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IRPMU –Modernization of Signalling & Telecom

Systems on Ghaziabad-Kanpur Section

UM71 AFTC Factory Assembly
and Site Installation Instruction

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Howard Revell
Executive Engineer

Manas Bose
Engineering Manager

Iyyappan
Project Director

Technical Reference

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Executive Engineer

17-01-2011

00535-ND-09-WI-00147

1.1

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We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

© Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)
UM71 TC Assembly & Installation Instruction

REVISION HISTORY
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0.2
1.0
1.1

Howard Revell
Howard Revell
Howard Revell
Howard Revell

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Peer review comments included
Released
Updated to match UM71 Manual Version
D (22/11/2010)

21.07.09
20.10.09
2.11.09
17.01.11

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00535-ND-09-WI-00147

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We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

© Ansaldo STS, 2009

....................................4 TMU/”O”Bond Parallel Connections .................... 8 6...........................................................................................................................................1 Plain Line ...... Materials and Tools............................................................................16 Presetting TMUs...............................................................................................................................................................1 Responsibilities . 8 6............................................................................................................... 13 7...........................................................2 Quality and Condition of Parts and Equipment ......................6........................................................................................14 Plugging-in and Presetting Tx Modules ..9 7......11 7........................6 5.....................................................4..........................................................................................................2 Security Arrangements......................................... 7 6.......................... 11 7.......................................3 TMU/”O”Bond Equipment Connections ....................................................................................................................................................................................................................................................................................... 7 6.................................................3 IT Points ..8 Labelling ...........................................10 Line-side Quad Cable Connections ....................... 13 7.........................................4 ABBREVEATIONS AND DEFINITIONS.....1 General.............................................................................................10 7...............12 Earthing and Equipotential Bonding of AFTC Rack .....................................2 ESJ Zones..................................................... Reproduction....................................................... 7 6.................... 6 5..................................................................................................................................18 APPENDIX E: ...................................................8 Intermediate Transmitter Installation.......................................17 APPENDIX D: ........................................................................................................................................................................................................... 8 6..................6 Earthing and Equipotential Bonding in LSCs .......6............................................................................. 14 7.... use or disclosure to third parties without express authority is strictly forbidden.................................................. 12 7.................................16 APPENDIX C: .................................................4................................................................... 10 7..1 Bonds ...........................................................................................................................................6..................................... 8 7 SITE INSTALLATION .........7 6............4 SCOPE ..................3 Quality and Condition of Track...2 Quality and Condition of Parts.............19 APPENDIX F: ......................11 7..............................4...3 UM71 Mounting Frames........................................................................................................ 7 6....................20 Technical Reference Date Executive Engineer Released 17-01-2011 Doc No..................................................................................4 IRJs ........................................................................................10 7............................................................1 Trackside Safety Considerations ....4 GENERAL ....................................................................................................................2 Rail Connections ....................... 14 APPENDIX A: ............................... 9 7...........................3 Documentation ............ Rev Page 00535-ND-09-WI-00147 1...4 Traction Current Equalisation and Earthing ............................................................... 9 7..10 7.......................................................................................................................................................................... 12 7................................................................................................15 Plugging-in and Presetting Rx Modules ...................IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction TABLE OF CONTENTS 1 2 3 4 5 OBJECTIVE..........4.................................................................................. 6 6 FACTORY ASSEMBLY ........................................................10 7................................................................................. 9 7.......................................................................................................................9 IRJ Installation...................................................................................................................................................................................................................6 Track and Equipment Connections ................................................................................................................................. 13 7.....................................................9 7......................................................11 7.................... 12 7.......................................1 UM71 Track Cables .....................................................................................................................................7 ESJ Installation...............................................................................................................................................................................................................................................11 Equipment Labelling.......13 Surge Protection Devices.....................................................5..................................................................................................... 2009 .. 9 7............................................................... © Ansaldo STS.................................................................................................................15 APPENDIX B: ...........................................6...........................................................................11 7.......................................... 13 7.....................................................................................................................................................................................7 Resistors ..............1 3(20) We reserve all rights in this document and in the information contained therein......................5 OHE Equipotential Earthing ...................................................................4 UM71 Electrical Connections ........................................................................................................5 Wiring Practices ..........4 REFERENCES ........................................................................................ 12 7..................... 6 5.

2009 . Revision 003 [5] UM71 AFTC Testing and Commissioning Instruction. Single Phase Traction System [4] N. and • Site installation and cabling of UM71 track circuits. a. supplying and installing any other UM71 equipment to Indian Railways where unbalanced operation applies. September 2001 [3] RDSO Code No. Rev Page 00535-ND-09-WI-00147 1.S1 Mounting Frame Dimensions. 2006/SIG/KfW/Rev.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction 1 OBJECTIVE The objective of this work instruction for the KfW Project is to ensure a consistent.2010 that contains installation and maintenance requirements for the application of UM71 track circuits operating in unbalanced bi-rail mode. Technical Specifications and Application Manual and Appendixes Version D. © Ansaldo STS. dated 11. 3 ABBREVEATIONS AND DEFINITIONS Reference 4 Meaning ESJ IB Electrical separation joint Impedance bond (conventional iron cored type) IRJ IT Insulated rail joint Intermediate transmission (feed point/Tx location) ITL KfW Integral transverse link German government-owned development bank “O”Bond Q Factor Air-core inductor (special type of very low impedance bond) Quality factor of UM71 tuned circuit OHE Rx Overhead equipment Receiver SPD STL Surge protection device Simple transverse link TMS TMU Total Management System of ASTS Tuning matching unit Tx Transmitter REFERENCES [1] Indian Railways UM71 Manual. Although this instruction is specifically targeted to the KfW Project it shall be considered when bidding. 535-BL-05-WI-00014.11. use or disclosure to third parties without express authority is strictly forbidden. TA-BE-03-D6-0037. 535-ND-09-WI-00176 Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. 50 Hz. 22 November 2011 [2] Indian Railways Signal Engineering Manual Part – II. SCOPE This work instruction has been updated to take account of the OEM and RDSO collaboration leading to the issue of Railway Board Letter. ETI/OHE/71(11/90). Appendix II Code for Bonding and Earthing for 25 kV. Revision 4 [6] EMC Work Instruction.1 4(20) We reserve all rights in this document and in the information contained therein. good quality approach to the activities concerning: 2 • Factory assembly and wiring of UM71 track circuits. Reproduction. No.c.

IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction [7] Typical Bonding and Earthing Plans for Block Sections. 535-ND-04-TYP-027A & 027B [8] ASTS TMS Checklists PMO-FRM-0005 Equipment History PMO-FRM-0006 Pre-Test Inspection PMO-FRM-0009 Final Assembly Pre-Delivery PMO-FRM-0012 Crimping Tool Register [9] ASTS TMS Procedures PMO-PRO-0016 Assembly work PMO-PRO-0024 Site work Nonconforming Product. 2009 . SAS-PRO-0037 [10] Technical Reference Date Executive Engineer Released 17-01-2011 Doc No.1 5(20) We reserve all rights in this document and in the information contained therein. © Ansaldo STS. use or disclosure to third parties without express authority is strictly forbidden. Rev Page 00535-ND-09-WI-00147 1. Reproduction.

2 • The ASTS Engineering Manager shall be responsible for specifying the correct parts. 5. use or disclosure to third parties without express authority is strictly forbidden. Additionally. In Section 6. TMU wiring Typical and actual track Bonding Plans relating to Section 7 of this instruction showing o o o o Location and connection of TMUs and “O”Bonds Location of STLs (ITLs are only required near substations/feeder points) Location of earthing points Location of earthing cables and strips Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. all line-side cabinets and equipment cases etc shall be secured by padlock when unattended by ASTS or MRT representatives. © Ansaldo STS. Rev Page 00535-ND-09-WI-00147 1. site installation shall also include all related UM71 site cabling and wiring. Setting to work. ASTS TMS Checklists and Procedures shall apply to this Project and shall be performed in accordance with references [8] & [9] as applicable in the factory and at site. Section 6 concerns the work activities in the factory and Section 7 concerns the work activities at site for the KfW Project.3 Documentation General reference documentation is given in Section 4 of this Instruction. • The ASTS Workshop Supervisor shall be responsible for the factory assembly activities described in Section 6 of this WI. specific KfW Project documentation comprises: Typical and actual Interface Circuits relating to Section 6 of this instruction showing o AFTC rack layouts o AFTC Microlok input wiring o AFTC Tx. • The North Central Railway shall be responsible for altering the traction earthing to suit double rail track circuit operation in accordance with the Contract conditions and Indian Railways procedures and practices referenced in [2] & [3]. Factory inspections shall include factory bell continuity testing of all wiring and any corrections thereto prior to delivery to site. Security Arrangements Following installation at site.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction 5 GENERAL This Instruction is divided into two parts. Reproduction. Rx. • The ASTS Project Manager shall be responsible for procuring the specified parts. equipment and tools and ensuring that the required installation standards are adopted and implemented by MRT.1 Responsibilities Persons concerned with the factory assembly and wiring and site installation and cabling of UM71 AFTCs for the KfW Project shall make themselves familiar with the relevant sections of references [1]. • The MRT Site Supervisor shall be responsible for site installation activites described in Section 7 of this WI. equipment and tools. factory assembly shall also include all related UM71 wiring and in Section 7. 2009 .1 6(20) We reserve all rights in this document and in the information contained therein. [2] & [3] and any queries arising from the reference material of this work instruction shall be raised with the KfW Project Engineering Manager. testing and commissioning of UM71 AFTCs is outside the scope of this Instruction and shall be conducted in accordance with reference [5]. 5. 5.

Additional particulars and clarifications are provided in this Instruction.3 & 14. and.4 UM71 Electrical Connections All electrical connection to the UM71 equipment modules is via PFC-12 connector blocks. PFC-0 coding plates and PFO blanking plates.S1 mounting frame profiles shall be in exact accordance with the approved details shown in Appendix A. Rev Page 00535-ND-09-WI-00147 1.1 FACTORY ASSEMBLY General The general assembly and wiring requirements for the UM71 Tx and Rx modules are mainly referenced in [1]. it is essential that the correct grade of connectors is used and that they are connected to the wires using the specified tools as follows: The PIDG Faston connectors shall be gold-flashed phosphor-bronze Tyco Part No. Reproduction. Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. 6. Important Note: Not meeting this requirement may result in poor alignment and poor lock-down of the UM71 Tx and Rx modules. Materials and Tools The quality and condition of all parts.3 UM71 Mounting Frames UM71 mounting frames that are locally produced for the KfW Project must be accurately machined to ensure that the N.1 7(20) We reserve all rights in this document and in the information contained therein. The punching of the N. Materials shall typically include: AFTC rack. PIDG Faston connectors. 2009 . Parts shall include: fuse holders. coding pins and locking cams.S1 modular mounting profiles are correctly and accurately reproduced on material of the correct thickness.2. 409775-1 The connector insertion/extraction tool shall be CSEE Part No. Tx mounting frames and Rx mounting frames. 00140879-3 The connector crimping tool shall be Tyco Part No. This is an extract of reference [4] that is verified to the original SNCF drawings. Poor electrical contact between the Tx and Rx modules and their PFC-12 contact blocks. This may result in random system failures and impair rail traffic operations due to: Mechanical wear from vibration at the module mounting lugs. © Ansaldo STS.2 Quality and Condition of Parts. Tools shall typically include: Double-action hand crimpers and PIDG Faston insertion/extraction pliers. Tools shall be maintained in accordance with the manufacturer’s instructions and tested at the prescribed intervals in accordance with the TMS. For long term system reliability. Wires are attached to these connector blocks using miniature PIDG Faston connectors. terminals.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction 6 6. 6. UM71 PFC-12 connectors. 2261193P00 Each PIDG Faston connector shall be examined when released from the crimping tool to confirm it has been correctly crimped and the Faston connector has not been distorted from its original shape. use or disclosure to third parties without express authority is strictly forbidden. Sections 13. 6. Any items not meeting these requirements shall be dealt with in accordance with reference [10]. materials and tools used for the assembly and wiring of UM71 equipment racks shall be inspected to ensure they are fit for purpose prior to being used.

Additionally.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction Important Note: Not meeting these specified requirements may result in poor quality electrical connections that will cause intermittent or complete system failures over time and impair rail traffic operations.5 Wiring Practices All wiring attached to UM71 Tx and Rx modules shall be twisted.g. by welding.6 Earthing and Equipotential Bonding in LSCs The UM71 equipment racks shall be fitted with a functional earth busbar as described in reference [6]. Reproduction.7 Resistors High reliability loading resistors. All wiring that does not comply with these requirements shall be rejected and replaced. The group of twisted/screened wires carrying the up-side Tx audio signals from the AFTC rack to the CT must be separated from the group of wires carrying the Rx audio signals from the CT rack to the AFTC rack. including B24 and N24 power wires. Such failures arising also present serious safety hazards when the signalling is non-operational. Equipotential earthing points for connection to adjacent racks/cabinets/ducts shall be designed and built into the AFTC rack structure for directly electrical connection at site.1 8(20) We reserve all rights in this document and in the information contained therein. shall be separately bonded using lugged copper braids tightly attached to bare metal as described in reference [6]. part no. the wires carrying the audio frequency signals shall be separated and routed as follows: The Tx and Rx audio signal wires should also be screened pairs ensuring the screening of the conductors is maintained right up to the Tx or Rx Unit respectively. 6. Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. 6. Important Note: Not meeting these requirements may result in electrical crosstalk between the track circuits that could cause intermittent or complete system failures and impair rail traffic operations. Any metalwork that is not electrically connected through the structure of the rack. Rev Page 00535-ND-09-WI-00147 1. 6. These connections shall be tested to confirm very low resistance and then sealed to prevent corrosion. 2009 . This busbar shall be directly attached to the AFTC rack metalwork both electrically and mechanically. use or disclosure to third parties without express authority is strictly forbidden. Such failures arising also present serious safety hazards when the signalling is non-operational. © Ansaldo STS. 6. Details of the resistor and mounting arrangement are shown in Appendix B. voltage checks and replacement. These resistors are fixed directly to the AFTC Rx 4 module mounting and one wire only is attached to each of the 4 screw terminals to ensure ease of maintenance. BHPR 200 Z S 261 J are utilised to replace relays for directly interfacing the UM71 Rx outputs to Microlok II Input cards. e. The minimum separation between these groups of wires shall be 100 mm.8 Labelling All equipment mounted on the AFTC rack shall be clearly and permanently labelled and all wires shall be clearly and permanently marked for ease of maintenance. All connections that do not comply with these requirements shall be rejected and replaced.

lugs.4 Traction Current Equalisation and Earthing The UM71 track circuit and traction return bonding is an integrated arrangement and shall be installed as shown in the approved typical drawings reference [7] for the KfW autoblock sections. metal pipes and signal wires etc shall not be left underneath the rails. Reproduction.6 of reference [1] but as modified for unbalanced bi-rail operation as specified in Section 11. general hand tools. cables. Rev Page 00535-ND-09-WI-00147 1. Parts shall typically include: “O”Bonds. UM71 camkey. Chapter XVII. use or disclosure to third parties without express authority is strictly forbidden.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction 7 SITE INSTALLATION 7. Lengths of released rail. IRJ or IT point. Cadweld or pin brazing or rail bolting materials as required. shall not be placed parallel to the track. 7.1 Plain Line In plain line sections. Tools shall typically include: Hydraulic crimpers. c) All staff shall be in possession of a valid certificate proving that they have attended an approved ‘track safety awareness course’. Ballast clearance not less than 50 mm level below the foot of the rail. © Ansaldo STS. 7. These plans incorporate the earthing rules as specified in Section 9. 2009 . bonds. Old/redundant metal rods. b) Personal protective equipment should be worn when working on or about the designated work site. 7.4.km in open line sections.1 Trackside Safety Considerations a) Installation staff involved shall be competent to undertake the work. Metal liners not permitted.3 of reference [1]. TMU protection covers. TMUs. concrete mounting bases. equipotential connections (STLs) are installed Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. 7. d) The appropriate measures will be taken to ensure the safety of all team members during their work on or about the track. Cadwelding or pin brazing kit.1 9(20) We reserve all rights in this document and in the information contained therein. To achieve this value in line with reference [2]. Any items not meeting these requirements shall be reported to the ASTS Project Manager by the MRT Site Supervisor. either new or old. Materials shall typically include: aluminium cable.g. mild steel tapes. shall not be permitted within 30 m of an ESJ zone. To achieve this.3 Quality and Condition of Track The quality and condition of the track shall meet the requirements specified by IR to meet a ballast resistance of 4 .2 Quality and Condition of Parts and Equipment The quality and condition of all parts. the traction current is equalised as far as possible in each rail and limited to 10% imbalance between rails. Old/redundant electrical connections of any type e. the following conditions must be addressed: Approved insulated liners/pads installed throughout the entire section of AFTCs including at level crossings and bridges etc..1. materials and tools used for the installation and cabling of UM71 track circuits shall be inspected to ensure they are fit for purpose prior to being used. tapes.

an “O”Bond shall also be installed across the rails.1. 800 to 1200 m apart. Additionally.3 of reference [1] is for the OHE masts to be directly bonded to the outer rails thereby ensuring all OHE metalwork remains at the same potential as the rails. © Ansaldo STS.5 OHE Equipotential Earthing The OHE equipotential earthing scheme is an integral part of the traction earthing and impacts directly on track circuit operation. 7. Important Note: Unbalanced bi-rail operation of UM71 with direct mast interconnection shall not allowed in station section.4. Refer to Appendix F. However. 2009 . 7. The principle of this earthing arrangement as described in Section 11. 7.4. ITs and IRJs where “O”Bonds must be located as part of the system design. Refer to Appendix E. it is essential to keep the rail-to-rail traction return voltage differential extremely low at this point and an “O”Bond is installed across the rails. The centre tap of this “O”Bond is not earthed. not cracked or damaged.5 below and the diagram in Appendix C. With this unbalanced bi-rail operation there is no requirement to provide ITLs as the regular OHE mast structure bonds provide a path to earth common to the two tracks. OHE mast bases to be cleared of any deposits of spoil. OHE mast to rail connections must be in good condition with rail and mast nuts and bolts tight.1 Bonds All UM71 “O”Bond to rail connections shall be carried out with 180 mm² multi-strand aluminium cable with light insulation to IS 1554 : Part1 : 1988. Rev Page 00535-ND-09-WI-00147 1.5. 7.4 IRJs At station/auto-block interfaces where IRJs must be installed in both rails of each track to prevent any unbalanced mono-rail circuit conditions being presented to the UM71 and impairing its operation. OHE mast base to be in sound condition. and further details are given in Section 7.4. Ideally these points will coincide with ESJs. The centre tap of the “O”Bond shall be connected to the traction return rail of the abutting DCTC. Refer to Appendix D.3 IT Points At intermediate transmission points. where it is essential to keep the rail to rail traction return voltage differential extremely low. If any in-section substation/feeder point is located in an autolock.2 ESJ Zones In ESJ zones where it is essential to keep the rail-to-rail traction return voltage differential extremely low an “O”Bond shall be installed across the rails at the centre of the ESJ zone. To minimise the variability of these earth path values on the operation of the UM71 AFTCs the OHE mast earth values should remain as high as is reasonably possible and this requires some additional installation precautions to be observed and implemented. Reproduction. This situation shall be raised with the ASTS Engineering Manager. use or disclosure to third parties without express authority is strictly forbidden.1 10(20) We reserve all rights in this document and in the information contained therein. Refer to Appendix C.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction between the rails of both tracks at convenient points. 7. ballast or rubbish.6 Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. Refer to Section 7. then additional “O”Bonds or Impedance bonds and ITLs may be required. the individual OHE masts are not specifically earthed and have a natural high earth value by virtue of their concrete bases and the local ground conditions.

6. © Ansaldo STS. transverse bonding and bonding for general earthing purposes shall be carried out with one or more 35 x 6 mm² GI bars securely attached to form low resistance electrical connections. 7.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction To avoid theft all STLs. the resistance value of the rail connections shall be measured using a Fluke 289 to ensure they are 1 m . If any are found to be 5 m then the cable shall be rejected.6. must be installed as specified in the documents.2 Rail Connections The pre-manufactured track cables shall be attached to the rails either by Cadwelding or pin brazing techniques or by bolting through stainless steel or copper ferrules inserted into the rails by a compression tool. These cables shall be pre-cut.7 m long 180 mm aluminium track cables are used to connect the TMUs and “O”Bonds to the rails at ESJs. washers and locknuts at IRJ and at intermediate transmission points at the same time as attaching the track cables. If they are 5 m then the connections shall be rejected and remade. After attachment to the TMU/”O”Bond termination points. 7. After attachment to the rail. using M13 copper tubular crimp lugs of type Cat. Reproduction.1 11(20) We reserve all rights in this document and in the information contained therein.6 Track and Equipment Connections It is critical that all UM71 connection cables and lugs are correctly assembled from the correct materials to the correct dimensions and with the correct tools and installed such that the resulting terminations are of good quality. 7. such that the wanted track circuit signal is not swamped due to the effects traction interference and/or crosstalk from adjacent track circuits either of the same or different frequencies. reference [1]. High ac currents may be flowing through the “O”Bond cables to ensure the traction return currents are balanced. Important Notes: 1. 2. Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. 7. ITLs. washers and locknuts. and high unwanted differential ac voltages will be generated if high resistance connections are present that may compromise the track circuit’s safe and reliable operation. use or disclosure to third parties without express authority is strictly forbidden. The resistance values of the crimp lug connections shall be measured before installation using a Fluke 289 to ensure they are 1 m .6. 319-27.4 TMU/”O”Bond Parallel Connections The pre-manufactured parallel cables shall be attached to the TMU/”O”Bond termination points using M13 stainless steel bolts.6. 2009 . The ESJ tuned circuit.1 UM71 Track Cables 2 3 m and 4. and pre-tested at the Depot to ensure accurate lengths and good quality low resistance terminations.3 TMU/”O”Bond Equipment Connections The pre-manufactured track cables shall be attached to the TMU/”O”Bond termination points using M13 stainless steel bolts. the resistance value of the equipment connections shall be measured using a Fluke 289 to ensure they are 1 m . intermediate transmission points and at IRJs. 7. If it is 5 m then the connection shall be rejected and remade. prelugged. The connection points shall be made with galvanised nuts and bolts and sealed with a corrosion preventative as described in reference [6]. 2 450 mm long 180 mm aluminium cables for parallel connections between TMUs and “O”Bonds shall be similarly pre-manufactured to the same quality. No. Rev Page 00535-ND-09-WI-00147 1.

Deviation from these tolerances will impair the Q factor of the tuned circuits.5 as indicated on the bonding plans. This practice also ensures there is no possibility of developing unwanted crosstalk in the tuned circuit cables due to excess cable or random cable loops. the screen and armouring shall also be earthed at the intermediate location in addition to the technical room and TMU.6 and all in accordance with the drawings in Appendix F.5 as indicated on the bonding plans. 2009 . Failure to follow this practice will impair the Q factor of the tuned circuits formed by the TMUs. or IT end shall be 1000 m using one pair or 2000 m using two pairs of quad cable as specified in Section 7. of conductor size 0.9 mm dia line-side quad cables installed between the UM71 Tx/Rx and the UM71 TMU shall be terminated at all points as shown in the interface circuits. Where these line-side cables pass through an intermediate location to reach a TMU.8.9 IRJ Installation Equipment abutting DCTCs at IRJs shall be installed with due care and attention observing the requirements of Section 7.5 as indicated on the bonding plans. Incorrect circuit pairing results in the cable transmission parameters being changed and may induce significant unwanted cross-talk levels in adjacent circuits. 7.6 and all in accordance with the drawings in Appendix E.e. between transmitter/receiver and TMUs at an ESJ. The screen. consistently using the same pair/s throughout. i. 2. The TMUs and “O”Bond shall be positioned as specified. The screens and metal armours of the Tx and Rx line-side cables shall be connected to the earth at both ends.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction After attachment the resistance value of the parallel connections shall be measured using a Fluke 289 to ensure they are 1 m . The 26 m length of the ESJ shall be measured and shall be within the tolerances permitted in Appendix D.7 ESJ Installation ESJ zones and equipment shall be installed with due care and attention observing the requirements of Section 7.9 mm dia. The pairs of 180 mm2 aluminium track cables shall be dressed so that they are in very close proximity between the outer rail and the TMU/”O”Bond. Important Notes: 1.3 of reference [1]. use or disclosure to third parties without express authority is strictly forbidden. Each transmission or reception circuit shall only use the conductors from the same pair. and using the techniques set out in Section 7. and metal armour shall be attached to the equi-potential earthing system at the technical room or at intermediate connection points by short straight cables of size not less than 4 mm2. 7. at the technical room end and at the TMU end. © Ansaldo STS. If it is 5 m then the connection shall be rejected and remade. 7. IRJ. Rev Page 00535-ND-09-WI-00147 1.10 Line-side Quad Cable Connections The 0.1 12(20) We reserve all rights in this document and in the information contained therein. and using the techniques set out in Section 7. Note the tuned circuit formed at IRJs is suitable for attachment to either a Tx or Rx track circuit end. 7. and using the techniques set out in Section 7. Non-metallic clamps shall be provided to hold these cables closely together.8 Intermediate Transmitter Installation Intermediate transmitter equipment shall be installed with due care and attention observing the requirements of Section 7. Reproduction. The maximum length of cable connected together for a Tx and Rx circuit shall not exceed Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. The maximum line-side cable length.6 and all in accordance with the drawings in Appendix D.

V5-V6 Nil V3-V4. © Ansaldo STS. 7.11 Equipment Labelling All line-side equipment and line-side quad cables shall be clearly identified with good quality permanent labels for ease of maintenance. or to the input of a receiver shall be lightly twisted between the transmitter or the receiver and the line-side quad cable terminations. 2009 . Each pair of wires.1 13(20) We reserve all rights in this document and in the information contained therein.75 4. The functional earth shall be integrated with the AFTC rack earth.5 4 3. The Tx module locking cam should then be rotated with the key and the Tx module be observed to be pulled down and fully locked in position correctly (This can be checked by observing the position of the cam at the rear of the rack). V5-V6 V2-V7 2. Earth wires shall be as short and straight as possible and of size not less 2 than 4 mm . connected in the same line-side circuit corresponding either to the output of a transmitter. These devices require an effective functional earth of 2 and this shall be installed as detailed in the interface circuit wiring diagrams.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction 2000m as stated above. The external modulation input is bypassed (fit strap M1-M3) Technical Reference Date Executive Engineer Released 17-01-2011 Doc No.13 Surge Protection Devices Surge protection devices shall be fitted in accordance with the wiring diagrams. 7.g. 7. coding pins are not binding and PFC-0 coding plates and PFO blanking plates are securely in place. that contact blocks are engaged correctly. use or disclosure to third parties without express authority is strictly forbidden. Reproduction. Lugged copper braids tightly attached to the specified terminating points shall be fitted to connect the AFTC rack to all other metalwork in the LSC. miniature relays.25 Connect MU t1 to Tx MU t2 to Tx V2 V7 V7 V8 V1 V7 V1 V8 Strap V3-V4. Rev Page 00535-ND-09-WI-00147 1.12 Earthing and Equipotential Bonding of AFTC Rack The AFTC rack shall be bonded and earthed in accordance with reference [6] and as shown in the interface circuits. Important Note: SPDs should not contain components that can fail to earth leaving permanent earth paths on vital cable cores. Any misalignment or other seating issues observed must be fixed before handing over for testing. 7. The output signal level (KEM) is preset correctly for the Tx frequency as follows: Frequency Hz 1700 2000 2300 2600 KEM 3. These connections shall be tested to confirm very low resistance and then sealed to prevent corrosion. that are connected to non-vital circuits unless the componets have been tested and certified to meet the minimum vital isolation requirement of 2000 V rms for 1 minute. For each Tx check: 1. or contain other ancillary devices e.14 Plugging-in and Presetting Tx Modules Each Tx module shall be carefully inserted into the mounting frame to ensure there is no misalignment.

Any misalignment or other seating issues observed must be fixed before handing over for testing. The Rx module locking cam should then be rotated with the key and the Rx module be observed to be pulled down and fully locked in position correctly (This can be checked by observing the position of the cam at the rear of the rack). The power selection is pre-set as follows: End fed tracks < 400 m. © Ansaldo STS. end fed tracks 400 m and all intermediate fed tracks. that contact blocks are engaged correctly. set the power level to low (no straps) End fed tracks < 400 m encountering a level crossing. In both case wire jumpers between internal terminals V1 & 1. 2009 .IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction 3. If the power delivered is > 12 VA and 21 VA then the high power setting shall be selected. Technical Reference Date Executive Engineer Released 17-01-2011 Doc No.15 Plugging-in and Presetting Rx Modules Each Rx module shall be carefully inserted into the mounting frame to ensure there is no misalignment. Connect the reception cable to terminals 9 & 10. For reception purposes at an ESJ or IRJ the KTMU shall be set at n = 1:1 and the serial inductors by-passed. The input signal level (KRV) is set preset as follows: Tracks < 400 m set the KRV to 20 (fit strap R3-R8) Tracks 400 m set the KRV to 30 (fit straps R5-R6. set the power level to high (fit straps M2-M4-M5) Important Note: The power settings shall be re-checked on site once the track circuit has been powered-up by measuring the voltage across the transmitter output terminals and the output current and then calculating the output power delivered. For each Rx check: 1.1 14(20) We reserve all rights in this document and in the information contained therein. coding pins are not binding and PFC-0 coding plates and PFO blanking plates are securely in place. and V2 & 4 This completes the site work and the installation should be handed over to the testing and commissioning team to carry out the activities described in reference [5]. The receiver pick-up time delay (t) is preset as follows: 2. IT and IRJ the KTMU shall be set at n = 10:1 and with the serial inductors in circuit. 7. R7-R8) 2.7. Connect the transmission cable to terminals E1 & E2.16 Presetting TMUs Each installed TMU requires the matching transformer ratios shall be preset in accordance with Section 7.7 Secs (fit strap C-C2) 7.2 of reference [1]. Reproduction. as follows: For transmission purposes at an ESJ.3 – 2. Rev Page 00535-ND-09-WI-00147 1. use or disclosure to third parties without express authority is strictly forbidden. If the power delivered is 12 VA then the low power setting shall be selected.

IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction APPENDIX A: SNCF N. 2009 .S1 Standard Dimensions Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. © Ansaldo STS. Reproduction. Rev Page 00535-ND-09-WI-00147 1. use or disclosure to third parties without express authority is strictly forbidden.1 15(20) We reserve all rights in this document and in the information contained therein.

2009 .1 16(20) We reserve all rights in this document and in the information contained therein. © Ansaldo STS. Rev Page 00535-ND-09-WI-00147 1. Reproduction.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction APPENDIX B: BHPR Resistor Installation Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. use or disclosure to third parties without express authority is strictly forbidden.

© Ansaldo STS. 2009 . use or disclosure to third parties without express authority is strictly forbidden.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction APPENDIX C: Provision of STLs "#$% $ ! ! "#$% $ Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. Rev Page 00535-ND-09-WI-00147 1. Reproduction.1 17(20) We reserve all rights in this document and in the information contained therein.

1 18(20) We reserve all rights in this document and in the information contained therein. / 213 2&3 4* 5 5* 5 5 5 * 5 5: 2+3 =* > 213 =* ' * > > * 8 9 8 9 5 &6) 7 1') . use or disclosure to third parties without express authority is strictly forbidden. © Ansaldo STS. 2009 .IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction APPENDIX D: ESJ Installation +( &1 &0 &1 +) +) 2&3 2&3 &'() 2&3 &) @- 2+3 ! 2+3 . 7 5 !! )'(0. 7 2+3 ? 213 +))) * )'+) * )'+) Technical Reference Date Executive Engineer Released 17-01-2011 &'() &'() &) &) Doc No. Reproduction.'< !! )'(0. - . Rev Page 00535-ND-09-WI-00147 1.

1 19(20) We reserve all rights in this document and in the information contained therein. © Ansaldo STS. use or disclosure to third parties without express authority is strictly forbidden.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction APPENDIX E: Intermediate Transmitter Installation Technical Reference Date Executive Engineer Released 17-01-2011 Doc No. 2009 . Rev Page 00535-ND-09-WI-00147 1. Reproduction.

7 5 !! )'(0. - * * 8 9 8 9 5 &6) 7 1') .1 20(20) We reserve all rights in this document and in the information contained therein. / * )'+) Technical Reference Date Executive Engineer Released 17-01-2011 &'() &) Doc No. © Ansaldo STS.IRPMU (Modernization of Signalling in CNB-GZB section) UM71 TC Assembly & Installation Instruction APPENDIX F: Insulated Rail Joint Installation !" @- &'() $ $ # ! 2&3 &) " 2&3 2&3 4* 5 5* 5 5 5 * 5 5: 2+3 =* > % 2+3 213 =* ' 213 . 7 > > 2+3 ? 213 +))) .'< !! )'(0. Rev Page 00535-ND-09-WI-00147 1. use or disclosure to third parties without express authority is strictly forbidden. 2009 . Reproduction.