervisor at once for proper procedures 8 3 4 Track Circuit Checks A regular schedule should be established to verify every AF 902 904 track circuit s shunt level The interval of the inspection will vary for each installation Track circuits with poor or changing ballast conditions will require more frequent inspection A calibrated 0 2 ohm should be placed at the entry center and exit point of the each circuit while monitoring the shunt level and occupancy status of the TCS under test The shunt level should drop below 100 at each location and occupancy should be indicated The shunt level and occupancy can be monitored on the front panel display or b
13. A MICROLOK II can communicate to multiple AF 902 904 units through a multi drop RS 485 link Terminating resistors must be connected at the physical end of the link 1 e at the AF unit farthest from the MICROLOK II Connecting the terminating resistors at the end unit 1s accomplished by closing the four SW1 DIP switches on the back of the AF motherboard See Figure 6 4 Otherwise the four SW1 DIP switches should remain open SM 1F2 0001 Rev 2 May 2011 6 1 Installation and Adjustment lt Mu uw AnsaldoSTS AF 902 AF 904 CONNECTION GENERATION II TO ADDITIONAL DA 15 SLAVES FEMALE CONNECTOR RTS DCD GND 8 Typical Microlok Master To 902 904 Generation II Units Powered By Same Battery Microlok Protocol Or Half Duplex Genisys Protocol 6 2 For full duplex Genisys Protocol RTS and DCD need not be connected Serial commons are interconnected through a battery that powers Microlok II units Load resistors L are provided by DIP Switch SW 1 on the rear of the AF 902 AF 904 Generation II cardfile The individual switches of SW must all be in the OPEN or CLOSED position The resistors are connected into the circuit when the switches are in Load resistor Lm 15 240 Ohm gt watt and is installed on master DCD only as shown MASTER MICROLOK II CPU CONN A PORT 2 PORT 1 20 2 A22 E4 A16 A2 A18 4 24 C6 A26 C8 A28 C10 A30 C12 A10 A12 E20 E20 5 C18 A32 C18 A32
14. EO IE E lt OFF SW QN P H P B F F E E E E 016 8 7 9G C SM 1F2 0001 Rev 2 May 2011 6 7 Installation and Adjustment AnsaldoSTS 6 5 2 Calibration This section provides an overview to using the web page interface to calibrate an AF 902 904 The web page interface provides an alternative to using the front panel interface to calibrate an AF 902 904 The calibration procedure 15 the same for both interfaces A detailed calibration procedure is provided Section 6 6 NOTE Before entering the setup mode to make any tuning or calibration adjustments you must turn off the power to an AF 902 partner 5 and to both adjacent track circuit AF 902 904 systems Calibration of an AF 902 904 system involves three main steps as follows 1 Tuning the bond for the maximum transfer of power to and from the track 2 Setting the AF 902 904 transmission power to set the rail current to a level that assures that a train reliably receives the track signal data 3 Setting the AF 902 904 receiver signal to a level that provides reliable train occupancy and broken rail detection 6 5 2 1 Tuning Tuning adjusts the impedance of the bond to provide maximum transfer of the track signal to the rail It is typically performed at 400 Hz below the specified track carrier frequency 9 5 kHz to 16 5 kHz This will result in a low variance in the amplitude of the spa
15. Rx Level and Shunt Level are then calculated for each direction and displayed on the web page When the AF 902 904 system performs the calculations it assigns the current received signal level to the 162 shunt level Calibrations must always be performed at nominal track ballast conditions If you recalibrate a system under extreme ballast conditions the AF 902 904 will assign the 162 shunt level to an incorrect received signal level When the TCS is unable to calculate valid values for these parameters it will display Variance Gain and Rx Level 0 and Shunt Level as This would indicate an incorrectly wired or adjusted track circuit or it will be the normal and acceptable result of calibrating a Cab Loop track circuit Cab Loop track circuits do not have a received signal and do not determine occupancy When the calibration is successful the power levels and calculated values will be stored in the TCS s EEPROM on the cardfile 6 6 Detailed Calibration Procedure The first step in setting up a new or modified track circuit 1s to tune the track coupling units Tuning matches the impedance of the AF 902 904 to the bond impedance allowing maximum power transfer Tuning is done at the coupling units mounted near the track bond The coupling unit contains two identical circuits which are separated by a dashed line down the middle of the PCB The operator should take care in determining which of these circuits 15 to be tuned before
16. are assigned to westbound or northbound track circuits and three frequencies F2 F4 and F6 go eastbound or southbound The two remaining frequencies FO and F7 are usually used in special work areas Specifically the layout of the mainline track circuits should follow the two three frequency rotations shown in Figure 2 1 If it is not possible to separate two track circuits of the same carrier frequency by two intervening track circuits then separation by one intervening track circuit plus a set of insulated joints 1s acceptable As shown in Figure 2 1 carrier frequency F1 contains data that informs the train of the next cab signal frequency F3 Onboard the train one receiver is tuned to F1 and the other to F3 As the train approaches the 350 or 500 MCM bond signal F1 drops out Once valid data and level is detected on F3 the vehicle ignores the data arriving from the old receiver The new data is then decoded and the vehicle logic retunes the receiving filter previously tuned to F1 to the next cab signal frequency in the sequence of track circuit frequencies refer to Figure 2 2 The track circuit 1s arranged so that the train 1s always heading toward the transmitter This 1s controlled by the two assigned Direction Control bits within the message received from the MICROLOK II Each wayside track circuit continuously transmits digitally formatted data to the vehicle using FSK modulation The track MICROLOK II determines most of
17. the peak of the waveform xy z mV xyz milliamps Multiply mV by 10 to convert reading to milliamps SM 1F2 0001 Rev 2 May 2011 11 3 N Tektronix Setup Procedure AnsaldoSTS 77 AnsaldoSTS N 74 AnsaldoSTS Parts List 12 PARTSLIST 12 1 Track Circuit Cardfile Overview The cardfiles supplied for the AF 902 and AF 904 track circuits are listed Table 12 1 Table 12 2 lists the part numbers for each variation of cardfile and indicates which cardfile motherboard has direction relays The location of these relays is shown in Figure 12 1 and Figure 12 2 Table 12 1 AF 902 904 Track Circuit Cardfiles N12361001 N12360501 Table 12 2 AF 902 904 Track Circuit Cardfiles Du Power Input Direction Relays Part Number AF 902 115 Vac N12200202 AF 904 115 Vac N12200204 AF 904 115 Vac N12200210 12 2 Track Circuit Cardfile Table 12 3 16 the parts list for the AF 902 904 track circuit cardfile The figures associated with this table are Figure 12 1 and Figure 12 2 Table 12 3 Track Circuit Cardfile Parts List Used On IN Part 1 N12200202 Description Number 2 N12200204 3 N12200210 Screw 8 32 x 7 16 Fil Hd SS 890 Washer SSLockNo 10 J4751210109 A SM 1F2 0001 Rev 2 May 2011 12 1 5 Parts List 77 AnsaldoSTS Used On uu Part 1 N12200202 Description Number 2 N12200204 EE NO 8 Screw SS 10 32 x 3 8 Pan 90 Transformer 115 230 V25 VA 7340009
18. Address and Track Circuit ID STEP SETTING THE COMMUNICATIONS ADDRESS SETTING THE TRACK CIRCUIT ID NUMBER 1 Obtain track circuit MICROLOK Serial Protocol or Peer Obtain track circuit ID from Control Line drawings address from hardware drawings Traverse restricted menu as described in Table 6 4 Traverse restricted menu as described in Table 6 4 SET UP SET UP Toggle ENTER for TUNE MENU Toggle ENTER for TUNE MENU Toggle MODE to MLOK MENU Toggle MODE ID Toggle for addr xx Toggle ENTER for tkid xxxx ADJUST addr 1 127 for Serial Protocol or ADJUST tkid 0 4095 ADJUST the Peer address 1 to 65535 Toggle ENTEH for ID IMENU Toggle ENTER for MLOK MENU Toggle ESCAPE for SET UP Toggle ESCAPE for SET UP Toggle MODE to AC Toggle MODE to AC Toggle ENTER for CON FIRM Toggle ENTEH for CON FIRM Toggle ENTER to scroll through all parameter settings Toggle ENTER to scroll through all parameter settings Accept by toggling ENTER Accept by toggling ENTER Reject by toggling ESCAPE Reject by toggling ESCAPE If all parameters are CONFIRMED unit will write setup If all parameters are CONFIRMED unit will write setup parameters to EEPROM and DONE parameters to EEPROM and DONE Toggle ENTEH for system reset Toggle ENTEH for system reset Record track circuit MLOK Addr on Track Circuit Data Record track circuit ID on Track Circuit Data
19. BOND N LL Figure 2 2 Cab Signal Sequencing SM 1F2 0001 Rev 2 May 2011 2 8 AV Typical Applications AnsaldoSTS The first eight bits are used for synchronizing the onboard decode function The next 36 or 38 bits contain train control data The last 16 bits of the message are the CRC bits for error detection Message configuration and bit assignments are described in Section 3 Two types of speed restrictions are initiated by the ATC system block speed restrictions and zone speed restrictions Block speed restrictions are selected by the Maintainer for each AF 902 904 track circuit Zone speed restrictions limit the target speed for a control line The AF 902 904 system enables the selection of the maximum line speed and target speed permitted to be transmitted by a track circuit The Distance to Go bits represent the distance to the target speed which is the desired speed of the train at the end of the control line Train detection and signal communications are similar to those of the mainline continuous rail territory with the exception of the Berthed recognition bits contained in the message 2 2 Yard Track Circuits In addition to their use for station to station operations the AF 902 904 track circuits are also used in storage yards which are characterized by short track circuits and slow train movement Here the system allows automatic movement of cars for the purpose of making up new train configurations
20. Figure 6 1 1 Resistors R are 470 Ohm watt 2 4 the closed position 6 Do not connect COMMUNICATION COMMON to ground SM 1F2 0001 Rev 2 May 2011 N 4 AnsaldoSTS Installation and Adjustment 6 4 Vital Parallel Output Terminations A provision for terminating an unused vital parallel output is available See Figure 2 7 and Figure 2 8 When the VPO is unused place the jumper for that track circuit in position 2 3 to terminate the output 6 5 System Setup Procedure Using the Network Interface The AF 902 904 system s TCS includes a built in web server user interface The web server interface can be used instead of using the front panel toggle switch interface A PC using Internet Explorer web browser version 6 0 or later can be connected to the internal server through the front panel or the Ethernet port Connection can be a direct cable connection or through a network switch An Ethernet switch can be used to access any one of an installation s AF 902 904 from a single location The Setup tab on the AF 902 904 web page is the entry point to the calibration and configuration features of the system Entry 15 password protected and also requires the user to be close to the AF 902 904 TCS After the password is correctly entered the user 1s required to toggle the Enter switch on the front panel This confirms that the user is working with the correct AF 902 904 and that calibration or configuration 1s not being attempt
21. HA w uw 7 AnsaldoSTS Dive SM 1F2 0001 AF 902 AF 904 Generation ll Audio Frequency Track Circuit System Field Maintenance Manual Description Installation and Adjustment Maintenance Troubleshooting Copyright 201 1 SM 1F2 0001 Rev 2 Ansaldo STS USA Inc May 2011 74 AnsaldoSTS Notices Proprietary Notice This document and its contents are the property of Ansaldo STS USA Inc formerly known as Union Switch amp Signal Inc and hereinafter referred to as ASTS USA This document is furnished to you on the following conditions 1 That no proprietary or intellectual property right or interest of ASTS USA is given or waived in supplying this document and its contents to you and 2 That this document and its contents are not to be used or treated in any manner inconsistent with the rights of ASTS USA or to its detriment and are not to be copied reproduced disclosed or transferred to others or improperly disposed of without the prior written consent of ASTS USA Important Notice ASTS USA 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 1s impos
22. II TUNE Tuning Procedure Levl Input Rec Level CALI BRAT Calibration Procedure Shnt Shunted with respect to Level MLOK MICROLOK II Address Set Menu aaaa Changeable Parameter ID Track Circuit ID Set Menu tkid Track Circuit ID Parameter PSWD Password pwr Output Pulsewidth RSTR Restricted Menu SM 1F2 0001 Rev 2 May 2011 ry AnsaldoSTS N 4 AnsaldoSTS Installation and Adjustment 6 6 2 Test Equipment and Tools The equipment and tools required for the tuning and calibration procedures are listed below The test engineer should select the appropriate tools for the required test procedure e Spectrum Analyzer Tektronix TDS 3012B or C Oscilloscope or Hewlett Packard HP3560A Dynamic Signal Analyzer See Section 11 for Tektronix TDS 3012B setup instructions e Current Probe Tektronix A621 AC Current Probe or Fluke 801 1000s Current Transformer e AAR Style 1 2 in hex socket wrench used for loosening tightening AAR standard terminal posts e Red tags for identifying failed system components e Two VOLTREX 855 B Insulated Tip Plugs for system component Front Panel test probes Handheld radios with 2 mile 3 2 km range minimum e Track Shunt 0 25 ohms total resistance The track shunt resistor itself 1s 0 20 ohms and the leads to the rails are 0 05 ohms 6 6 3 Transmit Power Adjustments During the test procedure it may become necessary to adjust the output power in order to meet speci
23. Resistors 2 8 SM 1F2 0001 Rev 2 May 2011 77 AnsaldoSTS JUMPER TERMINATING RESISTORS JUMPER Typical Applications JUMPER TERMINATING RESISTORS JUMPER 55 e m 1 j 5 po R iia a lili Ju Jz8 n JAG 148 342 ll Iu L JL J Iu un L JL J iu pie 33 n LN J3 Ja Ji pne 328 329 224 464 Jas a Soe cT 7 232 Js 42 m 1 J8 J48 lu 1 m L 1 N LDE SIN C L J J53 I I A JA o3 m JA TN F lir RLYIN fiL v2 r 777 4 r a p m pec mS r 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 LI 1 1 1 1 1 I LI LI 1 1 1 1 1 1 1 LI 1 1 1 1 1 1 1 1 1 1 1 1 1 I 1 1 1 1 1 1 1 l 1 1 1 1 1 1 1 l 1 1 1 1 1 1 1 1 1 LI 1 1 1 1 1 1 1 LI 1 1 1 1 1 1 1 LI 1 1 1 1 1 1 1 LI 1 1 1 1 1 1 1 1 1 1 1 1 1 I 1 LI 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 LI 1 1 1 1 1 1 1 l 1 1 1 1 1 rls zs p i ee a ee i ee a p I La l mm ra Js re mi J58 m 05 DIG 012 Je J J58 J78 Jee J o vx 20 89 Cz 58 Keve A oj KEYS Doc 12 Ek 5 1 e en E 5 l E z E 8
24. This unit could be replaced due to either e Circuit failure Aluminum box leaking not water tight A medium sized flat blade screwdriver is required to remove the circuit board The power to the two AF 902 904 track circuits connected to the Coupling Unit must be turned off prior to replacing the circuit board 10 2 3 Bond Replacement The bond track circuit consists of a few meters of 350 or 500 MCM heavy conductive cable typically arranged in an S shape between the rails and connected at end points to the rails The cables from the coupling units are single loop wires that induce signals into the Loop and into the rails Once these cables are installed and verified as operational there 1s very little if anything that may require replacement If any damage occurs to this hardware refer to the site s equipment and cable plans and the manufacturer s equipment manual 10 3 Verification of System Repair To ensure that the repairs have been performed correctly and that all replacement modules are fully functional system verification testing must be performed This verification procedure uses the AF 902 904 track circuit system test This specific test 1s described Section 8 3 4 and consists of two procedures tuning and calibration 10 2 SM 1F2 0001 Rev 2 May 2011 AN E 4 AnsaldoSTS Troubleshooting The AF 902 904 tuning procedure performs the following functions e Entry of carrier frequency e Tuning of both
25. UNIT TECHNICIAN S ACTION ACTION Record final capacitance E gt W Track Circuit Data Sheet Figure 6 5 Toggle ENTER to automatically set direction of signal Receive East RxE Unit is now transmitting Record final capacitance E gt W on Track Circuit Data Sheet Figure 6 5 Toggle ENTER to complete tuning sequence and MM return to TUNE MENU Toggle ENTER for freq 0 0 Tune EAST coupling unit Toggle ADJUST to set frequency to Fc 400Hz Vary capacitance with JMP1 JMP8 JMP10 Toggle ENTER for pwr xx JMP1 7 to peak voltage across Set pulsewidth to pwr 5096 TP2 and TP1 5 and 6 6 7 2 Coupling Unit Tuning Theory Changing the capacitance value in a coupling unit simultaneously tunes it to a different center frequency and changes the efficiency of the tuned circuit As you decrease the capacitance value both the center frequency and the circuit s efficiency increase The result 1s that a capacitance value selected by peaking the signal at track circuit center frequency will actually result in a coupling unit that is tuned above track circuit center frequency Therefore if you select a capacitance that gives the highest signal at some frequency below the desired operational center frequency Fc you will have better performance at Fc The best overall offset 16 to set the tuning frequency to Fc 400 Hz If after calibration you find that the variance is higher than 7 you may want
26. Yard track circuits use the same carrier frequency assignments and rotations as the mainline track circuits F3 and F5 for west north circuits and F2 and F6 for east south circuits However for yard track circuits it is only necessary to separate two track circuits of the same carrier frequency by one intervening track circuit Figure 2 3 shows this configuration INSULATED JOINTS RUNNING RAILS DIRECT INJECT DIRECT INJECT COUPLING UNIT COUPLING UNIT AF 902 904 MAIN DETECTION AND CAB SIGNAL Figure 2 3 Single Rail Track Circuit 2 4 SM 1F2 0001 Rev 2 May 2011 7 AnsaldoSTS Typical Applications The cab signal 1s injected into the rails via direct inject connection of the coupling unit to the rails See Figure 2 6 The direct injection method 15 used because only one rail of the track circuit contains insulated joints S bond O bond I bond coupling methods will not function in areas where one rail of the track circuits are tied together Vital commands such as speed coupling uncoupling and direction are transmitted to the vehicle via the cab signaling system Non vital bi directional data including vehicle health information diagnostics and testing commands is transmitted via the train to wayside communication system 2 3 Cab Only Transmission in Crossovers A typical crossover arrangement of a cab only transmission loop is shown in Figure 2 4 A transmission loop 15 installed within the rails
27. coupling units The AF 902 904 calibration procedure carries out the following system functions e Entry of Carrier Frequency Track ID and MLOK Address e Setting of the Transmitter Tap and Vout to set rail current Irail e Setting of the Receiver Tap and Shunt Data Threshold e Verification of 0 25 ohm shunt sensitivity NOTE Depending on the repair or replacement that 1s performed the tuning procedure may not be required Tuning is required as a setup procedure and when a coupling unit 15 replaced or if the track circuit frequency is changed Replacement of AF 902 904 track circuit PCBs do not warrant the tuning procedure The calibration procedure should however be performed to verify the repairs SM 1F2 0001 Rev 2 May 2011 10 3 uw 7 Troubleshooting 4 AnsaldoSTS 77 AnsaldoSTS 10 4 SM 1F2 0001 Rev 2 May 2011 5 E Cw 4 AnsaldoSTS Tektronix Setup Procedure 11 TEKTRONIX SETUP PROCEDURE This procedure uses the Tektronix TDS 3012B Oscilloscope and Tektronix A621 AC Current Probe to measure AF 902 904 peak currents It assumes that the user is familiar with the basic operation of the Tektronix TDS 3012B The procedure also assumes that the basic user settings language time etc of the instrument have been configured It 15 provided as an aid to setting up the Tektronix equipment prior to the actual tuning of the AF 902 904 system The following paragraphs are intended to help the user become familiar with
28. if the first character 1s displayed After the password has been entered the user is asked to confirm the value A password that is modified and then confirmed immediately becomes the system password The default password can only be restored by physically replacing the EEPROM on the motherboard 4 2 8 3 5 Calibration Menu Via the Calibration menu the user sets the operating parameters of the AF 902 AF 904 system The function and use of each submenu is described in Section 6 5 2 of this manual 4 2 8 4 Accept Menu This menu is used to confirm the changes that have been made to the restricted access system parameters The Accept menu is a group of menus that sequentially prompt the maintainer to confirm the modifications that have been made to the system parameters The parameter identifier 15 displayed first followed by the new value shown on both the top and bottom displays The operator must toggle the Enter switch to confirm that both displays indicate the correct parameter or the Escape switch to abort the modification After each modified parameter has been confirmed a Password Entry menu is activated This menu 15 similar to the menu described above If the correct password 15 entered the system parameters are written to the system EEPROM and will be used for all subsequent operations 4 10 SM 1F2 0001 Rev 2 May 2011 n E 7 AnsaldoSTS Serial and Network Communications 5 SERIAL AND NETWORK COMMUNICATIONS The commu
29. nennen nnns 10 1 10 2 1 AF 902 904 TCS and Power Supply 10 1 10 2 2 Coupling Unit nennen nnns 10 2 10 2 3 BONG Replacement uu uu uu uu uu uuu u raa vx uir dva wu dx Gag dV Ri 10 2 10 3 Verification of System 10 2 11 TEKTRONIX SETUP PROCEDURE U uuu uu 11 1 12 PARTS EIO 12 1 12 1 Track Circuit Cardfile Overview ssss sessssscessssscesssssscsssusscessunssenqnnnseennasstts 12 1 12 2 Track Circuit amantes 12 1 12 3 Cardfile Motherboard Direction Relays ssssssseessssssscsessssssssssssesasssssnnnnns 12 3 12 4 AF 902 and AF 904 Cardfile 5 12 3 12 5 UNIS RENE 12 3 13 RAIL TEAM AND TECHNICAL SUPPORT 13 1 APPENDIX A CHARTS and TABLES SM 1F2 0001 Rev 2 May 2011 V Table of Contents Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 10 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7
30. o ojojol eoljo si sit o 9 9 lt 6 6 6 61 6 61 06 DISTANCE METERS A 3 SM 8051 Rev 6 0 March 2008 5 Charts and Tables AnsaldoSTS AnsaldoSTS End of Manual AZ A 4 SM 1F2 0001 Rev 2 May 2011
31. occupied When the train clears a track circuit the received signal threshold 15 restored and the AF 902 904 system responds accordingly From the receive cable the returning signal passes through an internal disconnect relay before being applied to the receiver transformer receiver transformer has five taps These taps allowed the older AF 902 904 equipment to be adjusted for different operating conditions such as track lead length direct injection vs bond injection and loop driving without a bond The AF902 904 Generation II system incorporates a self adjusting receiver gain and requires that the receiver tap on the rack always be set to the 2 position 9 SM 1F2 0001 Rev 2 May 2011 AV E 4 AnsaldoSTS Functional Description 3 4 Fail Over The left TCS of each AF 902 track circuit is called the Primary and the right pair 1s called the Backup These terms refer to the physical placement of the TCS The unit that 1s operating the track circuit 1s called the On Line unit and the other unit 1s called the Standby or Off Line unit This logical distinction 1s needed because a failed or powered off Primary unit could be replaced and or powered up without it becoming the On Line unit The Primary unit would remain the Standby unit until the power is cycled to both units or the Backup unit fails or 1s reset Each AF 902 904 TCS must pass its own continuous set of internal diagnostics In AF 902 systems if the On Line track circu
32. signal as a percent of the threshold Receive menu Signal Strength STR submenu 4 2 6 3 System Parameters This menu is used to display the current system configuration The following parameters are displayed block speed MICROLOK II address track ID Primary Backup frequency calibrated transmit power West and calibrated transmit power East 4 2 7 Events Menu This menu is used to select a submenu from which it is possible to display events and manage the event logging system The following submenus are available from the Events menu View Events and Clear Events 4 2 7 1 View Events Menu The View Events menu allows the user to view the event numbers logged by the AF 902 AF 904 system in the most recent first order 4 2 7 2 Clear Events Menu The Clear Events menu will erase all recorded event numbers from the AF 902 AF 904 memory 4 6 SM 1F2 0001 Rev 2 May 2011 74 AnsaldoSTS Note When a menu allows a value to be adjusted press the ADJ Up to 1D2 0180 02 SM 1F2 0001 Rev 2 May 2011 D SCREEN User Interface Leave web setup or timeou MENU VN NI E MENU Cancel Y SE EVNT EVNT 5 Denied 5 Cancel 0033 16 nx X 0059 System Reset UN MENU 104 E Invalid DIH DIH Cancel Ki A A re 2199 NEW SE AA AT EE 2 1 E E LPSWD Y E B eese l
33. the MICROLOK Peer Protocol A user interface to the AF 902 904 system for local operation monitoring configuration and calibration Remote AF 902 904 system monitoring using SNMP protocol SM 1F2 0001 Rev 2 May 2011 1 5 N Introduction 77 AnsaldoSTS ALPHANUMERIC LED DISPLAYS SYSTEM MONITOR LEDS SYSTEM RESET PUSHBUTTON CONFIGURATION SETUP SWITCHES MOMENTARY CONTACT SWITCHES SPRING RETURN TO CENTER ETHERNET CONNECTORS lt ETHERNET2 O O ETHERNET 1 JB T Figure 1 3 Track Circuit System TCS Front Panel 1D2 0175 00 1 6 SM 1F2 0001 Rev 2 May 2011 m 74 AnsaldoSTS Introduction 1 5 3 Power Supply Figure 1 4 shows the front panel of the Power Supply The location of the power supplies in the cardfile 16 shown in Figure 1 2 Each power supply in the AF 902 904 system provides regulated operating power for two TCS units WARNING Dangerous voltages are exposed when operating the power supply on an extender board Use extreme caution when working near exposed terminals Failure to do so could result in serious physical injury or loss of life The Power Supply front panel contains the following e SIX LEDs Three LEDs monitor left track circuit power and three monitor right track circuit power e Two separate power switches The upper power switch energizes the TCS to the immediate right of the Power Supply and is marked with a right arrow The lower power
34. the information in the data bits and passes this data on to each AF 902 904 track circuit via vital serial or Ethernet communications links where the data 1s logically processed and encoded for the track message 2 2 SM 1F2 0001 Rev 2 May 2011 c AnsaldoSTS Typical Applications T C 2103 T C 2102 T C 2101 T C 2100 T C 2099 F1 10 5 kHz 12 5 kHz F5 14 5 kHz F1 10 5 kHz 12 5 kHz REC 1 F1 HEC 2 F3 TRAFFIC DIRECTION I lt 99 T C 100 101 T C 102 T C 103 F4 13 5 kHz F6 15 5 kHz 2 11 5 2 F4 13 5 kHz F6 15 5 kHz TRAIN IN TRACK CIRCUIT 2103 RECEIVER 1 TUNED TO F1 RECEIVER 2 TUNED TO F3 APPROACH T C 2102 F1 OUT F3 RECEIVED T C 2103 T C 2102 T C 2101 T C 2100 T C 2099 F1 10 5 kHz F3 12 5 kHz F5 14 5 kHz F1 10 5 kHz F3 12 5 kHz REC 1 F3 REC 2 F5 TRAFFIC DIRECTION lt 1 T C 99 T C 100 T C 101 T C 102 T C 103 F4 2 13 5 kHz F6 215 5 kHz F2 11 5 kHz 13 5 kHz F6 2 15 5 kHz TRAIN IN TRACK CIRCUIT 2102 RECEIVER 1 TUNED TO RECEIVER 2 TUNED TO F5 APPROACH T C 2101 F1 OUT F5 RECEIVED 1D2 0189 00 Figure 2 1 Application of Cab Signal Frequencies to Track Circuits F RECEIVED RECEIVED _ a RU A ST 350 OR 500 MCM
35. to re tune the coupling unit You will need to reduce the capacitance by one or more increments to improve the variance The new capacitance will not provide the peak signal level at Fc instead the center of the coupling unit s passband will be closer to Fc To see if a change has been effective you must repeat the calibration of the AF 902 904 If you find a track circuit that is difficult to tune well enough to provide a low variance you can adjust the capacitance using the following fine tuning procedure Note that this is a more intensive process and should only be used if the normal tuning or the normal tuning plus a one or two step reduction in capacitance does not provide a satisfactory variance The AF 902 904 system will accept variances up to 15 but it should be possible to achieve variances less than 10 To fine tune a track circuit you will need a means to measure the received signal either at the coupling unit or at the AF 902 904 You can measure the signal in the same manner as with normal tuning You will also find that fine tuning is easier when using the web interface but it can be done using the front panel First peak the received track signal as described above at Fc 400Hz SM 1F2 0001 Rev 2 May 2011 6 15 A Installation and Adjustment AnsaldoSTS Stay in either the web interface or the front panel tuning mode Adjust the tuning frequency to Fc 200 Hz Space and measure the received signal lev
36. 1 Received Signal uu uuu u uuu u u u u Pekon va 8 1 VAAN CC uae u u u Gu nu 2 8 4 8 2 3 Event Code 8 6 8 3 Preventive Maintenance 8 6 8 3 1 Initial Preventive Maintenance 8 6 8 3 2 Equipment Cleaning 8 7 IV SM 1F2 0001 Rev 2 May 2011 v 7 AnsaldoSTS Table of Contents 8 3 3 Track Circuit 8 9 Bod 8 10 Mau e8liB ieejjc 9 1 SN FEM istoc u 9 1 9 2 Approach to 9 1 9 3 Troubleshooting 9 9 2 9 3 1 Faut 9 2 9 4 Front Panel Indicators and 9 3 9 3 9 4 2 902 904 Power 9 5 10 CORRECTIVE MAINTENANCGE a u 10 1 Doro m 10 1 10 2 Replacement
37. 24 m 1 7 2 Cardfile Power Input 115 VAC 10 at 50 60 Hz 50 watts per track circuit Input Power Protection 10 amp fuse Environmental 25 C to 70 C with 95 humidity non condensing 1 7 3 Coupling Unit Coupling Feed 6 000 ft 1 800 m maximum with twisted pair of 14 AWG Coupling Unit to Loop Feed lt 15 0 ft 5 m 14 AWG Tuned Circuit Connected to one turn loop 1 7 4 350 or 500 MCM Bond Cable Bond 350 or 500 MCM conductive Signal exchange Inductive Coupling Impedance 1 0 ohm approximately Cab signal current 105 milliamps at 9 5 kHz see Table 6 11 1 16 SM 1F2 0001 Rev 2 May 2011 N 74 AnsaldoSTS Introduction 1 8 References The following can be used as references 5 5 USA Service Manual 8054 Train to Wayside Communications TWC System Wayside Equipment Operation and Maintenance Service Manual e Refer to Specific site plans for detailed installation data and track coupling requirements SM 1F2 0001 Rev 2 May 2011 1 17 N Introduction 77 AnsaldoSTS ANY 77 AnsaldoSTS 1 18 SM 1F2 0001 Rev 2 May 2011 A mu 7 AnsaldoSTS Typical Applications 2 TYPICAL APPLICATIONS This section provides an overview of the AF 902 904 system and its functional responsibilities within the wayside application NOTE For assistance regarding non typical track circuits that are not described in this manual contact the Rail Team see Section 13 The AF 902 904 system has been designe
38. 5 I r gt DOGO AD UEANDDO Q DOODO x l mmm 29 t i C LP cr m O 2 INdUJ ASuednooso IEPA C ia e D HHO IO H2OIIN S L i dl ZN Ge NL ZIN zZz Z be Lb a I spa Buidnoo it i I o rur No MN MENTI EDEN 5 2 lt S tL k _ emi StS oP AA PN O a _ PIE NES a l c 2 T C c ME 3 I LU E UNE zN I ATL S E aod PNO i O _ LL SEAN 1 ZN3 AL JNA i gt 2 i v d vob ES l SN lesa CIN LZ LATOJ KIOJ ui RF TIENATA cf 8 O A h JOPDAUUOJ 4 c Vis E LL uw 3 911 21414 UNE a EULLENN I d E T SEXE 6 FO6 dAV 1 E a J O Ll Ll z FR La Y x UNO i L w nue re 1 Mi XM 1 x 1 ree T E LL e Mn lt 9 l er lt i woes e ava Sa ed i ddsudAzH cH cx L _ siu ku TAN IS LAN b d iU MEME CN p vuo 1 i J SUOJDJANNOJ
39. 6 6 SM 1F2 0001 Rev 2 2011 N 4 AnsaldoSTS Installation and Adjustment After setting the configuration values select the Commit button A yellow banner will briefly appear above the tables confirming that the values have been sent from your PC to the AF 902 904 for temporary storage At this time you can set the SNMP parameters provided by your network designer and set a new password if desired These functions have tabbed pages in the Setup Mode display Upon completion of Configuration you must exit the Setup Mode by selecting the Exit tab You will be presented with a page of all parameter values for review If the all values are correct select the confirmation button and re enter the system s password This must be the same password used to enter the Setup Mode You will be prompted to reset the AF 902 904 This be done using the front panel reset button or cycling power to the AF 902 904 If you are going to use the user selected AF 902 904 IP settings the default IP address switch SW1 1 Figure 6 3 must be placed in the OFF position The TCS must be removed from the cardfile to access switch SW Remove power from the TCS before removing the TCS from the cardfile When power is turned back on to the TCS it will use the IP network parameters that have been set Change your PC s address as described in Section 6 5 1 2 to operate in the same subnet as the AF 902 904 B
40. 77 ON LINE DIRECTION EAST O SELF HEALTH 1 O O PARTNER s 3 SYSTEM MONITOR LEDS CONFIGURATION SETUP SWITCHES MOMENTARY CONTACT SWITCHES SPRING RETURN TO CENTER 0 AUX 2 ETHERNET CONNECTORS lt ETHERNET O ETHERNET1 Figure 9 1 AF 902 AF 904 TCS Front Panel 9 4 SM 1F2 0001 Rev 2 May 2011 A E 4 AnsaldoSTS Troubleshooting 9 4 2 AF 902 904 Power Supply The power supply was designed specifically for application in the AF 902 904 track circuit cardfile Two separate power switches are on the front panel They are locking lever type switches that need to be pulled out in order to toggle Test points and LED indicators for each supply output six total are provided and are accessible through the front panel Each Power Amplifier Transformer output 1s also accessible at the front panel AII test points are fed through appropriate current limiting resistors to avoid shorting the outputs Figure 9 2 shows the indications test points and controls on the front panel of the Power Supply SM 1F2 0001 Rev 2 May 2011 9 5 Cw Troubleshooting 7 AnsaldoSTS MONITOR LEDS DC POWER TEST POINTS POWER RIGHT POWER SUPPLY LOCKING SUBSYSTEM POWER SWITCH AC POWER TEST POINTS POWER MONITOR LEDS gt gt DC POWER gt A 5 LO mr Sin O LOCKING SUBSYSTEM POWER SWITCH POWER SUPPLY 12360501 102 0181 00 Figure 9 2 902 904 Po
41. 8 9 11 l ai settings to be done with 0 20 ohm shunt in place across rail at receive end Current transformer on shunt 6 8 Test Documentation and Data Sheets The results of the setup and test procedures must be fully documented using the approved circuit plans and the test Data Sheets For specific information concerning a particular location s AF 902 904 installation refer to that location s circuit drawings Book of Plans test record sheets and any other installation data that may be available The type of information that 1s available may vary and depends on the railroad or transit authority s record keeping policy 6 20 SM 1F2 0001 Rev 2 2011 N 4 AnsaldoSTS Installation and Adjustment 6 9 Example of a Record Keeping Policy The approved circuit test plans are used to record the results of the setup procedure A circuit that has been tuned only should be checked in blue A circuit that has been both tuned and calibrated should be checked in green If corrections to the circuit plans are required as a result of any procedure the Test Engineer should document the changes using Yellow Out and Red In color coding In addition the test engineer 1s required to initial and date the changes and to further document the changes by using a Standard Discrepancy Action Item List with the installation test procedures to fully describe the discrepancy and the action taken The Data Sheets provided at the end of this se
42. 904 TCS Front Panel 4 2 2 Controls The AF 902 904 system has four up down SPDT toggle switches used to enter and examine data used in the setup and operation of the track circuit Each menu of the AF 902 904 system uses the control switches for the following purposes Mode Up Scrolls forward through selections or display parameters Mode Down Scrolls backward through selections or display parameters 4 4 SM 1F2 0001 Rev 2 May 2011 E E 7 AnsaldoSTS User Interface Adjust Up Increases the current parameter Where appropriate when the maximum value 15 reached the parameter rolls over to the minimum value In the Display submenus the Adjust Up switch is used to modify the display code Adjust Down Decreases the current parameter Where appropriate when the minimum value 1s reached the parameter rolls over to the maximum value In the display submenus the Adjust Down switch is used to modify the display code Enter Enters a submenu or confirms a parameter value Escape Backs out of a submenu or cancels an operation Aux 1 Enters the block speed menu This switch has no effect on the restricted access menus Aux 2 Enters the block speed menu This switch has no effect on the restricted access menus The menus system Hierarchy is shown in Figure 4 2 The values shown in Figure 4 2 are examples The actual values may or may not be the same as those shown in Figure 4 2 4 2 3 Restricted Access Menus Remove power to t
43. 904 system for train detection and cab signaling The Tune menu contains several sequential submenus to be used in conjunction with the track circuit setup and tuning procedure Because of the sequential nature of the tuning procedure a menu item may have both a function and a submenu By using the Frequency Adjust menus the user can change the carrier frequency in either the West to East or East to West signal transmission direction The Adj Up Adj Dn switches are used to modify the value that 1s displayed and the Enter switch moves to the Power Output menu The Power Output menus provide an adjustment of transmitter power The Adj Up Adj Dn switches are used to modify the value that 1s displayed and the Enter switch moves to the submenu 4 2 8 3 2 Microlok Il Menu SM 1F2 0001 Rev 2 May 2011 4 9 lt User Interface 7 AnsaldoSTS This menu permits the user to select the Address Adjust submenu which can be used to change the MICROLOK II station address 4 2 8 3 3 ID Menu With the ID menu option the user can enter the track identification number 1 to 4095 4 2 8 3 4 Utility Menu This menu can be used to access New Password The New Password function allows the user to change the default password The password 15 modified using the Adj Up Adj Down switches and toggling the Enter switch sequentially confirms each character The Escape switch backs up by one character or cancels the operation
44. AF 902 904 system Entry and detailed use of the Setup Mode pages are described in Section 6 of this manual 4 2 TCS Front Panel Operation The front panel menu system of the AF 902 904 unit can also be used to modify and display vital and non vital system parameters and to calibrate and configure the system It 1s provided for compatibility with older AF 902 904 systems Any operator can access any menu function except for the configuration functions which can be accessed only by authorized operators 4 2 1 Front Panel Displays The menu control system consists of two four character alphanumeric scrolling displays Discrete LEDs provide additional system operational mode and status information as listed Table 4 1 Figure 4 1 shows the switches and displays as well as the corresponding names and identification 4 2 SM 1F2 0001 Rev 2 May 2011 c uw E 7 AnsaldoSTS User Interface Table 4 1 TCS LED Indications Grup LED On Of Flashing W West North Normal relay West North Normal 4 Normal relay picked relay dropped Track Ohuni d E East South Reverse relay East South Reverse 2 picked relay dropped Track Shunted STATUS Failover link good Failover link bad Neal ipna dusi Vital processors have 2 Setup Mode detected a warning or processors are healthy meo eb For Future Use For Future Use For Future Use RESET RESET TCS is Resetting TCS not in Reset ETHERNET 2 RX TX N A Ethernet Interface is not E
45. B QI ss 72 012360401 1 5 12 5 6 vel l k 1 ALA mim lt lt NIO UJ UJ N OJ e eee cof Co NOTE FOR SHELF MOUNTED INSTALLATIONS USE BRACKET PART NUMBER M12201601 AND MOUNTING HARDWARE J4751200112 45000970108 AND J4751210111 THE BRACKET AND HARDWARE MUST BE ORDERED SEPARATELY COVER POP RIVET AND WASHER USED ON BOTTOM HALF OF MOTHER BORD ONLY REAR VIEW WITH BACK COVER ITEM 15 REMOVED Figure 12 1 AF 902 Track Circuit Cardfile 12 5 12 6 RN 77 AnsaldoSTS Parts List 65 INSTALL IN SLOTS ETO FOR SHELF MOUNTED INSTALLATIONS yj diu EI TEOJ AS A 1 3 5 7 9 11 13 15 17 amp 19 SHOWING STACKING USE BRACKET PART NUMBER 12201601 gt PONINA AAN VIEW C AND MOUNTING HARDWARE J4751200112 J5000970108 AND J4751210111 THE VIEW A PA E E BRACKET AND HARDWARE MUST SHOWING INSIDE OF BACK COVER ITEM 15 GROUND STUD BE ORDERED SEPARATELY SHOP HEAD INSIDE DIGITAL FSK TRACK CIRCUIT UNION SWITCH 8 SIGNAL S UNION SWITCH amp SIGNAL P N N12200204 S N 320500278 REV 10 1D2 0187 00 48 45 2 REAR VIEW WITH BACK COVER ITEM15 REMOVED Figure 12 2 AF 904 Track Circuit Cardfile SM 8051 Rev 6 0 March 2008 12 7 12 8 AnsaldoSTS RAIL Team and Technical Support 13 RAIL TEAM AND TECHNICAL SUPPORT The Rapid Action In
46. F 902 904 should be sufficient to permit the track circuit to operate over the complete ballast range 62 mA represents 10096 Over Drive 38 mA represents 16296 Over Drive AF902 Receiver Threshold Figure 8 3 Adjustment at Low Ballast Auto Calibration 100 mA represents 10096 Over Drive 38 mA represents 26396 Over Drive AF902 Receiver Threshold Figure 8 4 If Ballast Becomes High Auto Calibration 8 2 2 Variance Variance 15 a measurement of the differences the amplitudes in the wayside coupling unit between the Mark and Space frequencies The coupling unit is a LC circuit tuned to a specific frequency 8 4 SM 1F2 0001 Rev 2 May 2011 m uw E 7 AnsaldoSTS Preventive Maintenance If the variance is 0 both the Mark and Space frequency amplitudes are identical See Figure 8 5 The AF 902 904 system employs two type of coupling units One type of coupling unit is used with S bond O bond and I bond track circuits and requires being tuned to the specific operating carrier frequency The second type of coupling unit is used for all direct injection single rail AF 902 904 track circuit configurations The direct injection coupling unit does not require tuning 8 2 2 1 S Bond and Track Circuits If no in band interference is present the variance value obtained from the AF 902 904 is a measurement of how well the wayside coupling unit is tuned If the coupling unit is slightly off In tu
47. F2 0001 Rev 2 2011 N 4 AnsaldoSTS Installation and Adjustment AF 904 CAB LOOP DATA SHEET Location Cable Length to Cab Loop Coupling Unit 65 1000 ft 20 305 m Ft m Track Circuit ID 1 4095 MLOK Address 1 127 Peer Address 1 65535 Calibration Procedure Frequency kHz 9 5 10 5 11 5 12 5 13 5 14 5 15 5 16 5 Setting West to East East to West pwr Pulse Width 25 95 250mA I lt _ m 300mA Receiver Tap 2 Setting Not Applicable Inspector Date Figure 6 8 AF 904 Cab Loop Data Sheet SM 1F2 0001 Rev 2 May 2011 6 25 2 Installation and Adjustment AnsaldoSTS ANY 77 AnsaldoSTS 6 26 SM 1F2 0001 Rev 2 2011 N 4 AnsaldoSTS Installation and Adjustment re LIGHTNING PROTECTION RECOMMENDATIONS FOR AF 902 904 INSTALLATIONS All installations of AF 902 904 Systems should consider a lightning protection plan that includes the protection of both the power wiring and the track signal wiring The following sections are a checklist of wiring configurations and recommended protection 7 1 1 Primary AC Line Protection Primary AC Line Protection refers to the protection of the AC Mains at the Service Entrance 7 1 1 1 Split Single Phase 120 240VAC Feed This is a standard split single phase feed The center of the 240 AC split is utility earth grounded The recommended Primary Stage AC Line Protection is ASTS USA Part Numbe
48. Figure 2 8 Figure 2 11 Figure 4 2 Figure 5 1 Figure 5 2 Figure 5 3 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 8 1 Figure 8 2 vi lt 77 AnsaldoSTS List of Figures Typical Wayside Room 1 3 AF 902 904 Cardfile 1 5 Track Circuit System TCS Front 1 6 AF 902 AF 904 Power Supply ssssssss sssssssssssssscssensssnnsstsscennnssnnnassstcennnssnnnns 1 8 Inductive Coupling Unit Terminal Identification 1 9 Direct Injection Coupling Unit Terminal Identification 1 10 Typical S Track Cable Bond 1 10 Typical I Track Cable Bond 1 11 Typical Track Cable Bond Application Direct Injection 1 12 Application of Cab Signal Frequencies to Track Circuits 2 3 Cab Signal 9 2 3 Single Rail Track 0 rell NR TERRTRTTTFTFTTTTT 2 4 Typical Interlocking Cab Only Transmission 2 5 Inductive Coupling Unit Terminal Identification 2 6 Direct Injection Coupling Unit
49. II AF 902 lt gt S TRACK CONTROL w MALIS PRIMARY CONNECTIONS PANEL jv 350 OR BONDS VITAL PARALLEL OUTPUTS where used CENTRAL _ 7 gt LOOP CONTROL lt NON VITAL FACILITY LEGEND 5 SLAVE M MASTER NVLE NON VITAL LOGIC EMULATOR Figure 1 1 Typical Wayside Room Equipment 1 4 Safety Read and thoroughly understand this manual before attempting any of the procedures listed Pay particular attention to WARNING and CAUTION statements that appear throughout this manual Caution statements indicate conditions that could cause damage to equipment Warning statements indicate conditions that could cause physical harm serious injury or loss of life Always observe standard precautions familiar to trained electrical technicians Always adhere to all safety regulations stipulated by the railroad SM 1F2 0001 Rev 2 May 2011 1 3 N Introduction 77 AnsaldoSTS 1 5 Physical Description This section of the manual provides a brief description of the components of the AF 902 and AF 904 Generation II Digital Frequency Shift Keyed Track Circuit Controller Systems CAUTION This system operates directly from the AC mains Use caution when working near the backplane or on the power supply and especially when working on a TCS of Power Supply mounted on an extender board 1 5 1 Cardfile The AF 902 904 cardfile chassis is compatible with a standard 19 inch wide rack All power is s
50. ING Tos UNIT 6 AWG LOOP CABLE COLLAR FOR Js 9 BOND CABLE TWO TWISTED PAIRS 14 AWG BOND AND LOOP CABLE MOUNTING AF 90X TRACK TWO TWISTED PAIRS 14 AWG CIRCUIT B Figure 1 7 Typical S Track Cable Bond Application 1 10 SM 1F2 0001 Rev 2 May 2011 w 7 AnsaldoSTS Introduction NEUTRAL CONNECTION NEUTRAL CONNECTION TO SUBSTATION TO SUBSTATION TRAFFIC 11 5 FT 3 5M 350 OR 500 MCM TRACK A Bana Ree TRACK nH Rec TRACK C q D q D a MAX 15 FT LI TRACK A 8 B COUPLING e e TRACK B amp C COUPLING UNIT EE UNIT 6 AWG MAX 6 000 FT TWO TWISTED PAIRS 14 AWG AF 90X TRACK TWO TWISTED PAIRS 14 AWG CIRCUIT Figure 1 8 Typical I Track Cable Bond Application TO SUBSTATION TO SUBSTATION OPTIONAL OPTIONAL TRAFFIC 350 OR 500 MCM 350 OR 500 MCM 11 5 FT 3 5M 11 5 FT 3 5M INSULATED Je NE JOINTS TO V TRACK 8 TRACK A L I NEUTRAL NEUTRAL TRACK C CONNECTION J LE CONNECTION M q D m TRACK B amp C COUPLING UNIT MAX 15 FT ONE TURN COUPLING LOOP 6 AWG TWO TWISTED PAIRS 14 AWG TWO TWISTED PAIRS 14 AWG TRACK CIRCUIT Figure 1 9 Typical Track Cable Bond Application SM 1F2 0001 Rev 2 May 2011 1 11 N
51. Physical 27 e 1 4 J eee 1 4 1 5 2 Track Circuit System uu u 1 5 1 5 3 Power SUDpIY ssesssssressesssuseussnsssosrarsnssuneeeresvanreneessssvennnnmkvanrenreskenveunsnmusmreenros 1 7 LOA Wayslde anI a ima Ui qup desunt iid me 1 9 1 6 MICROLOXK II AF 902 904 1 13 1 6 1 RS 485 MICROLOK Serial Protocol aa nnne 1 13 1 6 2 ueeend due W 1 14 TAK el esios a diaii iA 1 16 iu WC 1 16 wc o 1 16 Nc UNIT 1 16 E EC oE Estonie 1 16 1 8 R rencesS 1 17 2 TYPICAL APPLICATIONS U uuu uuu u 2 1 2 1 Mainline Track Circuits 999 2 2 2 1 1 Track Circuit ID and Cab Signal 2 2 VWa TACK uuu uu u m 2 4 2 3 Cab Only Tra
52. RxE Toggle ENTER for pwr xx90 Using a Spectrum Analyzer with a Current Probe attach Set l a for W to E using a combination of Probe to Center of 350 or 500 MCM Bond and selecting a transmitter tap and ADJUST pwr monitor report rail current Irail at East track bond For l a setting refer to Table 6 10 or Table 6 11 Record l a and pwr on Track Circuit Data Sheet Figure 6 5 Toggle ENTER for Levl xx Record receiver tap and Levl for W gt E on Track Circuit Data Sheet Figure 6 5 The receiver tap should be tap 2 Toggle ENTER for Vari x96 Variance should be between 0 and 15 Record Vari x for W gt E Toggle ENTER for Shnt 151 171 The system will set the Shunt level to a nominal 16296 Record Shnt 151 17196 for W gt E when unshunted Note When SHUNT applied check that Shnt Apply 0 2 ohms shunt to track at center of East Bond lt 100 Record Shnt xx when shunted SM 1F2 0001 Rev 2 May 2011 6 17 A Installation and Adjustment AnsaldoSTS Toggle ENTEH to automatically set direction of signal travel East to West Toggle ENTER for Levl xx Record receiver tap and Levl for E gt W on Track Circuit Data Sheet Figure 6 5 The receiver tap should be tap 2 Toggle ENTER for Vari x96 Variance should be between 0 and 15 Record Vari x96 for E gt W Toggle ENTER for Shnt 151 171 The system will set the Shunt level t
53. Sheet Sheet Figure 6 5 Figure 6 5 6 7 1 AF 902 904 350 or 500 MCM Track Circuit Tuning For tuning of an AF 900 904 350 or 500 track circuit proceed with instructions Table 6 7 The table lists the Operator s Action for tuning an AF 902 904 system using the front panel interface The web page interface provides a means to perform all of these steps from the one tuning page in the Setup Mode see Section 6 5 2 1 Table 6 7 902 904 350 or 500 Tuning Instructions STEP AF 902 904 OPERATOR S TRACK COUPLING UNIT TECHNICIAN S ACTION ACTION Obtain track circuit frequency Fc from Control Line Set both coupling units to nominal capacitor Drawings setting vs frequency from Table 6 8 Traverse restricted menu as described in Table 6 4 to Verify that coupling unit JMP9 JMP16 is set to SET UP NORM position Toggle ENTER for TUNE MENU 2 Toggle ENTER to automatically set direction of signal Using Fluke Scopemeter 97 in Vac mode 4 Receive West RxW Monitor voltage at TP2 and TP1 TP5 and TP6 Toggle ENTER for freq 0 0 Tune WEST coupling unit Toggle ADJUST to set frequency to Fc 400 Hz Vary capacitance with JMP1 JMP8 JMP10 Toggle ENTER for pwr xx JMP1 7 to peak voltage across Set pulsewidth to pwr 50 TP2 and TP1 5 and 6 6 14 SM 1F2 0001 Rev 2 2011 N 4 AnsaldoSTS Installation and Adjustment STEP AF 902 904 OPERATOR S TRACK COUPLING
54. T 180 ret Faston FL87 x 020 22 18 AWG J7313990018 All Tag Sleeve 1 8 x 75 White Rivet Pop 1 8 Dia 0 251 SS Grommet Strip Nylon 1 8 12 2 SM 1F2 0001 Rev 2 May 2011 N 74 AnsaldoSTS Parts List Used On 2 1 N12200202 Description Number 2 N12200204 3 12200210 Label Transfer 5 Roll 7209935 A0775010003 999 Ribbon Thermal Transfer 0775010007 12 3 Cardfile Motherboard Direction Relays The motherboard N12300101 and N12300201 in the AF 902 904 cardfiles support the direction relays listed 1n Table 12 4 Motherboard N12300101 in the AF 902 two track circuit cardfile has two different types of relays Motherboard N12300201 in the AF 904 four track circuit cardfile has four relays two 12 volt relays 77261530413 and two socket relays 75817820017 Figure 12 1 and Figure 12 2 show the location of these relays on the respective motherboard Figure 2 7 shows the location of the direction relays on the AF 902 motherboard Note that the relays appear as dashed boxes between the PCB connectors in the second row Note that four track circuit motherboard N12300702 has no relays Table 12 4 Motherboard Direction Relays Parts List 1 462 1323 420 89 RLYIN 7261530413 RLY1R RLY2N RLY2R 12 4 902 and AF 904 Cardfile PCBs The AF 902 and AF 904 cardfiles contain the PCBs listed Table 12 5 The figures associated with this table are Figure 1 3 and Figure 1 4
55. Terminal Identification 2 7 AFO 902 Motherboard VPO Jumpers and Terminating Resistors 2 8 AF 904 Motherboard VPO Jumper and Terminating Resistors Detail 2 9 AF 904 Track and AC Connections and Typical Wiring 2 12 Menu System Hierarchy aE 4 7 RS 485 Communications 5 2 Non Redundant Peer Communications 5 3 Fully Redundant Peer Network Communications 0000 5 4 Typical Microlok Il Master To AF 902 AF 904 Generation Il Units Powered By Same Battery Microlok Protocol Or Half Duplex Genisys Protocol 6 2 SEUN PFFRFRFRFRRT M E 6 5 TCS Daughterboard Switch SW1 6 7 AF 902 904 Upper Cardfile Rear nns 6 12 AF 902 Track Circuit Data nennen enne 6 22 AF 902 Cab Loop Data 6 23 AF 904 Track Circuit Data 6 24 AF 904 Cab Loop Data Sheet a 6 25 Direct Injection AF 902 904 Track Circuit 8 2 AGJ
56. The Application Data package can also specify that neither protocol 1s selected This option can be used when the AF 902 904 system is used solely for train detection 1 6 1 RS 485 MICROLOK Serial Protocol When using the MICROLOK Serial Protocol the MICROLOK II will periodically transmit data messages to the AF 902 904 The AF 902 904 responds to the MICROLOK Il and logically processes the data before repeatedly transmitting the data to track This section lists the data fields within these messages Details of the message formatting and data encoding for MICROLOK application programming is provided Appendix A 1 6 1 1 Serial Message Data Received from Track Microlok Signal Message 24 data bits 8 header bits 8 address bits 24 Cyclic Redundancy Check CRC validation bits Protocol US amp S Vital Serial Link protocol Data from Track MICROLOK to AF 902 904 system Funci n Description Bits Name 01 2 West Berthed Berthed 1 train not in platform 0 train in platform 1 2 Couple Uncouple Couple Uncouple 10 couple to train 00 no action 0 point R SM 1F2 0001 Rev 2 May 2011 1 13 N Introduction 77 AnsaldoSTS 1 6 1 2 Serial Message Data Transmitted to Track Microlok II Bits Name Function Description 1 no block speed set 1 Standby unit is available 1 0 track occupied 1 track unoccupied 1 direction is in correspondence Spare bits th
57. USIMEON at Aion Sis LU L od one u l u a onto sant tuo cd ORI 8 3 SM 1F2 0001 Rev 2 May 2011 77 AnsaldoSTS Table of Contents Figure 8 3 Adjustment at Low Ballast Auto Calibration 8 4 Figure 8 4 If Ballast Becomes High Auto Calibration 8 4 Figure 8 5 Meaning of the Variance Parameter 8 6 Figure 9 1 AF 902 AF 904 TCS Front 9 4 Figure 9 2 AF 902 904 Power Supply Front Panel a 9 6 Figure 12 1 902 Track Circuit Cardfile 12 5 Figure 12 2 904 Track Circuit 12 7 SM 1F2 0001 Rev 2 May 2011 vii Table of Contents Table 4 1 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table 6 5 Table 6 6 Table 6 7 Table 6 8 Table 6 9 Table 6 10 Table 6 11 Table 6 12 Table 6 13 Table 8 1 Table 9 1 Table 9 2 Table 11 1 Table 12 1 Table 12 2 Table 12 3 Table 12 4 Table 12 5 Table 12 6 Table A 1 Table A 2 Table A 3 viii lt 77 AnsaldoSTS List of Tables JO ED T dO Oi aun hm 4 3 Network Microlok Peer 6 6 Track Circum Ethernet 6 6 jo
58. a Track Circuit System TCS replaces the CPU and Auxiliary boards The Generation II system supports all of the previous communications and track signal features and adds several new Ethernet port features e Optional singular or redundant Ethernet interface to the MICROLOK controller using MICROLOK Peer Protocol This option also provides 5 bit speed code data in the messages e Enhanced user interface using an integral web server Using Microsoft s Internet Explorer the user can connect to the AF 902 904 s web server to access all of the data and calibration functions previously displayed only on the system s front panel e Remote Monitoring via SNMP Using this network standard remote monitoring protocol the user can view the status of many of the AF 902 904 s key operating parameters The AF 902 904 system will also issue SNMP trap messages when system errors are detected MICROLOK is a registered trademark of Ansaldo STS USA Inc SM 1F2 0001 Rev 2 May 2011 1 1 N Introduction 77 AnsaldoSTS 1 3 System Overview The AF 902 904 system is a wayside component of an Automatic Train Control ATC system providing both train detection and transmission of digital cab signaling data for the Automatic Train Protection ATP function Figure 1 1 shows the AF 902 904 related equipment that 1s contained in a typical wayside room using serial communications between the MICROLOK II and AF 902 904 system To perform its primary functi
59. and Adjustment Because of the large dynamic range imposed by the needs of different track circuits the AF 902 904 Control cardfile incorporates five adjustable transformer taps for TCS Transmitter circuits These allow for variables such as different track lead lengths Adjustments are made via jumpers on the cardfile backplane Output power 15 varied by two means Coarse Output Transformer Taps 1 through 5 on back of the AF 902 904 motherboard Taps act to double output amplitude with each increased setting Primary TXB Backup Fine Pulse width the ON duty cycle percentage of a Full Cycle The Receiver Tap will always be set to Tap 2 position The AF 902 904 web interface provides a guided calibration procedure the Setup Mode Calibration tab You will be directed to set the specified track circuit frequency and then set the transmitter power level both directions Transmitter power is roughly adjusted by using Tx taps on the rear of the cardfile The output power 1s double for each step of the Tx tap Fine adjustment is performed by adjusting the signals pulse width using the on screen power levels 25 to 95 The right side of the Calibration page provides a table listing the calibration values from the last accepted calibration 6 5 2 3 Setting the Receiver Level The AF 902 904 system will automatically adjust the receiver level during the completion of the calibration sequence The values of Variance Gain
60. at are not used 1 6 1 3 Message Data Transmitted to the Track Cab Signal Signal Message 37 data bits 8 header bits 16 Cyclic Redundancy Check CRC validation bits Protocol Synchronous bit oriented similar to Synchronous Data Link Control SDLC Encoding NRZI Name Funcin 12 Identification of which controller is providing the message 1 Bifurcation jBifurcaton 000000020024 Bits 1 6 2 Microlok Peer Protocol When using the MICROLOK Peer Protocol the MICROLOK II will periodically transmit data messages to the AF 902 904 AF 902 904 responds to the MICROLOK II and logically processes the data before repeatedly transmitting the data to track This section lists the data fields within these messages Details of the message formatting and data encoding for MICROLOK II application programming is provided in Appendix A 1 14 SM 1F2 0001 Rev 2 May 2011 N g AnsaldoSTS Introduction 1 6 2 1 Peer Message Data Received from Track Microlok ll Signal Message 26 data bits 8 header bits 8 address bits 24 Cyclic Redundancy Check CRC validation bits Protocol MICROLOK Peer Protocol message Data from Track MICROLOK II to AF 902 904 system Function Description Traffic Direction 10 East 01 West Next Frequency Next Frequency See Appendix A Target Distance to Go Target Distance to Go See Appendix A Line Speed Line Speed oee Ap
61. bed in the following subsections 6 6 4 1 350 or 500 Bond Setup Procedure To setup the AF 902 904 system using a 350 or 500 MCM Bond in either an S or or I configuration follow the procedure given Table 6 4 Table 6 5 Table 6 7 and Table 6 9 use the Data Sheet Figure 6 5 at the end of this section Setting the MLOK address and the track circuit ID Table 6 6 can be performed at any time in the sequence Tuning Table 6 7 must be performed before calibration 6 6 4 2 Cab Loop Setup Procedure Follow the procedure in Table 6 4 and Table 6 12 and use the data provided at the end of this section Setting the MLOK address and track circuit ID Table 6 6 can be performed at any time the sequence The AF 902 904 system performs track signal transmission only 6 6 4 3 Direct Injection Track Circuit For setting up the AF 902 904 system using a direct injection track circuit follow the procedure in Table 6 4 Table 6 6 and Table 6 13 and use the Data Sheet Figure 6 6 at the end of this section Tuning is not required for a direct injection circuit 6 12 SM 1F2 0001 Rev 2 2011 N 4 AnsaldoSTS Installation and Adjustment 6 7 AF 902 904 Track Circuit System Setup and Test NOTE Before entering the setup mode to make any tuning or calibration adjustments you must turn off the power to an AF 902 partner 5 and to both adjacent track circuit AF 902 904 systems Table 6 4 Ente
62. ber and possibly a local block speed restriction The EEPROM also stores configuration information for the unit such as the MICROLOK II slave address I P addresses carrier frequency track circuit threshold voltages and other non volatile information needed to operate the AF 902 904 system The AF 902 904 system compares the local and remote block speeds if set to the MICROLOK II message s Line Speed and Target Speed If the local or remote block speed 15 slower than the message Line or Target Speed then the slower speed will be transmitted to the track as the Line and or Target Speed If the local or remote block speed is greater than that commanded by MICROLOK or is not set the MICROLOK II message s speed commands will be transmitted to the track 3 2 2 Equipment Room to Rails From the relay equipment room track leads of up to several kilometers total loop length 3 kilometers of 10 gauge wire connect the trackside coupling units to the direction relays The track leads are twisted pairs with intrinsic impedance Zo of approximately 100 ohms The coupling units are housed in weather tight enclosures and consist of two totally independent and isolated coupling circuits Each circuit has its own transformer and capacitor bank The transformer steps down the high voltage on the leads from the relay room to a low voltage suitable for driving the single turn track loop The capacitors are jumper selected to tune the track loop Tuning
63. cape front panel control switch position has no effect from this menu 4 2 5 Block Speed Menu This menu is used to select the Block Speed Adjust submenu from which it is possible to set or modify a block speed This menu option can also be entered immediately from any unrestricted access menu by toggling the Aux 1 or Aux 2 switch SM 1F2 0001 Rev 2 May 2011 4 5 uw g User Interface 7 AnsaldoSTS The Block Speed Adjust submenu 15 used to set a block speed The Adj Up Adj Dn switch modifies the current value the value displayed on the lower display and the Enter switch 15 used to enter the value The operator must then confirm the value by toggling the Enter switch again or reject the value by toggling the Escape switch to exit 4 2 6 Display Menu This option contains submenus that are used to display current system information The following submenus are available from the Display menu MICROLOK Message Track Message and System Parameters The Escape switch will move out of any Display submenu 4 2 6 1 Microlok ll Message This menu contains submenus that are used to display the current message to MICROLOK II from the AF 902 904 system and the current message from MICROLOK II to the AF 902 904 system 4 2 6 2 Track Message This menu contains submenus that are used to display the following information Current message being delivered to the track by the AF 902 904 system Transmit menu e Level of the received
64. ce and mark frequencies Both coupling units must be tuned each when they are the receiving end of the circuit Tuning 15 typically only done during the initial installation of the track circuit Retuning 1s usually only needed if a bond is replaced or a high variance value is noted during the setting of the rail current Prior to tuning a track circuit place the TCS Tx jumper on the back of the AF 902 904 cardfile to the 3 position and the Rx jumper to the 2 position Enter the Setup Mode as describe in Section 6 5 1 4 and select the Tuning tab The Tuning page provides the user with three controls direction frequency and power level The frequency should be set to 400 Hz below the designed track circuit carrier frequency After changing the controls select the Try button to send the desired values to the AF 902 904 for transmission Specific steps and details of the tuning procedure are given in Table 6 7 6 5 2 2 Setting the Rail Current Setting the rail current assures that the train 1s able to receive a reliable track signal The nominal value of Ikan for each carrier frequency is listed in Table 6 10 and Table 6 11 The rail current is set by adjusting the transmitter s power while measuring the bond current at the receiver end of the track circuit Prior to making any adjustment verify that the Rx tap on the rear of the cardfile 1s In the Tap 2 position 6 8 SM 1F2 0001 Rev 2 2011 N 4 AnsaldoSTS Installation
65. ck loop that transmits or receives 1s determined by the direction relays on the rear of the cardfile 3 3 Train Detection Each AF 902 904 system vitally monitors the status of a single track circuit The audio frequency carrier that is transmitted at one end of the track circuit and received at the other 15 used not only for the digital cab signal data but also for train detection The carrier level and the digital message are monitored by the receiver to determine track occupancy When a train shunts the rails of the monitored track circuit the signal 1s blocked This condition is recognized by the receiving AF 902 904 circuits as a drop below a preset signal threshold and is reported to the associated interlocking MICROLOK II system as an occupied circuit The AF 902 904 displays the track signal as a percentage of the shunt threshold Signal levels at or below 100 indicate an occupied track circuit An unoccupied track circuit is nominally 162 of shunt This value will normally drift up and down as ballast conditions change Communications of track occupancy are sent to the vital MICROLOK II using the MICROLOK Peer message over the Ethernet link or a MICROLOK Serial Protocol message over a RS 485 link Occupancy is also indicated on the DC voltage vital parallel output This output can be connected to a MICROLOK 1I Vital Input for faster occupancy state indication While the shunting train bridges adjacent track circuits both are reported as
66. correct data as compared to the predetermined threshold level and track ID it indicates that the track circuit is shunted by an occupying vehicle As the vehicle travels from track circuit to track circuit the car borne ATC system tunes a filter on the vehicle receiver to the correct next frequency allowing the vehicle to receive the data for the correct track frequency only The vehicle s ATP subsystem decodes the vital track data to perform the ATP functions SM 1F2 0001 Rev 2 May 2011 2 1 Typical Applications AnsaldoSTS 2 1 Mainline Track Circuits The AF 902 904 system is designed for simple highly reliable track interface applications using Jointless track circuits The carrier signals and modulated data signals are coupled to the rails via the 350 or 500 MCM bond and coupling unit at each end of the track circuit The amplitude of the carrier and the track ID data signals 1s used to determine track occupancy The modulated FSK data signal 1s used to transmit vital and non vital data to the vehicle 2 1 1 Track Circuit ID and Cab Signal Transmission As the train travels from track circuit to track circuit within the mainline territory station to station track occupancy and isolation of commands between track circuits is accomplished by alternating eight available data carrier frequencies Frequencies range from 9 5 to 16 5 kHz in 1 kHz steps and are numbered FO through F7 Three frequencies and F5
67. ction are used to record the results of the tests The top portion of the Data Sheet should be filled in before beginning the test As part of this the test engineer should record the track circuit length and the approximate cable length from the AF 902 904 to the nearest coupling unit Refer to the following test data sheets e Figure 6 5 AF 902 Track Circuit Data Sheet Figure 6 6 AF 902 Cab Loop Data Sheet e Figure 6 7 904 Track Circuit Data Sheet e Figure 6 8 AF 904 Cab Loop Data Sheet SM 1F2 0001 Rev 2 May 2011 6 21 5 Installation and Adjustment AnsaldoSTS AF 902 TRACK CIRCUIT DATA SHEET Location Track Circuit Length 65 1000 ft 20 305 m Feet Meters Cable Length to Nearest Bond 6000 ft max 1800 meters max Feet Meters Track Circuit ID 1 4095 MLOK Address 1 127 Peer Address 1 65535 Tuning Procedure Frequency kHz 9 5 10 5 11 5 12 5 13 5 14 5 15 5 16 5 Direction West to East East to West Coupling Unit Capacitance uF uF Calibration Procedure Transmitter Tap 1 3 4 5 Setting A pwr Pulse Width 25 95 2 ema ma ma Receiver Tap Setting Receiver Level Levl Vari Shunt Level Shnt Unshunted 151 171 151 171 151 171 151 171 _ G G 90 Shnt Shunted 100 100 100 100 Inspector Date Figure 6 5 AF 902 Track Circuit Data Sheet 6 22 SM 1F2 0001 Rev 2
68. d as a communications interface between the interlocking logic processed by MICROLOK II units and the equipment on the vehicle used for controlling the movement and speed of a train The AF 902 904 equipment takes serial input from adds local track identification information and transmits this combined data to the train through the rails The interface to MICROLOK II is a bi directional serial link or Ethernet link The communications interface to the train 1s a one way link where the car only receives information The AF 902 904 equipment transmits into one end of the track circuit information such as track circuit ID target speed line speed distance to go berthed direction next cab carrier frequency coupling uncoupling and bifurcation It also monitors the other end of the track circuit to detect train occupancy Vital wayside logic is typically performed by the MICROLOK II system typical wayside system is illustrated in Figure 1 1 AF 902 904 circuits are used for both train detection and cab signaling Crossovers and turnouts use the power frequency track circuits for train detection and AF 902 904 cab loops for data communications to the carborne ATC system PF track circuits are described in ASTS USA Service Manual 6087 The AF 902 904 signals are coupled into the track via S bonds O bonds I bonds or direct injection as described in Section 1 5 4 1 When the AF 902 904 receiver senses a low amplitude or in
69. d on then most likely the Standby unit is constantly resetting itself The AF 902 904 on line failure alarm turns on only after an AF 902 904 off line failure indicating that both AF 902 904 units have failed This causes an occupancy display and stops train movement The AF 902 904 FSK track circuit system notifies the maintainer of most faults through its front panel indicators Before performing any troubleshooting tests or diagnostics the maintainer should first make the following observations Are the power supply LEDs ON e Arethe TCS and power supply LEDs NORMAL e 5 a backplane connector loose or disconnected e Is there any physical damage anywhere near the track circuit equipment If no obvious faults are observed the maintainer should proceed with the standard troubleshooting techniques 9 2 SM 1F2 0001 Rev 2 May 2011 E 4 AnsaldoSTS Troubleshooting Table 9 2 Troubleshooting SYMPTOM PROBABLE CAUSE SUGGESTED REMEDY Track is unoccupied but low or no Check track bond and cabling receive signal 9 Bad coupling unit Check input and output cable lues to unit Defective Defective TCS Remove and Removeandrepace Conductive debris across track Inspect and remove debris Intermittent track occupancy Signal threshold level setting on TCS Adjust or replace indications not correct Receiver levels are low Track carrier frequencies are out of Check tuning procedure specifica
70. dby Port 2 255 255 255 192 255 fess 255 192 LP Port ses 172 25 2 65 72 Ps P 5 Controller I P Addresses ETHERNET2 Part 2 MAC Normal Address 22 72252111 72 s p fin LP Port 60000 60000 Standb MICROLOK Track I D 21 21 D 4D95 4 LAB RACK2 roe Track Circuit eer LAB RACK LEFT PRIMARY Name PRIMARY Commit 0 25 f7 10 5 6c am N Figure 6 2 Setup Page SM 1F2 0001 Rev 2 May 2011 6 5 A Installation and Adjustment AnsaldoSTS The Network MICROLOK Peer Protocol table is replaced with a smaller table when the RS 485 MICROLOK Serial protocol is used This table only requires you to enter the AF902 904 s slave address Table 6 1 Network Microlok Peer Protocol Network MICROLOK II AF 90x PEER Address The AF 902 904 s Peer Protocol Address The MICROLOK s Peer Protocol Address Controller Addresses Ethernet1 The IP address of the MicROLOK II that is connected to the AF 902 904 s ETHERNET 1 port This is the MICROLOK II s internal port address it should be set to 60000 unless the MICROLOK II s application program has defined a different port number The IP address of a second standby MicROLOK II connected to the AF 902 904 s port If used This is the MICROLOK II s internal port address it should be set to 60000 unless I P Port the MICROLOK II s application program has defined a different port number If Controller Add
71. e etc Once the track circuit is adjusted with high ballast resistance the received signal strength can change as the ballast changes The value of the received signal strength is displayed on the web page and front panel of the AF 902 904 If the track circuit 1s recalibrated the threshold of the receiver will be changed For example if the ballast value 1s low and the received signal level 1s 60 performing recalibration will adjust the threshold of the receiver to a new value Figure 8 3 shows the new threshold of the receiver The new value is now 38 mA which represents 162 overdrive value 8 2 1 2 Calibration During Low Ballast Conditions If after a calibration the ballast would change back to a very high value the overdrive may be much more now than the 162 See Figure 8 4 As can be reasoned the 38 mA threshold now represents an overdrive of 26396 2 63 2 100 mA 38 mA Because of the safety implications the value of overdrive 1s continuously monitored by SM 1F2 0001 Rev 2 May 2011 8 3 A Preventive Maintenance 7 AnsaldoSTS the AF 902 904 track circuit If this value exceeds approximately 180 the track circuit 1s turned off for a period of time and Error is recorded The calibration function when performed with low ballast does not present a safety issue only a reliability issue in operation The calibration should only be performed when the ballast 15 nominal or high The overdrive of the A
72. e main display It AF 902 904 20 perform steps 16 19 displayed signal contains two small vertical red lines using the Vertical a red triangle and two blue brackets Scale knob This display is used to rough adjust the Main Displ c w 4 AnsaldoSTS Tektronix Setup Procedure Step rv Control Observe 21 Horizontal Position Adjust until red triangle is over left Red vertical cursor is near center of Knob most red vertical line main display Adjust until blue brackets just Horizontal Scale enclose the red triangle Scale on main display will expand Re adjust until red cursor line is Horizontal Position centered orbe D play Center frequency signal is centered Adjust until baseline of waveform is batomoj Vertical Position approximately one unit from the aje bottom of the Main Display Verica Scae um until center frequency signal is Center frequency amplitude 25 Vertical Vertical Scale approximately 4 to 6 units high changes Turn until center frequency peak is Peak of waveform is easy to 26 Horizontal Scale approximately 1 display scale unit 1 recognize cm wide at the base The amplitude of the peak signal can now be read in the display It is the value shown after the symbol Adjust until cursor line is at the Scaling center of the waveform A small 2 mV xy z milliamps d horizontal line on the cursor will be at or
73. e represented by impedance Bal is the ballast resistance of the track circuit SM 1F2 0001 Rev 2 May 2011 8 1 A Preventive Maintenance 7 AnsaldoSTS AF 902 Rail Impedance AF 902 Transmitter Receiver Figure 8 1 Direct Injection AF 902 904 Track Circuit The AF 902 904 receiver its coupling unit are represented as impedance and the AF 902 904 transmitter and its coupling unit are represented as and source voltage S The value of the ballast resistance changes with time and the conditions of the ballast material that supports the rails The lower the value of ballast resistance the lower the signal magnitude received at the input of the AF 902 904 receiver The signal strength received at the input of the receiver 1s displayed on the web page and front panel of the AF 902 904 The signal strength is displayed as a percentage of a shunt condition A value of 10046 represents the highest received signal level highest rail to rail impedance that will be detected as a shunt condition Thus values of signal strength should be much greater than 100 when the track circuit is not occupied Typical values of between 151 171 are normal If the ballast becomes low the percent displayed will be less than the normal value 8 2 1 1 Calibration During High Ballast Conditions The AF 902 904 track circuit 1s initially adjusted with high ballast resistance The inherent design of the AF 902 904 track ci
74. e system up and running This calls for prompt action fault isolation and trouble repair To achieve this the Maintainer may not be required to troubleshoot beyond the modular component level commonly referred to as the LRU level The entire troubleshooting process can be expedited by performing Go No Go replacement checks and repair The key to identifying the probable cause of failures 1s the use of a process of elimination This is the most effective and efficient approach to troubleshooting and fault isolation on any system SM 1F2 0001 Rev 2 May 2011 9 1 uw 7 Troubleshooting AnsaldoSTS 9 3 Troubleshooting Procedures 9 3 1 Fault Symptoms Every abnormal symptom 15 a result of a cause that has a remedy The maintainer must determine how severe the cause how much damage resulted and how difficult the repair process quick replacement versus system down time Table 9 2 gives a brief listing of symptoms probable causes and suggested remedies These remedies are to the LRU level to assist in swift repair The ATC system notifies the train dispatcher and general system maintainer of problems by an AF 902 904 off line or on line alarm AF 902 904 off line alarm is an indication that either the Primary or the Standby unit has failed reset If the Primary unit fails then a fail over occurs to the Standby unit This event most likely causes a sequential occupancy If the AF 902 904 off line alarm is toggling off an
75. ed from a remote location Be aware that most web browsers like Internet Explorer will cache web pages This can possibly lead to the display of old data When interfacing to the AF 902 904 caching should be disabled This is typically done in Internet Explorer by selecting Tools General Temporary Internet files Settings under Check for new version of stored pages select Every visit to the page 6 5 1 Configuration This manual will use the term configuration to refer to the setting of all system operational parameters except those associated with the frequency and power level of the track signal Configuration is typically performed only once when the AF 902 904 system is initially installed Since the parameter values are stored in the cardfile EEPROM the set parameter values will be still be in effect 1f the TCS is replaced 6 5 1 1 Setting the AF 902 904 to the Default IP Address When configuring a new system or if the IP addresses of a system have been lost the default IP addresses for the front panel Ethernet ports can be set by placing the 1 switch of switch bank SW to the ON position and resetting the AF 902 904 system SW1 is located near the front of the CPU daughter board on the TCS The TCS power must be turned off before removing the TCS from the cardfile to set the default IP address switch SW1 The final switch position for normal operation will be SW1 switches 1 and 32 OFF SW2 switch 2 OFF and all o
76. eer Network Communications 5 4 SM 1F2 0001 Rev 2 May 2011 N 4 AnsaldoSTS Installation and Adjustment 6 INSTALLATION AND ADJUSTMENT 6 1 Introduction circuit installation and adjustment depend on the assigned track circuit frequency and track coupling methods Installation procedures should be in accordance with those recommended by the equipment manufacturers for any equipment that interfaces to the AF 902 904 unit Refer to the specific site plans for detailed installation and track coupling requirements such as track circuit lengths frequency assignments track circuit identifications and wiring sheets 6 2 Recommended Test Equipment The following equipment is recommended for testing the AF 902 904 unit e Spectrum Analyzer Tektronix TDS 3012B or C Oscilloscope or Hewlett Packard HP3560A Dynamic Signal Analyzer Refer to Section 11 for Tektronix TDS 3012B setup instructions e Current Probe Tektronix A621 AC Current Probe or Fluke 801 1000s Current Transformer e AAR Style 1 2 in hex socket wrench used for loosening and tightening AAR standard terminal posts e Red tags for identifying failed system components e Two VOLTREX 855 B Insulated Tip Plugs for Front Panel test probes e Hand held radios with 2 mile 3 2 km range minimum e Track Shunt 0 25 ohms total resistance The track shunt resistor itself 1s 0 20 ohms and the leads to the rails are 0 05 ohms 6 3 Serial Link Termination
77. el with the AC voltmeter Then adjust the tuning frequency to Fc 200 Hz Mark and re measure the received signal level Be sure that the transmission 1s in the correct direction You must always tune at the receiver end If the Mark frequency 15 higher than the Space reduce the capacitance in the coupling unit by one step Repeat measuring and adjusting one capacitance step at a time until the Mark and Space are near the same value Remember that stepping the capacitance step may involve selecting and deselecting capacitors Also note that at the higher frequencies a small change in capacitance will have larger effect than at the lower frequencies If you change the capacitance and the Fc 200 Space frequency becomes greater than the Fc 200 Hz Mark frequency you are at or have passed the optimum capacitance Table 6 8 Coupling Unit Nominal Capacitance Setting NOTE FINAL TUNED SETTINGS WILL BE NOMINAL 2 2 0 uF MICRO FARADS FREQ FC 9 5kHZ 105 115 125 135 145 155 465 NOM CAP 20 0 uF 17 33 uF 15 00 uF 13 00 uF 11 00 uF 9 47 uF 8 47 uF 7 33 uF 6 7 3 AF 902 904 350 or 500 MCM Rail Current Calibration Table 6 9 contains the sequence of actions that must be performed to set the correct rail current for an AF 902 904 track circuit The rail current 1s set by adjusting the transmitter s output power The table lists the Operator s Action for setting the rail current using the front pane
78. fications Output power can be varied by two means Coarse As Figure 6 4 shows the Output Transformer Taps 1 through 5 on back of the AF 904 904 motherboard are selected by means of jumper wires connected between the numbered taps and Signal Common points labeled COM for AF 902 and RI through R4 and through T4 for AF 902 Taps act to double the output amplitude with each increased setting TXA Primary TXB Backup Fine Pulse width the ON duty cycle percentage of Full Cycle 5 increments from 25 to 99 This 1s set from the front panel PWR submenu option It is done during the calibration procedure and can be done only after the operator has traversed the Configuration menu with the correct password There is a separate pulse width setting for each direction of track circuit transmission After these are SET ACCEPTED they are stored in EEPROM SM 1F2 0001 Rev 2 May 2011 6 11 5 Installation and Adjustment AnsaldoSTS VPO VPO TERMINATING TERMINATING RESISTORS RESISTORS 5 m5 5 15 5 5 47 m4 47 m4 4 4 3 mia ma 3 4 3 2 4 m2 2 4 m2 2 2 VPO JUMPERS ko aj mi 1 i i TRACK4 TRACK3 TRACK2 TRACK 1 TRK3 amp 4 AF 904 Upper Cardfile Rear View VPO VPO TERMINATING TERMINATING RESISTOR RESISTOR VPO JUMPER AF 902 Upper Cardfile Rear View Figure 6 4 AF 902 904 Upper Cardfile Rear Views 6 6 4 Setup Overview There are several parts to the setup procedure as descri
79. formation Link Team RAIL Team is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product Contact the RAIL Team in the United States at 1 800 652 7276 or by e mail at railteam ansaldo sts us SM 8051 Rev 6 0 March 2008 13 1 5 ae RAIL Team and Technical Support AnsaldoS TS AV 77 AnsaldoSTS 13 2 SM 1F2 0001 Rev 2 May 2011 AnsaldoSTS Charts and Tables APPENDIX A CHARTS and TABLES Table 1 Next Frequency Chart FREQUENCY BINARY VALUE kHz 95 0 0 lo 105 0 O f 115 0 1 lo 125 0 1 1 185 1 O 0 x 145 JL LE 15 1 t oO Table A 2 Speed Chart representative speeds kph Value O SM 8051 Rev 6 0 March 2008 A 1 77 AnsaldoSTS Charts and Tables BINARY DISTANCE METERS 186 BINARY Distance Chart olo Os KT DI MIMI PITIO UI O T ol O Q O Oo oO GN OO LO CO O representative distance Table A 3 DISTANCE METERS SM 1F2 0001 Rev 2 May 2011 A Charts and Tables 77 AnsaldoSTS BINARY DISTANCE METERS BINARY ijlojlol j o cvxilolvojwailol sziojovolw iolwve zjiolo xivolol lvoj ojv wjo zrz lo o o volcw olololojlo l qmjeolol szi uoj uv idoj dvo rT mr r o o o
80. he partner AF 902 5 before entering the setup mode Erroneous entry of restricted access parameters may cause the system to behave in an unsafe manner It is therefore necessary that these parameters be configured only by qualified personnel Restricted access parameters can be modified only after a password is entered Modified parameters can be made operational only after all changes are confirmed When an operator enters the configuration submenu the On Line TCS will suspend normal operations and declare the track to be occupied The TCS suspends track transmission and MICROLOK II response and all outputs are put into safe state Normal operation resumes only after the system exits setup When a restricted access parameter is changed it must be changed to the same value in both the Primary and Backup units in an AF 902 system The only exception is the Block Speed setting This value is communicated from the On Line to the Backup unit If the Primary and Backup have different values at startup the most restrictive lowest speed will be used by both units Since the AF 904 does not have a Backup unit this function does not apply 4 2 4 Main Menu This menu is used to select a top level submenu function The following top level submenus are available from the Main menu Block Speed Display Events and Configuration These submenu functions are described in the following sections Since the Main menu is at the top of the hierarchy the Es
81. ical Applications 77 AnsaldoSTS A eut JU UL c 6 WOO CXIUN lt OXUW 0089 16 IENUEN 89198 XOLIN O siolsisej Buneutuue e qeo JO pue JOJON eu eui Jo ujBue eu uo Burpuedeg SLAIN uoneoidde c06 JV 1uepunpeJ JOJ UMOUS BUA SLYIN IZZ Juvds 0900 Z UOJ qpue s S Il Occ Jo weal SJ0JOSUUOJ ES 61 512218151510 l akl br 5 ef AL M CM A JUVdS 912 WOO 85 1 Zd LIN i L M M OXLS GIZ uas 4 15 gt 48 Loo M Zd LN I I x 1 2 5 i Vic 1 k Cd 1 qoos gt 4 4 in D DOM M i oos O fl Fu w axus 15 M din i ll w l M sus sp PUN ZU E o I l d 1N LLLA l UOJ 1 ELLO bP 9 EF komono Jojoeuuo 206 Il MO IOSMOIIN 2 11 Figure 2 10 AF 902 Typical Serial Link Connections SM 1F2 0001 Rev 2 May 2011 77 AnsaldoSTS A Typical Applications CN gt gv SIVPJED I a5 SIOJOSBUUOT MDBJI E e D OOO GJ
82. ions are also displayed 4 1 3 View Events Page The View Events page provides a display of the log of AF 902 904 system events warnings and critical errors This data aids in diagnosing a malfunctioning system The user 15 given the option of setting a logging threshold for events More detailed events are logged at the higher thresholds e Logging Threshold 2 TCS will only log critical system errors and warnings e Logging Threshold 5 Critical system errors warnings and informational events will be logged e Logging Threshold 8 Additional operational information details will be logged such as changes in message data SM 1F2 0001 Rev 2 May 2011 4 1 uw g User Interface 7 AnsaldoSTS e Logging Threshold 15 This level 1s designed to be used in detailed troubleshooting of difficult problems with the guidance of Ansaldo Technical Support It displays many cryptic messages of system diagnostic tests Logging Threshold 2 or 5 should be used for normal operation Setting the threshold too high can make 1t difficult to identify system faults among the lesser important informational events The time associated with each event 1s the time from the last reset 4 1 4 Front Panel View Page The Front Panel View page shows all of the data present on the front panel discrete LEDs and the meaning of the LED states 4 1 5 Setup The Setup page provides password protected entry to the pages used to configure and calibrate an
83. it controller fails the Standby track circuit automatically switches into operation 3 5 Microlok ll Communications Link Monitoring The AF 902 904 system continuously monitors the status of the communications with the MICROLOK II The following is a set of possible fault conditions that could be detected by an AF 902 904 system The faults pertain to master messages and peer messages sent by the MICROLOK II to the AF 902 904 system Timeouts If an AF 902 904 system does not receive a valid message from the MICROLOK II in 3 seconds it will declare the link to be down CRC Mismatch If a CRC does not match for a message received from MICROLOK II the AF 902 904 system will discard the invalid message Incorrect Length If a response message from the MICROLOK II is either too long or too short because of any data bytes or CRC mismatch the incomplete message will be discarded No Acknowledgment If peer message acknowledgments are not received by the AF 902 904 system from MICROLOK the AF 902 904 system will declare the link to be down SM 1F2 0001 Rev 2 May 2011 3 3 uw 7 Functional Description 4 AnsaldoSTS 77 AnsaldoSTS 3 4 SM 1F2 0001 Rev 2 May 2011 E E 7 AnsaldoSTS User Interface 4 USER INTERFACE 4 1 Integrated Web Server The TCS front panel of the AF 902 904 system contains two Ethernet ports Each of these ports provide three communications features MICROLOK Peer Protocol communications be
84. l interface The Setup Mode s Calibration page provides both a guide and the controls required to perform all of these steps see Section 6 5 2 2 Table 6 9 902 904 350 or 500 Calibration Procedure 902 904 OPERATOR S TRACK COUPLING UNIT TECHNICIAN S ACTION ACTION Prior to starting a calibration verify that the Partner unit in an AF 902 system is turned OFF Set Receiver tap to the 2 postion 1 2 Obtain track circuit frequency Fc from Control Line Drawings 6 16 SM 1F2 0001 Rev 2 May 2011 N 4 AnsaldoSTS Installation and Adjustment Traverse restricted menu as described in Table SET UP Toggle ENTER for TUNE MENU Toggle MODE to CALI BRAT Toggle ENTER for freg xx x ADJUST frequency to Fc Toggle ENTEH to automatically set direction of signal Receive West RxW Toggle ENTER for pwr xx9e Unit is now transmitting Set l 4 for E to W using a combination of Using a Spectrum Analyzer with a Current Probe attach selecting a transmitter tap and ADJUST pwr Probe to Center of 350 or 500 MCM Bond and monitor report rail current Irail at West track bond For l a setting refer to Table 6 10 or Table 6 11 Record laj transmitter tap and pwr for E gt W on NOTE At cross bonding points the S bond is doubled Track Circuit Data Sheet Figure 6 5 The resulting lran is the sum 7 Toggle ENTEH to automatically set direction of Move to East track bond signal Receive East
85. ling Units should be protected in a Line to Ground configuration at the Main Terminal Board The recommended Line to Ground Protection Device is the ASTS USA Part Number J7927360180 This device 15 a Gas Tube Arrester Assembly It is designed to mount on standard AAR Terminal posts that are spaced 2 3 8 inches center to center SM 1F2 0001 Rev 2 May 2011 7 1 A Installation and Adjustment AnsaldoSTS 7 1 5 Communication Ports Any communication lines leaving the Signal House should have Line to Ground Protection using the ASTS USA Part Number 77927360180 7 1 6 Microlok Il Lightning Protection Considerations Since the Ansaldo MICROLOK II Controller interfaces to the AF 902 904 it 1s important to consider protection for the controller In particular protection should be provided for the House Battery Feed to the MICROLOK II Controller This will include both Line to Line L L and Line to Ground L G protection methods The recommended L L protection device for the 12VDC Power to the MICROLOK is ASTS USA Part Number J7257090519 This protector mounts onto standard AAR Terminal Posts on 1 inch centers The recommended L G protection devices are Gas Tube Arrester assemblies ASTS USA Part Number J7927360180 Be sure to have this protection as close to the MICROLOK II Cardfile as possible NOTE To optimize the protection the lines or line pairs must terminate at the protection devices and from there continue on t
86. ll be setting up the AF 902 904 s Ethernet port s addresses and the addresses of the connection MICROLOK II s if Peer Protocol communications is in use Figure 6 2 Table 6 1 Table 6 2 and Table 6 3 are examples of the Setup page and data that is to be entered 6 4 SM 1F2 0001 Rev 2 May 2011 A Z AnsaldoSTS Installation and Adjustment After all parameters have been set you must click on the Commit button to transfer the data to the AF 902 904 You must exit the Setup Mode using the Exit tab before the values will be retained by the AF 902 904 in its cardfile EEPROM Digital FSK Track Circuit Setup Microsoft Internet Explorer provided by Ansaldo STS USA File Edit Favorites Tools x ix 5h A J Search 52 Favorites E 62 wl Address lel http 172 25 1 112 setup html Links gt Setup Configure Calibrate Tune SNAKP Config Upload New Password X Exit Network MICROLOK Peer Protocol Track Circuit Ethernet Ports AF 90x PEER 1to Port 1 I P 2 ps NEN Mme Address 3 65535 Address 172 295 1112 1 2 105 l 1112 Microlok PEER 1to Port 1 AES 1 65535 Die E 255 255 255 192 255 255 255 i 92 Port 1 172 25 1 65 172 25 fi 65 Controller I P Addresses ETHERNET1 Gateway Normal Port 1 MAC E E MICHOLDE 172 25 1 111 172 e f finn Address 0 25 f7 10 5 6b LP Port 60000 60000 pride 172252112 e 112 Stan
87. nactive characters are displayed constantly Initially AAAA is displayed and the leftmost character is active The Adj Up Adj Dn switches are used to advance the active character through the elements of the password character set The Enter switch selects the current value of the active character and activates the next character The Password 15 stored in the EEPROM for each TCS If the TCS requires replacement the password 15 retained for the cardfile slot position The initial AF 902 904 password is four underscore characters _ _ The password can be changed through the front panel or using the Ethernet web server interface 4 2 8 2 Restricted Menu Option This submenu option 15 used to select a restricted access submenu If the proper password has not been entered using the Password Entry menu the submenus of the Restricted menu are not available If there 1s a Backup unit in an AF 902 system 1t must be turned off prior to entering the Restricted menu The following sections describe the submenus available from the Restricted menu Exiting from the Restricted menu will cause the unit to reset After entering the Restricted menu two menu selections are available Setup and Accept 4 2 8 3 Setup Menu Selecting this menu by toggling the Enter switch will make five submenu selections available to the Maintainer Tune MICROLOK ID Utility and Calibration 4 2 8 3 1 Tune Menu The Tune submenu is used to configure the AF 902
88. nd safe operation of the AF 902 904 Track Circuits 8 3 1 Initial Preventive Maintenance Tasks Table 8 lists the key preventive maintenance actions to be taken during the early phases of operation of the AF 902 904 Track Circuit units or until a regular and stable maintenance regimen is established for all subsystems of the transit system that affect the operation of the track circuits The time intervals recommended in Table 8 1 can then be made longer 8 6 SM 1F2 0001 Rev 2 2011 c uw E 7 AnsaldoSTS Preventive Maintenance Table 8 1 Key Preventive Maintenance Actions Review the received signal Once every two weeks Logs should be kept If low values of level received levels are consistently viewed the NOTE If levels are consistently cause of these low levels must be analyzed less than 160 the Variance and the problem solved measurement should not be performed until the receiver levels are stable Collect and analyze the event Once every two weeks Clear memory after reviewing the event codes for all track circuits codes Switch over to the standby Once every four weeks This ensures that the reserve unit will come units on line Once the reserve unit is on line the normal unit can be switched to be on line This test is to ensure the system s availability remains high Check variance values Once every four weeks Values should range between 0 and 5 If the values are greater than stated the NOTE The sh
89. new TCS is used to replace the CPU and Auxiliary boards of an older system Connectors for the track circuit connection serial communications to a MICROLOK II calibration Jumpers and AC power on located on the rear of the cardfile 1 4 SM 1F2 0001 Rev 2 May 2011 N 74 AnsaldoSTS Introduction 904 0176 00 1D2 1 5 2 RIGHT POWER SUPPLY RIGHT POWER SUPPLY P POWER SUPPLY LEFT POWER SUPPLY 2 I ETHERNET2 ETHERNET2 POWER SUPPLY N12360501 POWER SUPPLY N12360501 ETHERNET1 NS ELIS TOS 5 Figure 1 2 AF 902 904 Cardfile Configuration Track Circuit System TCS Figure 1 3 shows the front panel of the Track Circuit System The location of these Track Circuit Systems in the cardfile 15 shown in Figure 1 2 The TCS front panel contains the following Two alphanumeric displays These are used to monitor the data used in setup and operation of the track circuit The upper display is red and the lower display is green Four spring loaded Up Down toggle switches These switches are used for inputting data required for setup conditions A system Reset switch 18 LEDs These supply system information as described in Section 4 2 1 Two Ethernet ports that support Communications with MICROLOK II s using
90. nications between the AF 902 904 and the MICROLOK II can be configured in many ways If the Serial Protocol is used the front panel Ethernet ports can be wired to a network to facilitate system setup and monitoring This section provides several examples for system communications wiring NOTE network equipment switches must be rated for IOOBaseT operation SM 1F2 0001 Rev 2 May 2011 5 1 N Serial and Network Communications AnsaldoSTS MICROLOK II UNN Rx Tx RTS CTS 1 O COM2 To AF 90x Cardfiles o Ij Rx Tx RTS CTS To COM3 To AF 90x Cardfiles additional Rx Tx RTS CTS AF 90x COM4 To AF 90x Cardfiles Cardfiles POWER SUPPLY POWER SUPPLY Remote PC configured to monitor SNMP messages Router Can also be a DHCP server to give IP addresses to local PCs Local PC for web tool access Can get network address from Local PC for web tool DHCP if present or will need to access Will will need to be manually configured for be manually configured for network Address of AF90x direct connection to hardware can be obtained with a AF90x Address of AF90x discovery tool or manual input hardware can be obtained Can access all HW on network with a discovery tool or manual input 1D2 0177 00 Figure 5 1 RS 485 Communications 5 2 SM 1F2 0001 Rev 2 May 2011 5 77 AnsaldoSTS MICROLOK Il 1D2 0178 00 SM 1F2 0001 Rev 2 May 2011 5 COM
91. ning the variance is several percent Ideally the variance should be zero However values up to 19 are acceptable 8 2 2 2 Direct Inject Track Circuits Because the direct injection coupling unit is not tuned the variance measured with these track circuits is very low Typical values are between 0 and 5 depending on the cable length between the room and field located coupling unit With no in band interference the variance value is a constant magnitude However if in band noise is present the variance displayed by the AF 902 904 will vary between values because the noise adds and subtracts to the Mark and Space signal amplitudes SM 1F2 0001 Rev 2 May 2011 8 5 A Preventive Maintenance 7 AnsaldoSTS Variance 096 epnudury Mark F Space F Frequency Variance 096 Mark F Space F Frequency Figure 8 5 Meaning of the Variance Parameter 8 2 3 Event Code Monitoring The web page interface provides a display of errors warnings and operational events detected by the TCS The Event threshold level can be adjusted to log only errors 11 set to errors and warnings if set to 2 and errors warnings and events if set to 5 Higher levels will show excessive number of events and are only useful for advanced troubleshooting 8 3 Preventive Maintenance Tasks Preventive maintenance tasks are to be performed on a scheduled basis as described in this subsection to ensure reliable a
92. nsmission 55 2 5 2 4 System Connection 2 6 Je FUNCTIONAL DESCRIPTION UU 3 1 Orta MOU OM 3 1 3 2 Wayside to Train Message 0 3 1 3 2 1 Message Data 3 1 3 2 2 Equipment Room to Rails RON Revo Eau 3 1 So Tane CION T 3 2 MELOS 3 3 3 5 Microlok ll Communications Link 3 9 ME dhgpdlig2ie ee 4 1 4 1 Integrated Web Sel VOL 4 1 4 1 1 View Current Data 4 1 4 1 2 View Configuration nennen nnne nennen nnns nnn nnns 4 1 4 1 3 View Events 4 1 4 1 4 Front Panel View Pade sas uson irado e kokos Ei kapa KKK KI kren KEA Eva ka ne VESAK ARS 4 2 EZ E p 4 2 4 2 TCS Front Panel Operation sseooeeneennnnneeeennnnnnnnnnnneeeennnnnnnnnneseeeernnnnnnnssssssettss 4 2 FO Panel VS uu uuu anos uu u das nrmo uuu 4 2 SM 1F2 0001 Rev 2 May 2011 iii lt w Table of Contents 7 AnsaldoSTS j o CONU OO SETE E gE
93. o a nominal 162 Record Shnt 151 171 for E gt W when unshunted NOTE When SHUNT applied check that Shnt lt 100 RECORD Shnt xx9o when shunted If calibration is denied by the AF 902 904 the display will show Denied If calibration is accepted the display returns to Set Up To exit press ESC and then press Enter when Sure is displayed Or press ESC to device calibration and return to Set Up If all parameters are CONFIRMED unit will write setup parameters to EEPROM and DONE Press RESET button for system reset After reset system front panel LEDs should show by being lit ON LINE SELF U LOK COMM LEVEL DATA Table 6 10 Rail Current Settings 350 MCM and 500 MCM Circuits NOMINAL ee 2 MILLIAMP FREQ FC kHz 9 5kHz 105 135 145 155 16 5 NOMINAL lna mA Table 6 11 Rail Current Settings Direct Injection Circuits NOMINAL HUN Tv 2 KUR FREQ FC kHz 9 5kHz 105 NOMINAL lna mA 6 18 SM 1F2 0001 Rev 2 May 2011 N 4 AnsaldoSTS Installation and Adjustment For the AF 902 power down the Primary unit and repeat the calibration procedure for the Backup unit NOTE Backup unit must have same MLOK address TRK ID Fc password and executive software version as the Primary unit 6 7 4 AF 902 904 Cab Loop Current Calibration Table 6 12 contains the sequence of actions that must be performed to set the correct rail cur
94. o the equipment protection device must not be connected via branch Tee wiring 7 2 SM 1F2 0001 Rev 2 2011 uw E 7 AnsaldoSTS Preventive Maintenance 8 PREVENTIVE MAINTENANCE 8 1 Introduction This section describes the maintenance tasks required for the AF 902 904 track circuit unit coupler and AF 902 904 350 or 500 MCM bond These preventive maintenance tasks are to be performed on as scheduled basis whereby the components are inspected cleaned tested and adjusted at periodic intervals to ensure the proper operation of the AF 902 904 unit 8 2 Importance of Preventive Maintenance Regular Preventive Maintenance Inspection PMI can prevent failures and system malfunctions Maintenance personnel are responsible to keep the AF 902 904 unit in safe and satisfactory operating condition at all times This is accomplished through regular inspections cleaning testing and required adjustments of the unit By maintaining up to date repair and PMI records and reviewing the history of these activities maintenance schedules can be set to prevent circuit performance deterioration PMI can lead to the discovery of questionable conditions before major malfunctions can occur potentially causing train traffic problems and eventually total train stoppage Track circuit bobbles can be minimized by both corrective and preventive maintenance practices Preventive maintenance 15 the monitoring of specific paramete
95. of the crossover The loop 15 transposed approximately every 13 feet 4 meters to prevent induced electrical interference between the cab loop and the rails The loop is connected to a coupling unit which in turn is connected to the output of one of the two transmitter groups In these crossovers train detection 15 done via standard power frequency track circuits Note that 1n certain applications crossovers may also be controlled by AF 902 904 equipment in a direct injection configuration as shown in Figure 2 3 TO RELAY ROOM TO COUPLING UNITS F TO COUPLING UNITS TO COUPLING UNITS NON KIA NO A TO COUPLING UNITS TO COUPLING UNITS TO COUPLING UNITS Figure 2 4 Typical Interlocking Cab Only Transmission Loop SM 1F2 0001 Rev 2 May 2011 2 5 Typical Applications AnsaldoSTS 2 4 System Connection Diagrams The AF 902 cardfile 1s a self contained unit that consists of the Primary track circuit A and its redundant Backup track circuit B The AF 904 cardfile contains four independent track circuits Figure 2 5 shows cabling terminal identification Inductive Coupling and Figure 2 6 shows the cabling terminal identification Direct Injection Figure 2 7 shows the location of the jumpers on the AF 902 motherboard that connect the terminating resistor s across the Vital Parallel Output VPO when it is not used There 1s one jumper and terminating resistor for each track circuit Figure 2 8
96. ol Can Used to blow out dust and foreign matter from delicate components and electrical surfaces 8 3 2 2 Equipment Room Cleaning Procedures When cleaning the AF 902 904 track circuit cardfile in the equipment room safety warnings should be adhered to and precautions should be taken to prevent personal injury WARNING Hazardous voltages and current may be present Use extreme caution when working near exposed terminals Never use wet cloths near exposed electrical equipment To clean the cardfile perform the following procedure 1 Remove dust and dirt from all accessible surfaces using a soft bristle brush 2 Using compressed air blow out dust and dirt from inaccessible areas around terminal blocks fuse holders and other areas where live electrical conductors are exposed CAUTION When using compressed air to blow out dirt and dust particles from cardfiles always direct air at an angle relative to the PCBs so that damage will not occur to the mounted components 3 Wipe exterior and interior surfaces not exposed to electrical circuitry with a lint free cloth dampened with a solution of water and household cleaner to remove all dirt and foreign matter 4 Dry all surfaces with lint free cloth Using compressed air or a soft bristle brush remove all dust and dirt particles from cardfiles wiring and other areas that may not be accessible using standard cleaning methods 8 8 SM 1F2 0001 Rev 2 May 2011
97. ons of train detection and cab signaling the AF 902 904 system encodes data from the track logic processor on the wayside and transmits it through the track where the signal 1s picked up and decoded by the car borne ATP equipment This data 1s used for direction line speed target speed track length next track circuit frequency berthing and coupling uncoupling information In Figure 1 1 vital track logic is performed by the Track MICROLOK II system Interlocking logic and control of switch machines and signals are performed by the Interlocking MICROLOK II Non vital logic 1s performed by Non Vital Logic Emulator NVLE units Routing is performed automatically by the train ID through the wayside communications system from the local control panel by fleeting or from central control The AF 902 904 system comprises the trackside equipment and processing equipment within the signal equipment room The trackside equipment consists of track coupling units wire bonds and track loops As shown in Figure 1 1 the processing equipment for an AF 902 system contains Primary and Backup circuits The MICROLOK II units and NV LE units may also be duplicated for fail over conditions 1 2 SM 1F2 0001 Rev 2 May 2011 n E 7 AnsaldoSTS Introduction VITAL CENTRAL h CONTROL FACILITY NON VITAL REMOTE 5 SS S VITAL 5 INTERLOCKING SWITCH MICROLOK Il gt RELAYS gt MACHINES AND SIGNALS TRACK MICROLOK
98. pendix A BHL OOO 0 train in platform Bifurcation Bifurcation 1 point 0 point R Couple Uncouple Couple Uncouple 10 couple to train 01 uncouple from train 00 no action Remote Block Speed Remote Block Speed See Appendix A 1 6 2 2 Serial and Peer Message Data Transmitted to Track Microlok ll Bits Name Function Description 1 no block speed set 0 Standby unit not available 1 Standby unit is available 1 track unoccupied 0 direction not in correspondence 1 direction is in correspondence Spare bits that are not used 1 6 2 3 Message Data Transmitted to the Track Cab Signal Signal Message 39 data bits 8 header bits 16 Cyclic Redundancy Check CRC validation bits Protocol Synchronous bit oriented similar to Synchronous Data Link Control SDLC Encoding NRZI SM 1F2 0001 Rev 2 May 2011 1 15 N Introduction 77 AnsaldoSTS Track Circuit ID Identification of present track circuit Primary Backup Identification of which controller is providing the message Train direction of travel gamer irequency next back cireuii frequency of the next track circuit 7 Distance to Go Distance oftargetspeed Line Speed Maximum speed permitted within track circuit E 1 7 Specifications 1 7 1 Track Circuit Track Circuit Length 1 000 ft 305 m maximum 65 ft 19 812 m minimum Shunt Sensitivity 0 25 ohms Pre Post Shunting 5 0 ft 1 5
99. proceeding SM 1F2 0001 Rev 2 May 2011 6 9 Installation and Adjustment A NOTE The following procedures detail calibration using the front panel Calibration can also be done through the web server interface The same procedural steps are followed The two TCS units in an AF 902 system are distinguished by using standard text for the left unit circuit and BRACKETS for the RIGHT UNIT circuits Tuning affects both the transmitted and received signal levels making it MANDATORY that the tuning procedure be performed first as part of the setup routine For preventive maintenance purposes since the system 15 operational and tuning has been completed at some earlier date calibration alone be performed as the sensitivity check However if calibration is marginal it may be necessary to perform both the tuning procedure and calibration procedures The detailed steps to tuning are provided in Table 6 7 Calibration of the signal power must be performed after the tuning procedure since it 1s affected by the resulting tuning signal levels Specific steps and details of the calibration procedure are given in Table 6 9 6 6 1 Testing Codes and Abbreviations 6 6 1 1 Basic character and case assignments used for performing the test procedures are as follows 6 10 Controller Board Front Panel Display Abbreviation Codes AAAA Upper Menu or Command Aaaa Label Parameter BKSP Block Speed MLOK MICROLOK
100. r J7927360147 This device 16 to be mounted directly to the Breaker Panel and wired to the main feeders through dedicated breakers 7 1 2 120VAC Isolated Ungrounded Feed Some Signal House AC Feeds are brought into the House through an Isolation Transformer The House side of that transformer will be a floating neither side grounded 120VAC feed If this 1solated 120V AC feed never leaves the House the Primary Protection device to be used at the Service Panel is ASTS USA Part Number J7927360144 If this 1solated 120V AC 1s distributed throughout the House and leaves the House the Primary Protection device to be used at the Service Panel is the ASTS USA Part Number J7927360178 7 1 3 Secondary AC Line Protection The Secondary AC protection 15 for those lines carrying the protected AC Power coming into the House to remote devices or locations outside the Signal House This power 15 usually located on the main Terminal Board and on adjacent terminal posts The preferred device to be used as Line to Line protection 1s the ASTS USA Part Number J7927360181 but the ASTS USA Part Number J7927360182 can also be used in most applications In the event a protected 1solated AC feeder 15 sent outside the Signal House then those lines would also need to be protected Line to Ground In either case the protection devices are the same as those mentioned above 7 1 4 Signal Wiring All track wires between the house and the AF 902 904 Coup
101. raises the reactance of the track loop to the selected carrier frequency This raises transmitter efficiency since smaller currents are required to flow in the long track leads SM 1F2 0001 Rev 2 May 2011 3 1 uw 7 Functional Description AnsaldoSTS Likewise when a track loop has been selected to be a receiver the low voltage from the track loop is stepped up to drive the leads back to the relay room The tuning of the track loop provides a small increase in received signal strength Due to the differences in transmitter and receiver impedance the coupling unit is adjusted to provide some benefit to both transmitter and receiver The tuning is necessarily very broad and does not result in any appreciable frequency selectivity between the jointless track circuits The AF 902 904 system does not use a conventional impedance bond Instead a few meters of 350 or 500 MCM cable are connected between the two rails in an S shape with an end of the 5 bonded to each rail Single turn track loops are mounted inside of the upper and lower parts of the S Currents circulating in the transmitting track loop are induced into the S and onto the track Likewise currents from the track circulate 1n the S and are induced into the receiving track loop This type of bond has a strong directionality with the ratio of the length to the width of the S determining the directivity like the front to back ratio on an RF directional antenna The tra
102. rcuit ensures that it functions correctly over a range of 100 162 represented by a term called overdrive This overdrive is illustrated Figure 8 2 8 2 SM 1F2 0001 Rev 2 May 2011 A E 7 AnsaldoSTS Preventive Maintenance c ES 100 mA represents 10096 Over Drive E 62 mA represents 162 Over Drive cc N o LL lt Figure 8 2 Adjustment at High Ballast When the track circuit is initially adjusted for example a 10 5 kHz circuit with high ballast resistance the threshold level of the track circuit s receiver is 100 mA The 100 mA represents an overdrive value of 1 or expressed in percentage 100 With only an overdrive of 100 or 1 the track circuit would become occupied 11 the ballast resistance changes to any lower value than assumed at the initial adjustment value So it can operate over a changing ballast value overdrive is added to the track circuit A track circuit with no overdrive would operate very unreliably The overdrive can be achieved via increasing the source voltage OR decreasing the threshold value of the receiver With the AF 902 904 track circuit overdrive 1s obtained by changing the threshold of the receiver Thus in the figure above an overdrive value of 1 62 or 162 1s obtained by adjusting the receiver threshold to 62 mA Note that the magnitude of overdrive 15 selected as a function of frequency shunting sensitivity minimum ballast rail to rail voltag
103. rent for an AF 902 904 track circuit The rail current 1s set by adjusting the transmitter s output power The table lists the Operator s Action for setting the loop current using the front panel interface The Setup Mode s Calibration page provides both a guide and the controls required to perform all of these steps see Section 6 5 1 5 The AF 902 904 only transmits a track signal to the cab loop it does not receive its signal so no occupancy detection can occur Therefore upon completion of calibration the AF 902 904 system will not have a valid receive level variance or shunt level These parameters will display either a zero or value on the front panel and web page displays Table 6 12 AF 902 904 Cab Loop Track Circuit Setup Traverse restricted menu as described in Note All cab loops employ a single coupling unit at the Table 6 4 to transmit end SET UP Toggle ENTER for TUNE MENU Toggle The AF 902 904 system does not receive a signal back from MODE to CALI BRAT the track Toggle ENTER for freq xx x ADJUST frequency to freq 16 5 Toggle ENTER for DIR E gt W RxW Check cab loop wiring to ensure proper connections Toggle ENTER for pwr xx9e AF 902 904 signal wire to 1 2 4 5 Cab loop wire to 7 8 10 11 Select appropriate transmitter tap and Using a Spectrum Analyzer with a Current Probe attach ADJUST pwr xx to set ICabloopto probe to cab loop wire and monitor report loop current
104. resses Ethernet2 The IP address of the MICROLOK II that is connected to the AF 902 904 s This is the MICROLOK II s internal port address it should be set to 60000 unless I P Port the MICROLOK II s application program has defined a different port number If The IP address of a second standby MicROLOK II connected to the AF 902 904 s MICROLOK II ETHERNET port If used This is the MICROLCK II s internal port address it should be set to 60000 unless I P Port the MICROLOK II s application program has defined a different port number If used Normal MICROLOK II I P Port Standby MICROLOK II The Track Circuit Ethernet Ports information must be provided by your systems network designers Table 6 2 Track Circuit Ethernet Ports Track Circuit Ethernet Ports The AF 902 904 s ETHERNET 1 port s IP address The subnet mask for ETHERNETI port The gateway address for ETHERNETI port The hardware address for ETHERNET this is not changeable The AF 902 904 s ETHERNET port s IP address The subnet mask for ETHERNET port The gateway address for ETHERNET port The hardware address for ETHERNET this is not changeable Table 6 3 Track The Track 1 0 number that will be included in the Track Message This number Track 1 0 must be assigned by the system designer uw This is text message displayed on the top of the web pages to help the maintainer TEGULI identify the specific track circult
105. right corner of display is 500 KS s Vertical CH1 yellow 7 then a Asie to turn off analog Yellow trace turns off Vertical off Red trace shows on display if not 5 Vertical Math red Press button oo On Select FFT source as 1 Displays CH1 Right side of display 277 Select FFT vertical scale to Linear kulon RMS Displays Linear RMS ra bon 2 Select FFT window to Rectangular Displays Rectangular Right side of display shows Cursor 14 Right Side of Display 3 Select V Bars Red vertical line may appear on button display Turn knob unti cursor position is Cursor moves off screen This is a 16 Coarse Adjust Knob greater than 100 kHz This is the rough adjustment to move one of the parameter on the display cursors off of the screen Red vertical line will change from c Turn knob until cursor position is Cursor may be in display area This Coarse Adjust Knob close to the center frequency that the is a rough adjustment and will be AF 902 904 system is transmitting fine tuned in the next step Press to deselect Coarse adjust and Coarse Button fine tune cursor position to center Cursor may be on display frequency Information in right corner of display If the red data signal is visible covers the display and Observe the small red line displayed makes it difficult to Reduce the amplitude of the at the top of th
106. ring AF 902 904 Front Panel Restricted Menu For Setup From MAIN MENU toggle ENTEH Toggle MODE to CNFG MENU Toggle ENTER for PSWD MENU Toggle ENTEH for pswd AAAA ADJUST characters and ENTER the default is four underscores _ Unit enters RSTR MENU Toggle ENTER If pswd is OK unit goes into SET UP Table 6 5 provides the sequence of steps to enter the Setup mode by using the web server interface Table 6 5 Entering AF 902 904 Setup Using the Web Server Interface SELECT the SETUP tab ENTER the 4 character password the default is four 5 Toggle the ENTER switch on the front of the AF 902 904 TCS The drop down box will rise and you will be in the Setup Mode Table 6 6 provides the sequence of steps required to set the AF 902 904 system s communications address and Track ID using the front panel interface Section 6 5 describes setting these parameters using the web page interface If the system 1s using the RS 485 MICROLOK Serial Protocol then the AF 902 904 system s address 1s a number from 1 to 127 If the system 15 using the Ethernet MICROLOK Peer Protocol then the AF 902 904 system s address is a number from 1 to 65535 The Track ID number is a number between and 4095 that 1s assigned by the system architects and should be obtained from the track plan SM 1F2 0001 Rev 2 May 2011 6 13 A Installation and Adjustment AnsaldoSTS Table 6 6 Setting the Communications
107. roach that will lead to identifying the cause of a system s stoppage or abnormal operation The responsibility of the maintenance personnel is to locate the cause of failure and repair the condition as soon as possible This can be accomplished only if a systematic approach is taken by qualified personnel who are familiar with the test equipment and testing procedures Basic concepts to apply to any troubleshooting situation are listed Table 9 1 Table 9 1 Basic Troubleshooting Concepts CONCEPT SUGGESTED ACTIONS Observe and analyze the The symptom may identify the site location sub system hardware vs symptom software causes or cable communications link Sectionalize the system If it is difficult to identify the faulty subsystem the maintainer should proceed to sectionalize the system in halves until the site and subsystem are known Localize the fault within the Identify the LRU and test by using available software or control panel Subsystem diagnostics Isolate the cause Continue troubleshooting the LRU for modular replacement or adjustment Repair the failure The trouble can be corrected by adjustment component replacement or wire repair Check repair and operation Verify that the repair has been properly done by checking the operation of the system for any other fault symptoms and irregularities Never assume that the first fault found was the only fault The priority of field maintenance personnel is to get th
108. rs in a timely manner Corrective maintenance is the replacement of a failed unit in a timely fashion There are several key parameters of the AF 902 904 track circuit that can be monitored to determine the health of the track circuit These parameters are displayed by the AF 902 904 and can be checked by the maintainer The several major AF 902 904 track circuit parameters to be monitored are e Received Signal Level This parameter is important because it verifies that the received signal level 1s within the operating range of the receiver circuit An unoccupied track circuit should have a received signal level between 8 and 55 Shunt Level As with the Received Signal Level this value indicates the track signal level If the value changes to near 10046 due to changes in ballast conditions a recalibration may be required or a false occupancy could be indicated e Variance This parameter be used to determine whether the coupling unit is tuned correctly or a coupling unit has failed Variance can also indicate whether interference from another source is becoming a problem in the reliable operation of the track circuit e Events The web page Events page displays the errors warnings and operational events that have been detected by the AF 902 904 5 The most recent display 1s displayed first 8 2 1 Received Signal Level A model of the AF 902 904 track circuit can be represented as shown in Figure 8 1 The rails ar
109. shows the location of the jumpers and terminating resistors on the AF 904 motherboard There is one jumper and terminating resistor for each track circuit Figure 2 9 illustrates typical wiring connections for Track Circuits and 2 Figure 2 10shows the typical serial link connections between the MICROLOK II ports and the AF 902 connectors Figure 2 11 depicts the typical connections between the AF 904 connectors and track circuits 1 2 3 and 4 TB1 1 TB2 1 TRANSMITTER 1 TRANSMISSION LOOP 2 TB1 2 TB2 2 TB1 3 TB2 3 TRANSMITTER 2 TRANSMISSION LOOP 1 U TB1 4 TB2 4 Figure 2 5 Inductive Coupling Unit Terminal Identification 2 6 SM 1F2 0001 Rev 2 May 2011 w 7 AnsaldoSTS Typical Applications J1 INPUT 1 DIRECT 1 FROM TRANSMITTER J1 CAB LOOP 1 A COMMON 1 GND 3 Ji DIRECT2 NEUS 10 CAB LOOP 2 FROM TRANSMITTER Ji COMMON 2 Figure 2 6 Direct Injection Coupling Unit Terminal Identification SM 1F2 0001 Rev 2 May 2011 2 7 lt Cw Typical Applications 4 AnsaldoSTS JUMPER JUMPER TERMINATING RESISTOR TERMINATING RESISTOR J8A R2 C2 EZ 11776616925 R 116 2148 c tia Dim A o o CONTROLLER 2B MOTHER BOARD AF 902 SI RUXILIRRY 2B CONTROLLER RUXILIRRY RUXILIRRY 1B CONTROLLER 2R AUXILIARY 2A I Co 4 2 N 1D2 0172 00 Figure 2 7 AFO 902 Motherboard VPO Jumpers and Terminating
110. sible to take into account every eventuality that may arise with technical equipment in service Please consult an ASTS USA local sales representative 1n the event of any irregularities with our product ASTS USA expressly disclaims 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 ASTS USA spare parts are used as replacements SM 1F2 0001 Rev 2 May 2011 77 AnsaldoSTS Revision History Revision History Nature of Revision July 2010 Initial Release 5 5 59 955 5 505 00222 Release Note added to Section 1 5 4 2 Note added to Section 2 Removed old 2 2011 Section 2 4 Train Detection in Double Crossover Revised Section 6 5 1 1 and Section 6 5 2 1 Added Section 6 7 2 Revised Table 6 4 Table 6 7 Table 6 9 and Table 6 12 SM 1F2 0001 Rev 2 May 2011 w Z AnsaldoSTS Table of Contents Table of Contents 1 GENERAL INFORMATION a enmana ac Ri maus U u uuu u 1 1 1 1 Safety Summary a a c ssa as sas c sas aa aaa 1 1 120 r OOU CHOU NER TERCER 1 1 ES OVENI CW 1 2 1 3 1 5
111. switch energizes the 5 to the immediate left of the Power Supply is marked with a left arrow These switches are locking lever type switches that must be pulled out to change position e Twelve voltage test points There are four DC and two AC test points for each subsystem supply SM 1F2 0001 Rev 2 May 2011 1 7 N Introduction 77 AnsaldoSTS POWER MONITOR LEDS DC POWER TEST POINTS RIGHT POWER SUPPLY LOCKING SUBSYSTEM POWER SWITCH AC POWER TEST POINTS POWER MONITOR LEDS DC POWER TEST POINTS a A D c O LOCKING SUBSYSTEM POWER SWITCH POWER SUPPLY N12360501 Figure 1 4 AF 902 AF 904 Power Supply 1 8 SM 1F2 0001 Rev 2 May 2011 I 77 AnsaldoSTS Introduction 1 5 4 Wayside Components The required supporting trackside components for the AF 902 904 system are the track coupling units wire bonds and track loops From the equipment room track leads of up to several kilometers total loop length connect the trackside coupling units to the direction relays The track leads are twisted pairs with the intrinsic impedance Zo of approximately 100 ohms 1 5 4 1 Track Coupling Units Figure 1 7 Figure 1 8 Figure 1 9 and Figure 1 10 show track coupling units for S I O and direct injection track cable bond applications AF 902 904 coupling units interface the track signals with the cardfile receiver and transmitter circuits They also provide for tuning
112. the control layout of the Tektronix TDS 3012B Oscilloscope Observe that there are buttons along the bottom and right edge of the display The function of these buttons will change depending on other menu button selections The current functions will be shown on the display There 15 a set of buttons along the top right side of the instrument Only the Cursor Select and Coarse buttons and the adjustment knob between to the Coarse and Cursor buttons will be used in this procedure The remaining controls are grouped in four columns Vertical Horizontal Trigger and Acquire This procedure will call out a control by Group Control button or knob As an example if adjustment of the position knob in the Horizontal group 15 required the procedure will identify the control as Horizontal Position The following table lists the steps In the setup procedure SM 1F2 0001 Rev 2 May 2011 11 1 RN w Tektronix Setup Procedure 7 AnsaldoSTS Table 11 1 Tektronix Setup Procedure Step Comm Si _ _ Display shows instrument settings Connect to CH1 and clamp around Current Probe AF 902 904 transmitted signal line Range Switch Set the Current Probe Range Switch to 10 Using instructions in this manual Table 6 9 Set up the AF 902 904 system to transmit a constant center frequency Display will show several cycles of Display shows menu of options Adjust knob until the Sample Rate Horizontal Scale lower
113. ther SWI and SW2 switches in either the ON or Off positions The default IP address for ETHERNETI 15 169 254 1 10 and ETHERNET 1s 169 254 2 20 If the IP addresses for your Ethernet ports are known this step can be skipped SM 1F2 0001 Rev 2 May 2011 6 3 Installation and Adjustment AnsaldoSTS 6 5 1 2 Setting The PC s Network IP Address To connect to a TCS using the default address set the PC s TCP IP network address to 169 254 1 11 with a subnet mask of 255 255 255 0 and directly connect to ETHERNETI port on the AF 902 904 Or you can set your PC s TCP IP network address to 169 254 2 2 with a subnet mask of 255 255 255 0 and directly connect to ETHERNET port on the AF 902 904 To use a non default address set the PC to an unused subnet address The direct connection Ethernet cable CAT 5 may be a standard straight through cable or a cross over cable Proceed as follows to set a Windows PC s TCP IP address 7 Click Start Settings or Control Panel Network Connections 9 In the window that opens right click on your network connection and select Properties 9 In the window that opens scroll down to Internet Protocol TCP IP and select Properties 10 Select Use the following IP address and type in the desired IP address and Subnet mask Use 169 254 1 11 255 255 255 0 or 169 254 2 11 255 255 255 0 or an unassigned subnet address and gateway for non default use 11 Select OK buttons to close all
114. thernet Interface IS sending receiving data sending receiving data LINK Physical connection to Ethernet Interface is not N A network established sending receiving data ETHERNET 1 RX TX N A Ethernet Interface is not Ethernet Interface IS sending receiving data sending receiving data LINK Physical connection to Ethernet Interface is not network established sending receiving data ON LINE ON LINE TCS is on line TCS is off line HEALTH Unit is functioning Unit is off line or not SELF d correctl functioning The partner unit for AF THE partner unit for PARTNER 902 is functioning AF 902 is not correctl functioning U LOK Communication not U LOCK Communication i ON COMM established to Microlok II tO MIGIGIOR BES BEE LOCAL Block Speed Set is Local FEK Speed is REMOTE Block Speed Set is Remote Block Speed is Hemote not set TRK CLEAR LEVEL Track is Clear Track is occupied DATA Track is Clear Track is occupied SM 1F2 0001 Rev 2 May 2011 4 3 uw g User Interface 7 AnsaldoSTS ALPHANUMERIC l LED DISPLAYS SYSTEM MONITOR LEDS SYSTEM RESET PUSHBUTTON i STATUS 2 O O U LOK COM O LOCAL BLK SPEED REsET D O REMOTE 77 O LEVEL ETHERNET 2 TRK CLEAR LINK O O DATA ETHERNETI LINK O 5 CONFIGURATION SETUP SWITCHES MOMENTARY CONTACT SWITCHES SPRING RETURN TO CENTER ETHERNET CONNECTORS lt ETHERNET q ETHERNET 1 BI OU TES Figure 4 1 AF 902 AF
115. tion limits Verify coupling unit adjustment When performing the tuning or Adjacent track circuit ON Turn power OFF of adjacent track calibration procedures the proper circuit carrier frequency cannot be arte achieved Y Adjusting wrong circuit in coupling Check for correct TX or RX side of unit track circuit HEALTH indicator OFF Primary or Backup unit is faulty Replace defective module The AF 902 904 1s continually running diagnostics on the entire track circuit system Any failure of these diagnostics will signal the MICROLOK unit of track occupancy This will maintain the track circuit in a safe state not allowing any train traffic until the system 15 again operating correctly 9 4 Front Panel Indicators and Controls 9 4 1 AF 902 904 TCS This front panel consists of two four character alphanumeric scrolling displays and four up down SPDT toggle switches that can be used to enter and examine data used in the setup and operation of the track circuit Eighteen discreet LEDs provide additional information In addition the web page interface provides all of the front panel information In a more convenient format See Section 4 2 Figure 9 1 shows the indications connectors and controls on the front panel of the TCS SM 1F2 0001 Rev 2 May 2011 9 3 Cw Troubleshooting 7 AnsaldoSTS ALPHANUMERIC a LED DISPLAYS TATUS 2 O O U LOK COM pre SYSTEM RESET PUSHBUTTON Gus
116. to the track circuit carrier frequency track coupling units are housed in weather tight enclosures and consist of two independent and isolated signal coupling circuits Each circuit has its own transformer and a jumper adjusted capacitor bank for frequency tuning as required for the track loops The dimensions of the track coupling unit 16 W x 8 H x 1071 40 64 cm x 20 32 cm x 25 4 cm The unit can be mounted on the wayside ground base or on a wall The coupling units and track circuits are connected through twisted pair 14 cabling that measures a maximum of 6 000 ft 1 830 m Figure 1 5 shows cabling terminal identification Inductive Coupling and Figure 1 6 shows the cabling terminal identification Direct Injection TB1 1 TB2 1 TRANSMITTER 1 TRANSMISSION LOOP 2 1 2 2 2 1 3 2 3 TRANSMITTER 2 TRANSMISSION LOOP 1 TB1 4 TB2 4 Figure 1 5 Inductive Coupling Unit Terminal Identification SM 1F2 0001 Rev 2 May 2011 1 9 E 77 AnsaldoSTS Introduction J1 INPUT 1 DIRECT 1 FROM TRANSMITTER J1 A CAB LOOP 1 J1 COMMON 1 GND 3 J1 DIRECT 2 NEU CAB LOOP 2 FROM TRANSMITTER n COMMON 2 Figure 1 6 Direct Injection Coupling Unit Terminal Identification TRAFFIC gt 23 7 350 OR 500 23 7 350 OR 500 TRACK A TRACK B keo rs TRACK C B q D q D E MAX 15 FT TRACK A amp B COUPLING 40 TRACK B amp C COUPL
117. tos o ms LIO o PN z ka as br net 5 N m _ qc e 4 gt bz n gt gt gt a d a o a ar lt a E 3 T x c c c 5 e Lr z te c 2 2 J o 2 o J o tc c 3 z x m x E x x uzis o 2 5 5 D4 ma 5 o mia i O EJ 1D2 0173 00 Figure 2 8 AF 904 Motherboard VPO Jumper and Terminating Resistors Detail SM 1F2 0001 Rev 2 May 2011 2 9 77 AnsaldoSTS N zo l spun Z Lf jndu ASuednooo ENA II MO IO amp OIIN OL ple 2 7 ARE LTEM FIE EE MIEL 1 2 FIE bo E E I ZM3 ilu I l zo 731 zo 1 2 Jo SJOJOSUUOJ YORI cvi UNAJO YORI ERIT CL 18v3 Typical Applications SIM MAPI PNI Jl ZNAN INM CRI LZS 3 91 07 9 vd INI tA NA I E JJ er 9 Lf 10 9SUUO O c06 4V pem cn s CONO zx I x ZL Eh i i SW l og 55 Ale xH MILI i dl I J t I 1 I 1 i l J SHOIlO3NNOO dadMOd 902 Track and AC Connectors and Typical Wiring Figure 2 9 SM 1F2 0001 Rev 2 May 2011 2 10 Typ
118. tween the AF 902 904 and the MICROLOK II remote monitoring using SNMP and a user interface web server The web server provides the maintainer a convenient way to monitor system operation and to configure and calibrate AF 902 904 system operational parameters using Microsoft s Internet Explorer All front panel operations can be accomplished through this web interface The web interface provides five primary pages These pages are selected by clicking on one of the five tabs on the upper right area of the main page 4 1 1 View Current Data Page The View Current Data page displays dynamic system data and is the AF 902 904 s home page This page shows the data contained in the messages between the MICROLOK II and the AF 902 904 and the track message data is displayed decoded values as well as the binary bit patterns for the data fields The current shunt level and the track s signal variance 15 displayed at the bottom of the page Variance is derived from the amplitude difference between the track signals mark and space frequencies A small variance indicates that the coupling unit 15 well tuned 4 1 2 View Configuration Page The View Configuration page displays static system configuration parameters The parameters associated with the communications to the MICROLOK Ethernet port addresses SNMP configuration and track circuit identification and calibration setting are displayed The AF 902 904 system software components vers
119. unt level should coupling unit should be retuned If the be approximately 15096 to 16096 variance is still high after retuning analysis of before this measurement is other causes should be investigated made The current Variance and Shunt Levels are displayed at the bottom of the AF 902 904 MessageData home webpage The readings should be observed for up to a minute to determine if the variance is steady ing because of interference 8 3 2 Equipment Cleaning Procedure Cleaning is necessary to remove all accumulated dirt and other foreign matter from the AF 902 904 track circuit unit coupler and track bonds that form the AF 902 904 system A six month cleaning interval is recommended While cleaning any of these system components the maintainer must exercise the necessary caution in order not to damage or dislodge any wires or connectors 8 3 2 1 Cleaning Materials The following cleaning materials are required to effectively clean the unit and remove unwanted debris The cleaning supplies are of commercial grade and may be purchased from any cleaning supplier SM 1F2 0001 Rev 2 May 2011 8 7 SA Preventive Maintenance 7 AnsaldoSTS Item Use Household Cleaner Mild liquid cleaner used to clean exterior surfaces Lint Free Cloths Used to clean and dry exterior surfaces Soft Bristle Brush Used to remove dust and foreign matter from terminal blocks electrical connections and equipment surfaces Air in Aeros
120. upper and lower parts of the S and inside the O part As Figure 1 8 shows the track loops are on both sides of the I bond S and I bonds are used in areas where there are no insulated joints that define the track circuit boundaries O bonds are used in areas where an insulated joint 1s used in each rail to define the track circuit boundaries The AF 902 904 must be connected so that the track signal is always injected into the track end farthest away from the end that the train 1s entering The direction relays mounted in the rear of the cardfile will switch the transmission direction based upon the data the message received from the vital wayside controller 1 12 SM 1F2 0001 Rev 2 May 2011 N 74 AnsaldoSTS Introduction 1 6 MICROLOK AF 902 904 Communications Communication between MICROLOK II and AF 902 904 system is conducted using either the legacy RS 485 MICROLOK Serial Protocol or with the new MICROLOK Peer Protocol over an Ethernet network Each protocol has its own message data format and described in the sections below The most significant differences are five bit speed code fields and the optional remote block speed field used only in the Peer Protocol messages The part number of a TCS specifies the communication protocol and the encoding of speed and distance codes The communications protocol and related parameters are pre programmed and can only be changed by uploading a new Application Data package
121. upplied to the system circuit boards via the backplane motherboard The cardfile requires two 115 VAC 10 at 50 60 Hz nominal power connections Each line connection feeds power to one half of a power supply which supplies the 5 with the required voltages Both Primary units in the AF 902 cardfile are powered from the same AC power feed Both Backup units are powered from the same second AC feed Figure 1 2 shows the layout of a AF 902 904 cardfile Each cardfile contains six circuit boards all of which plug into the interconnecting motherboard mounted on the back of the cardfile In AF 902 systems each cardfile contains two redundant track circuits Each half of the cardfile contains two TCS units and a single Power Supply The Power Supply board provides two independent supplies for the Primary and Backup units of one track circuit The AF 904 cardfile has the same layout for four independent non redundant track circuits The four TCS and two Power Supplies are configured as four separate track circuits The AF 902 904 1s modular in design which allows for easy removal and replacement of individual circuit boards Each TCS in an AF 902 904 system stores its configuration parameters on an EEPROM mounted on the cardfile backplane Replacement of a TCS may be done with little reconfiguring calibration procedure must be performed to verify proper track circuit operation full configuration and calibration must be performed whenever a
122. uw E 7 AnsaldoSTS Preventive Maintenance 8 3 3 Track Circuit Inspection Track circuit inspection should take place at least once a year or more frequently 1f desired This inspection procedure consists of observing the physical condition of the equipment and performing any actions or operations that may affect the function of the item under test It may be necessary to take appropriate cleaning steps prior to inspection Knowledgeable maintenance personnel who are familiar with the operational functions of the system should inspect for appearance smell sound and feel of the equipment Any of these observation methods can alert the maintenance personnel of fault conditions 8 3 3 1 902 904 Room Equipment The following inspection procedures should be used 1 Check the AF 902 904 front panel to ensure that all controllers and power supplies are properly and fully inserted 2 Check that the cable connections to the rear of the cardfile are intact tight and free from nicks cuts and fraying 8 3 3 2 Track Side Components The following inspection procedure should be used 1 Check all cable connections from the AF 902 904 cardfile connectors on the rear panel to the track circuit coupling units for any signs of nicks breaks kinks corrosion or fraying 2 Check all cable connections from the AF 902 904 coupling units to the appropriate 350 or 500 MCM bond locations for any signs of nicks breaks kinks corrosion or fraying
123. wer Supply Front Panel 9 6 SM 1F2 0001 Rev 2 2011 E 4 AnsaldoSTS Troubleshooting 10 CORRECTIVE MAINTENANCE 10 1 Introduction This section describes the procedures necessary to access replace and repair the AF 902 904 track circuit system s components to the LRU level that 1s practical at the field maintenance level Corrective maintenance is an unscheduled process initiated by a system failure or resulting from unsatisfactory preventive maintenance data After a system fault has been localized by performing the necessary troubleshooting and diagnostic testing the maintainer 15 required to adjust or replace the component Following the component adjustment or replacement the maintainer is required to perform system repair verification 10 2 Replacement Repair The AF 902 904 track circuit system comprises three major components AF 902 904 FSK cardfile AF 902 904 track coupling unit e 350 or 500 bond The suggested repairs at the field level are designed to minimize system downtime and reduce the need for specialized or sophisticated test equipment 10 2 1 902 904 TCS and Power Supply Replacement 10 2 1 1 Required Tools The only tool required 1s a medium sized flat blade screwdriver 10 2 1 2 Procedure Power supply replacement requires disconnecting the AC Power After having identified the faulty system component replace it by following the procedure below 1 Identify the power suppl
124. windows There will be a several second delay while Windows is changing your Ethernet port s address 6 5 1 3 Connecting to the AF 902 904 After the AF 902 904 IP address 1s known or set to the default and the PC is configured to the same subnet the PC can connect to the AF 902 904 system s internal web server Open Internet Explorer and type in the IP address of the AF 902 904 Ethernet port on the Address line This will be default address or your network s designated address Internet Explorer should show the View Current Data page for the AF 902 904 6 5 1 4 Entering Setup Selected the Setup tab and wait for the Password drop down window to appear Enter your 4 character password If you have not previously set a new password the default 1s 4 underscores ___ _ If the correct password has been entered you will be prompted to toggle the Enter switch on the front of the 902 904 5 This 1s the lower left toggle switch When this 15 completed the drop down box will rise and you will be in the Setup Mode 6 5 1 5 Setting the Configuration Parameters In the Setup Mode you will have a new set of tabs to select the parameters that you will be adjusting Please be careful if you select one of the original tabs View Current Data View Configuration etc you will immediately exit Setup Mode and all changes will be lost When setting up a new system the first tab you should select 1s the Configuration tab On this page you wi
125. y associated with the 5 to be replaced 2 Turn OFF the corresponding Locking Subsystem Power Switch CAUTION Turning OFF the wrong Power Switch will cause a general system failure 3 Turn the captive thumb screws at the top and bottom of the defective TCS module counterclockwise until loose 4 Grasp the Module Ejectors next to the thumb screws at the top and bottom and pull the TCS straight out from the board guides Remove it from the cardfile SM 1F2 0001 Rev 2 May 2011 10 1 uw 7 Troubleshooting AnsaldoSTS 5 Install the replacement TCS in the board guides and slide it in until the TCS engages the cardfile connector 6 Turn the TCS thumb screws clockwise until they are finger tight and the 5 15 firmly positioned against the cardfile frame 7 ON the associated Power Switch NOTE When a TCS is replaced the calibration procedure should be rerun to verify the settings and update the threshold calculations 10 2 2 Coupling Unit Replacement The is mounted an aluminum box which 15 installed within 15 feet 4 572 m of the rail The coupling circuit is a single 9 x 13 x 3 32 22 86 cm x 32 02 cm x 238 cm circuit board This circuit board has two identical circuits and two terminal strips for external connection of inputs and outputs This single circuit board is used for two track circuits the local transmit circuit and the receiver circuit for an adjacent track circuit
126. y using the web server interface to the maintainer PC Conduct tests for both 5 units in the AF 902 system It is not recommended that track circuits be routinely recalibrated if they are able to accurately detect the test shunt As described in Section 8 2 1 the receive level can be affected by extreme ballast conditions Therefore recalibration should only be done at nominal ballast conditions 8 3 4 1 Track Circuit Sensitivity As part of the calibration portion of the routine the regularly scheduled PMI will require testing for track circuit sensitivity Before this test can be performed tuning should be performed in order to tune the two associated coupling units to the desired track circuit frequencies 9 5 10 5 11 5 12 5 13 5 14 5 15 5 16 5 KHz The tuning frequency and track circuit sensitivity information can be found on the initial installation track circuit Data Sheet 8 10 SM 1F2 0001 Rev 2 2011 E 4 AnsaldoSTS Troubleshooting 9 TROUBLESHOOTING 9 1 Introduction This section describes the methods and procedures that can be used by qualified maintainers to identify test 1solate and repair faulty conditions 1n the AF 902 904 track circuit repairs will be to the Lowest Repairable Unit LRU that 1s practical for field maintenance situations 9 2 Approach to Troubleshooting The process of isolating a failed or faulty component s is called troubleshooting This is a carefully planned app

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