UM71 AFTC Assembly and Installation Instruction (V 1 1)

IRPMU Modernization of Signalling & Telecom
Systems on Ghaziabad-Kanpur Section
UM71 AFTC Factory Assembly

and Site Installation Instruction
Document Producer
Checked by
Approved by
Howard Revell
Executive Engineer
Manas Bose
Engineering Manager
Iyyappan
Project Director
Technical Reference
Date
Doc No.
Rev
Page
Executive Engineer
17-01-2011
00535-ND-09-WI-00147
1.1
1(20)
Released
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
Revision
Prepared by
Changes/Comments
Date
0.1
0.2
1.0
1.1
Howard Revell
Howard Revell
Howard Revell
Howard Revell
Draft
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
DISTRIBUTION
This document is to be distributed as shown on the following table. Any subsequent update after the initial
issue must be fully distributed.
Copy No.
1
2
3
4
5
6
Holder
Technical Reference
Date
Executive Engineer
17-01-2011
Released
Location
Design Manager
V&V Manager
Tester In Charge
Commissioning Engineer
Site Manager
Project File
Pvt
Ptv
Pvt
Pvt
Pvt
Pvt
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
2(20)
Ansaldo STS, 2009

TABLE OF CONTENTS
1
2
3
4
5
OBJECTIVE...............................................................................................................................................4
SCOPE ......................................................................................................................................................4
ABBREVEATIONS AND DEFINITIONS....................................................................................................4
REFERENCES ..........................................................................................................................................4
GENERAL .................................................................................................................................................6
5.1
Responsibilities .................................................................................................................................. 6
5.2
Security Arrangements....................................................................................................................... 6
5.3
Documentation ................................................................................................................................... 6
6 FACTORY ASSEMBLY .............................................................................................................................7
6.1
General............................................................................................................................................... 7
6.2
Quality and Condition of Parts, Materials and Tools.......................................................................... 7
6.3
UM71 Mounting Frames..................................................................................................................... 7
6.4
UM71 Electrical Connections ............................................................................................................. 7
6.5
Wiring Practices ................................................................................................................................. 8
6.6
Earthing and Equipotential Bonding in LSCs ..................................................................................... 8
6.7
Resistors ............................................................................................................................................ 8
6.8
Labelling ............................................................................................................................................. 8
7 SITE INSTALLATION ................................................................................................................................9
7.1
Trackside Safety Considerations ....................................................................................................... 9
7.2
Quality and Condition of Parts and Equipment .................................................................................. 9
7.3
Quality and Condition of Track........................................................................................................... 9
7.4
Traction Current Equalisation and Earthing ....................................................................................... 9
7.4.1
Plain Line ....................................................................................................................................9
7.4.2
ESJ Zones.................................................................................................................................10
7.4.3
IT Points ....................................................................................................................................10
7.4.4
IRJs ...........................................................................................................................................10
7.5
OHE Equipotential Earthing ............................................................................................................. 10
7.5.1
Bonds ........................................................................................................................................10
7.6
Track and Equipment Connections .................................................................................................. 11
7.6.1
UM71 Track Cables ..................................................................................................................11
7.6.2
Rail Connections .......................................................................................................................11
7.6.3
TMU/OBond Equipment Connections ....................................................................................11
7.6.4
TMU/OBond Parallel Connections .........................................................................................11
7.7
ESJ Installation................................................................................................................................. 12
7.8
Intermediate Transmitter Installation................................................................................................ 12
7.9
IRJ Installation.................................................................................................................................. 12
7.10 Line-side Quad Cable Connections ................................................................................................. 12
7.11 Equipment Labelling......................................................................................................................... 13
7.12 Earthing and Equipotential Bonding of AFTC Rack ......................................................................... 13
7.13 Surge Protection Devices................................................................................................................. 13
7.14 Plugging-in and Presetting Tx Modules ........................................................................................... 13
7.15 Plugging-in and Presetting Rx Modules ........................................................................................... 14
7.16 Presetting TMUs............................................................................................................................... 14
APPENDIX A: .................................................................................................................................................15
APPENDIX B: .................................................................................................................................................16
APPENDIX C: .................................................................................................................................................17
APPENDIX D: .................................................................................................................................................18
APPENDIX E: .................................................................................................................................................19
APPENDIX F: .................................................................................................................................................20
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
3(20)
Ansaldo STS, 2009

OBJECTIVE
The objective of this work instruction for the KfW Project is to ensure a consistent, good quality
approach to the activities concerning:
Factory assembly and wiring of UM71 track circuits; and
Site installation and cabling of UM71 track circuits.
SCOPE
This work instruction has been updated to take account of the OEM and RDSO collaboration leading
to the issue of Railway Board Letter, No. 2006/SIG/KfW/Rev, dated 11.11.2010 that contains
installation and maintenance requirements for the application of UM71 track circuits operating in
unbalanced bi-rail mode. Although this instruction is specifically targeted to the KfW Project it shall
be considered when bidding, supplying and installing any other UM71 equipment to Indian Railways
where unbalanced operation applies.
ABBREVEATIONS AND DEFINITIONS

Reference
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
OBond
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, Technical Specifications and Application Manual and
Appendixes Version D, 22 November 2011
[2]
Indian Railways Signal Engineering Manual Part II, September 2001
[3]
RDSO Code No. ETI/OHE/71(11/90), Appendix II Code for Bonding and Earthing for 25
kV, a.c. 50 Hz, Single Phase Traction System
[4]
N.S1 Mounting Frame Dimensions, TA-BE-03-D6-0037, Revision 003
[5]
UM71 AFTC Testing and Commissioning Instruction, 535-BL-05-WI-00014, Revision 4
[6]
EMC Work Instruction, 535-ND-09-WI-00176
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
4(20)
Ansaldo STS, 2009

[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, SAS-PRO-0037
[10]
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
5(20)
Ansaldo STS, 2009

GENERAL
This Instruction is divided into two parts. Section 6 concerns the work activities in the factory and
Section 7 concerns the work activities at site for the KfW Project. In Section 6, factory assembly
shall also include all related UM71 wiring and in Section 7, site installation shall also include all
related UM71 site cabling and wiring.
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.
Factory inspections shall include factory bell continuity testing of all wiring and any corrections
thereto prior to delivery to site. Setting to work, testing and commissioning of UM71 AFTCs is
outside the scope of this Instruction and shall be conducted in accordance with reference [5].
5.1
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], [2] & [3] and any queries arising from the reference material of this work instruction shall be
raised with the KfW Project Engineering Manager.
5.2
The ASTS Engineering Manager shall be responsible for specifying the correct parts,
equipment and tools.
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.
The ASTS Workshop Supervisor shall be responsible for the factory assembly activities
described in Section 6 of this WI.
The MRT Site Supervisor shall be responsible for site installation activites described in Section
7 of this WI.
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].
Security Arrangements
Following installation at site, all line-side cabinets and equipment cases etc shall be secured by
padlock when unattended by ASTS or MRT representatives.
5.3 Documentation
General reference documentation is given in Section 4 of this Instruction.
Additionally, 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, Rx, 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 OBonds

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.
Rev
Page
00535-ND-09-WI-00147
1.1
6(20)
Ansaldo STS, 2009

6
6.1
FACTORY ASSEMBLY
General
The general assembly and wiring requirements for the UM71 Tx and Rx modules are mainly
referenced in [1], Sections 13.3 & 14.2. Additional particulars and clarifications are provided in this
Instruction.
6.2
Quality and Condition of Parts, Materials and Tools

The quality and condition of all parts, 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. Any items
not meeting these requirements shall be dealt with in accordance with reference [10]. Parts shall
include: fuse holders, terminals, PIDG Faston connectors, UM71 PFC-12 connectors, PFC-0 coding
plates and PFO blanking plates.
Materials shall typically include: AFTC rack, Tx mounting frames and Rx mounting frames.
Tools shall typically include: Double-action hand crimpers and PIDG Faston
insertion/extraction pliers.
Tools shall be maintained in accordance with the manufacturers instructions and tested at the
prescribed intervals in accordance with the TMS.
6.3
UM71 Mounting Frames

UM71 mounting frames that are locally produced for the KfW Project must be accurately machined
to ensure that the N.S1 modular mounting profiles are correctly and accurately reproduced on
material of the correct thickness.
Important Note:
Not meeting this requirement may result in poor alignment and poor lock-down of the UM71 Tx and
Rx modules. This may result in random system failures and impair rail traffic operations due to:
Mechanical wear from vibration at the module mounting lugs, coding pins and locking cams;
and,
Poor electrical contact between the Tx and Rx modules and their PFC-12 contact blocks.
The punching of the N.S1 mounting frame profiles shall be in exact accordance with the approved
details shown in Appendix A. This is an extract of reference [4] that is verified to the original SNCF
drawings.
6.4
UM71 Electrical Connections

All electrical connection to the UM71 equipment modules is via PFC-12 connector blocks. Wires are
attached to these connector blocks using miniature PIDG Faston connectors. For long term system
reliability, 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. 00140879-3
The connector crimping tool shall be Tyco Part No. 409775-1
The connector insertion/extraction tool shall be CSEE Part No. 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.
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
7(20)
Ansaldo STS, 2009

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. Such
failures arising also present serious safety hazards when the signalling is non-operational. All
connections that do not comply with these requirements shall be rejected and replaced.
6.5
Wiring Practices
All wiring attached to UM71 Tx and Rx modules shall be twisted, including B24 and N24 power
wires. Additionally, 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.
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. The minimum separation between these groups of wires shall
be 100 mm.
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. Such failures
arising also present serious safety hazards when the signalling is non-operational. All wiring that
does not comply with these requirements shall be rejected and replaced.
6.6
Earthing and Equipotential Bonding in LSCs

The UM71 equipment racks shall be fitted with a functional earth busbar as described in reference
[6]. This busbar shall be directly attached to the AFTC rack metalwork both electrically and
mechanically. Any metalwork that is not electrically connected through the structure of the rack, e.g.
by welding, shall be separately bonded using lugged copper braids tightly attached to bare metal as
described in reference [6]. These connections shall be tested to confirm very low resistance and
then sealed to prevent corrosion.
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.
6.7
Resistors
High reliability loading resistors, part no. BHPR 200 Z S 261 J are utilised to replace relays for
directly interfacing the UM71 Rx outputs to Microlok II Input cards. 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, voltage checks and replacement. Details of the resistor and mounting
arrangement are shown in Appendix B.
6.8
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.
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
8(20)
Ansaldo STS, 2009

SITE INSTALLATION
7.1
Trackside Safety Considerations

a) Installation staff involved shall be competent to undertake the work.
b) Personal protective equipment should be worn when working on or about the designated
work site.
c) All staff shall be in possession of a valid certificate proving that they have attended an
approved track safety awareness course.
d) The appropriate measures will be taken to ensure the safety of all team members during
their work on or about the track.
7.2
Quality and Condition of Parts and Equipment

The quality and condition of all parts, 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. Any
items not meeting these requirements shall be reported to the ASTS Project Manager by the MRT
Site Supervisor.
Parts shall typically include: OBonds, TMUs, TMU protection covers.
Materials shall typically include: aluminium cable, concrete mounting bases, mild steel tapes,,
lugs, Cadweld or pin brazing or rail bolting materials as required.
Tools shall typically include: Hydraulic crimpers, Cadwelding or pin brazing kit, UM71 camkey, general hand tools.
7.3
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 .km in open line sections. To achieve this value in line with reference [2], Chapter
XVII, the following conditions must be addressed:
Approved insulated liners/pads installed throughout the entire section of AFTCs including at
level crossings and bridges etc;
Metal liners not permitted;
Ballast clearance not less than 50 mm level below the foot of the rail;
Old/redundant electrical connections of any type e.g. bonds, cables, tapes, shall not be
permitted within 30 m of an ESJ zone, IRJ or IT point;
Old/redundant metal rods, metal pipes and signal wires etc shall not be left underneath the
rails;
Lengths of released rail, either new or old, shall not be placed parallel to the track.
7.4
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.
These plans incorporate the earthing rules as specified in Section 9.6 of reference [1] but as
modified for unbalanced bi-rail operation as specified in Section 11.1.3 of reference [1].
7.4.1
Plain Line
In plain line sections, the traction current is equalised as far as possible in each rail and limited to
10% imbalance between rails. To achieve this, equipotential connections (STLs) are installed
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
9(20)
Ansaldo STS, 2009

between the rails of both tracks at convenient points, 800 to 1200 m apart. Ideally these points will
coincide with ESJs, ITs and IRJs where OBonds must be located as part of the system design.
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. Refer to Section 7.5 below
and the diagram in Appendix C.
Important Note:
Unbalanced bi-rail operation of UM71 with direct mast interconnection shall not allowed in station
section.
7.4.2
ESJ Zones
In ESJ zones where it is essential to keep the rail-to-rail traction return voltage differential extremely
low an OBond shall be installed across the rails at the centre of the ESJ zone. The centre tap of
this OBond is not earthed. Refer to Appendix D.
7.4.3
IT Points
At intermediate transmission points, where it is essential to keep the rail to rail traction return voltage
differential extremely low, an OBond shall also be installed across the rails. Refer to Appendix E.
7.4.4
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. Additionally, it is essential to keep the rail-to-rail traction return voltage differential
extremely low at this point and an OBond is installed across the rails. The centre tap of the
OBond shall be connected to the traction return rail of the abutting DCTC. Refer to Appendix F.
If any in-section substation/feeder point is located in an autolock, then additional OBonds or
Impedance bonds and ITLs may be required. This situation shall be raised with the ASTS
Engineering Manager.
7.5
OHE Equipotential Earthing

The OHE equipotential earthing scheme is an integral part of the traction earthing and impacts
directly on track circuit operation. The principle of this earthing arrangement as described in Section
11.1.3 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. Refer to Appendix C. However, 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.
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.
OHE mast bases to be cleared of any deposits of spoil, ballast or rubbish;
OHE mast base to be in sound condition, not cracked or damaged;
OHE mast to rail connections must be in good condition with rail and mast nuts and bolts
tight.
7.5.1
Bonds
All UM71 OBond to rail connections shall be carried out with 180 mm multi-strand aluminium cable
with light insulation to IS 1554 : Part1 : 1988, and further details are given in Section 7.6
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
10(20)
Ansaldo STS, 2009

To avoid theft all STLs, ITLs, transverse bonding and bonding for general earthing purposes shall be
carried out with one or more 35 x 6 mm GI bars securely attached to form low resistance electrical
connections. The connection points shall be made with galvanised nuts and bolts and sealed with a
corrosion preventative as described in reference [6].
7.6
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.
Important Notes:
1. High ac currents may be flowing through the OBond cables to ensure the traction return
currents are balanced, and high unwanted differential ac voltages will be generated if high
resistance connections are present that may compromise the track circuits safe and reliable
operation.
2. The ESJ tuned circuit, must be installed as specified in the documents, reference [1], 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.
7.6.1
UM71 Track Cables

2
3 m and 4.7 m long 180 mm aluminium track cables are used to connect the TMUs and OBonds to
the rails at ESJs, intermediate transmission points and at IRJs. These cables shall be pre-cut, prelugged, using M13 copper tubular crimp lugs of type Cat. No. 319-27, and pre-tested at the Depot to
ensure accurate lengths and good quality low resistance terminations.
2
450 mm long 180 mm aluminium cables for parallel connections between TMUs and OBonds shall
be similarly pre-manufactured to the same quality.
The resistance values of the crimp lug connections shall be measured before installation using a
Fluke 289 to ensure they are 1 m . If any are found to be 5 m then the cable shall be rejected.
7.6.2
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.
After attachment to the rail, the resistance value of the rail connections shall be measured using a
Fluke 289 to ensure they are 1 m . If they are 5 m then the connections shall be rejected and
remade.
7.6.3
TMU/OBond Equipment Connections

The pre-manufactured track cables shall be attached to the TMU/OBond termination points using
M13 stainless steel bolts, washers and locknuts.
After attachment to the TMU/OBond termination points, the resistance value of the equipment
connections shall be measured using a Fluke 289 to ensure they are 1 m . If it is 5 m then the
connection shall be rejected and remade.
7.6.4
TMU/OBond Parallel Connections

The pre-manufactured parallel cables shall be attached to the TMU/OBond termination points using
M13 stainless steel bolts, washers and locknuts at IRJ and at intermediate transmission points at the
same time as attaching the track cables.
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
11(20)
Ansaldo STS, 2009

After attachment the resistance value of the parallel connections shall be measured using a Fluke
289 to ensure they are 1 m . If it is 5 m then the connection shall be rejected and remade.
7.7
ESJ Installation
ESJ zones and equipment shall be installed with due care and attention observing the requirements
of Section 7.5 as indicated on the bonding plans, and using the techniques set out in Section 7.6 and
all in accordance with the drawings in Appendix D.
Important Notes:
1. The 26 m length of the ESJ shall be measured and shall be within the tolerances permitted in
Appendix D. The TMUs and OBond shall be positioned as specified. Deviation from these
tolerances will impair the Q factor of the tuned circuits;
2. 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/OBond. Non-metallic clamps shall be provided
to hold these cables closely together. Failure to follow this practice will impair the Q factor of the
tuned circuits formed by the TMUs. 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.
7.8
Intermediate Transmitter Installation

Intermediate transmitter equipment shall be installed with due care and attention observing the
requirements of Section 7.5 as indicated on the bonding plans, and using the techniques set out in
Section 7.6 and all in accordance with the drawings in Appendix E.
7.9
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, and using the techniques set out in
Section 7.6 and all in accordance with the drawings in Appendix F.
Note the tuned circuit formed at IRJs is suitable for attachment to either a Tx or Rx track circuit end.
7.10
Line-side Quad Cable Connections

The 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, consistently using the same pair/s
throughout.
The screens and metal armours of the Tx and Rx line-side cables shall be connected to the earth at
both ends, i.e. at the technical room end and at the TMU end. The screen, 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.
The maximum line-side cable length, of conductor size 0.9 mm dia, between transmitter/receiver and
TMUs at an ESJ, IRJ, or IT end shall be 1000 m using one pair or 2000 m using two pairs of quad
cable as specified in Section 7.8.3 of reference [1]. Each transmission or reception circuit shall only
use the conductors from the same pair. Incorrect circuit pairing results in the cable transmission
parameters being changed and may induce significant unwanted cross-talk levels in adjacent
circuits.
Where these line-side cables pass through an intermediate location to reach a TMU, the screen and
armouring shall also be earthed at the intermediate location in addition to the technical room and
TMU. 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.
Rev
Page
00535-ND-09-WI-00147
1.1
12(20)
Ansaldo STS, 2009

2000m as stated above. Each pair of wires, connected in the same line-side circuit corresponding
either to the output of a transmitter, or to the input of a receiver shall be lightly twisted between the
transmitter or the receiver and the line-side quad cable terminations.
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.
7.12
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.
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. These connections shall be tested to confirm very low
resistance and then sealed to prevent corrosion.
7.13
Surge Protection Devices

Surge protection devices shall be fitted in accordance with the wiring diagrams. These devices
require an effective functional earth of 2
and this shall be installed as detailed in the interface
circuit wiring diagrams. Earth wires shall be as short and straight as possible and of size not less
2
than 4 mm . The functional earth shall be integrated with the AFTC rack earth.
Important Note:
SPDs should not contain components that can fail to earth leaving permanent earth paths on vital
cable cores, or contain other ancillary devices e.g. miniature relays, 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.
7.14
Plugging-in and Presetting Tx Modules

Each Tx module shall be carefully inserted into the mounting frame to ensure there is no
misalignment, that contact blocks are engaged correctly, coding pins are not binding and PFC-0
coding plates and PFO blanking plates are securely in place. 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).
Any misalignment or other seating issues observed must be fixed before handing over for testing.
For each Tx check:
1. The output signal level (KEM) is preset correctly for the Tx frequency as follows:
Frequency
Hz
1700
2000
2300
2600
KEM
3.5
4
3.75
4.25
Connect
MU t1 to Tx
MU t2 to Tx
V2
V7
V7
V8
V1
V7
V1
V8
Strap
V3-V4, V5-V6
Nil
V3-V4, V5-V6
V2-V7
2. The external modulation input is bypassed (fit strap M1-M3)
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
13(20)
Ansaldo STS, 2009

3. The power selection is pre-set as follows:
End fed tracks < 400 m, set the power level to low (no straps)
End fed tracks < 400 m encountering a level crossing, end fed tracks 400 m
and all intermediate fed tracks, 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. If the power delivered is 12 VA then the low power setting
shall be selected. If the power delivered is > 12 VA and 21 VA then the high power setting shall be
selected.
7.15 Plugging-in and Presetting Rx Modules

Each Rx module shall be carefully inserted into the mounting frame to ensure there is no
misalignment, that contact blocks are engaged correctly, coding pins are not binding and PFC-0
coding plates and PFO blanking plates are securely in place. 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). Any
misalignment or other seating issues observed must be fixed before handing over for testing.
For each Rx check:
1. 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, R7-R8)
2. The receiver pick-up time delay (t) is preset as follows:
2.3 2.7 Secs (fit strap C-C2)
7.16 Presetting TMUs

Each installed TMU requires the matching transformer ratios shall be preset in accordance with
Section 7.7.2 of reference [1], as follows:
For transmission purposes at an ESJ, IT and IRJ the KTMU shall be set at n = 10:1 and with
the serial inductors in circuit. Connect the transmission cable to terminals E1 & E2;
For reception purposes at an ESJ or IRJ the KTMU shall be set at n = 1:1 and the serial
inductors by-passed. Connect the reception cable to terminals 9 & 10;
In both case wire jumpers between internal terminals V1 & 1, 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].
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
14(20)
Ansaldo STS, 2009

APPENDIX A:
SNCF N.S1 Standard Dimensions
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
15(20)
Ansaldo STS, 2009

APPENDIX B:
BHPR Resistor Installation
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
16(20)
Ansaldo STS, 2009

APPENDIX C:
Provision of STLs
"#$% $
!
"#$% $
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
17(20)
Ansaldo STS, 2009

APPENDIX D:
ESJ Installation
+(
&1
&0
&1
+)
+)
2&3
2&3
&'()
2&3
&)
@-
2+3
2+3
, -
.
/
213
2&3 4* 5
5* 5 5
5 * 5 5:
2+3 =*
>
213 =*
'
>
>
*
8 9
8 9
5
&6)
7
1')
;'<
!! )'(0;
!! )'(0;
2+3 ? 213 +)))

* )'+)
* )'+)
Technical Reference
Date
Executive Engineer
Released
17-01-2011
&'()
&'()
&)
&)
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
18(20)
Ansaldo STS, 2009

APPENDIX E:
Intermediate Transmitter Installation
Technical Reference
Date
Executive Engineer
Released
17-01-2011
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
19(20)
Ansaldo STS, 2009

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
, -
*
8 9
8 9
5
&6)
7
1')
;'<
!! )'(0;
!! )'(0;
>
>
2+3 ? 213 +)))
.
/
* )'+)
Technical Reference
Date
Executive Engineer
Released
17-01-2011
&'()
&)
Doc No.
Rev
Page
00535-ND-09-WI-00147
1.1
20(20)
Ansaldo STS, 2009

UM71 AFTC Assembly and Installation Instruction (V 1 1)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

UM71 AFTC Assembly and Installation Instruction (V 1 1)

Uploaded by

Copyright:

Available Formats

IRPMU Modernization of Signalling & Telecom

Systems on Ghaziabad-Kanpur Section

UM71 AFTC Factory Assembly

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Factory assembly and wiring of UM71 track circuits; and

Site installation and cabling of UM71 track circuits.

ABBREVEATIONS AND DEFINITIONS

Electrical separation joint

Insulated rail joint

Integral transverse link

Air-core inductor (special type of very low impedance bond)

Surge protection device

Total Management System of ASTS

Indian Railways Signal Engineering Manual Part II, September 2001

N.S1 Mounting Frame Dimensions, TA-BE-03-D6-0037, Revision 003

UM71 AFTC Testing and Commissioning Instruction, 535-BL-05-WI-00014, Revision 4

EMC Work Instruction, 535-ND-09-WI-00176

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

ASTS TMS Checklists

ASTS TMS Procedures

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Location and connection of TMUs and OBonds

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Quality and Condition of Parts, Materials and Tools

UM71 Mounting Frames

UM71 Electrical Connections

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Earthing and Equipotential Bonding in LSCs

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Trackside Safety Considerations

Quality and Condition of Parts and Equipment

Quality and Condition of Track

Traction Current Equalisation and Earthing

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

OHE Equipotential Earthing

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Track and Equipment Connections

UM71 Track Cables

TMU/OBond Equipment Connections

TMU/OBond Parallel Connections

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Intermediate Transmitter Installation

Line-side Quad Cable Connections

Ansaldo STS, 2009

IRPMU (Modernization of Signalling in CNB-GZB section)

Earthing and Equipotential Bonding of AFTC Rack

Surge Protection Devices

Plugging-in and Presetting Tx Modules

2. The external modulation input is bypassed (fit strap M1-M3)

Ansaldo STS, 2009