645 Russell Street Batesburg, SC 29006 Service Manual 6486 ACCUTECT Lightning Protection Networks N35200101 N34200102 N34200103 Field Installation and Test Procedure May, 2001 2001, Union Switch & Signal Inc. Printed in USA An ANSALDO Signal Company
REVISION HISTORY Original Publication November, 1996 Revision May, 2001
TABLE OF CONTENTS Section Topic Page 1 GENERAL INFORMATION...1-1 1.1 INTRODUCTION... 1-1 1.2 R.A.I.L. Team and Technical Support... 1-2 2 INSTALLATION AND TESTING...2-1 2.1 Tools Required... 2-1 2.2 Mechanical Mounting...2-1 2.3 Connecting the LPN to the Main Power Source... 2-1 2.4 Connecting the Power to Individual ACCUTECTs... 2-1 2.5 Testing the Power Connection... 2-6 2.6 ACCUTECT Signal Wire Connection... 2-6 2.7 Testing the Signal Wire Integrity... 2-6 3 TROUBLESHOOTING...3-1 3.1 Equipment Required...3-1 3.2 Testing the B24WD/N23WD feed... 3-1 3.3 Testing the signal line protection... 3-1 List of Figures Figure 1-1 - Front View of the ACCUTECT Lightning Protection Network (LPN)... 1-2 Figure 2-1 - Wiring diagram showing the connections for a 1-way Lightning Protection Network (N35200101)... 2-3 Figure 2-2 Wiring diagram showing the connections for a 2-way Lightning Protection Network (N35200102)... 2-4 Figure 2-3 Wiring diagram showing connections for a 3-way Lightning Protection Network (N35200103)... 2-5 List of Tables Table 1-1 Assembly and Subassembly Part Number References... 1-1 SM6486 (05/01) i
This page is intentionally blank. ii SM6486 (05/01)
SECTION 1: GENERAL INFORMATION 1.1 INTRODUCTION The N35200101, N35200102 and N35200103 are self-contained lightning protection networks designed to protect 1, 2 or 3 ACCUTECT wheel detectors, respectively. These part numbers refer to complete assemblies and include a 12-way AREMA terminal block, a steel mounting plate, a printed circuit board and all AREMA hardware necessary for wiring. A bag containing the hardware needed to mount the assembly into a wayside junction box is also included. Once these assemblies are installed, the terminal block and steel plate should never require changing under normal service conditions. The printed circuit board can easily be removed from the terminal block, should it need replacing. The piece numbers for individual boards are clearly marked on the white board tag. The assembly and subassembly part numbers and their functions are summarized in Table 1-1. Complete Assembly including Mounting Plate and Terminal Block Encapsulated Printed Circuit Board Assembly Only Number of ACCUTECT Wheel Detectors that can be Protected N352001-01 N353001-01 1 N352001-02 N353001-02 2 N352001-03 N353001-03 3 TABLE 1-1. ASSEMBLY AND SUBASSEMBLY PART NUMBER REFERENCES With the except of the printed circuit boards listed above, replacement parts are not available for the ACCUTECT LPN. Refer to Section 3: Troubleshooting to verify the integrity of the units. Please contact your sales or customer service representative for ordering information should the unit be determined to be inoperable. The lightning protection network (LPN) assemblies are designed to fit in standard classyard, wayside junction boxes with a single 12-way AREMA terminal block mounted on one side of the terminal block support bracket. The LPN assembly mounts on the side of the terminal board support bracket that is opposite the side where the existing terminal block is mounted. To determine how many ACCUTECTs can be protected by a particular LPN, refer to a tag located on the front of the LPN assembly (refer to Figure 1-1). One of three squares will be marked to indicate whether one, two or three ACCUTECTs can be protected by the LPN. This can also be quickly determined by looking at the AREMA hardware on the terminal block (there are only twelve terminals on the block, and they are divided into three groups with four terminals in each group). Looking left to right, if only the first group of terminals has all the necessary AREMA hardware installed, then only one ACCUTECT can be protected. Similarly, if the first and second groups of terminals have all the necessary AREMA hardware installed, then two ACCUTECTs can be protected. Finally, SM6486 (05/01) 1-1
SECTION 1: GENERAL INFORMATION if all 12 terminals are populated with the AREMA hardware, then three ACCUTECTs can be protected by that LPN. FIGURE 1-1 - FRONT VIEW OF THE ACCUTECT LIGHTNING PROTECTION NETWORK (LPN) 1.2 R.A.I.L. TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link (R.A.I.L.) Team is comprised of experienced product and application engineers ready to assist and resolve technical issues concerning any US&S product. Any questions regarding the contents of this Service Manual can be answered by contacting the R.A.I.L. Team via e-mail at railteam@switch.com or a toll-free call to 800-652-7276. 1-2 SM6486 (05/01)
SECTION 2: INSTALLATION AND TESTING 2.1 TOOLS REQUIRED 7/16" Nut-driver AREMA wrench 2.2 MECHANICAL MOUNTING 1. Remove the small plastic bag from the terminal block. The bag should have two hexhead, 1/4-20 x 1/2" bolts and two 1/4" split lock washers. 2. Position the LPN assembly against the support brackets, align the mounting plate with the pre-tapped holes, and secure it to the brackets with the two bolts and lock washers that are provided. 2.3 CONNECTING THE LPN TO THE MAIN POWER SOURCE There are two wires (one red and one black) attached to the LPN circuit board. The red wire is labeled B24WD-MAIN and the black wire is labeled N24WD-MAIN. To bring power to the LPN, these two wires must be connected to the main 24 VDC feed coming to the junction box. This 24 VDC is accessed from the AREMA terminal strip on the opposite side of the support bracket. It is important to connect the main power in the correct polarity, although the LPN is protected internally from reverse power applications. RED is positive and BLACK is negative. The protected individual ACCUTECT B24WD and N24WD feeds are then distributed from the LPN. NOTE Neatly dress all wiring to avoid the possibility of pinching the wires under the junction box lid. WARNING For correct polarity, RED wire is positive and BLACK wire is negative. Do not reverse the polarity of the connections to the ACCUTECT detector head, otherwise damage to the ACCUTECT detector head may occur. 2.4 CONNECTING POWER TO INDIVIDUAL ACCUTECTS (REFER TO FIGURES 1-1, 2-1, 2-2 AND 2-3) Silk-screened labels appear on the printed circuit board in the area around the twelve AREMA terminals. This circuit board is divided into three sections: ACCUTECT #1, ACCUTECT #2, and ACCUTECT #3. Each section contains a group of four AREMA terminals, as indicated in Figure 1-1. In each of these groups of four terminals, two of the terminals are labeled B24WD and N24WD. These terminals will provide protected 24 VDC power to one ACCUTECT unit. SM6486 (05/01) 2-1
SECTION 2: INSTALLATION AND TESTING The power leads going to each of the ACCUTECT Wheel Detectors must be moved from the original AREMA terminal block to the appropriate terminals of the LPN. Examples 1. If a single ACCUTECT is being protected by a 1-way LPN, then 24 VDC power for that ACCUTECT will come from the B24WD and N24WD terminals in the ACCUTECT #1 group (refer to Figures 1-1 and 2-1). 2. If two ACCUTECTs are being protected by a 2-way LPN, then the 24 VDC power will come to each ACCUTECT separately from the B24WD and N24WD terminals in the ACCUTECT #1 and ACCUTECT #2 groups, respectively (refer to Figures 1-1 and 2-2). 3. If three ACCUTECTs are being protected by a 3-way LPN, then the 24 VDC power for three units will come from the B24WD and N24WD terminals in the ACCUTECT #1, ACCUTECT #2, and ACCUTECT #3 groups, respectively (refer to Figures 1-1 and 2-3). NOTE The power leads going to each of the ACCUTECT Wheel Detectors must be moved from the original AREMA terminal block to the appropriate terminals of the LPN. 2-2 SM6486 (05/01)
SECTION 2: INSTALLATION AND TESTING FIGURE 2-1 - WIRING DIAGRAM SHOWING THE CONNECTIONS FOR A 1-WAY LIGHTNING PROTECTION NETWORK (N35200101) SM6486 (05/01) 2-3
SECTION 2: INSTALLATION AND TESTING FIGURE 2-2 - WIRING DIAGRAM SHOWING THE CONNECTIONS FOR A 2-WAY LIGHTNING PROTECTION NETWORK (N35200102) 2-4 SM6486 (05/01)
SECTION 2: INSTALLATION AND TESTING FIGURE 2-3 - WIRING DIAGRAM SHOWING CONNECTIONS FOR A 3-WAY LIGHTNING PROTECTION NETWORK (N35200103) SM6486 (05/01) 2-5
SECTION 2: INSTALLATION AND TESTING 2.5 TESTING THE POWER CONNECTIONS After completing the 24 VDC power distribution wiring, use a voltmeter to measure the voltage across the B24WD and N24WD terminals of the protected groups. That is, for a 1-way LPN, measure the voltage across the B24WD and N24WD terminals of the ACCUTECT #1 group, for a 2-way LPN, measure the voltage across the B24WD and N24WD terminals of the ACCUTECT #1 and ACCUTECT #2 groups. For a 3-way LPN, measure the voltage across the B24WD and N24WD terminals of the ACCUTECT #1, ACCUTECT #2, and ACCUTECT #3 groups. NOTE There is insertion loss in the LPN which will drop about two volts when a wheel is detected. The voltage measured at the B24WD and N24WD terminals of the LPN should not measure below 21 volts when a wheel is detected. If the voltage drops below 21 volts, adjust the main 24 volt power supply to provide at least 21 volts when a wheel is detected. 2.6 ACCUTECT SIGNAL WIRE CONNECTION The previous section described the silk-screened labels on the circuit board and the ACCUTECT #1, ACCUTECT #2, and ACCUTECT #3 terminal groups and the 24 VDC power distribution terminals in each group. This section describes steps for protecting the ACCUTECT signal wires. In each ACCUTECT group of four terminals, there are two terminals labeled 1X and 2X. These terminals are where the ACCUTECT signal wires (coming from the wheel detector itself) and the wires carrying this signal back to the computer room are to be connected. Refer to Figures 1-1 through 2-3. 2.7 TESTING THE SIGNAL WIRE INTEGRITY The integrity of the signal wires is to be checked by artificially triggering the ACCUTECT detector head (out at the rails) and verifying with someone in the control room that the computer has indicated that the detector has triggered. The wheel detector head can be artificially triggered by placing a piece of steel against the side of the detector closest to the rail (the internal magnet will pull the steel to it) and then pull the steel away. 2-6 SM6486 (05/01)
SECTION 3: TROUBLESHOOTING If an LPN unit is suspected of failure, use the following procedures to verify operation. 3.1 EQUIPMENT REQUIRED Simpson 260 Analyzer or equivalent AREMA Wrench 3.2 TESTING THE B24WD / N24WD FEED 1. Locate the junction box that services the suspected LPN or ACCUTECT unit. 2. Configure the Simpson 260 as a voltmeter. Measure the voltage across the B24WD- MAIN and N24WD-MAIN terminals, which is where the LPNs red and black wires are connected. The voltage should be between 21 and 27 volts. 3. If main VDC power is being supplied to the LPN, check the individual B24WD / N24WD feeds leaving the LPNs. a. For a 1-way LPN, measure the voltage across the B24WD / N24WD in the ACCUTECT #1 group of terminals. The voltage should be at least 21 volts, although the ACCUTECTs will operate with a voltage as low as 18 volts. b. For a 2-way LPN, measure the voltage across the B24WD/ N24WD in the ACCUTECT #1 and ACCUTECT #2 groups of terminals. The voltages should be at least 21 volts, although the ACCUTECTs will operate with a voltage as low as 18 volts. c. For a 3-way LPN, measure the voltage across the B24WD / N24WD in the ACCUTECT #1, ACCUTECT #2, and ACCUTECT #3 groups of terminals. The voltages should be at least 21 volts, although the ACCUTECTs will operate with a voltage as low as 18 volts. 4. In most cases, a failure of the B24WD/N24WD feed circuit(s) will result in a very low output voltage. 3.3 TESTING THE SIGNAL LINE PROTECTION 1. If the signal line protection is suspected of failure, disconnect the corresponding ACCUTECT signal lines (including the wires from the ACCUTECT itself and the wires to the computer room) from the 1X and 2X terminals of the LPN. 2. Set the Simpson Analyzer to measure Ohms on the Rx 100 scale. 3. Connect the Simpson test leads across the suspect 1X and 2X terminals. The meter should indicate an open circuit. 4. Reverse the polarity of the Simpson connection. The meter should indicate an open circuit. NOTE A failure of the signal line protection will typically indicate a short circuit or partial short circuit in one or both polarities. SM6486 (05/01) 3-1
SECTION 3.0: TROUBLESHOOTING This page is intentionally blank. 3-2 SM6486 (05/01)