Produced by Invensys Rail, Technical Publications Group, Chippenham.
This manual has been produced with care to ensure the information contained within is correct at the time of printing. Any inaccuracies or omissions should be reported in writing to the Team Leader Technical Publications Group at the following address:
This manual forms part of the documentation for the WESTRONIC 1024 equipment, as supplied by Invensys Rail.
The purpose of this manual is detailed in Section 1 - Introduction.
Information in this manual may be changed due to Invensys Rail's policy of continued product development and improvement. If necessary, the manual will be amended and re-issued as appropriate.
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HISTORY SHEET
REVISION DATE REASON FOR REVISION AND COMMENT
1.1 Dec 2007 Initial Issue.
1.2 Jan 2008 NR comments on Rev 1.1 incorporated.
1.3 Jan 2008 Additional NR comments incorporated.
2.1 August 2009 ECO0014431
CPU-2 Access Flash Card LED added.
CPU-2MTM added.
Battery Back Up Unit Battery and CPU-2 Lithium Battery maintenance details added.
3.1 July 2010 ECO0019441
Signaller’s Alarm Panel and Dual d.c. Power Supply rack added.
COP32-NO and COP-32TM added.
4.1 December 2010 ECO0020990
AIP-8 and DIP-TMW 24V modules added.
RTU Housing added.
4.2 December 2010 Engineering comments on Rev. 4.1 incorporated.
Module/card and housing coding peg information added.
RTU information removed (to X1369-16-EN-MN00054).
5.2 July 2011 Engineering comments on Rev. 5.1 incorporated.
External PSUs added and CPU-2 lithium battery replacement requirements amended.
6.1 September 2011
ECO0023404
New Triple TDM Housing added.TRAININ
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SAFETY PRECAUTIONS
WARNINGS
Warnings are given to highlight the DANGER to PERSONNEL of serious injury or death when handling, operating or maintaining equipment.
CAUTIONS
Cautions are given to highlight the possibility of DAMAGE to EQUIPMENT, or DEGRADATION of EQUIPMENT OPERATION when handling, operating or maintaining equipment.
AUTHORITY
The following instructions do not supersede any current company or statutory safety instructions/regulations, which must be complied with.
Before handling, operating or maintaining any material, obtain the necessary authority.
GENERAL SAFETY PRECAUTIONS
Assess the need for Personal Protection Equipment (PPE) before undertaking installation, maintenance or manual operations.
Use PPE to prevent abrasions and to minimize the risk of infection from pigeon, rat droppings, etc.
Rat bites must be treated immediately.
Abrasions and cuts must be treated immediately.
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WARNING- LEPTOSPIRAL JAUNDICE
Leptospiral Jaundice can be contracted through contact with contaminated water, particularly if rats are present. The infection enters through broken skin and early stages mimic influenza: jaundice (Weil’s Disease) can occur later. The disease is treatable but the following precautions must be observed:
Cover all exposed cuts and abrasions with waterproof plaster BEFORE starting work.
Always wear protective clothing.
Apply thorough first aid immediately to wounds.
Seek medical assistance if you have sustained any injury or if you feel ill.
WARNING - LETHAL VOLTAGE
Electrical power within this system/equipment is at a level considered, by the European Council Low Voltage Directive 73/23/EEC, as amended by Directive 2006/95/EC, to be sufficient to kill.
Always assume conductors are live until proved dead.
Before attempting any maintenance task, ensure that equipment is isolated from electrical supplies.
When the electrical supplies cannot be isolated, testing/maintenance tasks are to be undertaken only by personnel who are aware of the dangers involved and after all necessary precautions have been taken.
WARNING - HEAVY EQUIPMENT
Manual handling must only be carried out by trained personnel.
All manual handling must be in accordance with the Manual Handling Operations Regulations 1992 Statutory Instrument 1992 No. 2793.TRAIN
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WARNING - BATTERIES
When handling batteries containing liquid electrolyte, protective clothing must be worn to safeguard against the possibility of electrolyte coming into contact with skin or eyes.
If contact with electrolyte does occur, wash the affected area immediately with copious amounts of clean water and seek immediate medical attention.
WARNING - WORKING PRACTICES
Unauthorised interruption of the system may endanger the safe operation of the railway. Before attempting any maintenance on the equipment, obtain the necessary permission from the relevant authority. Ensure the consequence of any interruption has been fully considered and understood.
If a component or equipment becomes overheated or burnt, a toxic fume hazard may exist. Isolate the power to the equipment, ventilate the area and allow the equipment time to cool before carrying out repairs.
When working on equipment, especially in the confines of a train or a cubicle, do not wear metal rings, bracelets, watches, etc. These articles can cause personal injury or damage to equipment by becoming entangled in components or causing a short circuit.
Care has been taken to ensure that no sharp edges are present. However, take care that no sharp edges have been created or exposed during installation or maintenance. Always check for sharp edges before undertaking any installation or maintenance activities.
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WARNING - HANDLING OF LITHIUM BATTERIES
Observe the following procedures when handling Lithium batteries:
• NEVER attempt to recharge a non-rechargeable Lithium battery - it may vent or explode.
• NEVER short circuit a Lithium battery -it may overheat or vent.
• NEVER place equipment containing a Lithium battery on a conductive surface.
• NEVER carry a Lithium battery in a pocket or container with other batteries or conductive material, unless battery terminals are suitably insulated.
• NEVER crush, puncture or attempt to open a Lithium battery. This can release hazardous material or cause spontaneous ignition.
• NEVER store equipment containing Lithium batteries above 70ºC.
• NEVER expose a Lithium battery to fire. Incineration or overheating of a Lithium battery can result in venting or an explosion.
• ALWAYS insulate battery terminals before transporting batteries.
• ALWAYS observe the polarity of Lithium batteries and ensure correct connection.
• ALWAYS insulate terminals before disposal.
ACCIDENT PROCEDURES
If a Lithium battery is damaged and venting or spillage occurs, proceed as follows:
Evacuate the area and ventilate with fresh air.
Wear face mask, goggles and gloves while cleaning up.
Disconnect batteries without creating any sparks and place battery in a remote, well ventilated area.
Lithium battery liquid is corrosive. Use plenty of clean water to remove spillage.
Use carbon dioxide extinguishers for fires involving Lithium batteries.
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Caution - Electrostatic Sensitive Devices
Certain Printed Circuit Cards (PCCs) equipment contain Electrostatic Sensitive Devices (ESDs) which may be damaged or destroyed by incorrect handling.
These PCCs are to be handled in accordance with the following precautions and with any additional local instructions for handling ESDs:
When removing or installing PCCs, wear a tested wrist strap and cord connected to the cubicle/vehicle frame.
Grasp PCCs by their handles or edges only. Do not touch the devices.
Ensure that all spare PCCs, and those being returned for repair, are enclosed in the original packaging or in anti-static bags.
Caution - Use of Mobile Phone/Mobile Radio Units
Do not operate any mobile radio units or mobile phones within close proximity of open cubicles, as radio frequency emissions can affect the operation of computer based equipment. Whenever possible, keep cubicle/cabinet doors closed and equipment covers fitted.
1.1 PURPOSE OF MANUAL........................................................................................211.2 LAYOUT OF MANUAL..........................................................................................211.3 TECHNICAL ADVICE.............................................................................................211.4 TRAINING AND EXPERIENCE OF MAINTENANCE PERSONNEL...................22
SECTION 2 — SYSTEM DESCRIPTION ............................................................................. 23
2.1 INTRODUCTION TO WESTRONIC 1024 ...........................................................232.1.1 General ..............................................................................................................232.1.2 System Equipment ...........................................................................................242.1.3 Additional Equipment .....................................................................................272.1.4 Housing Connectivity ......................................................................................282.1.5 System Configurations ....................................................................................312.2 SERIAL DATA COMMUNICATION......................................................................352.3 DIGITAL INPUTS AND OUTPUTS ........................................................................352.3.1 Digital Inputs using DIP-TM or DIP-TMW (No Associated COP Module) .362.3.2 Digital Inputs using DIP S2 4HP or DIP S2 8HP (No Associated
COP Module) ....................................................................................................372.3.3 Digital Outputs using DOP-64TM (No Associated COP Module) .............392.3.4 Digital Outputs using DOP S2 4HP or DOP S2 8HP (No Associated
COP Module) ....................................................................................................402.3.5 Digital Input/Outputs with COP32-NO Module...........................................422.3.6 Digital Input/Outputs with COP S2 4HP Module .........................................442.4 ANALOGUE INPUTS .............................................................................................462.5 ADDRESS AND CONFIGURATION SWITCHES.................................................472.5.1 Configuration Switch .......................................................................................472.5.2 Address Switches .............................................................................................482.6 MODULE CODING................................................................................................482.7 POWER DISTRIBUTION........................................................................................492.7.1 General ..............................................................................................................492.7.2 Battery Back-up Power Supply .......................................................................492.8 SYSTEM CHANGEOVER.......................................................................................502.9 GENERAL ALARMS ...............................................................................................512.10 CONFIGURATION OF SPARES HOLDINGS ......................................................532.11 INSTALLATION SITE DRAWINGS........................................................................53
7.1 EQUIPMENT PART NUMBERS .......................................................................... 1597.1.1 Line Replaceable Unit Part Numbers.......................................................... 1597.2 TECHNICAL SPECIFICATION OF EQUIPMENT ............................................. 1617.2.1 Power Requirements .................................................................................... 1617.2.2 Environmental Limits .................................................................................... 1617.2.3 Storage Limits ................................................................................................ 1617.2.4 EMC................................................................................................................. 1627.2.5 Testability ....................................................................................................... 1627.2.6 Reliability ........................................................................................................ 1627.2.7 Maintainability ............................................................................................... 1627.2.8 IP Rating.......................................................................................................... 1627.2.9 Dimensions .................................................................................................... 1627.2.10 Fuse Types and Ratings................................................................................ 163
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LIST OF TABLES
Table 2.1 - Westronic 1024 Replaceable Modules..........................................................24Table 2.2 - COP Module Truth Table ................................................................................42Table 2.3 - SW1 Configuration Switch Settings ...............................................................47Table 2.4 - SW2 Configuration Switch Settings ...............................................................48Table 2.5 - SA-1TM Alarm Connections............................................................................51Table 3.1 - CPU-2MTM COM3 Pin Out .............................................................................63Table 3.2 - Module and Housing Coding Pegs................................................................84Table 3.3 - Battery Back-up Unit - Alarm Output Socket Pin Allocations......................88Table 5.1 - Status Indications........................................................................................... 109Table 5.2 - Possible Faults and Causes .......................................................................... 119Table 6.1 - CPU-2MTM Modem DIL Switch Settings .................................................... 134Table 6.2 - Invensys Rail Rack Mounted and Standalone Modem Link Settings ...... 150Table 7.1 - Westronic 1024 LRU Part Numbers............................................................. 159Table 7.2 - Battery Back-up System LRU Part numbers................................................ 160Table 7.3 - External D.C. Power Supply Part Numbers ................................................ 160Table 7.4 - Modem Part Numbers .................................................................................. 160Table 7.5 - Equipment Power Requirements................................................................. 161Table 7.6 - Equipment Dimensions ................................................................................ 162Table 7.7 - Fuse Locations and Ratings.......................................................................... 163
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Intentionally Left Blank
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LIST OF FIGURES
Figure 2.1 - Typical Westronic 1024 Equipment in a Standard 19 inch Housing ........23Figure 2.2 - Typical Westronic 1024 Equipment in a Triple TDM 19 inch Housing ....23Figure 2.3 - Block Diagram of Typical Westronic 1024 TDM System............................29Figure 2.4 - Block Diagram of Typical Westronic 1024 TDM System
(with S2 Equivalent Connectors) ....................................................................30Figure 2.5 - Point-to-Point Single System .........................................................................31Figure 2.6 - Point-to-Point Dual System ............................................................................32Figure 2.7 - Westronic 1024 with WESTCAD ...................................................................33Figure 2.8 - WESTCAD TDM Sub-systems........................................................................34Figure 2.9 - DIP-TM Input Connections.............................................................................36Figure 2.10 - DIP-TMW Input Connections.......................................................................37Figure 2.11 - DIP S2 4HP-xxV Input Connections ............................................................38Figure 2.12 - DIP S2 8HP-xxV Input Connections ............................................................38Figure 2.13 - DOP-64TM Output Connection..................................................................39Figure 2.14 - DOP S2 4HP Output Connection................................................................41Figure 2.15 - DOP S28 HP Output Connection................................................................41Figure 2.16 - COP32-NO Output Connection .................................................................43Figure 2.17 - COP S2 4HP Output Connection................................................................45Figure 2.18 - AIP-8 Input Connections ..............................................................................46Figure 2.19 - Address and Configuration Switches.........................................................47Figure 2.20 - Typical Module and Housing Coding ........................................................48Figure 2.21 - Typical Alarm System Block diagram.........................................................52Figure 2.22 - Typical Office Alarm Panel Connections ...................................................53Figure 3.1 - Typical Standard Westronic 1024 Housing .................................................56Figure 3.2 - Standard 19 inch Housing Rear View Showing Backplanes ......................57Figure 3.3 - Typical 1024 Triple TDM 19 inch Housing (with One TDM Fitted)...........58Figure 3.4 - CPU-2 Processor Module...............................................................................59Figure 3.5 - Processor Transition Module (CPU-2TM).....................................................61Figure 3.6 - Processor Transition Module (CPU-2MTM) .................................................62Figure 3.7 - System Arbiter Module ..................................................................................64Figure 3.8 - System Arbiter Transition Module (SA-1TM) ...............................................66Figure 3.9 - Digital Input Module (DIP-64)........................................................................67Figure 3.10 - Digital Input Transition Module (50V version shown) ..............................68Figure 3.11 - Digital Input Transition Module (with Wetting).........................................69Figure 3.12 - Digital Input Transition Module (DIP S2 4HP) (24V version shown) .......70Figure 3.13 - Digital Input Transition Module (DIP S2 8HP) (24V version shown) .......72Figure 3.14 - Digital Output Module (DOP-64)................................................................73Figure 3.15 - Analogue Input Module (AIP-8) ..................................................................74Figure 3.16 - Digital Output Transition Module (DOP-64TM)........................................75Figure 3.17 - Digital Output Transition Module (DOP S2 4HP) .....................................76Figure 3.18 - Digital Output Transition Module (DOP S2 8HP) .....................................77Figure 3.19 - Digital Output Module (COP32-NO)..........................................................78Figure 3.20 - DIP-COP Monitor Link Module ...................................................................79Figure 3.21 - Digital Output Module (COP S2 4HP) ........................................................80Figure 3.22 - 5V PSU Without Back-up Connector ..........................................................81Figure 3.23 - PSU with Battery Back-up Input Connector ...............................................82Figure 3.24 - Power Filter Module .....................................................................................83Figure 3.25 - Battery Back-up Unit.....................................................................................87
HP Horizontal Pitch. A unit of measurement for card racks, equal to 0.2 inches.
I/O Input / Output.
IP International Protection (rating).
LAN Local Area Network.
LCD Liquid Crystal Display.
LED Light Emitting Diode.
Link Module DIP-COP Monitor Link Module - A passive module providing con-nections for 32 monitoring outputs from the COP32-NO to its adja-cent DIP-64 module.
LRU Line Replaceable Unit. A card or module replaceable at first line maintenance.
max Maximum.
min Minimum.
MTBF Mean Time Between Failures.
NX Entry / Exit (panel).
PFM Power Filter Module.
PMUX Panel Multiplexer
PPE Personal Protection Equipment.
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PSTN Public Service Telephone Network.
PSU Power Supply Unit.
RMA Returned Material Authorisation.
RTU Remote Terminal Unit
S2 Legacy TDM System
SA System Arbiter.
SIL Safety Integrity Level.
TBA To Be Advised.
TDM Time Division Multiplex.
TM Transition Module.
U A unit of measurement equal to 44.45 mm (1.75 inches).
USB Universal Serial Bus.
WESTCAD Westinghouse Control And Display (equipment).
Westronic 1024 Invensys Rail microprocessor based data transmission system.
Term Definition
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164
SECTION 1 — INTRODUCTION
1.1 PURPOSE OF MANUAL
This manual provides system description and First Line Maintenance information for the Invensys Rail Westronic 1024 system.
1.2 LAYOUT OF MANUAL
The manual is divided into the following seven Sections as follows:
Section 1 - Introduction
Section 2 - System Description
Section 3 - Equipment Description
Section 4 - Preventive Maintenance
Section 5 - Fault Finding
Section 6 - Corrective Maintenance
Section 7 - Reference Information.
1.3 TECHNICAL ADVICE
Should further technical advice or information be required, please contact:
1.4 TRAINING AND EXPERIENCE OF MAINTENANCE PERSONNEL
Any personnel associated with the maintenance of Westronic 1024 equipment shall have received specific training carried out by, or on behalf of, Invensys Rail.
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SECTION 2 — SYSTEM DESCRIPTION
2.1 INTRODUCTION TO WESTRONIC 1024
2.1.1 General
The Westronic 1024 is a microprocessor based data transmission system designed to interface directly with signalling equipment. It is compatible with WESTCAD control and display equipment and meets safety integrity level (SIL) 1.
Figure 2.1 — Typical Westronic 1024 Equipment in a Standard 19 inch Housing
Figure 2.2 — Typical Westronic 1024 Equipment in a Triple TDM 19 inch Housing
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Westronic 1024 can be used to provide point to point communication for the remote control of signalling equipment.
Westronic 1024 may also be used to interface to NX panel and remote interlocking equipment.
Two different types of 19 inch wide 6U high housing (Figure 2.1 and Figure 2.2) can be used to house 1024 equipment:
• The standard 19 inch wide 6U high housing has a system capacity of 1024 inputs or outputs per housing.
• The Triple TDM 6U 19 inch housing can hold up to three systems, each with a capacity of 128 inputs or outputs.
The housings may be mounted in an equipment rack or cubicle, as best suits the location and are fitted with slot-in modules. The small number of module types reduces spares holding requirements, especially in organisations with several installations.
When operating as a point to point TDM, similar housings are required at both Office and Field locations.
No additional shielding is required to achieve electromagnetic compatibility (EMC).
Westronic 1024 requires minimum maintenance and the provision of a comprehensive set of LED indicators facilitates rapid fault diagnosis. The condition of every input and output is indicated.
The Westronic 1024 is compliant with Network Rail Specification RT/E/PS/00801.
2.1.2 System Equipment
The Westronic 1024 system is based on plug replaceable modules which are inserted into slots within the housing.
Each housing provides slots for up to 16 input or output modules, two processor modules, two PSUs and a system arbiter (changeover control) module.
The following module types can be used:
Table 2.1 — Westronic 1024 Replaceable Modules
Module DescriptionLocation in Housing
CPU-2A processor module fitted with a flash disk containing application and system data.
Front
CPU-2TMOne per CPU-2 module, these modules provide connection points for COM and LAN ports.
Rear
CPU-2MTM As CPU-2TM but with an integral modem. Rear
SA-1A System Arbiter module used in dual systems to control which of two CPU-2 modules is on-line. Also provides LED system status indications.
Front
SA-1TM
A System Arbiter Transition Module provides six configurable outputs and eight configurable inputs for external alarm and acknowledgement purposes. These inputs and outputs can be used to interface an Office Alarm Panel if required.
Rear
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DIP-64A digital input module accepting 64 parallel inputs with wetting voltages up to 50V a.c or d.c. via a Transition Module (see below). The state of all inputs is indicated by LEDs.
Front
AIP-8An analogue input module, providing connections for eight analogue, 8-bit multi-range inputs and analogue to digital conversion of the inputs.
Front
DOP-64A digital output module, providing 64 outputs with drive voltages up to 50V a.c or d.c. The state of all outputs is indicated by LEDs.
Front
DIP-TM 24VA passive Digital Input Transition Module providing connections for 64 digital inputs, with resistor networks to condition inputs of 24V a.c. or d.c. to suit the DIP-64 module to which it is connected.
Rear
DIP-TM 50VA passive Digital Input Transition Module providing connections for 64 digital inputs, with resistor networks to condition inputs of 50V a.c. or d.c. to suit the DIP-64 module to which it is connected.
Rear
DIP-TMW 24V
A passive Digital Input Transition Module, providing connections for 64 digital inputs, with resistor networks to condition inputs of 24V a.c or d.c. to suit the DIP-64 module to which it is connected. The module contains fuse protected d.c. to d.c. conversion to provide a 24V wetting supply up to a maximum of 240 mA in total.
Rear
DIP S2 4HP-24V
A passive Digital Input Transition Module providing 37-way D connection for COP S2 monitoring inputs and 32 digital inputs, via an S2 equivalent connector, with resistor networks to condition inputs of 24V a.c. or d.c. to suit the DIP-64 module to which it is connected.
Rear
DIP S2 4HP-50V
A passive Digital Input Transition Module providing 37-way D connection for COP S2 monitoring inputs and 32 digital inputs, via an S2 equivalent connector, with resistor networks to condition inputs of 50V a.c. or d.c. to suit the DIP-64 module to which it is connected.
Rear
DIP S2 8HP-24V
A passive Digital Input Transition Module providing connections for 64 digital inputs, via two S2 equivalent connectors, with resistor networks to condition inputs of 24V a.c. or d.c. to suit the DIP-64 module to which it is connected.
Rear
DIP S2 8HP-50V
A passive Digital Input Transition Module providing connections for 64 digital inputs, via two S2 equivalent connectors, with resistor networks to condition inputs of 50V a.c. or d.c. to suit the DIP-64 module to which it is connected.
Rear
DOP-64TMA passive Transition Module providing connections for 64 outputs, with transorb protection to protect the DOP-64 module when switching inductive loads.
Rear
DOP S2 4HP
A passive Transition Module providing connections for 32 digital inputs and a further 32 digital inputs via an S2 equivalent connector, with transorb protection to protect the DOP-64 module when switching inductive loads.
Rear
DOP S2 8HPA passive Transition Module providing connections for 64 outputs via S2 equivalent connectors, with transorb protection to protect the DOP-64 module when switching inductive loads.
Rear
COP32-NOA Transition Module providing 32 voltage free relay output contacts and 32 monitoring outputs.
DIP-COPA passive module providing connections for 32 monitoring outputs from the COP32-NO to its adjacent DIP-64 module.
Rear
COP S2 4HPA Transition Module providing 32 voltage free relay output contacts via an S2 equivalent connector, and a monitoring output via a 25-way D connector.
Rear
PSU-5V dc
5V d.c. power is supplied to the modules by either one or two PSUs (power supply units) fitted into the housing. Each PSU is capable of powering a fully populated housing. Where two PSUs are fitted, their outputs are combined to provide a high availability, dual redundant supply. A variant capable of accepting a back-up supply input is also available.
Front
RFM110A PSU filter module, one per PSU, providing a mains input voltage On/Off switch and filtering. Only used where mains supply is 110V a.c.
Rear
RFM240A PSU filter module, one per PSU, providing a mains input voltage On/Off switch and filtering. Only used where mains supply is 240V a.c.
A separate 19 inch rack or cubicle mounted battery back-up unit is available to provide up to 6 minutes emergency supply in the event of a mains failure. This facility is only available for housings using 110V a.c. supply.
Further details of the modules are given in Section 3 of this manual.
2.1.3.2 External Rack Mounted D.C. Dual PSUs
Various separate 19 inch 3 U rack or cubicle mounted dual power supplies are available. These power supplies are intended to supply a highly regulated d.c. supply where needed for wetting voltages, alarm outputs etc.
The output from each PSU is monitored before being connected in a diode OR/Parallel arrangement. Failure of a PSU will result in a voltage free alarm output.
Further details of the available Dual d.c. PSUs, are given in Section 3 of this manual.
2.1.3.3 Office Alarm Panel
The Office Alarm Panel provides the signaller with an indication of the status of each of the TDM Channels. The alarm panel is interfaced to the system via the SA-1TM module.
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2.1.4 Housing Connectivity
A block diagram of a typical 19 inch Westronic 1024 housing is shown in Figure 2.3. Figure 2.4 shows a typical housing equipped with modules having S2 compatible connectors.
Triple TDM housings have similar connectivity and only differ in the number of I/O cards in each TDM system.
All active modules are inserted into the front of the housing and plug into a backplane and/or connectors on their associated Transition Module.
Transition Modules are fitted into the rear of the housing and provide terminations for the I/O and communication cabling.
EMC protection is provided by shielded front panels on all modules and by blank panels fitted into all spare slots.
The backplane(s) provides 5V d.c. power distribution from the PSUs to the modules and also dual Controller Area Network data busses known as CAN-Bus 1 and CAN-Bus 2. In dual systems, CAN-Bus 1 is associated with System 1 and CAN-Bus 2 with System 2.
Changeover between systems is controlled by the System Arbiter (SA-1) module. The SA -1 can be set for manual or auto changeover. The SA-1 outputs control signals to set and hold the selected CPU-2 module on-line and to inform the DIP-64 and DOP-64 modules of which CAN-bus contains on-line data.
The Standard Westronic 1024 housing has 16 I/O slots, configurable to support any combination of input/output module types. The Triple TDM housing has three independant sets of two I/O slots.
Certain systems require additional validation of outputs when interfacing to an interlocking. This is acheived by controlling each ‘interlocking’ output using two DOP64 module bits. The interlocking output state is not active (contact closed) until both controlling bits are in the required state.
For these outputs the DOP64-TM module is replaced with a COP32-NO or COP S2 4HP module.
Using a COP32-NO module:
The use of a COP32-NO module reduces the number of outputs from 64 to 32. Also 32 inputs on an adjacent DIP-TM module are used to monitor the status of the 32 complementary outputs pairs from the DOP 64. For each DOP-64 module that has an associated COP 32-NO module, there must be a DIP-64 module fitted into the adjacent slot. (refer to paragraph 2.3.5).
Using a COP S2 4HP module:
The use of a COP S2 4HP module reduces the number of outputs from 64 to 32. Also up to 32 inputs on one DIP-TM module are used to indicate the complimentary pairs status of the all the COP S2 4HP modules in the housing.
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Figure 2.3 — Block Diagram of Typical Westronic 1024 TDM System
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-1T
M
110 V or
230 V a.c.
RF
M11
0or
RF
M24
0 110 V or
230 V a.c.
Opt
o-co
uple
r
Opt
o-co
uple
r6
Gen
eral
Ala
rms
I/O8
digi
tal i
nput
s
6 di
gita
l out
puts
(Ala
rms
I/Os
can
be
conn
ecte
d to
an
Offi
ce A
larm
Pan
el)
8
PS
U M
onito
ring
5 V
d.c
.5
V d
.c.
5 V d.c.
5 V d.c.
Inpu
t Pow
er(1
10 V
or
230
V a
.c.)
The
CP
U-2
MT
M is
fitte
d w
ith a
n in
tegr
ated
M
odem
NO
TE
2:
Sys
tem
1C
onne
ctio
ns
Sys
tem
2C
onne
ctio
ns
32 D
igita
l O
pto-
Isol
ated
Flo
atin
g In
puts
24 V
or
50 V
a.c.
or
d.c.
32 N
/O R
elay
C
onta
cts
12 V
to 5
0 V
a.c.
or
d.c.
(see
not
e 2)
64 D
igita
l O
pto-
Isol
ated
Flo
atin
g In
puts
24 V
or
50 V
a.c.
or
d.c.
64 D
igita
l O
pto-
Isol
ated
Out
puts
12 V
to 5
0 V
a.c.
or
d.c.
CA
N B
us 1
CA
N B
us 2
5 V
d.c
.
5 V
d.c
.
Eac
h of
the
32 o
utpu
ts a
re d
eriv
ed
from
a p
air
of c
ompl
emen
tary
ou
tput
s fr
om th
e D
OP
-64
mod
ule.
NO
TE
1:
AIP
-8
8 A
nalo
gue
Opt
o-Is
olat
edF
loat
ing
Inpu
tsM
ulti
Ran
ge
volta
ge o
r cu
rren
t
NO
TE
3:
In a
Trip
le T
DM
Hou
sing
, up
to th
ree
TD
M s
yste
ms
can
be
f itte
d, e
ach
with
a m
axim
um o
f tw
o D
IP o
r D
OP
mod
ules
.
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Page 30 of 164 SECTION 2 — SYSTEM DESCRIPTION
Figure 2.4 — Block Diagram of Typical Westronic 1024 TDM System (with S2 Equivalent Connectors)
CP
U-2
TM
Or
CP
U-2
MT
M(S
ee N
ote
1)
CP
U-2
TM
Or
CP
U-2
MT
M(S
ee N
ote
1)
LAN
Por
t (R
J45)
RS
232
Con
nect
ion
RS
232
Con
nect
ion
RS
232
Con
nect
ion
RS
232/
Mod
em C
onne
ctio
n C
PU
-2T
Mor
Mod
em In
put/O
utpu
t (C
PU
-2M
TM
)
LAN
Por
t (R
J45)
RS
232
Con
nect
ion
RS
232
Con
nect
ion
RS
232
Con
nect
ion
RS
232/
Mod
em C
onne
ctio
n C
PU
-2T
Mor
Mod
em In
put/O
utpu
t (C
PU
-2M
TM
)
(See
Not
e 1)
(See
Not
e 1)
CP
U-2
(Sys
2)
CP
U-2
(Sys
1)
On-
Line
Sys
tem
Iden
tity
Sig
nal
DO
P-6
4
DO
P S
2 4H
Por
DO
P S
2 8H
P
DIP
-64
DIP
S2
8HP
DO
P-6
4
CO
P S
2 4H
P
DIP
-64
DIP
S2
4HP
SA
-1
To
addi
tiona
lD
IP o
r D
OP
mod
ules
up
toa
tota
l of 1
6M
odul
es(s
ee N
ote
3)
RF
M11
0or
RF
M24
0
PS
UP
SU
SA
-1T
M
110 V or
230 V a.c.
RF
M11
0or
RF
M24
0 110 V or
230 V a.c.
Opt
o-co
uple
r
Opt
o-co
uple
r6
Gen
eral
Ala
rms
I/O8
digi
tal i
nput
s
6 di
gita
l out
puts
(Ala
rms
I/Os
can
be
conn
ecte
d to
an
Offi
ce A
larm
Pan
el)
8
PS
U M
onito
ring
5 V
d.c
.5
V d
.c.
5 V d.c.
5 V d.c.
Inpu
t Pow
er(1
10 V
or
230
V a
.c.)
The
CP
U-2
MT
M is
fitte
d w
ith a
n in
tegr
ated
M
odem
NO
TE
2:
Sys
tem
1C
onne
ctio
ns
Sys
tem
2C
onne
ctio
ns
32 D
igita
l O
pto-
Isol
ated
Flo
atin
g In
puts
24 V
or
50 V
a.c.
or
d.c.
32 N
/O R
elay
C
onta
cts
12 V
to 5
0 V
a.c.
or
d.c.
(see
not
e 2)
64 D
igita
l O
pto-
Isol
ated
Flo
atin
g In
puts
24 V
or
50 V
a.c.
or
d.c.
64 D
igita
l O
pto-
Isol
ated
Out
puts
12 V
to 5
0 V
a.c.
or
d.c.
CA
N B
us 1
CA
N B
us 2
5 V
d.c
.
5 V
d.c
.
Eac
h of
the
32 o
utpu
ts a
re d
eriv
ed
from
a p
air
of c
ompl
emen
tary
ou
tput
s fr
om th
e D
OP
-64
mod
ule.
NO
TE
1:
AIP
-8
8 A
nalo
gue
Opt
o-Is
olat
edF
loat
ing
Inpu
tsM
ulti
Ran
ge
volta
ge o
r cu
rren
t
Mon
itorin
g bi
ts fr
om
othe
r C
OP
S
2 m
odul
es
in th
e sy
stem
NO
TE
3:
In a
Trip
le T
DM
Hou
sing
, up
to th
ree
TD
M s
yste
ms
can
be
fitte
d, e
ach
with
a m
axim
um o
f tw
o D
IP o
r D
OP
mod
ules
.
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164
2.1.5 System Configurations
2.1.5.1 Point-to-Point TDM
A point to point system comprises an Office housing and a Field housing, controlled by the Office. Office and Field housings can both accept inputs and provide outputs.
An input to a DIP-64 module at the Office is mapped to appear as an output of the same channel number at a DOP-64 module in the equivalent slot at the Field housing. Similarly, an input at a Field housing DIP-64 is mapped to appear at the equivalent DOP-64 at the Office.
The quantity of DIP-64 and DOP-64 modules fitted is determined by system requirements, up to a combined maximum of 16.
Point-to-point systems may be either single (Figure 2.5) or dual (Figure 2.6). The preferred configuration is a dual system, using two CPU-2 modules per housing and two independent diversely routed communication links.
Figure 2.5 — Point-to-Point Single System
The duplicated system is configured to produce a very high availability of data transfer. This is achieved by using a single set of I/O modules and duplicating the processor module and, if used, the communication lines and modems. It would be normal in this situation to also fit duplicate PSUs.
DIP-64 andDOP-64modules
Modem
Modem
Tel
ecom
ms
Line
A
Inputs fromswitch contacts
relay contacts etc.
Outputs todrive relaysindicators etc.
REMOTELOCATION
Westronic 1024Office TDM
CPU-2module
System 1
Westronic 1024Field TDM
DIP-64 andDOP-64modules
CPU-2module
System 1
Outputs todrive relaysindicators etc.
Inputs fromswitch contacts
relay contacts etc.
OFFICELOCATION
NOTE: External modem not requiredwhen a CPU-2MTM is fitted. The CPU-2MTM incorporatesan internal modem.
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Figure 2.6 — Point-to-Point Dual System
The dual systems are designated System 1 and System 2 respectively.
2.1.5.2 Westronic 1024 with WESTCAD Configured as Panel Processor
Westronic 1024 can be used to provide both Office and Field TDM functions in a WESTCAD panel processor system. This is illustrated in Figure 2.7.
Operation of the NX panel controls (push buttons, switches etc.) causes voltages from those contacts to be applied to or removed from inputs of the DIP-64 modules in the Office TDM housing. The DIP-64 modules sense the changes of state of the inputs, causing the CPU-2 module to generate serial messages for onward transmission over serial links to the WESTCAD panel processor.
The WESTCAD is a computer based system providing panel processing facilities for the control and indication of signalling and train movements on an NX panel.
The WESTCAD extracts the input information from the serial data message, carries out the panel processing function and generates an outgoing data message which is transmitted via duplicated modem links to the Field TDM at the interlocking location.
DIP-64 andDOP-64modules
Modem Modem
Modem Modem
Tel
ecom
ms
Line
A
Tel
ecom
ms
Line
B
Inputs fromswitch contacts
relay contacts etc.
Outputs todrive relaysindicators etc.
REMOTELOCATION
Westronic 1024Office TDM
CPU-2module
System 1
CPU-2module
System 2System Arbiter
Westronic 1024Field TDM
DIP-64 andDOP-64modules
System ArbiterCPU-2module
System 1
CPU-2module
System 2
Outputs todrive relaysindicators etc.
Inputs fromswitch contacts
relay contacts etc.
OFFICELOCATION
NOTE: External modem not requiredwhen a CPU-2MTM is fitted. The CPU-2MTM incorporatesan internal modem.
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164
Figure 2.7 — Westronic 1024 with WESTCAD
Signalling NX Panel
WESTCAD Changeover Unit (part)
WESTCAD'A'
WESTCAD'B'
WESTCAD Changeover Unit (part)
Tele
com
ms
Line
A
Tele
com
ms
Line
B
RemoteInterlocking
Controls Indications
OPERATINGFLOOR
EQUIPMENTROOM
REMOTERELAYROOM
To Technician's TerminalTo Technician's Terminal
Westronic 1024Office TDM
CPU-2module
System 1
CPU-2module
System 2System Arbiter
Westronic 1024Field TDM
System ArbiterCPU-2module
System 1
CPU-2module
System 2
ControlsIndications
NOTE:External Modem not required when a CPU-2MTM is fitted.The CPU-2MTM incorporates an internal modem
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The Field TDM at the interlocking location decodes the data and latches outputs on its DOP-64 modules. These outputs are connected as Controls to the interlocking.
Indications from the interlocking are similarly transferred via the DIP-64 modules in the Field TDM over the modem links to the WESTCAD, which generates outgoing serial data messages to the Office TDM at the panel. The Office TDM sets and latches outputs on its DOP-64 modules to drive indications (lamps, buzzers etc.) on the NX panel.
2.1.5.3 TDM Field Sub-system
Westronic 1024 may also be used as a Field TDM housing to connect remote inputs and outputs (such as alarms) to a WESTCAD. The WESTCAD can accept I/O from multiple Fields, each via its own modem link.
Modem links may be point-to-point using Invensys Rail V23 modems, or over open networks using Telindus Aster 5 modems (or other suitably approved modem). No external modem is required at the WESTRONIC 1024 end if the CPU-2 Transition Module is a CPU-2MTM. The CPU-2MTM has an integral modem that can be configured to communicate with the Invensys Rail V23 modem or the Telindus Aster 5 modem.
Figure 2.8 — WESTCAD TDM Sub-systems
WESTCAD'A'
WESTCAD'B'
WESTCAD Changeover Unit (part)
Modem Modem
Modem
TelecommsLine
To Technician's TerminalTo Technician's Terminal
Westronic 1024Field TDMs
DIP-64 andDOP-64modules
CPU-2module
System 1
OutputsInputs
Modem
DIP-64 andDOP-64modules
CPU-2module
System 1
OutputsInputs
TelecommsLine
WESTCAD(Office)
Fields atmultiplelocations
Note: Field TDMs may be single (as shown) or dual systems.
NOTE: External Modem not required when a CPU-2MTM is fitted.The CPU-2MTM incorporates an internal modem
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164
2.2 SERIAL DATA COMMUNICATION
The Westronic 1024 Office and Field housings are connected via an RS-232 serial channel and modem connection. The RS-232 connection is made on the CPU-2TM module.
Dual systems use duplicated channels, one connected to each CPU-2TM in the housing.
The link operates at either 1200, 9600 or 19200 baud.
• 1200 baud is typically used on point to point telecomms lines using CPU-2MTM integral modems, Invensys Rail rack mounted or shelf mounted modems;
• 9600 / 19200 baud is used where the link is routed over an open network using theCPU-2MTM integral modems or the Telindus Aster 5 (or other suitably approved) modems. The extra transmission speed is required to accommodate the additional protocols needed over this type of link.
The modems are described in Subsection Figure 3.7 of this manual.
2.3 DIGITAL INPUTS AND OUTPUTS
The following description is divided into several parts:
• Inputs via a DIP transition module (DIP-TM or DIP-TMW) with no associated COP module (COP-32NO),
• Inputs via a S2 connector compatible DIP transition module (DIP S2 4HP or DIP S2 8HP) with no associated COP module (COP S2 4HP),
• Outputs from DOP-64TM transition module,
• Outputs from S2 connector compatible DOP S2 4HP or DOP S2 8HP transition module.
• Inputs and Outputs where a COP-32NO module is fitted. This description is combined due to the interactive nature of the system.
• Inputs and Outputs where a COP S2 4HP module is fitted. This description is combined due to the interactive nature of the system.
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2.3.1 Digital Inputs using DIP-TM or DIP-TMW (No Associated COP Module)
Inputs to the Westronic 1024 are interfaced to a DIP-64 module via two 37-way D-type connectors on the associated DIP transition module (Figure 2.9) or DIP-TMW module (Figure 2.10). The DIP-TM or DIP-TMW module is a passive Transition Module providing connections for 64 inputs, with resistor networks to condition inputs of 24V /50V a.c or d.c. for the DIP-64 module.
The DIP-TMW supplies an internally derived 24V wetting supply, whereas the digital inputs to a DIP-TM require a seperate external wetting supply of 24 or 50V a.c or d.c, to suit the voltage rating of the DIP-TM.
Each input is opto isolated and wired in groups of 32 inputs, with separate common returns for each grouping.
Inputs are configured to accept:
• Floating (non-earthed) inputs at 24V or 50V (a.c. or d.c.), with a nominal wetting current of 2 mA. Input voltage must be the same for all inputs to one module. The associated Transition module type is selected according to the input voltage required.
• Inputs as volt-free contacts, with an open resistance of not less than 250 kOhms and a closed resistance not greater than 100 Ohms.
The CPUs poll each DIP Module and read the status of the inputs. The CPU processes this information and creates a serial message which it outputs via the CPU-2TM. The DIP module SYS1 and SYS2 Scan LEDs flash as the data is read.
Figure 2.9 — DIP-TM Input Connections
1 Amp fuse S33 - 36Common
Wettingpowersource
Wetting power sources 50 V or 24 V a.c. or d.c.to suit voltage rating of connected DIP-TM xxV
S1
S32
DIP-TMModule
Input 1
Input 32
1 Amp fuse S33 - 36Common
Wettingpowersource
S1
S32
Input 33
Input 64
Upper 37-wayD-type connector
Lower 37-wayD-type connectorTRAIN
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164
Figure 2.10 — DIP-TMW Input Connections
2.3.2 Digital Inputs using DIP S2 4HP or DIP S2 8HP (No Associated COP Module)
Inputs to the Westronic 1024 are interfaced to a DIP S2 4HP module via one 37-way D-type connector and one DIN41612 connector on a DIP S2 4HP transition module (Figure 2.9) or via two DIN41612 conectors on DIP S2 8HP transition module (Figure 2.10). The DIP S2 4HP or DIP S2 8HP module is a passive Transition Module providing connections for 64 inputs, with resistor networks to condition inputs of 24V /50V a.c or d.c. for the DIP-64 module.
The digital inputs to a DIP S2 transition module require a seperate external wetting supply of 24 or 50V a.c or d.c, to suit the voltage rating of the DIP S2 transition module.
Each input is opto isolated and wired in groups of 32 inputs, with separate common returns for each grouping.
Inputs are configured to accept:
• Floating (non-earthed) inputs at 24V or 50V (a.c. or d.c.), with a nominal wetting current of 2 mA. Input voltage must be the same for all inputs to one module. The associated Transition module type is selected according to the input voltage required.
• Inputs as volt-free contacts, with an open resistance of not less than 250 kOhms and a closed resistance not greater than 100 Ohms.
The CPUs poll each DIP S2 transition module and read the status of the inputs. The CPU processes this information and creates a serial message which it outputs via the CPU-2TM. The DIP module SYS1 and SYS2 Scan LEDs flash as the data is read.
S33 - 36Common
Wettingpowersource
Wetting power source 24 V internally derived from 5 V supply
S1
S32
DIP-64TMWModule
Input 1
Input 32
Upper 37-wayD-type connector
Lower 37-wayD-type connector
Usedinternally
+ -
S33 - 36Common
Wettingpowersource
S1
S32
Input 33
Input 64
Usedinternally
+ -
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Figure 2.11 — DIP S2 4HP-xxV Input Connections
Figure 2.12 — DIP S2 8HP-xxV Input Connections
1 Amp fuse S33 - 36Common
Wettingpowersource
Wetting power sources 50 V or 24 V a.c. or d.c.to suit voltage rating of connected DIP S2 4HP-xxV
S1
S32
DIP S2 4HPModule
Input 1
Input 32
1 Amp fuse S13c - 32cCommon
Wettingpowersource
S1a
S32a
Input 33
Input 64
Upper 37-wayD-type connector
Lower DIN41612S2 compatible connector
1 Amp fuse S13c - 32cCommon
Wettingpowersource
Wetting power sources 50 V or 24 V a.c. or d.c.to suit voltage rating of connected DIP S2 4HP-xxV
S1a
S32a
DIP S2 8HPModule
Input 1
Input 32
1 Amp fuse S3c - 32cCommon
Wettingpowersource
S1a
S32a
Input 33
Input 64
Right Hand DIN41612S2 compatible connector
Left Hand DIN41612S2 compatible connector
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2.3.3 Digital Outputs using DOP-64TM (No Associated COP Module)
Outputs from the Westronic 1024 are fed to two 37-way D-type connectors on a DOP-64TM module from its associated DOP-64 module.
An output comprises the voltage from an external power supply, switched by the DOP-64 according to the state of the associated remote input. The voltage is then used to drive a load.
Each output is capable of being set ON, OFF or FLASHING. The output FLASHING mode is synchronized across modules using a synchronization message class originated by the on-line system. The flashing rate will be either 0.5 seconds or 1 second as defined by the setting of the configuration switch (see Table 2.3).
Each output is opto isolated and wired in two groups of 32 outputs with separate common returns for each grouping.
An external drive supply of 12 - 50V a.c. or d.c. is switched by each output to drive resistive or inductive loads. A maximum output current of 500 mA per output is permitted, with the total module output restricted to 8 A. The output stages must be protected using external fuses.
On start-up the module’s failure mode operation is set by the system reading the status of a rear backplane DIL switch, or configured in data. The switch and/or configuration data are set in one of two modes:
• All outputs to freeze when system communication is lost.
• All outputs to Off when system communication is lost.
Serial messages received by the CPU-2 module are processed. Any output data change is transmitted to the DOP-64 modules over the CAN-Bus.
Both CPU-2s, System 1 and System 2, transmit data over their CAN-Bus to all I/O modules in the housing. The DOP module processes both sets of data but only sets its output states using the data from the on-line system. Only the on-line system Scan LED flashes..
Figure 2.13 — DOP-64TM Output Connection
4 Amp fuse P33 - 36Common
Drivepowersource
Drive power sources 50 V or 24 V a.c. or d.c.
P1
P32
DOP-64TM
Output 1
Output 32
4 Amp fuse P33 - 36Common
Drivepowersource
P1
P32
Output 33
Output 64
Upper 37-wayD-type connector
Lower 37-wayD-type connector
Load 64
Load 1
Load 32
Load 33TRAININ
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2.3.4 Digital Outputs using DOP S2 4HP or DOP S2 8HP (No Associated COP Module)
Outputs from the Westronic 1024 are fed either to two S2 compatible DIN 41612 connectors on a DOP S2 8HP module, or to one S2 compatible DIN 41612 connector and one 37-way D-type connector on a DOP S2 4HP module, from its associated DOP-64 module.
An output comprises the voltage from an external power supply, switched by the DOP-64 according to the state of the associated remote input. The voltage is then used to drive a load.
Each output is capable of being set ON, OFF or FLASHING. The output FLASHING mode is synchronized across modules using a synchronization message class originated by the on-line system. The flashing rate will be either 0.5 seconds or 1 second as defined by the setting of the configuration switch (see Table 2.3).
Each output is opto isolated and wired in two groups of 32 outputs with separate common returns for each grouping.
An external drive supply of 12 - 50V a.c. or d.c. is switched by each output to drive resistive or inductive loads. A maximum output current of 500 mA per output is permitted, with the total module output restricted to 8 A. The output stages must be protected using external fuses.
On start-up the module’s failure mode operation is set by the system reading the status of a rear backplane DIL switch, or configured in data. The switch and/or configuration data are set in one of two modes:
• All outputs to freeze when system communication is lost.
• All outputs to Off when system communication is lost.
Serial messages received by the CPU-2 module are processed. Any output data change is transmitted to the DOP-64 modules over the CAN-Bus.
Both CPU-2s, System 1 and System 2, transmit data over their CAN-Bus to all I/O modules in the housing. The DOP module processes both sets of data but only sets its output states using the data from the on-line system. Only the on-line system Scan LED flashes
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164
Figure 2.14 — DOP S2 4HP Output Connection
Figure 2.15 — DOP S28 HP Output Connection
4 Amp fuse P33 - 36Common
Drivepowersource
Drive power sources 50 V or 24 V a.c. or d.c.
P1
P32
DOP S2 4HPModule
Output 1
Output 32
4 Amp fuse P13c - 32cCommon
Drivepowersource
P1a
P32a
Output 33
Output 64
Upper 37-wayD-type connector
Load 64
Load 1
Load 32
Load 33
Lower DIN41612S2 compatible connector
4 Amp fuse
Drivepowersource
Drive power sources 50 V or 24 V a.c. or d.c.
DOP S2 8HPModule
Output 1
Output 32
4 Amp fuse P13c - 32cCommon
Drivepowersource
P1a
P32a
Output 33
Output 64Load 64
Load 1
Load 32
Load 33
Right Hand DIN41612S2 compatible connector
Left Hand DIN41612S2 compatible connector
P13c - 32cCommon
P1a
P32a
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2.3.5 Digital Input/Outputs with COP32-NO Module
Certain systems require additional validation of outputs when interfacing to an interlocking. This is acheived by controlling each ‘interlocking’ output using two DOP64 module bits. The interlocking output state is not active (contact closed) until both controlling bits are in the required state.
For these outputs the DOP64-TM module is replaced with a COP32-NO module. Using a COP32-NO module reduces the number of outputs from 64 to 32. Also 32 inputs on an adjacent DIP64-TM module are used to monitor the status of the 32 complementary outputs pairs from the DOP 64.
The DOP64 module provides 64 output states configured to form 32 complementary pairs, (output 1 and 33, 2 and 34 etc). Each complementary pair of outputs are passed through a relay circuit on the COP32-NO module to provide 32 voltage free output states.
Each output is capable of being set ON, OFF or FLASHING. The output FLASHING mode is synchronized across modules using a synchronization message class originated by the on-line system. The flashing rate will be either 0.5 seconds or 1 second as defined by the setting of the configuration switch (see Table 2.3).
Note: Although outputs are capable of being flashed; in practice this is unlikely to be required.
The COP32-NO module monitors the outputs from the DOP64 to check that they are in a complementary state by passing each pair though a relay logic circuit. The resulting outputs from this circuit are output via the COP32-NO upper 37-way connector. A DIP-COP Monitor link module is fitted between the upper connector of the COP32-NO and the upper connector of the adjacent DIP64-TM. The monitored outputs are loop back to the DIP-TM module as inputs 1 to 32.
Inputs 33 to 64 are connected to the lower connector of the DIP-TM or DIP-TMW in the normal manner as detailed in paragraph 2.3.1.
Table 2.2 details the outputs from the COP32-NO module for each possible state of a complementary output pair from the DOP 64 Module. The complementary pair O/P bits 1 and 33 are used as an example. All other complementary pairs, e.g O/P bits 2 and 34, 3 and 35 etc, will be the same.
The LEDs on the front panel of the DOP64 and DIP 64 modules will reflect state of the complementary pairs, refer to Figure 2.16.
Table 2.2 — COP Module Truth Table
DOP64 Output Bits(one example shown)
State of O/P 1 (Output via relay circuit and 96-way connector)
State of Monitored O/P 1(Output via monitoring logic and 37-Way connector)O/P Bit 1 O/P Bit 33
Low Low Contact Open Off
High Low Contact Closed On
Low High Contact Open On
High High Contact Open Off
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164
Figure 2.16 — COP32-NO Output Connection
The
upp
er a
nd lo
wer
bl
ocks
of L
ED
on
the
DO
P-6
4 sh
ould
dis
play
C
ompl
emen
tary
sta
te,
e.g
if le
d 1
is
illum
inat
ed, t
hen
LED
33
shou
ld b
e ex
tingu
ishe
d
Low
er L
ED
Blo
ck(L
ED
s fo
r O
/Ps
33 to
64)
Upp
er L
ED
Blo
ck(L
ED
s +F
or O
/Ps
1 to
32)
DO
P-6
4
CP
U-2
CO
P32
-NO
O/P
1
Mon
itor
Logi
c C
ircui
t
O/P
64
Rel
ay
Circ
uit
Load
1
Driv
eP
ower
Sou
rce
Driv
eP
ower
Sou
rce
48 V
d.
c.P
ower
Sou
rce
b1-b
4
b29-
b32
Load
32
O/P
32
O/P
1
1 A
1 A
Driv
e po
wer
sou
rce
50 V
M
ax, a
.c. o
r d.
c.
32 D
igita
l Inp
uts
(I/P
s 33
to 6
4).
Inpu
t to
low
er c
onne
ctor
(37
-way
D ty
pe)
as p
er F
igur
e 2.
7
DIP
-64T
MD
IP-6
4
DIP
-CO
P M
onito
r L
ink
Mo
dule
I/P 1
(m
onito
ring
of D
OP
O/P
1 a
nd O
/P 3
3)
Low
er C
onne
ctor
(96-
way
DIN
416
12 c
onne
ctor
)
I/P32
(m
onito
ring
of D
OP
O/P
32
and
O/P
64)
CP
U-2
LED
for
I/Ps
1 to
32.
All
lit w
hen
O/P
s fr
om D
OP
-64
are
in
com
plem
enta
ry s
tate
An
extin
guis
hed
LED
m
eans
that
the
asso
ciat
ed
O/P
pai
r is
not
in a
co
mpl
emen
tary
sta
te
i.e if
bot
h hi
gh (
1)
or if
bot
h lo
w (
0).
LED
for
I/Ps
33 to
64.
Ref
lect
s st
atus
of i
nput
s.Li
t = H
igh
(1),
E
xtin
guis
hed
= L
ow (
0)
c32c1
O/P
64
O/P
1
O/P
1
O/P
64
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2.3.6 Digital Input/Outputs with COP S2 4HP Module
Certain systems require additional validation of outputs when interfacing to an interlocking. This is acheived by controlling each ‘interlocking’ output using two DOP64 module bits. The interlocking output state is not active (contact closed) until both controlling bits are in the required state.
For these outputs the DOP64-TM module is replaced with a COP S2 4HP module. Using a COP S2 4HP module reduces the number of outputs from 64 to 32, therefore only the lower connector is used for the outputs. The upper connector is used for the following:
• 24V d.c. input power (pins 1 and 2)
• Relay Common (pin 11)
• 0V (pins 24 and 25)
• Complimentary output pairs monitoring bitOne bit (output on pin 10) is used to indicate the status of the 32 complimentary output pairs. If all 32 output pairs are complimentary, then the bit is high (1), but if one or more of the output pairs are not complimentary, the bit is low (0).
The complimentary output pair status bit for each of the COP S2 4HP modules are all output to a DIP S2 4HP transition module (normally the last DIP-TM in the system). The complimentary output pair status bit of the first COP S2 4HP is input to pin 1 of theDIP S2 4HP upper connector, the status bit from the second COP S2 4HP is input to pin 2 of the DIP S2 4HP upper connector etc.
The DOP64 module provides 64 output states configured to form 32 complementary pairs, (output 1 and 33, 2 and 34 etc). Each complementary pair of outputs are passed through a relay circuit on the COP S2 4HP module to provide 32 voltage free output states.
Each output is capable of being set ON, OFF or FLASHING. The output FLASHING mode is synchronized across modules using a synchronization message class originated by the on-line system. The flashing rate will be either 0.5 seconds or 1 second as defined by the setting of the configuration switch (see Table 2.3).
Note: Although outputs are capable of being flashed; in practice this is unlikely to be required.
Inputs 33 to 64 are connected to the lower connector of the DIP S2 4HP in the normal manner as detailed in paragraph 2.3.2.
Table 2.2 details the outputs from the COP S2 4HP module for each possible state of a complementary output pair from the DOP 64 Module. The complementary pair O/P bits 1 and 33 are used as an example. All other complementary pairs, e.g O/P bits 2 and 34, 3 and 35 etc, will be the same.
The LEDs on the front panel of the DOP64 and DIP 64 modules will reflect state of the complementary pairs, refer to Figure 2.17.
The COP S2 4HP module monitors the outputs from the DOP64 to check that they are in a complementary state by passing each pair though a relay logic circuit. The resulting outputs from this circuit are output via the COP S2 4HP upper 25-way connector. A connection is made between the upper connector of each COP S2 4HP and the upper connector of the DIP S2 4HP.
TRAININ
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164
Figure 2.17 — COP S2 4HP Output Connection
The
upp
er a
nd lo
wer
bl
ocks
of L
ED
on
the
DO
P-6
4 sh
ould
dis
play
C
ompl
emen
tary
sta
te,
e.g
if le
d 1
is
illum
inat
ed, t
hen
LED
33
shou
ld b
e ex
tingu
ishe
d
Low
er L
ED
Blo
ck(L
ED
s fo
r O
/Ps
33 to
64)
Upp
er L
ED
Blo
ck(L
ED
s fo
r O
/Ps
1 to
32)
DO
P-6
4
CP
U-2
CO
P S
2 4H
P
O/P
1
Mon
itor
Logi
c C
ircui
t
O/P
64
Rel
ay
Circ
uit
Load
1
Driv
eP
ower
Sou
rce
Driv
eP
ower
Sou
rce
1 2
Load
32
O/P
32
O/P
1
1 A
1 A
Driv
e po
wer
sou
rce
50 V
M
ax, a
.c. o
r d.
c.
32 D
igita
l Inp
uts
(I/P
s 33
to 6
4).
Inpu
t to
low
er c
onne
ctor
(37
-way
D ty
pe)
as p
er F
igur
e 2.
7
DIP
T
ran
siti
on
M
od
ule
DIP
-64
Low
er C
onne
ctor
(96-
way
DIN
416
12 c
onne
ctor
)
CP
U-2
One
LE
D fo
r ea
ch
CO
P m
odul
e in
the
asso
ciat
ed s
yste
m.
A li
t LE
D m
eans
that
al
l the
out
put p
airs
in
the
asso
ciat
ed C
OP
m
odul
e ar
e in
a
com
plem
enta
ry s
tate
.
An
extin
guis
hed
LED
m
eans
that
not
all
outp
ut p
airs
in th
e as
soci
ated
CO
P
mod
ule
are
in a
co
mpl
emen
tary
sta
te.
LED
for
I/Ps
33 to
64.
Ref
lect
s st
atus
of i
nput
s.Li
t = H
igh
(1),
E
xtin
guis
hed
= L
ow (
0)
c32
c13
O/P
1
O/P
64
+24V
d.
c.
0V
10 11 24 25
CO
P O
utP
ut
Rel
ay C
omm
on
Fro
m o
ther
CO
P S
2 M
odul
es in
hou
sing
(if
app
licab
le)
Upp
er C
onne
ctor
(25-
way
D ty
pe)
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2.4 ANALOGUE INPUTS
Analogue Inputs to the Westronic 1024 are input to an AIP-8 module via two 25-way D-type connectors (Figure 2.18). The AIP-8 module is an 8 channel Transition Module providing connections for up to eight analogue inputs, which can be voltage or current based.
The module will accept input signal ranges of:
• 0-10V
• 0-5V
• 0-20mA
• 4-20mA
• 0-5V (from rear transition connector J1).
The range of each input is individually set for each channel by factory set jumpers on the main board and the signal is measured to 8-bit ADC resolution.
A wetting power supply of 24V (190mA maximum) is supplied by the AIP-8 module for powering attached voltage or current sensors.
The AIP-8 module is seen by the CPU-2 cards as a DIP-64 module. The CPUs poll the Module and read the status of the inputs. The CPU processes this information and creates a serial message which it outputs via the CPU-2TM. If the AIP-8 is part of a dual system, both SYS1 and SYS2 Scan LEDs will flash as the data is read. If part of a single system, then only the SYS1 LED will flash.
Figure 2.18 — AIP-8 Input Connections
11
10
12
13
9
8
7
6
5
4
3
2
1
23
22
24
25
21
20
19
18
17
16
15
14
N/C
CH1 V+ in
CH1 I in
WET -
CH4 I out
CH4 V- in
WET +
CH2 V+ in
CH2 I in
WET +
CH3 V+ in
CH3 I in
WET +
CH4 V+ in
CH4 I in
WET +
WET -
CH3 I out
CH3 V- in
WET -
CH2 I out
CH2 V- in
WET -
CH1 I out
CH1 V- in
11
10
12
13
9
8
7
6
5
4
3
2
1
23
22
24
25
21
20
19
18
17
16
15
14
N/C
CH5 V+ in
CH5 I in
WET -
CH8 I out
CH8 V- in
WET +
CH6 V+ in
CH6 I in
WET +
CH7 V+ in
CH7 I in
WET +
CH8 V+ in
CH8 I in
WET +
WET -
CH7 I out
CH7 V- in
WET -
CH6 I out
CH6 V- in
WET -
CH5 I out
CH5 V- in
Upper 25-wayD-type connector
Lower 25-wayD-type connector
Key:
WET + and WET - = 24 V output voltage to power external sensorsCH1 V+ in to CH8 V+ in = Positive terminal input for voltage sensorsCH1 V- in to CH8 V- in = Negative terminal input for voltage sensorsCH1 I in to CH8 I in = Current in terminal input for current sensorsCH1 I out to CH8 I out = Current out terminal input for current sensorsN/C = Not connectedTRAININ
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164
2.5 ADDRESS AND CONFIGURATION SWITCHES
Mounted on the CAN-Bus backplane, behind the first CPU-2TM module are two switches, SW1 and SW2 as shown in Figure 2.19.
Figure 2.19 — Address and Configuration Switches
2.5.1 Configuration Switch
The lower switch (SW1) is a four-position DIP switch the position of which is read on start-up by both CPUs.
SW1(1) is used to determine the required status of the outputs (freeze or all extinguished) following a system communication failure. SW1(2) is used to set the synchronized rate of the flashing outputs at 0.5 or 1.0 seconds. SW1(3) and SW1(4) are spare discrete settings.
Table 2.3 details the Switch SW1 settings:
For the required settings for a specific housing, please refer to the scheme drawings for that installation.
Table 2.3 — SW1 Configuration Switch Settings
SW1 POSITION
OFF (0) ON (1)
1 Freeze All Extinguished
2 0.5 Sec 1.0 Sec
3 Spare
4 Spare
SW2Address
Switches
SW1Configuration
Switches
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2.5.2 Address Switches
The upper switch SW2 is an eight position DIP switch used to set the housing address and is read by both CPUs on start-up.
Note: In a Triple TDM housing there are three CAN-Bus backplanes each with its own DIP switch. Each switch is used to set the address of the associated TDM.
The eight bit DIP address is used in conjunction with the Network Rail supplied ‘Scheme Address’, manufacture code and equipment type (configured as part of the database) to form the complete ‘System Transmission Address’ for communication over an open network topography. The switches set a two digit hex code as shown in the Table 2.4 example below:
For the required settings for a specific housing, please refer to the scheme drawings for that installation.
2.6 MODULE CODING
Each 1024 module is equipped with an arrangement of coding pegs that engage with coding pegs and coded holes in the housing. This ensures that any particular module will only be able to be fitted in a slot that is coded to accept it. The coding pegs fitted to modules are coloured grey, whilst the coding pegs in the housing are coloured red, see Figure 2.20.
Details of the module and housing coding used can be found in Table 3.2.
Figure 2.20 — Typical Module and Housing Coding
Table 2.4 — SW2 Configuration Switch Settings
SW2 Switch 8 7 6 5 4 3 2 1
Switch setting 0 0 1 0 1 1 0 1
Hex Code 2 D
Grey Coding Pegs(Module)
Red Coding Pegs(Housing)TRAIN
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164
2.7 POWER DISTRIBUTION
2.7.1 General
The Westronic 1024 housing is powered by a supply of either 110V a.c. or 230V a.c, 50/60 Hz, which is input to Power Filter Module(s) (PFM) in the 1024 housing. The supply is filtered and fed to an associated PSU.
In the case of Triple TDM housings, each of the fitted TDM systems are powered independantly.
For systems employing two PSUs, the PSU outputs are configured in a parallel redundant arrangement. Each PSU outputs 5V d.c. to power each of the modules in the housing via the housing backplane. If one PSU fails, the remaining PSU is capable of suppling all the housing power requirements.
In 19 inch housings only, each PSU output is monitored by an associated System Arbiter module. If one PSU fails, an alarm is output via the on-line processor. The System Arbiter module has a Reset button which is used to reset the PSU alarm system when a PSU fault has been repaired.
2.7.2 Battery Back-up Power Supply
The back-up supply at remote equipment rooms is sometimes supplied from a diesel generator. Unlike modern UPS (uninterruptible power supply) equipment, generators take time to start-up and supply power to the signalling system. The battery back-up unit is provided to supply power to the Westronic 1024 equipment for the period between power loss and the generator supply becoming available.
The battery back-up unit is a separate 2U high 19 inch wide housing, capable of powering a single Westronic 1024 housing for up to six minutes in the case of a mains supply failure.
When the battery back-up unit is used, the standard housing PSUs are replaced with PSUs having a 5V d.c. input connector on their front panel. The battery back-up unit is cable connected to these connectors.
The battery back-up unit is powered by the same 110V a.c. supply as the Westronic 1024 housing. While the mains 110V a.c. supply is operational the battery back-up units 5V d.c. outputs are inactive. If the mains supply fails, the battery back-up unit outputs an alarm (via the System Arbiter Module) and supplies 5V d.c. to the Westronic 1024 housing via the PSU input connectors.TRAIN
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2.8 SYSTEM CHANGEOVER
A System Arbiter Module (SA-1) is provided to enable auto or manual changeover between the System 1 and System 2.
A front panel rotary switch operates as follows:
SYS 1 - Sets and holds System 1 on-line, irrespective of the health of the System.
AUTO - If the Watchdog output from the on-line System fails, and providing the Watchdog from the hot-standby System is present, automatic changeover to the hot-standby system will occur.
SYS 2 - Sets and holds System 2 on-line, irrespective of the health of the System.
The Arbiter constantly monitors each CPU via separate RS-422 links, providing indications at the front panel The Arbiter controls which system is on-line at any one time, according to the setting of the front panel rotary switch. The other system is in hot standby mode.
If the on-line system fails, the auto changeover is only implemented if the standby system is outputting a healthy Watchdog signal and the front panel switch is set to Auto.
Should the System Arbiter Module be removed or fail, System 1 will be on-line.
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164
2.9 GENERAL ALARMS
The facility is provided for the connection of external alarms, PSU and EFA alarms and EFA acknowledgement buttons if required by the Scheme.
Operation of the alarms will be defined in the Scheme application software contained within a CF Card fitted to each CPU-2 module.
Signals are taken from the serial output of the CPU-2 module and from the logic within the SA-1 module. If a fault occurs, the appropriate LEDS are lit. The SA-1 also provides an output to drive the Audible alarm.
Hardware connections are made via the 25-way I/O connector on the System Arbiter Transition Module (SA-1TM). Eight digital inputs and six digital outputs are provided for this purpose. Connections are given in Table 2.5. The condition of the inputs and outputs is indicated on LEDs on the Arbiter transition module’s panel.
Connectivity is scheme specific and will be shown in the Scheme drawings.
A Signaller’s Alarm Panel may be connected to the system, Figure 2.21 shows a typical alarm system block diagram and Figure 2.22 shows a typical SA-1TM Module to Alarm Panel connections.
For system layout and connectivity for a particular alarm panel refer to the drawings pack for that installation.
Spares holders must ensure that the spares they hold are compatible with their configurations of Westronic 1024 and that the data and processor configurations are kept up to date.
2.11 INSTALLATION SITE DRAWINGS
The definitive record of each installation is the site drawings for that installation, therefore, these drawing must be kept up to date and accurate. If there is any doubt as to the accuracy of the drawings on site, a copy of the master drawings is available from Network Rail Records Group at York.
EFA ACK HI
EFA ACK LO
13
14
25
1
10
23
22
9
6
18
7
19
8
20
21
RLYCON
BUZZNO
LAMPNO
DO WET+
DOUT0
DOUT1
DOUT2
DOUT3
DOUT4
DOUT5
DO COM
SA-1TM PART 25-WAY D-TYPE CONNECTOR
TDM BUZZER
ACK ALARM E
WH
SYSTEM A ON LINE E
WH
SYSTEM A FAULT E
RD
SYSTEM A AVAIL E
WH
SYSTEM B ON LINE E
WH
SYSTEM B FAULT E
RD
SYSTEM B AVAIL E
WH
N24
N24
B24
B24
B24
N24
B24ACK ALARM
ALARM PANEL
BELDEN 9507 SCREENED CABLE
P
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Intentionally Left Blank
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164
SECTION 3 — EQUIPMENT DESCRIPTION
3.1 WESTRONIC 1024 HOUSINGS
3.1.1 Standard 19 inch Housing
The Westronic 1024 equipment is housed in a 19 inch Housing.
The 19 inch 6U EMC housing has front and rear access into which the modules are inserted. Blank panels are used to complete the EMC screen. A typical housing is shown in Figure 3.1.
If the housing is fitted with a COP32-NO module, the associated DOP-64 Module must be fitted adjacent to a DIP-64 Module (refer to paragraphs 2.3.5, 3.2.16 and 3.2.17).
Figure 3.2 shows a rear view of the housing with some modules removed to show the communications backplane. The communication backplane runs the full length of the lower 3U of the housing, connecting the DIP-64, DOP-64, System Arbiter and CPU-2 modules. The connectors fitted to the upper 3U of the housing connect the DIP-64 and DOP-64 modules to their rear fitted Transition modules.
Module addresses are fixed per slot.
3.1.2 Triple TDM Housing
Up to three independant sets of Westronic 1024 TDM equipment can be housed in the Triple TDM Housing.
The 19 inch 6U EMC housing has front and rear access into which the modules are inserted. Blank panels are used to complete the EMC screen. A typical housing is shown in Figure 3.3.
Three communication backplanes are installed in the lower 3U of the housing. Each backplane connects one set of DIP-64, DOP-64, System Arbiter and CPU-2 modules. The connectors fitted to the upper 3U of the housing connect the DIP-64 and DOP-64 modules to their rear fitted Transition modules.
If the housing is fitted with a COP32-NO module, the associated DOP-64 Module must be fitted adjacent to a DIP-64 Module (refer to paragraphs 2.3.5, 3.2.16 and 3.2.17).
Module addresses are fixed per slot.TRAININ
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Figure 3.1 — Typical Standard Westronic 1024 Housing
PSU Filter Modules(RFM110 or RFM 230)
CPU Transition Modules (CPU-2TM) or (CPU-2MTM)
DOP TransitionModules (DOP-64TM) DIP Transition
Modules (DIP-64TM)
System Arbiter TransitionModule (SA-1TM)
REAR VIEW
FRONT VIEW
5 V DC PSUsIf a battery back-up power supplyis used, these PSUs are replaced with versions fittedwith a front panel connector.
Processor Modules(CPU-2)
System Arbiter Module(SA-1)
Digital Input Modules(DIP-64)
Digital Output Modules(D0P-64)
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164
Figure 3.2 — Standard 19 inch Housing Rear View Showing Backplanes
Communications Backplane
Connectors(front module to rear fitted Transition module)
Address andconfigurationswitches are
located behindthis module.
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Figure 3.3 — Typical 1024 Triple TDM 19 inch Housing (with One TDM Fitted)
PSU Filter Modules(RFM110 or RFM 240)
CPU Transition Modules (CPU-2TM) or (CPU-2MTM)
DOP TransitionModule (DOP-64TM)
DIP TransitionModule (DIP-TM)
(50 and 24 V a.c./d.c. Versions Available)
System Arbiter TransitionModule (SA-1TM)
REAR VIEW
FRONT VIEW
5 V DC PSUsIf a battery back-up power supplyis used, these PSUs are replaced with versions fittedwith a front panel connector.
Processor Modules(CPU-2)
System Arbiter Module(SA-1)
Digital Input Module(DOP-64)
Digital Output Module(DIP-64)
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164
3.2 WESTRONIC 1024 MODULES
Each of the Westronic 1024 modules are described separately in paragraphs 3.2.1 to 3.2.20.
Module coding information for each module is detailed in section 2.6 and Table 3.2.
3.2.1 Processor Module (CPU-2)
3.2.1.1 General
The CPU-2 processor module is shown in Figure 3.1.
Figure 3.4 — CPU-2 Processor Module
The processor module is a 3U high, 8HP wide and 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The processor module consists of a main carrier card with a COTS (commercial off the shelf) based ETX processor daughter board. The daughter board allows for an easy future upgrade path as new processor modules becoming available.
POWER LED
WATCHDOG LED
FAULT LED
USB Cable Connectorsfor keyboard and mouse
Video Cable Connectorfor monitor
Module Release Handle
Flash Card Release Button
CAUTION:
FLASH DRIVE ACTIVITY LED
Flash CardThe second card holder, adjacentthe heat sink is NOT USED.
Date Installed Label
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The processor operating system software, Invensys Rail Limited’s application and system data software are all stored on a flash card which is inserted in the top of the processor module.The flash card can only be accessed when processor module is removed from the housing.
A processor module can be removed and replaced while the system is operating. The module has a two position ejector handle release mechanism, pressing the red button disconnects the power and then, providing the retaining screws have been unscrewed, pressing down the black handle will pull the module forward.
The processor minimum specification is:
• System Processor 500 MHz MMX - Fan-less Operation;
• 256 MB RAM;
• Five TTL Serial Bus ports;
• One RS-422 System Arbiter Interface;
• One Flash Disk Storage Interface;
• Two USB ports;
• One analogue video port;
• One LAN port (not used).
3.2.1.2 Connectors
External
The connectors on the front of the processor module are:
• High density D15 video connector.
• USB keyboard and mouse connectors.
• LAN (RJ45) connector.
The above connectors are for development use only. They are not used on the operational system.
Internal
The processor module is connected to the backplane by a 64-way DIN41612 connector. This enables communications with the DIP and DOP modules, external systems via the CPU Transition Module and, where applicable, with the System Arbiter module (used to pass State of Watchdog, the CPU availability and output state information).
3.2.1.3 Indications
The processor module LED indications are detailed in Table 5.1.TRAININ
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3.2.2 Processor Transition Module (CPU-2TM)
3.2.2.1 General
The Processor Transition Module (CPU-2TM) is shown in Figure 3.5.
The Processor Transition Module (CPU-2TM) is a 3U 8HP wide 112.5 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
This module supports all the necessary external connectivity, converting the processor module TTL serial channels to RS-232 and RS-422 line levels.
This module can be removed/replaced with the power applied.
3.2.2.2 Connectors
External
The Processor Transition Module has the following external connectors:
• COM3 - RS-232/MODEM - This is a 9-way D-type plug, used for to serial communications with the remote housing, via modems,
• COM4 - RS-422 - Not used,
• COM5 - RS-422 - Not used,
• COM6 - RS-232 - Not used,
• NET - Not used,
Note: Industry standard pin-outs apply to the above connectors.
Internal
The Processor Transition Module is connected to the backplane by a 64-way DIN41612 connector. This enables communications with the associated CPU-2 processor module.
3.2.2.3 Indications
The CPU-2TM LED indications are detailed in Table 5.1.
COM3 connector plugRS-232/Modem
COM4 Connector socketRS-422
COM5 connector socketRS-422
LAN connector socket
COM6 connector plugRS-232
POWER LED
Module Release Handle
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3.2.3 Processor Transition Module CPU-2MTM
The Processor Transition Module (CPU-2MTM) is shown in Figure 3.6.
The Processor Transition Module (CPU-2MTM) is a 3U 8HP wide 112.5 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
This module supports all the necessary external connectivity, converting the processor module TTL serial channels to RS-232 and RS-422 line levels. This module also incorporates an integral modem that can be configured via DIP switches to communicate in point to point V.23 mode or open V.32B mode. Refer to paragraph 6.3.3.2.
This module can be removed/replaced with the power applied.
Power LEDTransmit LED
Receive LED
Carrier Detect LED
COM3 connector socketModem
COM4 connector socketRS-422
COM5 connector socketRS-422
LAN connector socket
COM6 connector plugRS-232
Module release handle
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3.2.3.1 Connectors
External
The Processor Module Transition module has the following external connectors:
• COM3 - MODEM - This is a 9-way D-type socket, used for serial communications between the integral modem and the remote housing,
• COM4 - RS-422 - This is a 9-way D-type socket and may by used for inter processor communications between to office WESTRONIC 1024 sets of equipment,
• COM5 - RS-422 - Not used,
• COM6 - RS-232 - Not used,
• NET - Not used.
Note: Except for Com 3, industry standard pin-outs apply to the above connectors. The Pin Out for COM 3 is detailed below:
The Processor Transition Module is connected to the backplane by a 64-way DIN41612 connector. This enables communications with the associated CPU-2 processor module.
3.2.3.2 Indications
The CPU-2MTM LED indications are detailed in Table 5.1.
Table 3.1 — CPU-2MTM COM3 Pin Out
PIN FUNCTION
6 TX+
7 TX-
8 RX+
9 RX-
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3.2.4 System Arbiter Module (SA-1)
3.2.4.1 General
The System Arbiter module (SA-1) is shown in Figure 3.7.
Figure 3.7 — System Arbiter Module
The SA-1 is a 3U 4HP wide 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The System Arbiter Module constantly monitors the status of each Processor Module and both PSUs. The Arbiter Module controls which Processor is on-line instigating an auto-changeover if a fault is detected in the on-line processor.
The System Arbiter module contains eight optically insolated inputs and six outputs for general alarm use.
This module can be removed/replaced with the power applied and the system operating. The module has a two position ejector handle release mechanism, pressing the red button disconnects the power and then, providing the retaining screws have been unscrewed, pressing down the black handle will pull the module forward. Removal of the module causes the System 1 processor to default to the on-line condition.
POWER LED
WATCHDOG LEDs
ON-LINE LEDs
FAULT LEDs
PSU MONITORING
LEDs
RESET Buttonfor PSU Monitoring
LEDs
Changeover Switch
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3.2.4.2 Controls
The System Arbiter Module has a changeover switch that can be set to any one of the following three positions:
• SYS 1 - When switch in this position, selects and holds System 1 On-line,
• AUTO - When switch in this position the system will automatically be switched over if a fault is detected on the On-Line system and if the hot-standby system is available,
• SYS 2 - When switch in this position, selects and holds System 2 On-line.
The Reset button, when pressed, resets the PSU Monitoring LEDs to green following repair of a power supply fault. The LEDs normally show green, but latch to red in the event of a power supply failure - even if momentary.
3.2.4.3 Connectors
The System Arbiter Module is connected to the backplane by a 64-way DIN41612 connector.
3.2.4.4 Indications
The System Arbiter Module LED indications are detailed in Table 5.1.
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3.2.5 System Arbiter Transition Module (SA-1TM)
The System Arbiter Transition Module (SA-1TM) is shown in Figure 3.8.
Figure 3.8 — System Arbiter Transition Module (SA-1TM)
The System Arbiter Transition Module (SA-TM1) is a 3U 4HP wide 112.5 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The module has two miniature relays that are independently picked by each system PSU (PSU voltage sensing points). The contacts of each relay are connected to the D25 socket connector on the module’s front panel. The contacts are voltage free and capable of switching an external 50V a.c. or d.c. supply at 10 mA.
The module also has two miniature relays for EFA functions and an opto isolated digital input for EFA acknowledge. The acknowledge signal is operational within a voltage range of 12 to 24V d.c. or a.c.
This module can be removed/replaced with the power applied. Removing the module disables the associated System Arbiter module, causing System 1 to default to On-line.
3.2.5.1 Connectors
External
The 25-way D-Type Socket is used to present six assignable digital outputs, the PSU and EFA alarms and connect eight assignable digital inputs. Pin-outs are given in Table 2.5.
Internal
The System Arbiter Transition Module is connected to the backplane by a 64-way DIN41612 connector.
Indications
The System Arbiter transition module LED indications are detailed in Table 5.1.
Output LEDs
Input LEDs
25-way D-TypeSocket
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3.2.6 Digital Input Module (DIP-64)
The Digital Input Module (DIP-64) is shown in Figure 3.9.
Figure 3.9 — Digital Input Module (DIP-64)
The Digital Input Module (DIP-64) is a 6U 4HP wide 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot. Unused slots are fitted with blanking plates to prevent inadvertent use.
This module can be removed/replaced with the power applied and the system operating. Removing this module will affect operation of related system functions. The module has a two position ejector handle release mechanism, pressing the red button disconnects the power and then, providing the retaining screws have been unscrewed, pressing down the black handle will pull the module forward.
The 64 bit input module interfaces to the backplane via the J2 connector. This is used for connection of all external inputs.
When installed, the input module reads the unique slot address from the system backplane and only responds to messages that are applicable to this code.
3.2.6.1 Connectors
• J1 DIN41612 connectorUsed for connection of all external inputs, via the Digital Input Transition Module.
• J2 DIN41612 connectorInterfaces the Digital Input Module to both system processors via two separate CAN-Bus ports.
3.2.6.2 Indications
The Digital Input Module LED indications are detailed in Table 5.1.
INPUT LEDs
SCAN LEDs
POWER LED
J2 Backplane Connector
J1 External Inputs Connector(Inputs are connected via theDigital Input Rear Transition Module)
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3.2.7 Digital Input Transition Module (DIP-TM xxV)
A Digital Input Transition Module (DIP-TM xxV) is shown in Figure 3.10.
Figure 3.10 — Digital Input Transition Module (50V version shown)
The Digital Input Transition Module (DIP-TM xxV) is a 6U 4HP wide 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot. Blanking plates are fitted to unused slots.
Up to 64 external digital inputs are connected via two 37-way D-Type plugs and routed via a resistor network to the DIP-64 Module.
There are two versions of the DIP Transition Module:-
• Type 1 - 24V a.c. / d.c. input voltage (designated DIP-64T 24V),
• Type 2 - 50V a.c. / d.c. input voltage (designated DIP-64T 50V).
These modules can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
3.2.7.1 Connectors
External
External inputs are terminated on two 37-way D-Type plugs. Pins 1 to 32 of the upper D-type correspond to inputs 1 to 32, with pins 33 to 36 acting as common returns. The lower D-type connector pins 1 to 32 correspond to inputs 33 to 64 and again have a common return on pins 33 to 36.
Internal
The DIP Transition Module interfaces directly to a DIP-64 module via the DIN41612 J1 connector. The J2 connector is not used.
3.2.7.2 Indications
The DIP-TM LED indications are detailed in Table 5.1.
POWER LED
37-way D-typePlugs
J1DIN41612Connector
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3.2.8 Digital Input Transition Module (DIP-TMW 24V)
A Digital Input Transition Module with wetting is shown in Figure 3.11.
Figure 3.11 — Digital Input Transition Module (with Wetting)
The Digital Input Transition Module (DIP-TMW) is a 6U 4HP wide 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot. Blanking plates are fitted to unused slots.
Up to 64 external digital inputs are connected via two 37-way D-Type plugs and routed via a resistor network to the DIP-64 Module.
A 24V wetting supply is internally derived and made available on the 37-way D-Type plugs.
These modules can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
3.2.8.1 Connectors
External
External inputs are terminated on two 37-way D-Type plugs. Pins 1 to 32 of the upper D-type correspond to inputs 1 to 32, with pins 33 to 36 acting as a common positive wetting supply. The lower D-type connector pins 1 to 32 correspond to inputs 33 to 64 and again have a common positive wetting supply on pins 33 to 36.
Internal
The DIP Transition Module interfaces directly to a DIP-64 module via the DIN41612 J1 connector. The J2 connector is not used.
3.2.8.2 Indications
The DIP-TM LED indications are detailed in Table 5.1.
POWER LED
37-way D-typePlugs
J1DIN41612Connector
WettingCircuitry
Wetting SupplyLED
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3.2.9 DIP S2 4HP-xxV
A Digital Input Transition Module (DIP S2 4HP-xxV) is shown in Figure 3.12.
Figure 3.12 — Digital Input Transition Module (DIP S2 4HP) (24V version shown)
The Digital Input Transition Module (DIP S2 4HP xxV) is a 6U 4HP wide 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot. Blanking plates are fitted to unused slots.
Up to 32 external digital inputs from the COP S2 modules in the system, are connected via the upper, 37-way D-type, connector and routed via a resistor network to the DIP-64 Module.
Up to 32 external digital inputs are connected via the lower, S2 compatible, connector and routed via a resistor network to the DIP-64 Module.
There are two versions of the DIP S2 8HP Module:-
• Type 1 - 24V a.c. / d.c. input voltage (designated DIP S2 8HP-24V),
• Type 2 - 50V a.c. / d.c. input voltage (designated DIP S2 8HP-50V).
These modules can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
37-way D-typeConnector
S2 CompatibleDIN41612Connector
Power LED
J1DIN41612Connector
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3.2.9.1 Connectors
External
External inputs are terminated on the upper, 37-way D-type, conector. Pins 1 to 32 correspond to COP S2 inputs 1 to 32, with pins 33 to 36 acting as common returns.
The lower, DIN41612 connector pins 1a to 32a correspond to inputs 33 to 64, with pins 13c to 32c acting as common returns.
Internal
The DIP S2 4HP Module interfaces directly to a DIP-64 module via the DIN41612 J1 connector. The J2 connector is not used.
3.2.9.2 Indications
The DIPS2 4HP LED indications are detailed in Table 5.1.
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3.2.10 DIP S2 8HP-xxV
A Digital Input Transition Module (DIP S2 8HP-xxV) is shown in Figure 3.13.
Figure 3.13 — Digital Input Transition Module (DIP S2 8HP) (24V version shown)
The Digital Input Transition Module (DIP S2 8HP xxV) is a 6U 8HP wide 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot. Blanking plates are fitted to unused slots.
Up to 64 external digital inputs are connected via two S2 compatible connectors and routed via a resistor network to the DIP-64 Module.
There are two versions of the DIP S2 8HP Module:-
• Type 1 - 24V a.c. / d.c. input voltage (designated DIP S2 8HP-24V),
• Type 2 - 50V a.c. / d.c. input voltage (designated DIP S2 8HP-50V).
These modules can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
3.2.10.1 Connectors
External
External inputs are terminated on two DIN41612 conectors. Pins 1a to 32a of the right hand connector correspond to inputs 1 to 32, with pins 13c to 32c acting as common returns. The left hand connector pins 1a to 32a correspond to inputs 33 to 64 and again have a common return on pins 13c to 32c.
Internal
The DIP Transition Module interfaces directly to a DIP-64 module via the DIN41612 J1 connector. The J2 connector is not used.
3.2.10.2 Indications
The DIP-TM LED indications are detailed in Table 5.1.
S2 CompatibleDIN41612Connectors
Power LED
J1DIN41612Connector
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3.2.11 Digital Output Module (DOP-64)
The Digital Output module (DOP-64) is shown in Figure 3.14.
Figure 3.14 — Digital Output Module (DOP-64)
The Digital Output module (DOP-64) is a 6U 4HP wide 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
This module can be removed/replaced with the power applied. Removing this module will affect operation of related system functions. The module has a two position ejector handle release mechanism, pressing the red button disconnects the power and then, providing the retaining screws have been unscrewed, pressing down the black handle will pull the module forward.
The 64 bit output module interfaces to the backplane via the J1 connector. The J2 connector is used for connection of all outputs.
When installed the output module reads the unique slot address from the system backplane and only responds to messages that are applicable to this code.
3.2.11.1 Connectors
• J1 DIN41612 connectorUsed present all outputs to the Digital Output Transition Module,
• J2 DIN41612 connectorInterfaces the Digital Input Module to both system processors via two separate CAN-Bus ports.
3.2.11.2 Indications
The Digital Output Module LED indications are detailed in Table 5.1.
OUTPUT LEDs
SCAN LEDs
POWER LED
J2 Backplane Connector
J1 Output Connector(Outputs are connected via theDigital Output Rear Transition Module)
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3.2.12 AIP-8 Analogue Input Module
An Analogue Input Module is shown in Figure 3.15.
Figure 3.15 — Analogue Input Module (AIP-8)
The Analogue Input Module (AIP-8) is a 6U 4HP wide 160 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot. Unused slots are fitted with blanking plates to prevent inadvertent use.
This module can be removed/replaced with the power applied and the system operating. Removing this module will affect operation of related system functions. The module has a two position ejector handle release mechanism, pressing the red button disconnects the power and then, providing the retaining screws have been unscrewed, pressing down the black handle will pull the module forward.
This 8-bit ADC resolution input module is seen as a DIP-64 module by the CPU-2 module.
When installed, the input module reads the unique slot address from the system backplane and only responds to messages that are applicable to this code.
3.2.12.1 Connectors
External
For pin connections, see Figure 2.18.
Internal
The AIP-8 Module interfaces directly to the backplane via the J2 connector. The J1 connector is not used.
3.2.12.2 Indications
The AIP-8 LED indications are detailed in Table 5.1.
POWER LED
SCAN LEDS
ISOLATEDPOWER LED
25-way D-type AnalogueSignal Connectors
J1 DIN41612Connector
J2 DIN41612Connector
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3.2.13 Digital Output Transition Module (DOP-64TM)
A DOP-64TM Digital Output Transition Module is shown in Figure 3.16.
Figure 3.16 — Digital Output Transition Module (DOP-64TM)
The Digital Output Transition Module (DOP-64TM) is a 6U 4HP wide 112.5 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The DOP Transition module provides a means of connecting external outputs to the DOP-64 modules. Each output is fitted with a transorb to protect the module when switching inductive loads.
This module can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
3.2.13.1 Connectors
External
External outputs are terminated on two D37 way female connectors. Pins 1 to 32 correspond to outputs 1 to 32 with pins 33 to 36 acting as common returns. The second D type connector handles outputs 33 (37D pin 1) to 64 (37D pin 32) and again have common returns on pins 33 to 36.
Internal
The Transition module interfaces directly to a DOP module via a rear DIN41612 connector (J1). The J2 connector is not used.
3.2.13.2 Indications
The Digital Output Transition Module LED indications are detailed in Table 5.1.
POWER LED
37-way D-typeSockets
J1 DIN4162Connector
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3.2.14 DOP S2 4HP
A DOP S2 4HP Digital Output Transition Module is shown in Figure 3.17.
Figure 3.17 — Digital Output Transition Module (DOP S2 4HP)
The Digital Output Transition Module (DOP S2 4HP) is a 6U 4HP wide 112.5 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The DOP Transition module provides a means of connecting external outputs to the DOP-64 modules. Each output is fitted with a transorb to protect the module when switching inductive loads.
This module can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
3.2.14.1 Connectors
External
External outputs are terminated on one 37-way D-type connector (upper) and one S2 compatible DIN41612 connector (lower). Pins 1 to 32 of the upper connector correspond to outputs 1 to 32 with pins 33 to 36 acting as common returns. The lower connector handles outputs 33 (pin 1a) to 64 (pin 32a) and has common returns on pins 13c to 32c.
Internal
The Transition module interfaces directly to a DOP module via a rear DIN41612 connector (J1). The J2 connector is not used.
3.2.14.2 Indications
The Digital Output Transition Module LED indications are detailed in Table 5.1.
37-way D-typeConnector
S2 CompatibleDIN41612Connector
Power LED
J1DIN41612Connector
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3.2.15 DOP S2 8HP
A DOP S2 8HP Digital Output Transition Module is shown in Figure 3.18.
Figure 3.18 — Digital Output Transition Module (DOP S2 8HP)
The Digital Output Transition Module (DOP S2 4HP) is a 8U 4HP wide 112.5 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The DOP Transition module provides a means of connecting external outputs to the DOP-64 modules. Each output is fitted with a transorb to protect the module when switching inductive loads.
This module can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
3.2.15.1 Connectors
External
External outputs are terminated on two S2 compatible DIN41612 connectors. Pins 1a to 32a of the right hand connector correspond to outputs 1 to 32, with pins 13c to 32c acting as common returns. The left hand connector pins 1a to 32a correspond to outputs 33 to 64 and again have a common return on pins 13c to 32c.
Internal
The Transition module interfaces directly to a DOP module via a rear DIN41612 connector (J1). The J2 connector is not used.
3.2.15.2 Indications
The Digital Output Transition Module LED indications are detailed in Table 5.1.
S2 CompatibleDIN4162Connectors
Power LED
J1DIN4162
Connectors
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3.2.16 Complementary Output Module (COP32-NO)
A COP32-NO Digital Output Module is shown in Figure 3.19.
Figure 3.19 — Digital Output Module (COP32-NO)
The Digital Output Module (COP32-NO) is a 6U 4HP wide 112.5 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The COP32-NO module provides a means of connecting and monitoring the complementary paired outputs from the DOP-64 modules.
This module can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
3.2.16.1 Connectors
External
External outputs are terminated on D37 way and 96 way DIN41612 female connectors on the front of the module. The top, 37-way connector, provides 32 monitoring outputs. The lower, 96-way DIN41612 type connector provides 32 voltage free normally open relay contacts.
Internal
The Transition module interfaces directly to a DOP-64 module via a rear DIN41612 connector (J1). The J2 connector is not used.
3.2.16.2 Indications
The COP32-NO LED indications are detailed in Table 5.1.
POWER LED
37-way D-typeSocket
96-way DIN41612Socket
J1 DIN4162Connector
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3.2.17 DIP to COP Monitor Link Module
A DIP-COP Monitor Link Module is shown in Figure 3.20.
Figure 3.20 — DIP-COP Monitor Link Module
The DIP-COP Monitor Link Module is contained within a shielded metal box. Two 37 D-way connectors on the rear of the box are directly interconnected pin to pin, and are used to connect adjacent DIP-TM or DIP-TMW and COP32-NO modules together via their upper 37 D-way female connectors.
Removing this module will affect the monitoring of related system functions.
COP32-NO Module
DIP-64TM ModuleDIP-COP Monitor Link Module
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3.2.18 Complementary Output Module (COP S2 4HP)
A COP S2 4HP Digital Output Module is shown in Figure 3.21.
Figure 3.21 — Digital Output Module (COP S2 4HP)
The Digital Output Module (COP S2 4HP) is a 6U 4HP wide 112.5 mm deep Eurocard with an EMC front panel. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The COP S2 4HP module provides a means of connecting and monitoring the complementary paired outputs from the DOP-64 modules.
This module can be removed/replaced with the power applied. Removing this module will affect operation of related system functions.
3.2.18.1 Connectors
External
External outputs are terminated on D25 way and 96 way DIN41612 female connectors on the front of the module. The top, 35-way connector, provides:
• 24V d.c. input
• Monitoring output
• Relay common
• 0V input
The lower, 96-way DIN41612 type connector provides 32 voltage free normally open relay contacts.
Internal
The Transition module interfaces directly to a DOP-64 module via the top rear DIN41612 connector (J1). The J2 connector is not used.
3.2.18.2 Indications
The COP S2 4HP LED indications are detailed in Table 5.1.
25-way D-typeConnector
S2 CompatibleDIN4162Connector
Power LED
J1DIN4162
Connector
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3.2.19 Power Supply Modules
Two types of PSU may be fitted, a 5V d.c. PSU (Figure 3.22) and a 5V d.c. PSU (Figure 3.23) which has an additional 5V d.c. input connector on the front panel to enable a battery backup supply to be permanently connected.
Both PSU types are 3U 10HP wide 160 mm deep Eurocard with an EMC front panel and plug directly into the housing. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
Dual System 1024 housings have two PSUs (‘A’ and ‘B’) working in dual parallel mode to supply the DIPs, DOPs, CPUs and System Arbiter Modules. A single System housing will typically be fitted with only one PSU.
Note: All Input, Output and, (with the exception of the DIP-TMW module), Wetting supplies are exter-nal supplies.
The mains input range is 100 to 240V a.c. 50-60 Hz and output is a regulated 5V d.c with a maximum power rating of 80VA.
The Battery Back-up compatible version can be powered via a 5V d.c. output from the Battery Back-up Unit.
This module can be removed/replaced with the power applied and the system operating. The module has a two-position ejector handle release mechanism, pressing the red button disconnects the power and then, providing the retaining screws have been unscrewed, pressing down the black handle will pull the module forward.
Figure 3.22 — 5V PSU Without Back-up Connector
Monitoring Sockets
5 V d.c Trim Adjustment
POWER LED
DIN41612 H11Connector
ModuleReleaseHandle
PowerDisconnectionButtonTRAIN
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Figure 3.23 — PSU with Battery Back-up Input Connector
3.2.19.1 Controls
A 5V trim control access hole is provided on the front of the PSU to enable the PSU voltage output to be set up on installation or following replacement.
3.2.19.2 Indications
The PSU LED indications are detailed in Table 5.1.
3.2.19.3 Connectors
External
The connectors on the front of the PSU are:
• Monitoring Sockets - Two jack plug sockets, 0 Volts (black) and + 5 Volts (red) can be used to monitor the 5V output from the PSU,
• Battery Back-up Connector - Used to input a 5V d.c. back-up supply in the event of a(Battery Back-up compatible mains power supply failure,version only).
Internal
DIN41612 H11 Connector-Mounted on the rear of the PSU module to directly connect the module to the housing.
Monitoring Sockets
5 V d.c Trim Adjustment
POWER LED
ModuleReleaseHandle
PowerDisconnectionButton
Back-upPower InputConnector
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3.2.20 Power Filter Module
A Power Filter Module is shown in Figure 3.24.
Figure 3.24 — Power Filter Module
The Power Filter Module (PFM) is a 3U 10HP wide 112.5 mm deep Eurocard with an EMC front panel and plugs directly into the housing. Mechanical pin coding prevents the insertion of the module into an incorrect housing slot.
The Power filter module provides voltage surge protection and filtering of the mains input supply. This Module is compliant with the LVD and EMC standards.
There are two versions of the Power Filter Module:
• RFM-110 - For 110V a.c. input,
• RFM-230 - For 230V a.c input.
On dual systems only, this module can be removed/replaced with power applied to the other RFM and the system operating.
3.2.20.1 Controls
ON/OFF SwitchAn illuminated rocker switch used to switch the module On or Off.
3.2.20.2 Connectors
Mains Input ConnectorUsed to input the mains power supply to the housing.
3.2.20.3 Indications
The Power Filter Module indications are detailed in Table 5.1.
ON/OFF Switch
ModuleRelease Handle
PowerInputConnector
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3.2.21 Module and Housing Coding
Table 3.2 illustrates the position of coding pegs for each module (face plate viewed from rear) and its corresponding housing slot (viewed from front).
Table Key:
= Guide Pin = Guide Pin Location Hole
= Grey Peg (Module) = Red Peg (Housing)
= Empty Peg Location
Table 3.2 — Module and Housing Coding Pegs
Module TypeInvensys Part Number
Module Peg Coding Housing Peg Coding
CPU-2 612530823
DIP-64 612530825
DOP-64 612530826
SA-1 612980908
PSU-5V dc 615990243
PSU-5V dcwith battery back-up
615990246
CPU-2TM 612530824
CPU-2MTM 612530832
DIP-TM 24V 612530829
F E D D E F
F E D D E F
F E D D E F
F E D D E F
F E D
F E D D E F
A B C C B A
A B C C B A
A B C C B A
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DIP-TMW 24V 612530831
DIP-TM 50V 612530828
DIP S2 4HP-24V 612530849
DIP S2 4HP-50V 612530850
DIP S2 8HP-24V 612530846
DIP S2 8HP-50V 612530847
AIP-8 612530853
DOP-64TM 612530827
DOP S2 4HP 612530851
DOP S2 8HP 612530848
COP32-NO 612530840
COP S2 4HP 612530852
Table 3.2 — Module and Housing Coding Pegs (Continued)
Module TypeInvensys Part Number
Module Peg Coding Housing Peg Coding
A B C C B A
A B C C B A
FED DEF
FED DEF
FED DEF
FED DEFF E D D E F
A B C C B A
FED DEF
FED DEF
A B C C B A
FED DEF
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SA-1TM 615380526
RFM110 615380524No Coding Pegs or Guide Pin No Coding Pegs
RFM240 615380525
Table 3.2 — Module and Housing Coding Pegs (Continued)
Module TypeInvensys Part Number
Module Peg Coding Housing Peg Coding
A B C C B A
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3.3 BATTERY BACK-UP UNIT
3.3.1 Description
The Battery Back-up Unit (Figure 3.25) supplies 5V d.c. to up to two Westronic 1024 housings for a period of six minutes following a mains failure.
The unit is used in conjunction with Westronic 1024 housing PSUs fitted with Battery Back-up Input connectors on their front panel. Cable connections are permanently made between the Battery Back-up Unit and the PSUs.
Figure 3.25 — Battery Back-up Unit
With mains power applied to the Battery Back-up Unit, the unit maintains an internally fitted sealed, maintenance-free, lead acid battery in a fully charged condition.
In the event of a mains failure (sensed by the loss of mains input to the unit), battery supplied regulators within the Battery Back-up Unit automatically supply 5V d.c. to up to four connected PSUs.
The unit is rack mountable, 2U high and 19 inches wide.
30 A Fuse(primary fusein d.c. circuit)
MainsInput
Connector
ON/OFFSwitch
ALARM OUTPUTSocket
ENABLE/DISABLESwitch
Output 1AOutput 1B 16 AFuse(Output 1)
OUTPUT ONLED Output 1
BATTERY OKLED Output 1
FRONT VIEW
REAR VIEW
Output 2as for Output 1
Battery access cover
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3.3.1.1 Controls
• Front Panel - Disable / Enable switches (one per output). When set to Disable, prevents the output of the 5V d.c. upon loss of mains input. Used when unit is to be intentionally powered down.
• Rear Panel - On/Off Switch, sets the mains input supply On or Off. When set to On and mains input is present, the switch illuminates green.
3.3.1.2 Connectors
Front Panel
• Output Connectors for cable connection of 5V d.c.output to housing PSUs,
• O/P 1A connects to Westronic 1024 housing PSU A,
• O/P 1B available for connection to a second Westronic 1024 housing (if used) PSU A,
• O/P 2A connects to Westronic 1024 housing PSU B,
• O/P 2B available for connection to a second Westronic 1024 housing (if used) PSU B.
Rear Panel
• IEC mains input connector.
• Alarms Output socket. 9-way D-type with pin allocations as shown in Figure 3.3. Wiring is Scheme specific and will be shown in the Scheme drawings.
3.3.2 Indications
The Battery Back-up Unit indications are detailed in Table 5.1.
Note: Only one battery is fitted, powering both O/P 1 and O/P 2.
6 5V d.c. Out Channel 1 N/O alarm - closed when OK and enabled.
7 5V d.c. Out Channel 1 N/O alarm - closed when OK and enabled.
8 5V d.c. Out Channel 2 N/O alarm - closed when OK and enabled.
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3.4 12/50V D.C. PSU
3.4.1 Description
The 12/50V d.c. PSU, shown in Figure 3.26, comprises a 2U high 19 inch rack-mountable sub-rack, containing the PSU together with associated circuitry. The PSU provides a 12V 8A and a 50V d.c. 2A output from a 110V a.c. mains input. Output blocking diodes are included for each d.c. supply. These diodes permits the outputs from two separate PSUs to be joined together in a parallel redundant mode.
Figure 3.26 — 12/50V D.C. Power Supply (Front and Rear Views)
3.4.2 Monitoring Facilities
Monitoring points are provided on the front panel for the 50V d.c. output. These allow the outputs to be checked with a multimeter without disconnecting the PSU from its load. Remote monitoring facilities are also provided in the form of relay contacts, accessible via a connector at the rear of the PSU. These relay contacts reflect the condition of the d.c. output and are fed into the SA-1 Module.
12 V LED50 V LED
12 V Test Point 50 V Test Point
FRONT VIEW
REAR VIEW
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3.4.3 External Connections
All connections to the PSU are made via connectors on the rear panel of the module. The functions of these connectors are as follows:
• PL1 - Mains input to the PSU (via a filter unit).
• SK1 - D.C. Output 1 (12V) - unused.
• SK2 - D.C. Output 2 (50V).
• PL2 - External control of hold-up time for monitor relays.
• PL3 - Status (monitor) relay contact connections.
3.4.4 Indications
The units indications are detailed in Table 5.1.
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3.5 DUAL 24V D.C. 12A PANEL PSU
3.5.1 Description
The 24V 12A PSU (Figure 3.27) comprises a 3U high 19 inch rack mounted sub-rack containing two 24V PSUs (PSU 1A and PSU 1B) and associated circuitry. Internal circuitry connects the outputs from the two PSUs in dual redundancy mode. This is then output on a single connector (24V d.c. Output Socket 1) at the rear of the sub-rack
The sub rack is capable of housing two pairs of PSUs, each pair of PSUs being connected in dual redundancy mode.
Each PSU can be trimmed to provide an accurate 24V d.c. output.
Figure 3.27 — Dual 24V 12A PSU Rack
The subrack operates from two 110V a.c. supplies, each input being fed to the corresponding A or B PSUs in the rack. Should one 110V input voltage fail, the other is capable of powering all the PSU in the rack.
24 V Output LED
Trim Pot24 V Test point
0 V Test point
FRONT VIEW
REAR VIEW
24 V OutputLED (2)
24 V D.C. OutputSocket (2)
Mains Input Connector (A)
Illuminated On/OFF Switch (A)
Alarms OutputSocket (2)
16 A Fuse (2)
Illuminated On/OFF Switch (B)
Mains Input Connector (B)
A,.C. Input LED
PSU 1A PSU 1B
Position ofPSU 2A(If fitted)
Position ofPSU 2B(If fitted)
24 V OutputLED (1)
24 V D.C. OutputSocket (1)Alarms Output
Socket (1)
16 A Fuse (1)
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3.5.2 Monitoring Facilities
Monitoring Test Points are provided on the front of each PSU to enable the 24V d.c.output to be checked with a multimeter without disconnecting the PSU from its load. Remote monitoring facilities are also provided in the form of relay contacts, accessible via a connector at the rear of the PSU. These relay contacts reflect the condition of the d.c. output and may be used to switch monitoring equipment at a remote site, via a suitable transmission circuit.
3.5.3 External Connections
Two 3 Pin IEC connectors for mains Input (only one connector used).
Two 9-way D-type socket for monitoring d.c. output from the PSUs (only one connector used).
Two output connectors for 24V d.c. output (only one connector used).
On the front of each PSU, two test points for measuring the d.c. output of the PSU.
3.5.4 Indications
The units indications are detailed in Table 5.1.
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3.6 DUAL 24V D.C. OR 48V D.C. PSU
3.6.1 Description
The Dual 24V d.c. or 48V d.c. power supply (Figure 3.28) is a 19 inch 3U high rack mounted power supply. The unit is configured to provide a dual redundancy highly available regulated d.c. supply. Two variants of the unit are available, one providing a dual 24V d.c. output and the other a dual 48V d.c. output.
Figure 3.28 — Dual D.C. Power Supply Rack
The unit operates from two 50 Hz 110V a.c.or 240V a.c (autosensing) inputs that supply two d.c. PSU mounted in the front of the unit. Each PSU can be trimmed to provide an accurate d.c. output. Connectors are supplied at the rear of the to enable the status of the unit to be monitored. Also supplied at the rear is two test connectors to which a voltmeter can be attached to aid trimming of the output.
FRONT VIEW
REAR VIEW
PSU1PSU2
Power LED
Trim Pot
ON/OFF Switch 1
ON/OFF Switch 2
D.C OutletTest Sockets
Fuse 1Fuse 2
D.C OutletPower Socket
MonitorSockets
Mains Input 1Mains Input 2TRAIN
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3.6.2 Controls
3.6.2.1 Front
A trim pot is provided accessible from the front of each PSU that can be used during installation to gain an accurate d.c. output.
3.6.2.2 Rear
Two On/Off switches, one for each PSU. When set to On with the main voltage present, the switch illuminates green.
3.6.3 Connectors
The following connections are at the rear of the unit.
• Two 3 pin IEC connectors (one for each PSU) for mains input,
• Two 9-way D-type sockets for monitoring the outputs from the PSUs,
• Lemo type connector for the d.c. output from the unit,
• Two test connectors for measuring the d.c. output while trimming the PSUs,
3.6.4 Indications
The units indications are detailed in Table 5.1.
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3.7 MODEMS
Note: The CPU-2MTM Processor Transition Module incorporates an integral modem that an be con-figured to communicate in point to point V.23 mode or open V.32b mode. Refer to paragraph 3.2.3.
3.7.1 Invensys Rail Rack Mounted Modems
Invensys Rail 1200 baud V23 rack mount modems (Figure 3.29) are provided for point to point links over dedicated land lines. Modems are fitted into an enclosure at the Office, with all connections made at the rear.
Figure 3.29 — Rack Mounted Modem
3.7.1.1 Connectors
• DTEA 25-way D-type socket via which the data from/to the CPU-2 module is routed,
• LinesThe 4-wire telephone line for each modem is connected to the modem backplane via a Krone connector.
3.7.1.2 Power
Two 12V d.c. supplies, provided by rack mounted PSUs, are connected in duplicated mode via a terminal block. Power is distributed by the modem sub-rack backplane. Each modem requires up to 100 mA (typically 65 mA). A single system could be fitted with only one PSU.
3.7.1.3 Configuration
Modems are configured by means of links on the circuit board. Link setting requirements are detailed in Table 6.2.
3.7.1.4 Indicators
Modem indications are detailed in Table 5.1.
Modem Front PanelDetail
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3.7.2 Shelf Mounted Modems (Invensys Rail)
The Invensys Rail shelf mounted (standalone) modem (Figure 3.30) contains the same circuit card as is used in the rack mounted version. It is typically used at Field locations.
LED indicators are viewed through the front panel, which is removable to permit link setting for configuration purposes.
Figure 3.30 — Invensys Rail Shelf Mounted Modem
Power is supplied from a 12V d.c. supply. Connectors for power, data and line are made at the rear of the unit.
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3.7.3 Telindus Aster 5 Rack Mounted Modem
Telindus Aster 5 V29 rack mount modems (Figure 3.31) operating at 9600 or 19200 baud are provided for point to point links over open networks. They are typically used at Of ice locations.
Power for the modem is derived either from a 48V d.c. input to the CN4 enclosure, or from one or two PSU modules fitted to the enclosure.
Figure 3.31 — Telindus Aster 5 Rack Mounted Modem
3.7.3.1 Connections
Modems are fitted into a CN4 enclosure with all connections made at the rear of the enclosure. Connections are Scheme specific and are detailed in the Scheme drawings
3.7.3.2 Configuration
Modems are configured by Invensys Rail by means of a computer connection to the modem.
3.7.3.3 Indications
Modem indications are detailed in Table 5.1.
Populated rack w ith two PSU m odules Aster 5 m odem card
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3.7.4 Telindus Aster 5 Shelf Mounted Modem
Shelf mounted modems (Figure 3.32) are typically used at Field locations. Modems are configured to operate using the V29 protocol at 9600 baud, or V34 at 19.2 kbaud, over open communication networks.
Power may be 48V d.c. or 230/115V a.c. depending upon the model supplied.
Connections made at the rear of the unit comprise:
• power inlet - IEC connector,
• DTE - Data terminal equipment (CPU-2) interface D-type,
• CTRL - auxiliary connector for management control of the modem (not used with this application),
• LL - leased line connector,
• PSTN - public service telephone network connector (not used with this application).
3.7.4.2 Configuration
Modems are configured by Invensys Rail by means of a computer connection to the modem.
3.7.4.3 Indications
Modem indications are detailed in Table 5.1.
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3.8 SIGNALLER ALARM PANEL
The Signallers Alarm Panel can be an area on a lager panel, or a stand alone panel as dictated by the needs of the installation. For details of a a particular Alarm Panel, refer to the drawings pack for that installation.
Figure 3.33 shows the layout of a typical Alarm Panel.
Figure 3.33 — Typical Alarm Panel Layout
The Alarm Panel provides the signaller with an indication of the TDM systems availability and if a fault is detected the LED display will indicate the category of the fault and on which system it has occurred. Refer to subsection 5.5 for details. An audible alarm is provide and when sounds, can be silenced by the signaller by operating the Acknowledge button.
BFault
BAvail
AudibleAlarm
ACK
Signaller’s Alarm Panel
BOn-Line
AFault
AOn-Line
AAvail
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SECTION 4 — PREVENTIVE MAINTENANCE
4.1 INTRODUCTION
The maintenance and repair of the Westronic 1024 is based upon automatic system monitoring, fault reporting, isolation of the fault and the replacement of faulty equipment with known serviceable spares.
This section provides preventative maintenance instructions. The information is presented under the following headings:
• Safety Precautions,
• General Instructions,
• Preventative maintenance checks.
The system checks the health of each processor and serial link, reporting any fault detected. Serial link activity is also shown on LED indications on the modems.
Standard alarms include general alarms, power supply failure alarms and system alarms.
Software loading and upgrades may only be carried out by authorised personnel - it is not a first line maintenance activity.
Repair is limited to replacement of a faulty LRU (Line Replaceable Unit) with a serviceable spare.
Refer to subsection 6.4 for details of returning equipment to Invensys rail.
Refer to subsection 6.5 for disposal procedures of scrapped equipment.
Equipment removal and replacement procedures are given in sub-section 6.3.
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4.2 SAFETY PRECAUTIONS
WARNING: Refer to the Lethal Voltage warning located in the preliminary pages of this manual.
WARNING Unauthorised interruption of the system may endanger the safe operation of the railway. Before attempting any maintenance on the equipment, obtain the necessary permission from the relevant authority. Ensure the consequence of any interruption has been fully considered and understood.
WARNING If an equipment or component becomes overheated or burnt, a toxic fume hazard may exist. Isolate the power to the equipment, ventilate the area and allow the equipment time to cool before carrying out repairs.
WARNING When working on equipment, especially in the confines of a cubicle, do not wear metal rings, bracelets, watches, etc. These articles can cause personal injury, or damage to equipment, by becoming entangled in components or causing a short circuit.
Caution: Before using any item of test equipment, ensure it is fitted with a valid calibration label.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
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4.3 BASIC INSTRUCTIONS
To maintain the validity of the EMC Certification of the equipment, it is essential that only the cables specified for the system are used.
Ensure all cables are identified before disconnection. When re-connecting, ensure cables are fitted to the correct connectors.
Ensure that if a screened cable is replaced or disturbed, that the screen is correctly connected to earth as shown in the scheme drawings.
Cable routes must be preserved as originally specified (if in doubt, refer to the scheme drawings). Never re-route cables during maintenance.
When connecting cables to units, present the free connector squarely to the receptacle and take care not to bend the connector pins. Where fitted, tighten both jack screws to finger tightness only. To ensure the connectors are fully home, press the free portion firmly and then tighten each jack screw a little at a time.
Ensure the area in and around the equipment is kept clean and free from litter at all times.
Ensure that no objects are placed above or below the housings, so as to impede the cooling air flow.
Clearly label modules for repair to show the date of removal, system fault symptoms, identity of faulty component (if known) and the location. Send the faulty item of equipment to the next level of repair.
Maintain accurate records of maintenance activities carried out, in accordance with local procedures.
The procedure for returning suspect or faulty equipment to Invensys Rail is given in Section 6.4 of this manual.
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4.4 PREVENTIVE MAINTENANCE
The preventive maintenance checks for the Westronic 1024 are as follows:
4.4.1 Yearly Checks
4.4.1.1 CPU-2 Module
The CPU-2 module contains a lithium battery. A label is fitted to the front of the module detailing the date this module was installed or issued as aspare.
5 years after the date shown on the label, the module should be returned to Invensys Rail to have its lithium battery changed. If the five year period is due to expire in less than one years time, it is recommended that the CPU-2 module is removed from the installation or stores, as applicable, and replaced with a serviceable spare as detailed in paragraph 6.3.1.
4.4.1.2 For Dual Systems Only
To check that the Off-Line systems and the Changeover Units are serviceable, change over the systems as follows:
1. At the System Arbiter module, check the LEDs indicate as follows:
• Either ‘SYS 1’ or ‘SYS 2’ On-Line LED is illuminated to indicate which system is on-line,
• Both the on-line and off-line system’s ‘Watchdog’ LEDs are flashing,
• ‘Power’ LED is illuminated,
• ‘Fault’ LED is not illuminated,
2. If indications are not correct, see Section 5 for fault finding procedures.
3. Set the rotary switch to manually select the off-line system and observe that the systems switch over. Check the LED indications to ensure the system is working correctly.
4. Set the rotary switch to the ‘AUTO’ position.
Caution: These checks must only be carried out in engineering hours and with due regard to the effects on the signalling system. On completion of work, ensure the System Arbiter module rotary switch is left in the ‘AUTO’ position.
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4.4.1.3 For Systems Fitted with a Battery Back-up Unit
1. On systems equipped with a Battery Back-up Unit, check the ‘Battery OK’ LEDs are illuminated. If either of these LEDs is extinguished the battery has failed or is discharged.
2. If a mains failure occurred recently, allow time for the battery to re-charge. If the Battery OK LED remains extinguished, replace the battery as detailed in paragraph 6.3.19.
3. Check the air gap at the top and bottom of the unit has not been blocked off.
4. Upon successful inspection of the Battery Back-up Unit, isolate the a.c. power to the system and verify the unit is capable of supplying power for five minutes. Restore a.c. power to the system and reset any power supply related alarms as necessary.
5. The internal sealed lead acid battery has a quoted minimum life of five years. It is recommended that this battery should be replaced after four years of continuous service. Check the label detailing the working life of the battery to determine the length of time the battery has been in service. If the battery has been in service for four years or longer, purchase a new battery and use it to replace the life expired one it as detailed in paragraph 6.3.19.
4.4.1.4 For All Systems
Dusting and Cleaning
Carry out non-intrusive dusting with a lint free cloth as necessary to keep equipment in a clean condition. This can be carried out without power isolation.
If after dusting further cleaning is necessary, use a soft cloth moistened with a detergent solution, diluted according to the manufacturer’s instructions. Squeeze the cloth before use to remove any excess detergent solution. Do not use abrasive cleaners or pads.
On completion, dry off the surface with a dry lint free cloth.
Refer to Network Rail Signalling Maintenance Specification NR/SMS/EL31 for additional information.
PSU Output Voltage Check
Using a calibrated voltmeter, check the output voltage from each PSU is 5.0V d.c. Adjust if necessary by rotating the trim control on the PSU front panel.
Plugs and Sockets
Ensure that all plugs and sockets are correctly fitted and that screw fasteners are tightened.
Check that all wiring connections are correctly made.TRAININ
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SECTION 5 — FAULT FINDING
5.1 GENERAL
The information in this section is presented under the following headings:
1. Safety precautions (subsection 5.2).
2. Preliminary Checks (subsection 5.3).
3. Status Indications (subsection 5.4).
4. Signaller’s Alarm Panel LED Interpretation (subsection 5.5).
5. Fault Finding Method (subsection 5.6).
Rectify the most serious faults first, but eliminate local faults before proceeding to a remote location.
Clearly label modules for repair to show the date of removal, system fault symptoms, identity of faulty component (if known) and the location. Send the faulty item of equipment to the next level of repair.
The procedure for returning suspect or faulty equipment to Invensys Rail is given in Section 6.4 of this manual.
5.2 SAFETY PRECAUTIONS
Before proceeding with corrective maintenance, read the Safety Precautions and Basic Instructions contained within sub-sections 4.2 and 4.4.
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5.3 PRELIMINARY CHECKS
If a fault condition arises, carry out the following checks before changing any items of equipment.
5.3.1 Power Supply Units
1. Check that input voltage is present and correct.
2. Check that output voltage is present and correct.
5.3.2 Plugs and Sockets
1. Ensure that all plugs and sockets are correctly fitted and that screw fasteners are tightened.
2. Check that all wiring connections are correctly made.
5.3.3 Modules
Ensure that a full complement of modules is fitted and that each module is correctly positioned and secured.
WARNING: Mains voltages can kill. Take care when working with power supply units. See Safety Precautions.
The input supply for the PSU Assembly is 110V a.c or 230V a.c. nominal.
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5.4 STATUS INDICATIONS
The equipment status and fault indications take the form of lamps, neons, LEDs and LCD panels. Table 5.1 details these indicators and their meanings.
If an Alarm Panel is fitted, also refer to subsection 5.5.
Caution: Be aware that voltages may still be present even if indications have failed.
Table 5.1 — Status Indications
EQUIPMENTCARD / MODULE
INDICATOR DEFINITION FAULT INDICATION
Westronic 1024 Housing
CPU-2
POWERWhen lit, indicates the 5V d.c power supply to the CPU-2 module is present.
When extinguished, indicates 5V d.c to CPU-2 module not present.
WATCHDOGFlashes to indicate the CPU-2 program is operating correctly.
Steady On or Steady Off indicates a system fault.
HDDFlashes to indicate that the flash card is being accessed.
----
FAULTWhen extinguished, indicates no fault detected.
When lit indicates a system or serial communications link fault.
CPU-2MTM
TxTransmit Data - Follows the state of the TxD signal. Flickers rapidly when data is transmitted from the modem
----
RxReceive Data - Follows the state of the RxD signal. Flickers rapidly when data is received by the modem.
----
CDCarrier Detect - When lit indicates the modem is receiving a carrier signal.
----
POWERWhen lit, indicates 5V d.c. power supply to the module is available and the associated CPU-2 module is fitted.
When extinguished, either associated CPU-2 module has been removed or the 5V d.c. power is not present.
CPU-2TM POWERWhen lit, indicates 5V d.c. power supply to the module is available and the associated CPU-2 module is fitted.
When extinguished, either associated CPU-2 module has been removed or the 5V d.c. power is not present.
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Westronic 1024 Housing (Continued)
SA-1
POWERWhen lit, indicates the 5V d.c power supply to the System Arbiter module is present.
When extinguished, indicates the 5V d.c power supply to the System Arbiter module is not present.
WATCHDOGFlashes to indicate the associated System is operating correctly.
Steady On or Steady Off indicates a fault in the associated Systems’ communications to Office or Field as appropriate, or internally with the CAN-bus.
FAULTWhen extinguished, indicates no fault detected in the associated System.
When lit, indicates a fault has been detected in the associated System, or its communications.
ON-LINE
When lit, indicates the associated System is on-line.When extinguished indicates the associated System is not on-line.
---
PSU STATUSWhen green, indicates associated PSU output is present.
When red, indicates a fault with the associated PSU or its mains power supply.
SA-1TM
POWERWhen lit, indicates 5V d.c. power supply to the module is available and the associated SA-1 module is fitted.
When extinguished, either associated SA-1 module has been removed or the 5V d.c. power is not present.
OUT
One indication for each output. Indicates the condition of the output, lit when output On, extinguished when output Off or not used.
If output should be On and associated LED is extinguished, or if output should be Off and LED is lit.
IN
One indication for each input. Indicates the condition of the input, lit when input On, extinguished when input Off or not used.
If input should be On and associated LED is extinguished, or if input should be Off and LED is lit.
Table 5.1 — Status Indications (Continued)
EQUIPMENTCARD / MODULE
INDICATOR DEFINITION FAULT INDICATION
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Westronic 1024 Housing (Continued)
DIP-64
POWERWhen lit, indicates 5V d.c. power supply to the module is available.
When extinguished, the 5V d.c. power is not present.
SCAN SYS 1
SCAN SYS 2
One LED for each System.
Flashes to indicate when the DIP-64 module is addressed from that System.
For a housing fitted with dual CPU-2 modules, both SYS 1 and SYS 2 LEDs should flash.
For a single System, only SYS 1 LED will flash.
If indication is not flashing, card is not being addressed or is faulty.
Inputs1 to 64(Without associated COP32-NO module)
When lit indicates the input is present.
Associated Input LED is not lit when an input should be present, or is lit when an input should not be present.
Inputs1 to 64(with associated COP32-NO module)
Inputs 1 to 32, when lit indicate the associated output pair from the DOP64 is in a complementary state.
Inputs 33 to 64, when lit indicates the input is present.
Input 1 to 32, any LED not lit indicates the associated output pair from the DOP64 is not in a complementary state.
Input 33 to 64, Associated Input LED is not lit when an input should be present, or is lit when an input should not be present
AIP-8
POWERWhen lit, indicates 5V d.c. power supply to the module is available.
When extinguished, the 5V d.c. power is not present.
SCAN SYS 1
SCAN SYS 2
One LED for each System.
Flashes to indicate when the AIP-8 module is addressed from that System.
For a housing fitted with dual CPU-2 modules, both SYS 1 and SYS 2 LEDs should flash.
For a single System, only SYS 1 LED will flash.
If indication is not flashing, card is not being addressed or is faulty.
ISO PWR
When lit, indicates that internal isolated 24V d.c. wetting power supply is available for external sensors.
When extinguished, the internal isolated 24V d.c. power is not available.
DIP-TM,DIP S2 4HP-xxV,DIP S2 8HP-xxV orDIP-TMW
POWERWhen lit, indicates 5V d.c. power supply to the module is available and the associated DIP-64 module is fitted.
When extinguished, either associated DIP-64 module has been removed or the 5V d.c. power is not present.
Table 5.1 — Status Indications (Continued)
EQUIPMENTCARD / MODULE
INDICATOR DEFINITION FAULT INDICATION
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Westronic 1024 Housing (Continued)
DIP-TMW INT WETWhen lit, indicates that 24V d.c. power is available for inputs wetting.
When extinguished, either the 5V d.c. power is not present or the wetting voltage is not available.
DOP-64
POWERWhen lit, indicates 5V d.c. power supply to the module is available.
When extinguished, the 5V d.c. power is not present.
SCAN SYS 1
SCAN SYS 2
One LED for each System.
Flashes to indicate when the DOP-64 module is addressed from the on-line System only.
If neither indication is flashing, card is not being addressed or is faulty.
Outputs1 to 64
(Without associated COP32-NO module)
When lit indicates the output is present.
Output LED lit but no voltage being output.
Outputs1 to 64
(With associated COP32-NO module)
When lit indicates the output is present.
Outputs 1 to 32 should be in a complementary state to those of Outputs 33 to 64
Output LED lit but no voltage being output.
Outputs 1 to 32 not in a complementary state to those of Outputs 33 to 64
When lit, indicates 5V d.c. power supply to the module is available and the associated DOP-64 module is fitted.
When extinguished, either associated DOP-64 module has been removed or the 5V d.c. power is not present.
PSU 5V POWERWhen lit indicates the 5V d.c. output from the PSU is present.
When extinguished, the 5V d.c. output is not present.
PFM On/Off switchWhen lit indicates the switch is set to On and mains input supply is present.
When extinguished, indicates the switch is set to Off and/or the mains input supply is not present.
Battery Back-up Unit
AC POWERWhen lit indicates the mains input supply is present and the unit is switched On.
When extinguished, indicates the switch is set to Off and/or the mains input supply is not present.
BATTERY OKIndicates the internal battery is serviceable and charged.
When extinguished, indicates the internal battery is discharged or faulty.
OUTPUT ONWhen lit indicates the associated Output is available in the event of a mains failure.
When extinguished indicates, the associated output is not available.
Table 5.1 — Status Indications (Continued)
EQUIPMENTCARD / MODULE
INDICATOR DEFINITION FAULT INDICATION
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12/50V d.c. PSU
Front Panel
12VWhen lit indicateRear Panels that the 12V d.c. output is available.
When extinguished, fault on PSU or main power not present.
WETTING DRIVE ON
When lit indicators that the 50V d.c. output is available.
When extinguished, fault on PSU or main power not present.
Rear Panel MAINS ONWhen lit indicates that the mains input supply is present.
When extinguished, indicates mains input supply is not present.
Dual 24V d.c. Panel PSU
PSU
24V OUTPUTWhen lit indicates that the 24V d.c. output is available.
When extinguished, fault on PSU or main power not present.
A.C. INPUTWhen lit indicates that the mains input supply is present at PSU.
When extinguished, indicates mains power not present at PSU.
Rear PanelON/OFF Switch
When lit indicates Mains Power present.
When extinguished, indicates mains power not present
Rack Mounted Dual 24V d.c. or 48V d.c. PSU
PSU POWERWhen Lit indicates the Output from that PSU is available
When extinguished, fault on PSU or main power not present.
Rear PanelON/OFF Switch
When lit indicates Mains Power present.
When extinguished, indicates mains power not present
Alarm Panel If fitted, refer to Subsection 5.5
Table 5.1 — Status Indications (Continued)
EQUIPMENTCARD / MODULE
INDICATOR DEFINITION FAULT INDICATION
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Invensys Rail Modems
RDY LEDReady - When lit indicates that the power is On and the modem’s microprocessor is running.
Flashing signifies an internal modem fault.
TXD LED
Transmitted Data - Follows the state of the TxD signal. When lit indicates a ‘Space’ condition, when off indicates a ‘Mark’ condition.
Flickers rapidly when data is transmitted from the modem.
---
RXD LED
Received Data - Follows the state of the RxD signal. When lit indicates a ‘Space’ condition, when off indicates a ‘Mark’ condition.
Flickers rapidly when data is received from the line.
---
RTS LED
Request to Send. Follows the state of the RTS signal. When lit indicates an active condition i.e. the presence of signal from CPU-2 module to the modem requesting permission to transmit.
---
CTS LED
Clear to Send. Follows the state of the CTS signal. When lit indicates an active condition i.e. the presence of signal from modem to CPU-2 module indicating it is ready to accept data. If CTS is inactive, the modulator is clamped to the ‘Mark’ condition.
---
DCD LED
Data Carrier Detect - When lit indicates an active condition i.e. when modem is receiving carrier from the receive line and the demodulator is locked on. If DCD is inactive, RxD is clamped to the ‘Mark’ condition.
---
DSR
Data Set Ready indicator. Under normal operating conditions it follows the state of the DSR signal. When lit indicates an active condition. Signal sent from modem to CPU-2 module indicating that it is ready for operation. It follows the state of DTR and so the only time it is active is after a reset.
---
DTR LED
Data Terminal Ready. Follows the state of the DTR signal. When lit indicates an active condition. When lit, modem receiving a signal from the CPU-2 module indicating that the CPU-2 is able to accept data.
---
Table 5.1 — Status Indications (Continued)
EQUIPMENTCARD / MODULE
INDICATOR DEFINITION FAULT INDICATION
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Telindus Aster 5 rack mounted modems
PWRPower. When lit, indicates the Aster 5 is connected to the power supply and is switched On.
---
TST/142
Test. When extinguished, no test is active.
When On, a keyboard or interface test is active.
When blinking (50% On, 50% Off) a management system test is active. - not used with this system.
When flashing (20% On, 80% Off) keyboard or interface test is terminated by the management system - not used with this system.
---
PSTN
When lit, Aster 5 is in PSTN (public service telephone network) mode.
When extinguished, Aster 5 is in Leased Line mode.
---
DTR/108Lit whenever the Data Terminal Ready interface signal is active.
---
RTS/105Lit whenever the Ready To Send interface signal is active.
---
CTS/106Lit whenever the Clear To Send interface signal is active.
---
DSR/107Lit whenever the Data Set Ready interface signal is active.
---
TXD/103This LED monitors the incoming (to the modem) transmit data which is received from the CPU-2 module.
---
RXD/104This LED monitors the outgoing (from the modem) receive data which is transferred to the CPU-2 module.
---
LCD Panel
LCD panel provides the following information:
V29 or V34 - Link Type
a - Answer (field modems set to Answer)
c - Call (office modems set to Call)
9.6 or 19.2 - kbaud rate.
Data - Indicates that the modem has negotiated correcly with its counterpart at the other end of the link and has entered data mode.
Incorrect information displayed.
Table 5.1 — Status Indications (Continued)
EQUIPMENTCARD / MODULE
INDICATOR DEFINITION FAULT INDICATION
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5.5 SIGNALLERS ALARM PANEL LED INTERPRETATION
5.5.1 General
The Signaller’s Alarm Panel LED indicators are derived from the Serial Arbiter module (SA-1) that in turn is driven by signals from the Central Processor Unit (CPU-2) and the monitor outputs.
The LED mounted on the Alarm Panel indicate the status of the TDM systems. From the LED display, the technician can tell whether the system is working normally, or if not, the highest fault category present on the system. There are two categories, these are listed below in priority order.
• Power supply fault, where the power supply is one of a pair wired in parallel redundant mode.
• Loss or removal of a DIP or DOP Module(s).
• Should more than one fault be present simultaneously, the highest priority fault category is shown. When a fault is cleared, the Alarm Panel display either the highest fault category still present on the system, or the no-fault condition as applicable.
The sequence of events is shown in Figure 5.1:
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Figure 5.1 — Alarm Event Sequence Flow Chart
Start
FaultDetected
Audible Alarm OffSystem Avail LED OnSystem Fault LED OffSystem On-Line LED On
IsCat 1 Fault Present?
IsCat 2 Fault Present?
Audible Alarm SilentSystem Avail LED OffSystem On-Line LED OffSystem Fault LED On
Audible Alarm SoundsSystem Avail LED OffSystem On-Line LED OffSystem Fault LED Flashes
Signaller Acknowledges Fault Alarm
Technician Clears Fault
Audible Alarm SoundsSystem Avail LED OnSystem Fault LED FlashesSystem On-Line LED Off
Signaller Acknowledges Fault Cleared
Audible Alarm SilentSystem Avail LED OnSystem On-Line LED onSystem Fault LED On
Audible Alarm SoundsSystem Avail LED OnSystem On-Line LED ONSystem Fault LED Flashes
Signaller Acknowledges Fault Alarm
Technician Clears Fault
Audible Alarm SoundsSystem Avail LED OnSystem Fault LED FlashesSystem On-Line LED On
Signaller Acknowledges Fault Cleared
Yes
Yes YesNo
No No
Note:This flow Chart assumes the fault is detected on the On-line system. If a Cat 1 fault is detected the system will automatically switch over.
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5.6 FAULT FINDING PROCEDURE
5.6.1 Introduction
Faults on the Westronic 1024 or associated communications links will generally be notified as alarms on the parent system (e.g WESTCAD) or external connections (e.g. Panel) using outputs from the SA-1TM module (as described in sub-section 2.9 and shown in the Scheme drawings).
Diagnosis of the fault within the Westronic 1024 is by the use of the LED indicators listed and explained in Table 5.1.
Procedures for the removal and replacement of modules are given in subsection 6.3.
Carry out the preliminary checks in subsection 5.3 before looking for module failures.
Possible faults and repair actions are given in paragraph 5.6.3.
5.6.2 Re-setting of CPU-2 Module
Should a reset of a CPU-2 module be required, note that this module does not have a Reset button. To reset the module, do the following:
Unscrew the four captive screws securing the CPU-2 to the housing frame.
Press down the red button on the CPU-2 release handle to disconnect the power to the CPU-2.
Press down the black release handle then raise the handle back to its normal position.
Screw in the four captive screws to secure the CPU-2 module to the housing frame.
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5.6.3 Possible Faults and Causes
Table 5.2 — Possible Faults and Causes
FAULT POSSIBLE CAUSE REPAIR ACTION
Loss of Watchdog.
Communication link failure with remote end. Check communications link and modems as shown in Figure 5.4 Repair as necessary.
Loss of one input
Faulty input switch, contact or wiring.
Isolate the faulty input from the DIP-Transition Module.
Test the wiring to the input switch or contact. Repair as necessary.
Check the input switch or contact for correct operation, low resistance when closed and high resistance when open. Repair / replace as necessary.
Re-connect the repaired input to the DIP Transition Module.
Check for correct operation by observing the input LED on the front panel of the associated DIP-64 module.
If input has its own wetting supply, loss of that wetting supply.
Check wetting supply is present and the voltage (24 or 50V) matches the voltage shown on the DIP Transition Module. Note that the voltage may be either d.c. or a.c. Refer to the Scheme drawings.
If the wetting voltage is present, check the fuse fitted between the wetting supply and common pins of the DIP Transition Module. If the fuse has blown, investigate why.
Repair as necessary.
If input is dry contact, possible high resistance / dirty contact.
Isolate the faulty input from the DIP Transition Module.
Test the wiring to the input switch or contact. Repair as necessary.
Check the input switch or contact for correct operation. Check the resistance is not greater than 100 Ohms when closed and resistance not less than 250 kOhms when open. Repair / replace as necessary.
Re-connect the repaired input to the DIP Transition Module.
Check for correct operation by observing the input LED on the front panel of the associated DIP-64 module.
Faulty DIP-64 module.Replace the faulty DIP-64 module, as detailed in paragraph 6.3.4.
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Loss of one input (continued)
Faulty DIP Transition Module
Remove and inspect associated DIP Transition Module.
If the resistor network on the DIP Transition Module is overheated or burnt, check the voltage applied to that input is correct. Check the wiring from the controlling switch, relay contact etc. to the DIP Transition Module, looking for any short circuit between the input wiring and another voltage source. If a fault is found, it must be repaired before a replacement DIP Transition Module module is fitted.
Replace the faulty DIP Transition Module module, as detailed in paragraph 6.3.5.
Loss of group of inputs
If the lost inputs are on a single input group e.g. inputs 1-32 or 33 - 64, loss of wetting supply.
Check wetting supply is present and, if applicable, the voltage (24 or 50V) matches the voltage shown on the DIP Transition Module. Note that the voltage may be either d.c. or a.c. Refer to the Scheme drawings.
If the wetting voltage is present, check the fuse fitted between the wetting supply and the common pins of the DIP Transition Module. If the fuse has blown, investigate why.
Repair as necessary
Loss of all inputs
Loss of all wetting supplies. Investigate loss of supply and repair as necessary.
Incorrect wetting supply voltage.
Wetting voltage must match the voltage shown on the associated DIP Transition Module module (24V or 50V). Fit correct power supply or DIP Transition Module, as shown in the Scheme drawings.
Faulty DIP-64 module or no module fitted (incorrect slot?)
Check a DIP-64 module is correctly fitted into the slot connecting with the DIP Transition Module with the faulty inputs.
Replace the faulty DIP-64 module, as detailed in paragraph 6.3.4.
Faulty CPU-2 module
If associated Scan LED is not flashing, and power supplies are correct, reset CPU-2 module (see paragraph 5.6.2).
If fault still present, replace CPU-2 module with a serviceable spare, as detailed in paragraph 6.3.1.
Table 5.2 — Possible Faults and Causes (Continued)
FAULT POSSIBLE CAUSE REPAIR ACTION
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Loss of single output
Faulty driven indicator, relay etc. or associated wiring.
Check that drive voltage and return are present across indicator. If not present, trace wiring fault and repair as necessary. If present, replace indicator with a serviceable spare.
If the single output has its own drive supply, loss of that supply.
Check drive supply is present. Note that the voltage may be either d.c. or a.c. Refer to the Scheme drawings.
If the drive voltage is present, check the fuse fitted between the drive supply and the common pins of the DOP Transition Module. If the fuse has blown, investigate why.
Repair as necessary.
Faulty DOP-64 module.Replace the faulty DOP-64 module, as detailed in paragraph 6.3.4.
Loss of group of outputs
If lost outputs are on a single output group e.g. outputs 1-32 or 33 - 64, loss of drive supply.
Check drive supply is present. Note that the voltage may be either d.c. or a.c. Refer to the Scheme drawings.
If the drive voltage is present, check the fuse fitted between the drive supply and the common pins of the DOP Transition Module. If the fuse has blown, investigate why.
Repair as necessary.
DOP-64 failure.Replace the faulty DOP-64 module, as detailed in paragraph 6.3.4.
DOP Transition Module failure.Replace the faulty DOP Transition Module, as detailed in paragraph 6.3.5.
COP Module failure.Replace the faulty COP Module, as detailed in paragraph 6.3.8 or 6.3.10, as applicable.
Loss of all I/O from remote location
Communication link failure with remote housing.
Check communications link and modems as shown in Figure 5.4 or Figure 5.5 as appropriate. Repair as necessary.
Failure at remote end. Apply fault finding procedure at remote end.
Power failure at remote location. Investigate and repair as necessary.
CPU-2 module failure - check FAULT LEDReset CPU-2 module. If fault persists, replace the faulty CPU-2 module, as detailed in paragraph 6.3.1.
All outputs frozen or Off
Communication link failure with remote housing.
Outputs are configured to either freeze or to set to Off, using DIP switch SW1-1 (see subsection 2.4).
Check communications link and modems as shown in Figure 5.4 or Figure 5.5 as appropriate. Repair as necessary.
Table 5.2 — Possible Faults and Causes (Continued)
FAULT POSSIBLE CAUSE REPAIR ACTION
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Unable to set off-line System on-line (dual systems only).
Off-line System not available.
Check power supply to off-line System is correct. If not, repair as necessary.
Check communications link and modems as shown in Figure 5.4 or Figure 5.5 as appropriate. Repair as necessary.
Replace the off-line System CPU-2 module, as detailed in paragraph 6.3.1.
SA-1 or SA-1TM module faulty (System 1 held on-line by default).
Replace the SA-1 module, as detailed in paragraph 6.3.11.
If fault still present, replace the SA-1TM module, as detailed in paragraph 6.3.12.
Table 5.2 — Possible Faults and Causes (Continued)
FAULT POSSIBLE CAUSE REPAIR ACTION
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5.7 FAULT FINDING FLOW CHARTS AND GUIDES
Figure 5.2 — Initial Fault Finding Flow Chart
START
Check equipment status indicators (see Table 5.1) for
abnormal indications.
Carry out preliminary checksas detailed in sub-section 5.3.
Evaluate all available fault symptoms from connected systems e.g. WESTCAD.
Having determined the nature of thefault, go to one of the following
flow charts for fault location procedure.See also the Repair Actions in Table 5.2.
Processor Fault Finding Flow Chart
Remote Communication Links Fault Finding Flow Charts
Power supplyFault Finding Flow Chart
Local Input/OutputFault finding Flow Chart
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Figure 5.3 — Processor Fault Finding Flow Chart
Check PFM indicator is lit. If not and switch is set to On, investigate and repair input power supply fault.
If fault still present, replace5 V PSU.
If some inputs are incorrect or missing, see
Table 5.2 for repair action.
Yes No
.
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
START
If power has just been applied to the CPU-2, wait for
the processor to initialise.
IsPOWER
LED on CPU-2module
lit?Is
associated5 V POWER
LEDlit?
Replace CPU-2 module with a
serviceable spare.
IsWATCHDOG
LEDflashing?
IsWATCHDOG
LEDflashing?
IsWATCHDOG
LEDflashing?
END
Yes
Isassociated FAULT
LED on SA-1 moduleextinguished?
If fault persists, replace CPU-2 module with a
serviceable spare.
Do inputs on DIP-64 module correspond to
indications on the module front panel?
Re-boot CPU-2 module(see paragraph 5.5.2)
Check communications system to remote housing and repair if
If distant end is transmitting, report a communications link
failure.If distant end is not
transmitting, report a distant end
equipment failure.
IsCPU-2MTM
TX LED flashing?
Check connections to CPU-2MTM module
(see Scheme drawings for connection and
cable details).
If fault still persists, replace CPU-2MTM
module with a serviceable spare.
If fault still present, replace associated
CPU-2 module.
Using indications (see Table 5.1) check which link has failed.
Failure of a comms link will cause the associated WATCHDOG LED on the SA-1 module to stop
flashing.
Report distant end equipment
failure (suspect no data input to distant end modem).
IsCPU-2MTM
CD LEDlit?
Yes
No
No
Report communication
link failure (transmit direction).
If comms link OK, replace CPU-2MTM with a
serviceable spare
IsCPU-2MTMpower LED
lit?
Is5V Power LEDon each PSU
lit?
No
Replace CPU-2MTM
module
Yes
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Figure 5.6 — Local Input/Output Fault Finding Flow Chart
START
Is POWER LED lit on all I/O modules?
Is 5 V POWER
LED lit on PSUs?
Refer to the Power Supply Fault Finding Flow Chart
Replace suspectI/O module
Doessuspect I/O module
have an associated COP Module?
Replace suspectI/O Module
Does fault
Persist?
Replace associated
Transition Module
Do DOP-64
Upper and Lower LED blocks display
complementary State?
Replace DOP-64 Module
Does fault
Persist?
Suspect CPU-2 fault, refer to the
CPU-2 Fault Finding Flow
Chart
Replace modules in the following order until the fault is repaired:DOP-64DIP-64 or AIP-8DIP-COP Monitor Link Module (if applicable)COP ModuleDIP Transition Module
END
No No
YesYes
Yes
Yes
Yes
Yes
No
No
No
No
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Figure 5.7 — Power Supply - Fault Finding Flow Chart
Investigate loss of 230/110 V a.c power to IEC connector at PFM. Fuse locations and ratings are given in Table 7.7.
Check for:- correct mating of PFM IEC connector;
- correct connection of power lead to mains distribution board;
- check for correct mains input to cubicle
- check fuses within distribution board and mains plugs are not blown.
Yes No
.Yes
No
START
Isthe PFM module
On/Off switch indicator
lit?
Replace any DIP Transition Module,
AIP-8, DOP-64, CPU-2 or SA-1
module where the POWER LED is not
lit. Refer to Section 6 for procedure.
Is5 V POWER LEDon each PSU lit?
END
At the rear of the housing, ensure the On/Off switch on the PFM module(s) is set to On.
Replace the suspect PSU with a serviceable spare.
If the fault persists, re-fit the original PSU and
then replace the associated PFM with a
serviceable spare.
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SECTION 6 — CORRECTIVE MAINTENANCE
6.1 INTRODUCTION
This section provides corrective maintenance instructions which enables repair of the system by module replacement. The information is presented under the following headings:
Safety precautions (subsection 6.2).
Removal and replacement procedures (subsection 6.3).
Returns procedure (subsection 6.4).
Disposal procedure (subsection 6.5).
6.2 SAFETY PRECAUTIONS
Before proceeding with corrective maintenance, read the Safety Precautions and Basic Instructions contained within subsections 4.2 and 4.3.
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6.3 REMOVAL AND REPLACEMENT PROCEDURES
6.3.1 Processor Module (CPU-2)
6.3.1.1 Removal
This module can be replaced while the housing is powered up.
1. Refer to Figure 3.4 and Figure 3.7.
2. In a dual system, at the System Arbiter (SA-1) module, move the Changeover switch to select the CPU not being removed.
3. Unscrew the four captive screws securing the CPU-2 to the housing frame.
4. Press down the red button on the CPU-2 release handle to disconnect the power to the CPU-2.
5. Press down the black release handle on the CPU-2 to draw the module forward and to disconnect the backplane connector
6. Carefully remove the CPU-2 module from the housing and place it on an anti-static surface or in an anti-static bag.
7. Press the flash card release button so that it latches in the down position and carefully remove the flash card from the top of the CPU-2 module. Retain the flash card for fitting into the replacement CPU-2 module.
6.3.1.2 Replacement
1. Ensure the replacement CPU-2 module is the same type, and has the same modification state, as the one removed.
Caution: Removal of the CPU-2 module from a single system housing disables all inputs and outputs associated with that housing. Ensure the implications of this on the signalling system are fully appreciated before proceeding.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
Caution: There are two flash card slots on the CPU-2 module. Refer to Figure 6.1 and ensure the flash card is only inserted into the slot indicated in the Figure. It is easy to select the incorrect slot.
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Figure 6.1 — Location of Flash Card Holder
2. Check the flash card release button is latched in the down position, then carefully insert the flash card, retained previously, into the slot on the top of the CPU-2 module. The release button will return to the up position to lock the flash card in position.
3. If inserting a new or replacement module, check the label on the front of module that details the date the module was installed or issued as a spare. If it is more than four yeatrs since the date shown on the label, do not use that module and return it to Invensys Rail for a replacement lithium battery.Carefully insert the CPU-2 module into the housing.
4. Raise the black handle to fully engaged the CPU-2 module with the backplane.
5. Screw in the four screws to secure the CPU-2 module to the housing frame. The blue Flash Card Access LED (annotated HDD) will start to flash.
6. Wait until the Watchdog LED on the replaced CPU-2 module starts to flash.
7. On a dual system, at the System Arbiter module, check for flashing Watchdog LEDs from both CPUs then set the Changeover switch to select the CPU-2 just replaced.
8. Ensure the system operates correctly.
9. If the system operates correctly, on a dual system move the Changeover switch to the AUTO position. If the fault is still present, re-check the fitting of the flash card in the CPU-2 module.
CF Card fits here
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6.3.2 Processor Transition Module (CPU-2TM)
6.3.2.1 Removal
1. Refer to Figure 3.4 and Figure 3.5.
2. On a dual system, at the front of the housing, move the Changeover switch on the SA-1 module to select the System containing the CPU module not being removed.
3. At the CPU-2 module associated with the CPU-2TM module to be removed, unscrew the four screws securing the module to the housing frame.
4. At the associated CPU-2 module, press the red button on the release handle down to disconnect the power to the CPU-2 module.
5. At the associated CPU-2 module, press down the black release handle to draw the CPU-2 module forward. It is not necessary to fully remove the CPU-2 module.
6. Disconnect the cable(s) from the CPU-2TM module connectors.
7. Unscrew the four screws securing the CPU-2TM module to the housing.
8. Press down the black release handle to draw the CPU-2TM forward.
9. Carefully remove the CPU-2TM from the housing.
10. Place the removed module in a anti-static bag and send it to the next level of repair, refer to sub-section 6.4.
6.3.2.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Carefully insert the CPU-2TM module into the housing.
3. Raise the black handle to fully engage the CPU-2TM module with the housing.
4. Screw in the four screws to secure the CPU-2TM module to the housing frame.
5. At the front of the housing, push the associated CPU-2 module back into the housing.
6. Raise the black handle to fully engage the CPU-2 module.
7. Screw in the four screws to secure the CPU-2 module to the housing.
8. Wait until the Watchdog LED for the replaced CPU-2 module starts to flash.
9. On a dual system, at the Arbiter Module, set the Changeover switch to select the CPU just replaced and ensure the system operates correctly. If the system operates correctly, move the Changeover switch to the AUTO position.
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6.3.3 Processor Transition Module (CPU-2MTM)
6.3.3.1 Removal
1. Refer to Figure 3.4 and Figure 3.5.
2. On a dual system, move the Changeover switch on the SA-1 module to select the System containing the CPU module not being removed.
3. At the CPU-2 module associated with the CPU-2TM module to be removed, unscrew the four screws securing the module to the housing frame.
4. At the associated CPU-2 module, press the red button on the release handle down to disconnect the power to the CPU-2 module.
5. At the associated CPU-2 module, press down the black release handle to draw the CPU-2 module forward. It is not necessary to fully remove the CPU-2 module.
6. At the rear of the housing, disconnect the cable(s) from the CPU-2MTM module connectors.
7. Unscrew the four screws securing the CPU-2MTM module to the housing.
8. Press down the black release handle to draw the CPU-2MTM forward.
9. Carefully remove the CPU-2MTM from the housing.
10. Place the removed module in a anti-static bag and send it to the next level of repair, refer to subsection 6.4.
6.3.3.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Refer to Figure 6.2 and set the DIP switches the same as the switch on the removed module. If in doubt refer to Table 6.1or the drawings pack for that particular installation.
Figure 6.2 — Position of DIP switches on CPU-2MTM
Modem Configuration DIP Switches
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Notes: In V.32b mode office end is configured to Call and field end to answer.
Modem TX level and Rx sensitivity can be altered in line with switch settings.
3. Carefully insert the CPU-2MTM module into the housing.
4. Raise the black handle to fully engage the CPU-2TM module with the housing.
5. Screw in the four screws to secure the CPU-2TM module to the housing frame.
6. At the front of the housing, push the associated CPU-2 module back into the housing.
7. Raise the black handle to fully engage the CPU-2 module.
8. Screw in the four screws to secure the CPU-2 module to the housing.
9. Wait until the Watchdog LED for the replaced CPU-2 module starts to flash.
10. On a dual system, at the Arbiter Module, set the Changeover switch to select the CPU just replaced and ensure the system operates correctly. If the system operates correctly, move the Changeover switch to the AUTO position.
Table 6.1 — CPU-2MTM Modem DIL Switch Settings
SWITCH FUNCTIONSETTING
OFF ON
1 Answer Mode Calling Mode Answering Mode
2 Protocol V.32b mode V.23 mode
3 Transmit Level Normal (13dBm) High (-8.6dBm)
4 Receive Sensitivity Normal (-32.5dBM) High (-43dBm)
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6.3.4 DIP-64 or DOP-64 Modules
6.3.4.1 Removal
This module can be replaced while the housing is powered up.
1. Refer to Figure 3.9 and Figure 3.14.
2. Unscrew the two captive screws securing the module to the housing frame.
3. Press down the red button on the module release handle (on DOP-64 modules this disconnects the power to the module).
4. Press down the black release handle on the module to draw the module forward and to disconnect the backplane connector.
5. Carefully remove the module from the housing and place it on an anti-static surface or in an anti-static bag.
6.3.4.2 Replacement
1. Ensure the replacement module is the same type, and has the same modification state, as the one removed.
2. Carefully insert the module into the housing.
3. Raise the black handle to fully engaged the module with the backplane.
4. Screw in the two captive screws to secure the module to the housing frame.
Wait until the Scan LED(s) on the replaced module start to flash. Note that on the DOP-64 module, only the on-line Scan LED flashes.
On the module front panel, check the input or output indications correspond with the inputs or outputs that are actually present.
Ensure the system operates correctly.
For dual systems, check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
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6.3.5 DIP64-TM, DIP64-TMW or DOP64-TM Modules
6.3.5.1 Removal
1. Refer to Figure 3.10 and Figure 3.16 and Figure 3.20 (as applicable).
2. If applicable, remove the DIP-COP Monitor Link Module (refer to paragraph 6.3.9.1).
3. Release the DIP-64 or DOP-64 module associated with the TM module to be removed as follows:
a. Unscrew the two screws securing the associated module to the housing frame.
b. Press the red button on the release handle down (on DOP-64 modules this disconnects the power to the module).
c. Press down the black release handle to draw the module forward. It is not necessary to fully remove the module.
4. At the rear of the housing, disconnect the cables from the TM module connectors.
5. Unscrew the two screws securing the TM module to the housing.
6. Press down the black release handle to draw the TM forward.
7. Carefully remove the TM from the housing.
8. Place the removed module in an anti-static bag and send it to the next level of repair, refer to sub-section 6.4.
6.3.5.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Carefully insert the TM module into the housing.
3. Raise the black handle to fully engage the TM module with the housing.
4. Fasten the two screws to secure the TM module to the housing frame.
5. At the rear of the housing, re-connect the cables removed in paragraph 6.3.5.1 step 4.
6. At the front of the housing, re-insert the associated DIP-64 or DOP-64 module back into the housing as follows:
a. Push the module back into the housing.
b. Raise the black handle to fully engage the module.
c. Screw in the two captive screws to secure the module to the housing.
Caution: Removal of a DIP-TM or DIP-TMW or DOP-64TM module disables all 64 inputs or outputs associated with that module. Ensure the implications of this on the signalling system are fully appreciated before proceeding.
Caution: DIP TM modules are available in two voltage ranges, 24V and 50V. Ensure the correct voltage version is used as a replacement.
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7. If applicable, refit the DIP-COP Monitor Link Module (refer to paragraph 6.3.9.2).
8. Wait until the Scan LED(s) on the DIP-64 or DOP-64 module start to flash. Note that on the DOP-64 module, only the on-line Scan LED flashes.
9. On the DIP-64 or DOP-64 module front panel, check the input or output indications correspond with the inputs or outputs that are actually present.
10. Ensure the system operates correctly.
11. For dual systems, check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
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6.3.6 DIP S2 or DOP S2 Transition Modules
6.3.6.1 Removal
1. Refer to Figure 3.12, Figure 3.13, Figure 3.17 or Figure 3.18 (as applicable).
2. Release the DIP-64 or DOP-64 module associated with the Transition Module to be removed as follows:
a. Unscrew the two screws securing the associated module to the housing frame.
b. Press the red button on the release handle down (on DOP-64 modules this disconnects the power to the module).
c. Press down the black release handle to draw the module forward. It is not necessary to fully remove the module.
3. At the rear of the housing, disconnect the cables from the Transition Module connectors.
4. Unscrew the two screws securing the Transition Module to the housing.
5. Press down the black release handle(s) to draw the TM forward.
6. Carefully remove the Transition Module from the housing.
7. Place the removed module in an anti-static bag and send it to the next level of repair, refer to sub-section 6.4.
6.3.6.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Carefully insert the Transition Module into the housing.
3. Raise the black handle(s) to fully engage the Transition Module with the housing.
4. Fasten the two screws to secure the Transition Module to the housing frame.
5. At the rear of the housing, re-connect the cables removed in paragraph 6.3.6.1 step 4.
Caution: Removal of a DIP S2 or DOP S2 Transition module disables all 64 inputs or outputs associated with that module. Ensure the implications of this on the signalling system are fully appreciated before proceeding.
Caution: DIP Transition Modules are available in two voltage ranges, 24V and 50V. Ensure the correct voltage version is used as a replacement.
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6. At the front of the housing, re-insert the associated DIP-64 or DOP-64 module back into the housing as follows:
a. Push the module back into the housing.
b. Raise the black handle to fully engage the module.
c. Screw in the two captive screws to secure the module to the housing.
7. Wait until the Scan LED(s) on the DIP-64 or DOP-64 module start to flash. Note that on the DOP-64 module, only the on-line Scan LED flashes.
8. On the DIP-64 or DOP-64 module front panel, check the input or output indications correspond with the inputs or outputs that are actually present.
9. Ensure the system operates correctly.
10. For dual systems, check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
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6.3.7 AIP-8 Module
6.3.7.1 Removal
1. Refer to Figure 3.15 .
2. Disconnect the cables from the AIP-8 module connectors.
3. Unscrew the two screws securing the AIP-8 module to the housing.
4. Press down the black release handle to draw the AIP-8 forward.
5. Carefully remove the AIP-8 from the housing.
6. Place the removed module in an anti-static bag and send it to the next level of repair, refer to sub-section 6.4.
6.3.7.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Carefully insert the AIP-8 module into the housing.
3. Raise the black handle to fully engage the AIP-8 module with the housing.
4. Fasten the two screws to secure the AIP-8 module to the housing frame.
5. Re-connect the cables removed in paragraph 6.3.7.1 step 2.
6. Ensure the system operates correctly.
7. For dual systems, check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
Caution: Removal of an AIP-8 module disables all 8 inputs associated with that module. Ensure the implications of this on the signalling system are fully appreciated before proceeding.
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6.3.8 COP32-NO Module
6.3.8.1 Removal
1. Refer to Figure 3.19 and Figure 3.20.
2. Remove the DIP-COP Monitor Link Module (refer to paragraph 6.3.9.1).
3. Release the DOP-64 module associated with the COP32-NO module to be removed as follows:
a. Unscrew the two screws securing the associated module to the housing frame.
b. Press the red button on the release handle down to disconnect the power to the module).
c. Press down the black release handle to draw the module forward. It is not necessary to fully remove the module.
4. At the rear of the housing, disconnect the cables from the COP32-NO module connectors.
5. Unscrew the two screws securing the module to the housing.
6. Press down the black release handle to draw the module forward.
7. Carefully remove the module from the housing.
8. Place the removed module in a anti-static bag and send it to the next level of repair, refer to sub-section 6.4.
6.3.8.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Carefully insert the COP32-NO module into the housing.
3. Raise the black handle to fully engage the module with the housing.
4. Fasten the two screws to secure the module to the housing frame.
5. At the front of the housing, re-insert the associated DOP-64 module back into the housing as follows:
a. Push the module back into the housing.
b. Raise the black handle to fully engage the module.
c. Screw in the two captive screws to secure the module to the housing.
6. Re-connect the cables removed in paragraph 6.3.8.1 step 4.
7. Refit the associated DIP-COP Monitor Link Module (refer to paragraph 6.3.9.2).
8. Wait until the Scan LED on the DOP-64 module start to flash. Note that only the on-line Scan LED flashes.
9. On the DOP-64 module front panel, check the output indications (lower 32 LEDs) and output monitoring indications (upper 32 LEDs) correspond with the outputs that are actually present.
10. Ensure the system operates correctly.
11. For dual systems, check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
Caution: Removal of a COP-32TM module disables all 32 outputs and the associated 32 monitoring outputs associated with that module. Ensure the implications of this on the signalling system are fully appreciated before proceeding.
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6.3.9 DIP-COP Monitor Link Module
6.3.9.1 Removal
1. Refer to Figure 3.20.
2. Unscrew the four screws securing the DIP-COP Monitor Link Module to COP32-NO and DIP-TM or DIP-TMW modules.
3. Carefully pull the module from the housing.
4. Send the module it to the next level of repair, refer to subsection 6.4.
6.3.9.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Carefully align the module connectors with those of the associated COP-32-NO and DIP-TM or DIP-TMW modules and push the link module into place.
3. Screw in the four captive screws to secure the module to the COP-32-NO and DIP-TM or DIP-TMW modules.
4. Wait until the Scan LED on the DOP-64 module start to flash. Note that only the on-line Scan LED flashes.
5. On the DOP-64 module front panel, check the output indications (lower 32 LEDs) and output monitoring indications (upper 32 LEDs) correspond with the outputs that are actually present.
6. Check the upper block of LEDs on the associated DFIP 64 Module are all lit.
7. Ensure the system operates correctly.
8. For dual systems, check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
Caution: Removal of a DIP-COP Monitor Link Module disables all 32 monitoring outputs associated with that module. An associated fault indication will be generated.
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6.3.10 COP S2 4HP Module
6.3.10.1 Removal
1. Refer to Figure 3.19 and Figure 3.20.
2. Release the DOP-64 module associated with the COP S2 4HP module to be removed as follows:
a. Unscrew the two screws securing the associated module to the housing frame.
b. Press the red button on the release handle down to disconnect the power to the module).
c. Press down the black release handle to draw the module forward. It is not necessary to fully remove the module.
3. At the rear of the housing, disconnect the cables from the COP S2 4HP module connectors.
4. Unscrew the two screws securing the module to the housing.
5. Press down the black release handle to draw the module forward.
6. Carefully remove the module from the housing.
7. Place the removed module in a anti-static bag and send it to the next level of repair, refer to sub-section 6.4.
6.3.10.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Carefully insert the COP S2 4HP module into the housing.
3. Raise the black handle to fully engage the module with the housing.
4. Fasten the two screws to secure the module to the housing frame.
5. At the front of the housing, re-insert the associated DOP-64 module back into the housing as follows:
a. Push the module back into the housing.
b. Raise the black handle to fully engage the module.
c. Screw in the two captive screws to secure the module to the housing.
6. Re-connect the cables removed in paragraph 6.3.10.1 step 3.
7. Wait until the Scan LED on the DOP-64 module start to flash. Note that only the on-line Scan LED flashes.
8. On the DOP-64 module front panel, check the output indications (lower 32 LEDs) and output monitoring indications (upper 32 LEDs) correspond with the outputs that are actually present.
9. Ensure the system operates correctly.
10. For dual systems, check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
Caution: Removal of a COP S2 4HP module disables all outputs and the associated monitoring outputs associated with that module. Ensure the implications of this on the signalling system are fully appreciated before proceeding.
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6.3.11 SA-1 Module
6.3.11.1 Removal
This module can be replaced while the housing is powered up.
1. Refer to Figure 3.7.
2. At the module front panel, set the Changeover switch to SYS 1.
3. Unscrew the two captive screws securing the module to the housing frame.
4. Press down the red button on the module release handle to disconnect the power to the module.
5. Press down the black release handle on the module to draw the module forward and to disconnect the backplane connector
6. Carefully remove the module from the housing and place it on an anti-static surface or in an anti-static bag.
6.3.11.2 Replacement
1. Ensure the replacement module is the same type, and has the same modification state, as the one removed.
2. At the replacement module front panel, set the Changeover switch to SYS 1.
3. Carefully insert the module into the housing.
4. Raise the black handle to fully engaged the module with the backplane.
5. Screw in the two captive screws to secure the module to the housing frame.
6. Wait until the WD (Watchdog) LED(s) on the replaced module start to flash.
7. On the module front panel, check the indications are correct (see Table 5.1).
8. Check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
Caution: Removal of a SA-1 module causes dual systems to default to System 1 on-line. Ensure System 1 is serviceable before removing the SA-1 module.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
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6.3.12 SA-1TM Module
6.3.12.1 Removal
1. Refer to Table 3.8.
2. At the SA-1 module, set the Changeover switch to SYS 1.
3. At the rear of the housing, disconnect the alarms cable (if used) from the SA-1TM module connector.
4. At the front of the housing, unscrew the two captive screws securing the SA-1 module to the housing frame.
5. At the SA-1 module, press down the black release handle to draw the module forward. It is not necessary to fully remove the module.
6. At the rear of the housing, unscrew the four screws securing the SA-1TM module to the housing.
7. Press down the black release handle to draw the SA-1TM forward.
8. Carefully remove the SA-1TM from the housing.
9. Place the removed module in a anti-static bag and send it to the next level of repair, refer to subsection 6.4.
6.3.12.2 Replacement
1. Ensure the replacement module is the same type and has the same modification state as the one removed.
2. Carefully insert the SA-1TM module into the housing.
3. Raise the black handle to fully engage the SA-1TM module with the housing.
4. Fasten the two captive screws to secure the SA-1TM module to the housing frame.
5. At the front of the housing, push the SA-1 module back into the housing.
6. Raise the black handle to fully engage the SA-1 module.
7. Screw in the four screws to secure the SA-1 module to the housing.
8. Wait until the WD (Watchdog) LED(s) on the SA-1 module start to flash.
9. On the SA-1 module front panel, check the indications are correct (see Table 5.1).
10. Check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
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6.3.13 Power Filter Module
6.3.13.1 Removal
1. Refer to Figure 3.23.
2. For dual systems, set the other System on-line using the SA-1 Changeover switch.
3. At the PFM, set the On/Off switch to Off.
4. Disconnect the power input cable from the power input connector.
5. Unscrew the four captive screws securing the PFM to the housing.
6. Press down the black release handle to draw the PFM forward.
7. Carefully remove the PFM from the housing.
6.3.13.2 Replacement
Ensure the replacement module is the same type and has the same modification state as the one removed.
1. Carefully insert the PFM module into the housing.
2. Raise the black handle to fully engage the PFM module with the housing.
3. Fasten the four captive screws to secure the PFM module to the housing frame.
4. Re-connect the power input cable to the power input connector.
5. Set the On/Off switch to On and check the switch illuminates. If the switch does not illuminate, check power is being supplied to the unit.
6. For dual systems, wait until the WD (Watchdog) LED for the repaired system on the SA-1 module starts to flash.
7. On the SA-1 module front panel, check the indications are correct (see Table 5.1).
8. Check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
9. For single systems, check for correct operation.
Caution: Removal of a PFM powers down the associated System.
For a single System housing the entire housing is powered down.
For dual systems, ensure the remaining system is serviceable and is selected on-line
Caution: Use the correct voltage version of PFM. These are not interchangeable.
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6.3.14 Power Supply Unit
6.3.14.1 Removal
1. Refer to Figure 3.20 or Figure 3.22
2. For dual systems, set the other System on-line using the SA-1 Changeover switch.
3. For PSUs connected to a Battery Back-up Unit:
• At the Battery Back-up Unit, set the Enable/Disable switch associated with the PSU to Disable.
• Disconnect the power cables from the PSU back-up power input connector.
4. At the associated PFM, set the On/Off switch to Off.
5. Unscrew the four captive screws securing the PSU to the housing.
6. Press down the red button on the PSU release handle.
7. Press down the black release handle to draw the PSU forward.
8. Carefully remove the PSU from the housing.
6.3.14.2 Replacement
1. Ensure the replacement PSU is the same type and has the same modification state as the one removed.
2. Carefully insert the PSU into the housing.
3. Raise the black handle to fully engage the PSU module with the housing.
4. Fasten the four captive screws to secure the PSU module to the housing frame.
5. At the associated PFM, set the On/Off switch to On and check the switch illuminates. If the switch does not illuminate, check power is being supplied to the unit.
6. For PSUs connected to a Battery Back-up Unit:
a. Re-connect the power cables to the PSU back-up power input connector.
b. At the Battery Back-up Unit, set the Enable/Disable switch associated with the PSU to Enable.
7. At the PSU front panel, check the 5V POWER LED is illuminated.
8. Measure the voltage at the monitoring sockets on the PSU front panel and adjust the 5V d.c. trim adjustment if necessary to achieve 5.0 V.
9. For dual systems, wait until the WD (Watchdog) LED for the repaired system on the SA-1 module starts to flash.
10. On the SA-1 module front panel, check the indications are correct (see Table 5.1).
11. Check for correct operation with each CPU on-line in turn. On completion, ensure the Changeover switch on the SA-1 module is set to Auto.
12. For single systems, check for correct operation.
Caution: Removal of a PSU powers down the associated System.
For a single System housing the entire housing is powered down.
For dual systems, ensure the remaining system is serviceable and is selected on-line
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6.3.15 Telindus Aster 5 Shelf Mounted Modem
6.3.15.1 Removal
1. At the rear of the modem, set the power switch to Off (button out) position.
2. Disconnect the power supply lead from the modem.
3. Disconnect the line and data connectors.
4. The modem may now be removed.
6.3.15.2 Configuration
These modems and the spares holding are configured and labelled by Invensys Rail. Check the replacement modem is labelled as being programmed for the correct communications link.
6.3.15.3 Replacement
1. Ensure the replacement modem is the same type and has the same configuration as the one removed.
2. Set the configured replacement modem in position.
3. With power disconnected, connect the line and data connectors.
4. Connect the power supply lead.
5. Check the front panel indications for correct operation.
Caution: Do not re-route the modem cabling. The modem cabling must not share the same troughing with cables likely to be carrying any impulsive noise, such as relay wiring, otherwise misbehaviour may occur.
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6.3.16 Telindus Aster 5 Rack Mounted Modem
6.3.16.1 Removal
1. Undo the two front panel screws securing the modem to the card frame.
2. Using the front panel handles, gently slide the modem from the card frame.
3. Place the removed modem into an anti-static bag.
6.3.16.2 Configuration
These modems and the spares holding are configured and labelled by Invensys Rail. Check the replacement modem is labelled as being programmed for the correct communications link.
6.3.16.3 Replacement
1. Ensure the replacement modem is the same type and has the same configuration as the one removed.
2. Ensuring the modem is the correct way up, carefully align the module with the guides within the rack and slide the module fully into the rack.
3. Apply firm pressure on the module front panel to fully insert the module into the rack.
4. Secure with the front panel screws.
5. Check the front panel indications for correct operation.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
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6.3.17 Invensys Rail Rack Mounted Modems
6.3.17.1 Removal
1. At the modem to be replaced, undo the two front panel screws securing the modem to the frame.
2. Pull the handle at the base of the modem to release the modem.
3. Carefully withdraw the modem from the rack.
4. Place the removed modem into an anti-static bag.
6.3.17.2 Replacement
1. Check the replacement modem is the same type as the one removed.
2. Check that the configuration links are set as shown in the system drawings. The function of the links is shown in Table 6.2.
3. Ensuring the modem is the correct way up, carefully align the module with the guides within the rack and slide the module fully into the rack.
4. Apply firm pressure on the module front panel to fully insert the module into the rack.
5. Secure with the front panel screws.
6. Check the front panel indications for correct operation.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
Table 6.2 — Invensys Rail Rack Mounted and Standalone Modem Link Settings
LINK REQUIRED SETTING
LK2 Normal 20 ms
LK3 Constant
LK4 Out
LK5 Out (Normal)
LK6 Either header not fitted,
or set to Out position.
LK7
LK8
LK9 Normal -34 dBm
LK10 Normal -14 dBm
LK11 4-wire full duplex
LK12 600 ohm
LK13 Disabled
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6.3.18 Invensys Rail Shelf Mounted Modems
6.3.18.1 Removal
1. At the rear of the modem, disconnect the 12V power supply lead connector from the modem.
2. With power disconnected, disconnect the line and data connectors located adjacent to the power connector.
3. The modem may now be removed.
6.3.18.2 Configuration
These modems are configured using links, in the same manner as the rack mounted version. To access the links, proceed as follows:
1. At the front of the modem, identify the two anti-tamper caps (Figure 6.3) covering the front panel securing screws.
2. Using a fine blade screwdriver or similar, prise out and retain the anti-tamper caps.
3. Using a cross-head screwdriver, remove and retain the two front panel securing screws.
Figure 6.3 — Standalone Modem Front Panel Screw Positions
Caution: Refer to the Electrostatic Sensitive Devices caution located in the preliminary pages of this manual.
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Figure 6.4 — Standalone Modem Dis-assembled
4. Carefully remove the front panel and associated gasket from the front of the unit.
5. Withdraw the circuit card from the case. A connector is fitted to the rear edge of the card to allow withdrawal.
6. Set the configuration links as shown in Table 6.2.
7. Carefully re-fit the circuit card into the modem case.
8. Re-fit the front panel and gasket, checking for alignment with the LEDs on the front edge of the circuit card. Secure with the two cross-head screws and re-fit the anti-tamper caps.
6.3.18.3 Replacement
1. Set the configured replacement modem in position.
2. With power disconnected, connect the line and data connectors located adjacent to the power connector.
3. Connect the 12V power supply lead.
4. Check the front panel indications for correct operation.
FRONT PANELAND GASKET
CARD WITHDRAWS FROM CASE
Front Paneland Gasket
Card Withdraws From Case
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6.3.19 Battery Back-up Unit, Battery Assembly Replacement
6.3.19.1 Removal
1. Set the two Enable/Disable switches on the front of the Battery Back-up Unit to Disable.
2. At the rear of the unit, set the On/Off switch to Off.
3. At the rear of the unit, disconnect the power input IEC cable and alarm cable (if fitted).
4. At the front of the unit, disconnect the output cables.
5. With the unit supported, undo and retail the four screws and associated washers securing the unit front panel to the cubicle frame.
6. Withdraw the unit from the cubicle and place it on a suitable work surface.
6.3.19.2 Battery Assembly Replacement
1. Ensure the replacement battery assembly is the correct type - see Table 7.2 for part number.
2. At the rear of the unit, undo and retain the four screws and associated washers securing the battery assembly into the unit (shown in Figure 6.5).
3. Carefully withdraw the battery assembly from the unit, noting the position and orientation of the battery connections.
4. Disconnect the battery connections and place the battery assembly in a safe place.
5. Offer up the replacement battery assembly and connect it to the unit in the same manner as the original battery was connected.
6. Fit the replacement battery assembly into the unit, taking care not to trap or pinch any wiring.
7. Secure the replacement battery assembly to the unit using the original four screws and associated washers.
8. Add a label to the rear of the battery assembly access cover detailing the date the battery was installed and the working life date of the battery
Figure 6.5 — Battery Assembly Access Cover Screws
MainsInput
Connector
ON/OFFSwitch
ALARM OUTPUTSocket
REAR VIEW
Battery assembly access cover
Cover securing screws
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6.3.19.3 Replacement
1. Replace the Battery Back-up Unit in the cubicle and secure it with the original four screws and associated washers.
2. At the front of the unit, re-connect the output cables.
3. At the rear of the unit, re-connect the mains input connector and alarm output connector (if fitted).
4. Set the On/Off switch to On and check the switch illuminates.
5. At the front of the unit, set the Enable/Disable switches for outputs being used to Enable.
6. Check the front panel indications are correctly lit. Note that there may be a charging time required before the Battery OK LED comes on.
6.3.20 50V Power Supply
6.3.20.1 Removal
1. At the rear of the unit, disconnect the mains input cable from PL1 and disconnect the 50V output cable from SK2.
2. Disconnect monitor cables (if fitted).
3. At the front of the unit, remove and retain the four fixings securing the unit to the cubicle and withdraw the unit.
6.3.20.2 Replacement
1. Ensure the unit is the same type as the one removed.
2. Insert the unit into the cubicle and secure using the retained four fixings.
3. Connect the 50V output cable to SK2 and the mains power input cable to PL1
4. Check the front panel indicators for correct operation.
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6.3.21 Dual 24V D.C. 12A Panel Power Supply
6.3.21.1 Removal of a PSU
1. At the rear of the unit switch off the Both mains input switches (A and B, refer to Figure 3.27).
2. Unscrew the two captive screws securing the PSU to the rack.
3. Carefully remove the PSU from the housing.
4. Place the removed PSU in an anti-static bag and send it to the next level of repair.
6.3.21.2 Replacement of a PSU
1. Ensure the replacement PSU is the same type as the one removed.
2. Carefully insert the PSU into the rack, ensure it is fully engaged.
3. Fasten the two captive screws to secure the PSU module to the rack frame.
4. Reapply power by switching on the associated ON/Off Switch.
5. Connect a Voltmeter across the two test sockets at the front of the unit. and trim the PSU to the correct voltage output.
6. Set the mains input switch to ON.
7. Check all indications to see that the system is operating correctly.
6.3.21.3 Removal of Entire Dual Power Supply Rack
1. Switch Off the both mains ON/Off switches and remove the mains cables.
2. Remove both PSUs.
3. Disconnect monitoring cables and Power output cable.
4. Remove and retain the four fixings securing the unit to the cubicle or racking.
5. Send to the next level of repair.
6.3.21.4 Replacement of Entire Dual power Supply Rack
1. Ensure replacement rack is the same type as the one removed.
2. Place the rack in its correct location in the cubicle or racking and secure using the retained fixings.
3. Insert the PSUs.
4. Connect the monitoring cable D.C. output cable and connect the mains cables.
5. Set one mains switch to ON.
6. Connect a voltmeter across the two test sockets at the front of the PSU.
7. Trim the PSU to the correct voltage output.
8. Switch that PSU’s mains switch to OFF, switch ON the other PSU and trim to correct output voltage.
9. Switch ON both PSUs and check that the system operates correctly
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6.3.22 Dual 24V D.C. or 48V D.C. Power Supply
6.3.22.1 Removal of a PSU
1. At the rear of the unit switch off the associated mains input switch.
2. Unscrew the two captive screws securing the PSU to the rack.
3. Press down the red button on the PSU release handle.
4. Press down the black release handle to draw the PSU forward.
5. Carefully remove the PSU from the housing.
6. Place the removed PSU in an anti-static bag and send it to the next level of repair.
6.3.22.2 Replacement of a PSU
1. Ensure the replacement PSU is the same voltage and type as the one removed.
2. Carefully insert the PSU into the rack.
3. Raise the black handle to fully engage the PSU module with the rack.
4. Fasten the two captive screws to secure the PSU module to the rack frame.
5. Reapply power by switching on the associated ON/Off Switch.
6. Switch Off the other PSU.
7. Connect a Voltmeter across the two test sockets at the rear of the unit.
8. Trim the PSU to the correct voltage output.
9. Switch the other PSU back on.
10. Check all indications to see that the system is operating correctly.
6.3.22.3 Removal of Entire Dual Power Supply Rack
1. Switch Off both ON/OFF switches and remove the mains cables.
2. Remove both PSUs and place them in anti-static bags.
3. Disconnect monitoring cables.
4. Remove and retain the four fixings securing the unit to the cubicle or racking.
5. Send to the next level of repair.
6.3.22.4 Replacement of Entire Dual power Supply Rack
1. Ensure replacement rack is the same type as the one removed.
2. Place the rack in its correct location in the cubicle or racking and secure using the retained fixings.
3. Insert the PSUs.
4. Connect the monitoring cables
5. Connect the mains cables.
6. Set one mains switch to ON.
7. Connect a voltmeter across the two test sockets at the rear of the unit.
8. Trim the PSU to the correct voltage output.
9. Switch that PSU’s mains switch to OFF, switch ON the other PSU and trim to correct output voltage.
10. Switch ON both PSUs and check that the system operates correctly
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6.4 RETURNS PROCEDURE
To arrange the return of equipment to Invensys Rail, contact the Returns Co-ordinator at the following address:
The Returns Co-ordinator will request the following details of the equipment to be returned:
• Customer's name and address,
• Equipment description and serial number,
• Quantity being sent,
• Date equipment is being despatched,
• Equipment fault and symptoms,
• Any applicable diagnostic printouts,
• Date and time of failure,
• Equipment location at the time of failure,
• Any warranty details,
• Length of time the equipment had been in service before fault occurred,
• Details of any associated equipment failing at the same time.
The Returns Co-ordinator will provide a Returned Material Authorisation (RMA) number, which must be attached to the equipment and quoted in all correspondence.
Wherever possible, units being returned for repair should be shipped in their original packaging.
In cases where the equipment is covered by a Invensys Rail maintenance contract, it should be sent with a covering letter to the manager agreed in the Maintenance Contract at the address shown above. If no maintenance contract exists, mark the equipment 'For the attention of the Returns Co-ordinator'.
It is important for Westinghouse Rail Systems Limited to be provided with comprehensive information in the event of equipment failure. This information is used not only to assist in the diagnosis of the fault in a particular equipment, but also to build up data on failures so that modifications can be made to improve reliability in the future.
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6.5 DISPOSAL PROCEDURE
6.5.1 EC Countries
All electrical and electronic equipment should be disposed of in accordance with European Parliament and Council Directive 2002/96/EC dated January 27th 2003, and Directive 75/442/EEC dated July 25th 1975 and subsequent amendments.
Complete units should be handed over to a certified waste disposal vendor, who will dispose of the units sorted according to their materials.
If the user disposes of equipment, the units must be disassembled and disposed of according to their materials (e.g. plastics, metals, glass or electronics waste). Metals must be handed over to a scrap metal dealer, plastics and glass should be sent for recycling and electronic scrap materials should be handed over to a certified waste disposal vendor.
Equipment may also be disposed of by returning it to Westinghouse Rail Systems Limited, if a corresponding agreement is in force.
6.5.2 Non-EC Countries
Observe the relevant national laws and regulations when disposing of equipment under all circumstances.
6.5.3 List of Materials
A list of materials used is available from Westinghouse Rail Systems if required.
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SECTION 7 — REFERENCE INFORMATION
7.1 EQUIPMENT PART NUMBERS
7.1.1 Line Replaceable Unit Part Numbers
The line replaceable units (LRUs) for the Westronic 1024 and associated equipment are detailed in Table 7.1 to Table 7.4.
Table 7.1 — Westronic 1024 LRU Part Numbers
EQUIPMENT INVENSYS RAIL PART NUMBER
Standard Westronic 1024 Housing 614270309
Triple TDM Westronic 1024 Housing 616240246
Processor Module (CPU-2) 612530823
Processor Transition Module (CPU-2TM) 612530824
Processor Transition Module (CPU-2MTM) 612530832
System Arbiter Module (SA-1) 612980908
System Arbiter Transition Module (SA-1TM) 615380526
Digital Input Module (DIP-64) 612530825
Analogue Input Module (AIP-8) 612530853
50V Digital Input Transition Module (DIP-TM 50V) 612530828
24V Digital Input Transition Module (DIP-TM 24V) 612530829
50V Digital Input Transition Module (DIP S2 4HP-50V) 612530850
24V Digital Input Transition Module (DIP S2 4HP-24V) 612530849
50V Digital Input Transition Module (DIP S2 8HP-50V) 612530847
24V Digital Input Transition Module (DIP S2 8HP-24V) 612530846
Digital Input Transition Module with wetting (DIP-TMW) 612530831
Digital Output Module (DOP-64) 612530826
Digital Output Transition Module (DOP-64TM) 612530827
Digital Output Transition Module (DOP S2 4HP) 612530851
Digital Output Transition Module (DOP S2 8HP) 612530848
Table 7.1 — Westronic 1024 LRU Part Numbers (Continued)
EQUIPMENT INVENSYS RAIL PART NUMBER
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7.2 TECHNICAL SPECIFICATION OF EQUIPMENT
7.2.1 Power Requirements
The input power requirement of each item of equipment is detailed in Table 7.5.
7.2.2 Environmental Limits
7.2.2.1 Operating Limits
The Westronic 1024 will continue to operate under the following conditions:
• indoor use,
• altitude (up to 2000 m),
• temperature range (0 to +40 degrees C),
• A humidity of 5% to 75% maximum at 40 degrees C non-condensing,
• in an environment of pollution degree 2 as defined within EN 610010-1: 1993,
• The system is designed to tolerate the everyday shock and vibration associated with industrial applications in Railway equipment rooms,
• System temperature, humidity, shock and vibration are in accordance with NR/SP/SIG/00801 - Requirement Specification for TDM Systems.
7.2.3 Storage Limits
• Temperature range -20 to +70 degrees C,
• Humidity of 5% to 75% maximum at 40 degrees C non-condensing.
Table 7.5 — Equipment Power Requirements
EQUIPMENT POWER REQUIREMENT
Westronic 1024 Housing (fully populated).
110V a.c. nominal (95 to 130V a.c.) 50-60 Hz 100VA when fitted with 110V a.c. mains filter unit module
or
240V a.c. nominal (190 to 260V a.c.) 50-60 Hz 100VA when fitted with 230V a.c. mains filter unit module.
Battery Back-up Unit. 110V a.c. nominal (95 to 130V a.c.) 50-60 Hz 100VA.
Telindus Aster 5 rack mounted modem.
Powered via CN4 card nest. The CN4 card nest can be powered by -48V d.c. (no power modules required) or by 230/115V a.c. (one or two power modules required). Power consumption 5W per modem.
Telindus Aster 5 shelf mounted modem.
230V a.c. nominal (85 to 265V a.c.) 50 to 60 Hz
3 W., or -48V d.c. nominal (-18 to -72V d.c.) 3 W.
Invensys Rail rack mounted modem.12V d.c. nominal 9 - 15V d.c. 65 mA nominal at 12V d.c.
The system is CE marked as per European EMC directive 89/336/EEC with amendments; Emissions: EN55022 Class B; immunity: EN50082-1.
7.2.5 Testability
The system meets the requirements of the Network Rail TDM Specification NR/SP/SIG/00801.
7.2.6 Reliability
For a single failure capable of causing total loss of the 1024 system, a MTBF is as follows:
• The System has a minimum MTBF of 8,760 Hrs when fitted with a single processor at 512 bit capacity,
• The System has a minimum MTBF of 50,000 Hrs when fitted with dual processors at 512 bit capacity,
The MTBF for a single group of 64 Bits (one module) is as follows:
• Minimum MTBF of 4,000 Hrs when fitted with a single processor at 512 bit capacity,
• Minimum MTBF of 20,000 Hrs when fitted with dual processors at 512 bit capacity.
7.2.7 Maintainability
The system is designed to have a minimum maintained operational life of 15 years.
The system total modular design concept allows for future simple re-design should component obsolescent problems arise.
7.2.8 IP Rating
International protection (IP) class of protection against solids and liquids, IP20.
7.2.9 Dimensions
Table 7.6 — Equipment Dimensions
EQUIPMENT HEIGHT (mm) WIDTH (mm) DEPTH (mm)
Westronic 1024 housing. 266.7 (6U) 482.6 305
Westronic Triple TDM Housing 266.7 (6U) 482.6 305
Battery Back-up Unit. 88.8 (2U) 482.6 225
Invensys Rail Modem Rack. 134 482.6 270
Invensys Rail shelf mounted modem.
35 108 220
Telindus Aster 5 shelf mounted modem.
45 220 215
Telindus CN4 Card Enclosure. 270 445 330
Telindus Aster 5 rack mounted modem.
235 25 335
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7.2.10 Fuse Types and Ratings
Fuse types and ratings for Westronic 1024 and associated equipment is listed in Table 7.7.
Note: Ratings given are the maximum rating for the application. The rating of fuses actually fitted may be less. Refer to scheme drawings for the rating specified for your location.
Note: Refer to project specific wiring diagrams for wetting and drive supply fuse ratings.
Table 7.7 — Fuse Locations and Ratings
EQUIPMENT / MODULE
IDENTITY CHARACTERISTICMAXIMUM RATING
Westronic 1024 Housing mains lead(s)
--- Refer to cubicle drawings. ---
Battery Back-up Unit
FS1HBC 10 x 38 mm ceramic cartridge fuse Type gR.
16 Amp
FS2HBC 10 x 38 mm ceramic cartridge fuse Type gR.
16 Amp
FS3HBC 10 x 38 mm ceramic cartridge fuse Type gR.
30 Amp
DIP-64 wetting supply. See Note.
---BS714 cartridge fuse. For rating fitted, refer to cubicle drawings.
1 Amp
DOP-64 drive supply. See Note
---BS714 cartridge fuse. For rating fitted, refer to cubicle drawings.
