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Change History Issue Change Ref Date 1 First Issued October, 2007 2 Updated to include information on 48V tactile driver for
switched tactiles. Added detail on Detector Kits and Regulatory Signs Expansion Kit.
March 2008
3 Updated information on fitting of CU/TU100-48V tactile controller Added information on mounting CU/TU100 PSU in upper position of Amber aspect in Helios ELV head. Added note to keep separation between signal wiring and aux wiring in pole cap. (Mantis 0002948) Minor edits, spelling corrections etc.
October 2008
4 Updated information on transformer mains tappings and cross referred to installation instructions
January, 2009
5 TS004943 ELV Nearside Compatibility Information February 2009 6 TS005031 Tactiles with Fault output added
TS004971 Lamp transformer with 250V tap added TS004932 ELV nearside identification TS005002 Note that Green outputs cannot be lamp monitored if driving tactiles and/or audibles in parallel
April 2009
7 TS005031: Updates to Tactiles October 2009 8 TS005313: Added Cabinet Installation Information November, 2009 9 TS005411: Updates to ELV Audible Driver February 2010 10 TS005598: Low Inrush Transformer and Master Fuse
correction July 2010
11 TS006426: Correct location of where spare signal cores should be earthed
Feb 2012
12 TS006763: Specify the expansion cabinet more clearly in section 3.3
Oct 2012
13 TS007187: Add Warning Important ELV Considerations Sep 2013 14 TS007434: Update section 4.1.2 to make clearer Mar 2014 15 TS006828: Add Enhanced detector Backplane linking July 2014 16 TS007870: Add warning to use separate neutral returns
for green signals Jan 2015
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SAFETY INFORMATION
HEALTH AND SAFETY AT WORK DISCONNECT ALL POWER TO THE CABINET BEFORE REMOVING OR INSTALLING ANY EQUIPMENT INTO THE CABINET. SSaaffeettyy ooff MMaaiinntteennaannccee PPeerrssoonnnneell
In the interests of health and safety, when using or servicing this equipment the following instructions must be noted and adhered to: (i) Only skilled or instructed personnel with relevant technical knowledge and
experience, who are also familiar with the safety procedures required when dealing with modern electrical/electronic equipment are to be allowed to use and/or work on the equipment. All work shall be performed in accordance with the Electricity at Work Regulations 1989 or the relevant local, state and government regulations.
(ii) Such personnel must take heed of all relevant notes, cautions and warnings
in this Handbook and any other Document or Handbook associated with the equipment including, but not restricted to, the following:
(a) The equipment must be correctly connected to the specified incoming
power supply. (b) The equipment must be disconnected/isolated from the incoming
power supply before removing any protective covers or working on any part from which the protective covers have been removed.
(iii) Any power tools must be regularly inspected and tested.
(iv) Any ladders used must be inspected before use to ensure they are sound and
not damaged. When using a ladder, before climbing it, ensure that it is erected properly and
is not liable to collapse or move. If using a ladder near a carriageway, ensure that the area is properly coned and signed.
(v) Any personnel working on site must wear the appropriate protective clothing,
e.g. reflective vests, etc.
In the event of any person working elsewhere on the junction, it is recommended that the Mains Supply to the controller be switched off and the master switch locked in the ‘off’ position.
WARNING If you are not certain that the entire system is ELV, you must switch off the Mains Supply to the controller and lock the Master Switch in the ‘off’ position. If the controller uses an Expansion Cabinet, then the mains supply to
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the expansion cabinet must also be switched off and the Master Switch in the Expansion Cabinet locked in the off position.
In countries where both sides of the incoming supply are above earth potential, the Master Switch or Circuit Breaker should be opened. When re-commissioning signals, the following sequence is recommended:
1. Switch OFF the controller at the main switch 2. Switch ON the lamps on-off switch on the Manual Panel 3. Switch ON the controller at the main switch.
More specific safety information is given in the text of the handbook, where it relates to particular activities or situations. For Hardware Fail Flash Controllers Only (non UK only): If the controller needs to be changed to HFF after being installed (non UK only), or if the HPU is changed or any of the connections to the LSLS cards on the HPU are removed, the following procedure must be followed:
1) Ensure that the power to the controller is switched off. 2) Move the link on the CPU Card to its non-HFF position (see section 4.5.2). 3) Ensure that the link on the HPU is in the HFF position (see section 4.2). 4) Run the Controller Self-Test and confirm that it indicates that the controller
is set for HFF. Note that the signals will not flash when the controller is powered because the link on the CPU Card is in the non-HFF position.
5) Switch off the power to the controller. 6) Move the link on the CPU Card to its HFF position. 7) Switch on the power to the controller and ensure that the correct traffic
signals flash as the controller starts.
WARNING There are various RJ45 connectors used to connect to LSLS and I/O cards in the ST900 ELV cabinet. These are not Ethernet ports and should not be connected to other equipment, including PCs.
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WARNING
To isolate the equipment, the Master Switch must be in the
“Off” position.
Removal of the Electricity Board Fuse or Switching the Controller switch or the Manual Panel Signals On/Off switch to “Off” does not guarantee isolation of the
equipment.
WARNING
These (this) controller(s) require specific configuration to
enable them (it) to function correctly when installed.
The configuration process is a complex activity and should only be carried out by persons who are adequately
trained, have a full understanding of the needs of the county or region were the controller is to be used and are
experienced in the tasks to be undertaken.
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WARNING
Do not connect any device that has not been specifically designed or tested for compatibility with the ST900 ELV system. If in doubt, contact Siemens Poole for further information. ST900 ELV compatible equipment such as Helios ELV traffic signals, near-side pedestrian signals and ELV LED regulatory signs are all clearly marked “ELV”. If equipment is not marked “ELV” then additional care should be taken to ensure that it is suitable for use in an ELV system.
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It is important that all personnel are aware of the dangers to road users that could arise during repair and maintenance of traffic control equipment. Ensure that the junction area is coned and signed as necessary to warn motorists and pedestrians of any dangers and to help protect the personnel working on the site. Whilst repairing signals which are in an "all-out" condition, care must be taken to ensure that no spurious signals are lit during testing which could mislead drivers or pedestrians. Particular care is required where pedestrian audible devices are installed, to ensure that no false indications are given during, for example, cable testing. Personnel should also ensure the safety of pedestrians, especially children, who may come into contact with parts of the controller or signal poles. Safety Warning - Lithium Battery This equipment contains a Lithium battery. Do not short circuit, recharge, puncture, take apart, incinerate, crush, immerse, force discharge or expose to temperatures above the declared operating temperature range of the product, otherwise there is a risk of fire or explosion. Batteries should be handled and stored carefully to avoid short circuits. Do not store in disorderly fashion, or allow metal objects to be mixed with stored batteries. Keep batteries between -30°C and 35°C for prolonged storage. The batteries are sealed units which are not hazardous when used according to these recommendations. Do not breathe vapours or touch any internal material with bare hands. Battery disposal method should be in accordance with local, state and government regulations. In many countries, batteries should not be disposed of into ordinary household waste. They must be recycled properly to protect the environment and to cut down on the waste of precious resources.
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WARNING IMPORTANT ELV CONSIDERATIONS: To provide the most reliable operation, Siemens ELV controllers use a DC (unsmoothed) lamp supply which, in common with DC powered telecommunication equipment, is negative with respect to earth so as to avoid electrochemical corrosion effects. To maintain all street voltages within ELV limits, equipment outside the cabinet must be supplied with voltages within the band -48V RMS with respect to earth. Voltages positive with respect to ground / earth will result in overall voltages within the system being in excess of the ELV limit as defined by BS7671. Care should be taken to ensure that no LV (Mains Voltage) equipment is installed within the ELV street furniture as this will result in risks to personnel and risk of catastrophic failure of ELV equipment should such voltages be applied to the ELV equipment by accident. The Siemens ELV controller has been designed and proven to meet the following requirements for Protective Extra Low Voltage (PELV) and the operation of a signal compliance monitoring system with ELV voltages:
1) The Siemens ELV system is PELV and the earth is connected all the way through, as allowed for in BS7671 414.4.1. The source is a safety isolating transformer to BS EN 61558-2-6 as allowed in 414.3 (i). Protective Isolation within the controller cabinet is achieved between the PELV circuits and those higher than band I by ALL conductors having insulation rated for the highest voltage 250V, as mandated for in 414.4.2 (iii), and where the parts of the circuits are not wires / conductors, then physical isolation as allowed for in 414.4.2 (v) may be used. Any third party ELV sources installed in this system should follow the same guidance, re isolation and insulation and should adopt the same polarity and voltage range to avoid voltages in excess of ELV band 1 being present in the signalling / street furniture part of the system.
2) Terminations are IP2X (British standard finger proof i.e. not accessible to solid items of 12.5mm or greater).
Any third parties making alterations to such equipment / PELV installations must consider the electrical requirements for PELV and the above in what they do, and should only attempt such alterations if they are competent to do so. The controller monitors its signal outputs for both positive and negative voltages with respect to earth for its conflict system. In order to ensure the ELV voltage band is maintained, positive voltages with respect to earth are clamped by the controller. Should a positive voltage be applied to the signal outputs, the controller will consume current to maintain a maximum positive voltage of approximately 0.8 volts at the controller terminals.
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Should a source with a large current sourcing capability be applied, catastrophic damage may result. The extent and results of such damage cannot be predicted or guaranteed.
ST900 ELV Installation, Commissioning and Maintenance Handbook
2. SYSTEM OVERVIEW .................................................................................... 18
3. ELV HARDWARE OVERVIEW ..................................................................... 21 3.1 THE ELV CONTROLLER PRIMARY CABINET................................................................... 21 3.2 THE CONTROLLER RACK................................................................................................. 23 3.3 ELV CONTROLLER EXPANSION CABINET ...................................................................... 25
4. ST900 ELV SYSTEM COMPONENTS .......................................................... 25 4.1 LAMP SUPPLY TRANSFORMER ....................................................................................... 25
7. LEAVING SITE .............................................................................................. 95
8. ROUTINE MAINTENANCE PROCEDURES ................................................. 96 8.1 ROUTINE INSPECTION OF SIGNAL EQUIPMENT ........................................................... 96 8.2 ROUTINE INSPECTION AND ELECTRICAL TESTING OF CONTROLLER ....................... 96 8.3 ROUTINE SETUP CHECK ................................................................................................. 98
9. FAULT FINDING ........................................................................................... 99 9.1 SITE VISITS ....................................................................................................................... 99
9.1.1 On Receipt of a Fault Report ....................................................................................... 99 9.1.2 Before Going to a Site ................................................................................................. 99 9.1.3 On Arrival at the Site ..................................................................................................100
9.3 FAULT FINDING STARTING FROM THE SYMPTOMS ....................................................106 9.3.1 Fault Symptoms No Longer Apparent .........................................................................107 9.3.2 All Traffic Lights Off ....................................................................................................108 9.3.3 One Lamp (Or Lamp Group) Not Lighting ...................................................................109 9.3.4 One Lamp (Or Group of Lamps) Always Lit.................................................................112 9.3.5 Lamp (Or Lamp Group) Lighting at Wrong Time .........................................................113 9.3.6 Signals Not Dimming During Darkness .......................................................................115 9.3.7 Signals Dim During Daylight .......................................................................................116 9.3.8 Signals Cycling Dim-Bright-Dim Etc. ...........................................................................117
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9.3.9 Signals Not Changing At All, i.e. Stuck .......................................................................119 9.3.10 Signals Not Changing to Green on an Approach .........................................................124 9.3.11 Signals Changing Too Slowly......................................................................................128 9.3.12 Signals Changing Too Quickly ....................................................................................132 9.3.13 Faulty Input.................................................................................................................135 9.3.14 Faulty Output ..............................................................................................................138 9.3.15 Cabinet Alarm/Detector Fault Monitor .........................................................................140 9.3.16 Controller Not Running Required/Expected Mode .......................................................141 9.3.17 Intermittent Faults/Problem Sites ................................................................................144 9.3.18 Faults with Handset ....................................................................................................144
9.4 REPLACEMENT OF CARDS .............................................................................................146 9.4.1 Safety Requirements ..................................................................................................146 9.4.2 General Requirements ................................................................................................146 9.4.3 Access to Cards in ST900 ELV 19” Controller Rack ....................................................146 9.4.4 Replacement of HPU ..................................................................................................147 9.4.5 Replacement of LPU...................................................................................................147 9.4.6 Replacement of Main Processor Card .........................................................................147 9.4.7 Replacement of LSLS Card ........................................................................................147 9.4.8 Replacement of I/O Card ............................................................................................147 9.4.9 Replacement of Intelligent Detector Backplane Card ..................................................148 9.4.10 Replacement of the Manual Panel Card ......................................................................148 9.4.11 Replacement of SDE/SA Card and/or IRM/IMU Card ..................................................148 9.4.12 Replacing Components Other Than Cards ..................................................................149
9.5 LOGGING/RECORDING FAULTS AND VISITS ................................................................150
10. THE SELF-TEST FACILITY........................................................................ 151 10.1 INTRODUCTION ...............................................................................................................151 10.2 SELF-TEST PART ONE ....................................................................................................152 10.3 SELF-TEST PART TWO ...................................................................................................155 10.4 LSLS CARD FAULTS ........................................................................................................162 10.5 OTHER ERROR MESSAGES............................................................................................163
APPENDIX A - PART NUMBERS AND SPARES LIST ......................................... 166 A.1 PART NUMBERS ..............................................................................................................166
A.1.1 UK Only ......................................................................................................................167 A.1.2 Non-UK Only ..............................................................................................................167 A.1.3 Optional Parts .............................................................................................................167
A.2 SPARES LIST ...................................................................................................................168 A.2.1 Controller Fuses .........................................................................................................168 A.2.2 Other Spares ..............................................................................................................169
Figures FIGURE 1 – SYSTEM OVERVIEW ................................................................................................. 20
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FIGURE 2 – ST900 ELV CONTROLLER CABINET – VIEW OF RIGHT SIDE................................. 21 FIGURE 3 – ST900 ELV CONTROLLER CABINET - VIEW OF LEFT SIDE .................................... 22 FIGURE 4 – ST900 ELV 19” RACK - FRONT .................................................................................. 24 FIGURE 5 – ST900 ELV 19" RACK - REAR .................................................................................... 24 FIGURE 6 – ELV TRANSFORMER CONNECTIONS: 250V MAINS ................................................ 26 FIGURE 7 – ELV TRANSFORMER CONNECTIONS: 240V MAINS ................................................ 27 FIGURE 8 – ELV TRANSFORMER CONNECTIONS: 230V MAINS ................................................ 27 FIGURE 9 – ELV TRANSFORMER CONNECTIONS: 220V MAINS ................................................ 28 FIGURE 10 – ELV TRANSFORMER CONNECTIONS: 120V MAINS .............................................. 28 FIGURE 11 – ELV TRANSFORMER CONNECTIONS: 110V MAINS .............................................. 29 FIGURE 12 – HPU CARD ............................................................................................................... 32 FIGURE 13 – SK2 DETECTOR SUPPLY AND SOLAR CELL CONNECTIONS .............................. 32 FIGURE 14 – REGULATORY SIGNS SUPPLY CONNECTIONS .................................................... 34 FIGURE 15 20A TO 40A UPGRADE KIT INSTALLED .................................................................... 35 FIGURE 16 – LPU REAR CONNECTORS ...................................................................................... 37 FIGURE 17 – ST900 ELV PROCESSOR CARD AND PHS CARD (FRONT AND REAR VIEWS) ... 38 FIGURE 18 – MAIN PROCESSOR CARD ....................................................................................... 39 FIGURE 19 – PROCESSOR CARD LEDS ...................................................................................... 40 FIGURE 20 – PHS DAUGHTER CARD ........................................................................................... 41 FIGURE 21 – PHS CARD LEDS ..................................................................................................... 41 FIGURE 22 – PROCESSOR CARD SWITCH SETTINGS ............................................................... 43 FIGURE 23 – I/O CARD (SHOWING 16-OUTPUT VARIANT) ......................................................... 45 FIGURE 24 – I/O CARD ADDRESS SWITCH AND LEDS ............................................................... 46 FIGURE 25 –ORIGINAL VERSION INTELLIGENT DETECTOR BACKPLANE (REAR VIEW) ........ 47 FIGURE 26 –ENHANCED INTELLIGENT DETECTOR BACKPLANE CARDS SEPARATED FOR
CLARITY .................................................................................................................................. 48 FIGURE 27–EXTENDING THE IR LINK BETWEEN INTELLIGENT DETECTOR BACKPLANES
667/1/32910/950 ....................................................................................................................... 48 FIGURE 28 – SK6 AND SK7 CONNECTIONS FOR LOOP DETECTOR POWER .......................... 51 FIGURE 29 – LSLS CARD AND BACKPLANE ................................................................................ 52 FIGURE 30 – LSLS CARD ADDRESSIN ......................................................................................... 54 FIGURE 31 – MANUAL PANEL ....................................................................................................... 56 FIGURE 32 – AUDIBLE DRIVER MODULE – SINGLE OUTPUT TYPE .......................................... 59 FIGURE 33 – AUDIBLE DRIVER MODULE CONNECTIONS – SINGLE OUTPUT TYPE ............... 61 FIGURE 34 – DUAL LEVEL AUDIBLE DRIVER MODULE CONNECTIONS – SINGLE OUTPUT
WITH FAULT OUTPUT ............................................................................................................ 72 FIGURE 41 – SOLAR CELL CONNECTIONS ................................................................................. 73 FIGURE 42 – ABOVE-GROUND DETECTOR CONNECTIONS ...................................................... 74 FIGURE 43 REGULATORY EXPANSION PCB MODULE ............................................................... 75 FIGURE 44 LSLS CABLE TERMINATIONS FROM EXPANSION KIT ............................................. 76 FIGURE 45 EXPANSION KIT INSTALLED ...................................................................................... 76 FIGURE 46 50VA DETECTOR EXTENSION KIT INSTALLED ........................................................ 77 FIGURE 47 – ST900 ELV RACK FOR FITTING IN ALTERNATIVE CABINETS (FRONT)............... 80 FIGURE 48 – ST900 ELV RACK FOR FITTING IN ALTERNATIVE CABINETS (REAR) ................. 81 FIGURE 49 – LSLS REAR CONNECTIONS (TOP) ......................................................................... 82 FIGURE 50 – LSLS REAR CONNECTIONS (BOTTOM) ................................................................. 83 FIGURE 51 - STOOL INSTALLATION ............................................................................................ 89 FIGURE 52 - TERMINATION OF ARMOURED CABLE TO CET BAR ............................................ 91 LAST PAGE ........................................................................................................... 171
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11.. IINNTTRROODDUUCCTTIIOONN
1.1 Purpose The purpose of this handbook is to describe the procedures for the Installation and Commissioning of the ST900 ELV Controller and to provide guidance on routine maintenance and fault finding.
This handbook has been created in accordance with the requirements of BS EN 12675:2001 and BS 7987:2001.
Note Ongoing development means that some of the delivered items may differ in detail from the photographs included in this handbook.
1.2 Contact Us If you have any comments on this handbook, or need any further information, you can contact us at [email protected].
1.4 Pre-Requisites Before reading this handbook, you should be familiar with (as a minimum) sections 1 to 3 of the ST900 Controller General Handbook. Anyone undertaking installation, commissioning and first line maintenance on the ST900 ELV controller will also need the ST900 Family Handset Handbook (667/HH/32900/000). This provides details of how to access the controller handset port through which the user communicates with the controller.
1.4.1 Qualifications Only skilled or instructed personnel with relevant technical knowledge and experience, who are also familiar with the safety procedures required when dealing with modern electrical/electronic equipment, are to be allowed to use and/or work on the equipment. All work shall be performed in accordance with the Electricity at Work Regulations 1989 or the relevant local, state and government regulations. Any personnel working on the ST900 ELV Controller should have completed the following training courses:
HA Sector Scheme Sector 8 Modules 5XX M609 – Junction Traffic Controller Maintenance for ST900 ELV
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Training requirements for non UK users may be different.
1.4.2 Required Tools In addition to a standard Engineer’s tool kit, the following tools are required when carrying out any work on the ST900 ELV Controller:
Part Number T-bar key 667/2/20234/000 S-18 key – Main Cabinet 4/MC 289 Serial handset Techterm, or 667/4/13296/001 Old Oyster handset, or 667/4/13296/000 Larger Screened Oyster handset 667/4/13296/002 Manual Panel key Type 900 667/4/13651/000
1.4.3 Spares See Appendix A.2 for a full list of spares that are necessary when carrying out a site visit to the controller, whether for installation, commissioning or maintenance.
1.5 Definitions Bit
Binary digit (i.e. `0’ or `1’)
Byte
Eight bit data array (i.e. bits 0-7, and 8-15 are bytes)
Configuration data (aka Customer Data) and site specification
Data supplied by the customer as to how the controller is to function. It is recommended that the Controller Forms Handbook be used as the blank form for this.
Configuration EPROM
This contains all of the specific data for the site and gives the controller its personality, e.g. contains number of phases, types of phases, phases in stages, timings, etc. The EPROM goes on the Main Processor card. It has the part number: DT ***/### $$ where – DT is equivalent to 667/1/16 *** is a three-digit identifier. ### is the variant number and is specific to the particular junction. $$ is the issue number of the configuration. The part number of the above PROM would be 667/1/16***/### at issue $$
EM Controller identification number (ElectroMatic).
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CIC Configuration Identity Code (equivalent to EM above) Firmware EPROM This goes on the Main Processor card.
STS (Site to Scale)
A scale drawing of the intersection including controller position, detector loop positions and specification, cable routing and poles with signal head arrangements.
Word
Two-byte data array (i.e. bits 0-15 constitutes a data word)
Works Specification
Document produced by Siemens, which details the hardware required for the controller and includes Site Data, usually in the form of a printout of the data entered on the configurator.
1.6 Abbreviations AC.................. Alternating Current CLF ................ Cableless Linking Facility CLU ............... Cableless Linking Unit CPU ............... Central Processing Unit CRC ............... Cyclic Redundancy Code DC ................. Direct Current DFM ............... Detector Fault Monitor DPR ............... Dual Port RAM ELV ................ Extra Low Voltage EPLD ............. Erasable Programmable Logic Device EPROM.......... Erasable Programmable Read Only Memory ESB ............... Extended System Bus HI ................... High Intensity HFF ................ Hardware Fail Flash HPU ............... High Power Unit IC4 ................. Intersection Configurator v.4 (UK controller configuration application) IDB ................. Intelligent Detector Backplane I/O .................. Input/Output IMU ................ Integral Monitoring Unit (see IRM) IRM ................ Integral Remote Monitoring (aka London Monitoring Unit or IMU) KOP ............... Kit of Parts LED................ Light Emitting Diode LMU ............... Lamp Monitoring Unit LPU................ Logic Power Unit LSLS .............. Lamp Switch Low-Voltage Serial OMU .............. Outstation Monitor Unit OTU ............... Outstation Transmission Unit PCB ............... Printed Circuit Board PHS ............... Phase Bus Serial Interface Card PROM ............ Programmable Read Only Memory RAM ............... Random Access Memory RCD ............... Residual Current Device rms ................. Root Mean Square RMS ............... Remote Monitoring System RTC ............... Real Time Clock SA .................. Speed Assessment SDE ............... Speed Discrimination Equipment
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STC ............... Siemens Traffic Controls UTC ............... Urban Traffic Control VA .................. Vehicle Actuated
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22.. SSYYSSTTEEMM OOVVEERRVVIIEEWW The Siemens ST900 ELV Controller can be supplied either in a single-door outer case with a 6U logic accommodating the CPU and power supplies, with space for up to 16 x 4 channel detector cards, or 12 x 4 channel detector cards and a semi-integral OMU, UTMC OTU or MOVA unit . ELV Lamp Switch cards (LSLS) are located within the cabinet. Very large intersections may have additional Lamp Switch, I/O and Intelligent Detector Backplane cards located in an adjacent cabinet for ease of installation and maintenance. The ST900 ELV is also available as a free-standing logic rack housing the power supply, CPU and Lamp Switch cards. The essential differences between the ST800 Controller and the new ST900 ELV Controller are:
The Mains-powered 8-phase (24 output) Lamp Switch cards have been replaced with 32-output ELV lamp switch cards (LSLS cards) that drive and monitor the 48V LED aspects and drive 48V tactiles and 48V audible driver modules. The LSLS cards are mounted on the sides of the cabinet and connect to Backplanes that allow direct termination of the street cabling, avoiding the use of termination blocks and soft wire kits. Three LSLS cards are fitted in the primary cabinet, with additional cards (up to a maximum of 6 LSLS cards) being fitted in an adjacent expansion cabinet.
An HPU card distributes the 48V lamp supply from the Lamp Supply
Transformer to the LSLS cards and incorporates the Dim/Bright, A and B relays.
The Main Processor Card is now coupled with a daughter card (the PHS
card) that in turn provides high-speed serial connection to new LSLS cards, parallel IO cards and new Intelligent Detector Backplanes.
The new serial I/O cards are mounted on the rear panel of the controller
cabinet and allow direct termination of street cabling without resorting to the use of additional terminal blocks and soft wire conversion kits. Further information on the I/O card is in section 4.10
The new Intelligent Detector Backplanes are mounted in the rack. These
provide support for the connection of up to 4 standard Loop Detector Cards such as Siemens ST4S. The Backplane connects to a ribbon cable that terminates in a Loop Termination Board mounted on the cabinet rear panel. The Loop Termination board provides the termination point for 16 Loop Feeder pairs without the use of additional terminal blocks and twisted wire kits. Further information on the Intelligent Detector Backplanes is available in section 4.11
All Loop Detector Cards are powered from a dedicated output of the HPU.
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Each pushbutton is associated in the IC4 configuration with one specific
kerbside detector (if used), thus each pushbutton input and kerbside input must connected to its correct pushbutton / kerbside. Pushbuttons must not be commoned together and connected to a single input. If the pushbutton is pressed while the associated kerbside is active, an unlatched demand is inserted. If the pushbutton is pressed whilst the associated kerbside is inactive, a latched demand is inserted.
Internal SDE/SA is available (and does not require the /102 PLD), with the
SDE/SA loops connected to the new Intelligent Detector Backplanes (or new I/O cards if required).
With the new I/O cards and new Intelligent Detector Backplanes, the ST900 Family now supports up to 248 I/O lines. The combination of the new I/O cards and new Intelligent Detector Backplanes in the ST900 completely replaces existing I/O previously used in the ST800. Neither the main processor card I/O or the use of I/O expansion cards 667/1/27003/000 is supported in the ST900. The ST900 Family supports existing ST800 equipment such as Gemini, Gemini2, Tele12 OTU, IRM/IMU Card, SDE/SA Card (if the SoundMark Interface is required), etc. The controller conforms to the UK Highways Agency specification TR2500. The main components of the ST900 ELV system are shown in figure 1.
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Figure 1 – System Overview
Siemens Mobility, Traffic Solutions Sopers Lane, Poole, Dorset, BH17 7ER
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33.. EELLVV HHAARRDDWWAARREE OOVVEERRVVIIEEWW
3.1 The ELV Controller Primary Cabinet Figure 2 and Figure 3 show the ST900 ELV controller fitted in an ST900 ELV Controller Cabinet. CET bars are installed in the base of the cabinet. The Master Switch Panel and two LSLS cards are all installed on the right hand side panel of the cabinet. The Lamp Supply Transformer, HPU, third LSLS card and miscellaneous equipment are installed on the left hand side panel of the cabinet. Up to three I/O cards, loop termination cards, Audible Driver Modules, termination blocks and two sets of Cable Trunking are installed on the rear panel of the cabinet. The 19” Controller Rack is installed in an equipment frame at the front of the cabinet; this frame can be swung open to enable access to the rear of the frame and to the cards and components installed in the cabinet.
Figure 2 – ST900 ELV Controller Cabinet – View of right side
Siemens Mobility, Traffic Solutions Sopers Lane, Poole, Dorset, BH17 7ER
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Figure 3 – ST900
ELV Controll
er Cabinet - View of left side
LSLS 3
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3.2 The Controller Rack Figure 4 and Figure 5 overleaf show the 6U 19” ST900 ELV controller rack. The 19” Controller Rack is sub-divided into one 6U-high bay and two 3U-high bays, which may be expanded to four 3U-high bays by the addition of a 6U expansion kit. The 6U bay is fitted with (from left to right) LPU, Main Processor card and optionally an SDE/SA card and/or Integral Remote Monitoring IRM/IMU and/or integral TC12 OTU. The TC12 OTU, SDE/SA and IRM/IMU cards connect to the Main Processor using an Extended System Bus cable that connects across the rear of the cards. Additionally, the IRM/IMU and SDE/SA cards require +24V DC power from the LPU. When fitting either an IRM/IMU or SDE/SA card, an ST900 ELV SDE/SA & IMU Power Adapter Kit is used to allow connection between the LPU and the IRM/IMU and SDE/SA cards. Only one Power Adapter Kit is required per controller. The four 3U-high bays can be fitted with up to four Intelligent Detector Backplanes, supporting up to 16 Loop Detector cards. Additional loop detectors may be accommodated in one or two further 3U 19” racks fitted in the swing frame above and/or below the main 6U rack. Figure 5 shows the rear of the controller rack with two Intelligent Detector Backplanes. If required, a Gemini2 unit may be fitted in the bottom right bay, as shown in Figure 4. The 6U cards are held in the rack by a retaining strip at its upper front edge. To release the cards, loosen the clamping screws and move the retaining strip clear of the card guides. For some cabinets additional kits of parts are available. These are listed on the ST900 ELV Family Tree (667/DZ/32900/000). The kits provide the necessary installation instructions, brackets and other equipment that may be helpful during the installation. The standard controller items are used with these kits and are also listed in the ST900 Family Tree. Refer to Siemens Poole for the latest copy.
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Figure 4 – ST900 ELV 19” Rack - Front
Figure 5 – ST900 ELV 19" Rack - Rear
LPU
Main Processor Card
PHS Card
ST4S (x 8)
Gemini2
Card Guide
Rear of LPU Intelligent Detector Backplanes (x 2)
Gemini2
PHS
Main CPU
Retaining Strip
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3.3 ELV Controller Expansion Cabinet For large junctions, it may be necessary to fit an expansion cabinet, adjacent to the primary cabinet. The Expansion Cabinet Kit does not have a connection to the mains supply and is typically used to house IO cards and their associated cabling. Long-length serial cables are used to connect the IO cards in the expansion cabinet to the PHS in the primary cabinet. When mains-powered equipment is fitted into the expansion cabinet, a Expansion Cabinet kit ELV Master Switch is required. This kit allows a mains supply to be taken into the expansion cabinet and safely terminated. When an LSLS is to be fitted into the expansion cabinet, an LSLS Expansion Cabinet Kit is required. This kit includes a 20A lamp transformer, HPU, single LSLS and LSLS Backplane. Additional LSLS cards and LSLS backplanes can then be fitted up to a maximum of 3 LSLS cards in the Expansion Cabinet. See section 4.3 for more information. It is not necessary to have a separate Feeder Pillar for the expansion cabinet.
44.. SSTT990000 EELLVV SSYYSSTTEEMM CCOOMMPPOONNEENNTTSS This section introduces the main components of the ST900 ELV system.
4.1 Lamp Supply Transformer The Lamp Supply transformer provides the high current 48V supply to the ELV signal heads and a separate lower current 48V supply for Regulatory Signs. It additionally provides a low voltage AC supply for the operation of the LSLS card logic and a 24V DC supply for powering Loop Detectors, AGDs and the solar cell. The ELV transformer has two separate primary windings, so that it can be configured for either 220/230/240V/250V operation or for 110/120V operation.
Note
Issue 3 (and lower) Lamp Transformer has primary taps for 220/230/240V operation and 110/120V operation Issue 4 (and higher) Lamp Transformer has an additional primary tap for 250V operation
Figure 6 to Figure 11 below show the terminations for the issue 4 Lamp Transformer
4.1.1 Procedure for selecting transformer connections: With a suitable multimeter set to read AC volts, measure the incoming mains supply voltage and select the transformer tapping according to the table below:
Measured Voltage Select Transformer Tapping:
245V to 276V 250V (see Note above)
235V to 244V 240V
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225V to 234V 230V
187V to 224V 220V
115V to 138V
94V to 115V
120V
110V
Table 1 – Lamp Transformer Tappings
Note For a nominal 230V supply, if the measured voltage is below 196V or above 253V, then advice should be sought from the local electricity supplier
Connections to the transformer are made in accordance with Figure 6 to Figure 11
WARNING If a second transformer is fitted as part of the 20A to 40A upgrade kit, both transformers MUST be set to the same tapping selection.
Figure 6 – ELV Transformer Connections: 250V mains
240
220
110
Earth
Earth
250
230
120
120
0
Earth
Earth
Live Input
Live to LPU
Link 120V to 120V
Neutral Input
and to LPU
230
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Figure 7 – ELV Transformer Connections: 240V mains
Figure 8 – ELV Transformer Connections: 230V mains
240
220
110
Earth
Earth
250
120
120
0
Earth
Earth
Live Input
Live to LPU
Link 120V to 120V
Neutral Input
and to LPU
230
230
220
110
Earth
Earth
250
230
120
120
0
Earth
Earth
Live Input
Live to LPU
Link 120V to 120V
Neutral Input
and to LPU
230
240
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Figure 9 – ELV Transformer Connections: 220V mains
Figure 10 – ELV Transformer Connections: 120V mains
110
Earth
Earth
250
Earth
Earth
Live Input
Live to LPU
Neutral Input
220
230
Neutral to LPU
120
0 240
120
230
240
110
Earth
Earth
250
120
120
0
Earth
Earth
Live Input
Live to LPU
Link 120V to 120V
Neutral Input
and to LPU
230
230
220
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Figure 11 – ELV Transformer Connections: 110V mains
Note The LPU Mains Live wire is always connected to the extra 230V termination on the ELV transformer.
When operating on 110V or 120V Mains input, the LPU Mains Live wire remains connected to the extra 230V termination. This results in the LPU being supplied with 110V AC.
4.1.2 Low Inrush Transformer: Siemens Mobility, Traffic Solutions have developed a low inrush transformer that allows lower rating protection devices to be used, as shown below: - 1. 667/1/32980/500 – ST900ELV Low Inrush Transformer assembly (20A only) 2. 667/2/33086/500 – ST900 ELV Low Inrush Master Switch label 3. 516/4/02061/002 – Controller MCB 6A type D replaces the 20A type D MCB 4. 518/4/90638/007 – Master Fuse 16A HRC Cartridge to BS1361 replaces 30A 5. 25A Electricity Cut-it fuse should be used in place of the 45A
The lower rating Electricity Cut-out fuse encourages the Electricity Supplier to provide power without supply metering. The low inrush transformers are ONLY available in ST900/ST950ELV 20A controller cabinets, see Appendix A.1.1 for Part Numbers.
WARNING A low inrush transformer weighs about 20kg. In the very unlikely event of a transformer failing, appropriate lifting techniques MUST be used, and leather rigger gloves are recommended.
Earth
Earth
250
Earth
Earth
Live Input
Live to LPU
Neutral Input
220
230
Neutral to LPU
120
0 240
120
230
110
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4.2 HPU The HPU distributes the 48V lamp supply and low voltage logic supply from the Lamp Supply transformer to three LSLS cards. It has monitor circuitry and terminations for the connection of up to eight 48V regulatory signs, provides connections for the Solar Cell and 24V Loop Detector/AGD supply and incorporates the Dim/Bright, A and B relays. If the total lamp load exceeds 20A or more then three LSLS cards are required, see section 4.3. The HPU provides the following outputs: Supply
Voltage (nominal)
Measures as: (Note 2)
Connector
Lamp Supply 0V (Earthed) 0V PL4/6/7/ pins 1,2,3 (Bright) -48V DC rms nominal -44.6V DC PL4/6/7 pins 4.5.6 (Dim) -27.5V DC rms nominal -25.4V DC
-48V DC rms nominal -44.6V DC SK1 pins 1b, 2b, 3b, 4b, 5b, 6b, 7b, 8b
LSLS#1 Logic Supply 12.2V AC rms 12.2V AC PL4 pins 7 and 8 LSLS#2 Logic Supply 12.2V AC rms 12.2V AC PL6 pins 7 and 8 LSLS#3 Logic Supply 12.2V AC rms 12.2V AC PL7 pins 7 and 8
Loop Detector Supply 0V (Earthed) 0V SK2 3a -24V DC rms nominal -20.9V DC SK2 3b
Table 2 – HPU Outputs
Note The 48V DC Lamp supply, 48V DC Regulatory sign supply and 24V DC Loop Detector Supplies are all negative with respect to ground i.e. the positive side of each of these supplies is grounded.
Note When measuring any of the DC supplies, a normal multimeter set to DC Volts will NOT show the true rms voltage of the unsmoothed DC waveform. The multimeter will indicate the voltage shown in the “Measures as” column in table above.
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Figure 12 – HPU Card
The standard HPU configuration (used for all UK controllers) links TP2 (Red Amber Green) to TP1 (Common) as seen in Figure 12. For Hardware Fail Flash controllers (non UK only), the link is fitted between TP3 (Fail Flash) and TP1 (Common).
Figure 13 – SK2 Detector Supply and Solar Cell connections
See section 4.17 and Figure 31 for details of the cable connections to the Solar Cell.
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The following table details the connections on the HPU. Socket /Plug
Purpose Description
SK1 Reg. Signs -48V DC Connection for 8 off Reg. Signs Reg Sign Return (+) Reg-Sign Supply (-)
SK2 Detector Supply -24V DC supply for powering Loop Detector Cards and AGDs. Connects to a 12-way terminal block on the side panel of the cabinet. Det Com (+) and Det Sup (-)
SK2 Solar Cell Connection for 24V DC Solar Cell Connect Solar cell supply leads to Solar + and Solar -, observing correct polarity. Connect Solar Cell signal to Sol Sig.
PL1 & PL2
Relay Control Connection to CPU and LPU for relay control. PL1 and PL2 are identical. PL2 connects to Main Processor Card. PL1 connects to PL2 of second HPU unit, if fitted.
PL3 Reg. Sign Monitor Reg. Sign current monitor output to LSLS card. PL4, PL6, PL7
LSLS Lamp and Logic supplies
Lamp and logic supply connections to LSLS1, LSLS2, and LSLS3 cards.
PL5 Transformer Low Power
Detector, Reg. Sign, and 3 off LSLS logic supplies.
SK3 Transformer High Power and Earth
Bright, Dim, and Common connections from transformer. Earth connection to earth all supplies on HPU card.
Table 3 – HPU Connections
4.2.1 Regulatory Signs Monitoring The HPU is equipped with a Regulatory Signs supply as standard (SK1 on the HPU as shown in Figure 12 above). The supply can be monitored for up to eight regulatory signs. If the junction contains more than eight signs in total then a Regulatory Signs Supply and Monitoring kit is needed. This allows a further 12 regulatory signs to be powered and monitored.
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Figure 14 – Regulatory Signs Supply connections The HPU (and LSLS Card 1 through PL3) are fitted with the circuitry to monitor the regulatory signs. No external torroids are required in order to monitor the regulatory signs. If a second HPU is fitted, this can supply and monitor up to eight more regulatory signs; connect PL3 of HPU2 to the first Reg Sign input on SK5 of the LSLS Card connected to PL4 of HPU2 (i.e. the first LSLS connected to HPU2). LSLS card connections are described in section 4.13.
4.2.2 Regulatory Signs Expansion Kit Monitoring The regulatory signs extension kit provides for a further twelve ELV regulatory signs. These are arranged in two separately monitored blocks of 6. The kit contains lamp monitoring circuitry which must be linked to the external input(s) of an appropriate LSLS card. Two twisted pair cables, identical to that used for the HPU regulatory sign monitoring are supplied. The blue strand of the cable should be connected closest to the pcb (Return) of the external input.
A single LSLS can monitor a maximum of 18 extension kit regulatory signs plus the eight standard HPU powered signs.
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4.3 High-Current Capability Controllers For Controllers where the total lamp load will not exceed 20A, a single Lamp Supply Transformer and associated 20A HPU are fitted. For lamp loads up to 40A, an additional Lamp Supply Transformer and additional 20A HPU may be fitted. The additional Transformer and HPU can either be fitted alongside the first transformer and HPU on the side panel of the primary cabinet, or can be fitted in an expansion cabinet, see section 3.3.
Note When fitting a second HPU, a relay control cable must be connected from PL1 of the first HPU to PL2 of the second HPU.
Figure 15 20A to 40A Upgrade Kit Installed
Relay control cable
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If the total lamp load exceeds 20A or more than 3 LSLS cards are required, then the following options are available:
Note LSLS 1 must always be connected to PL4 of HPU1. The allocation of LSLS cards to HPU 1 or HPU 2 is done so that, as far as possible, the total load is distributed evenly across both transformers and HPU, and in no event does the current drawn from either HPU 1 or HPU 2 exceed 20A; this includes regulatory signs but excludes short-term red/amber periods. The number of LSLS cards connected to HPU1 or fitted in the Primary cabinet can be 1, 2 or 3; HPU1 and the primary cabinet do not need to be filled before moving to HPU2 and optionally an expansion cabinet.
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4.4 Logic Power Unit The Logic Power Unit (LPU) is a universal-input mains powered switch-mode converter providing +5V DC for the controller logic and +24V DC for the logic supplies of the I/O Cards and Intelligent Detector Backplanes. The +24V DC supply is routed to the main processor card and is then passed to the PHS and distributed to the Intelligent Detector Backplanes and I/O cards via the high-speed serial cables. With the addition of the Power Adapter Kit, the LPU also provides +24V DC power to the optional IRM/IMU and SDE/SA cards.
Note When powered from the LPU, the current drawn by the IRM/IMU restricts the number of I/O cards and/or Intelligent Detector Backplanes that can be fitted – refer to the ST900 General Family Handbook for details.
Z10 0V Return for Main Processor X4 5 d10, b10 +5V DC to Main Processor X4 9,
10 b8 +24V DC (to Power Adapter for
connection to SDE/SA and/or IRM/IMU where fitted)
Z6 Power Fail to Main Processor X4 8 d6, b6 +5V DC to Main Processor X4 11,
12 Z4 +24V DC to HPU PL2 1 d4 +24V DC to Main Processor X4 4 b2 0V Return (to Power adapter for
connection to SDE/SA and/or IRM/IMU where fitted)
Table 5 – LPU Rear Connections
4.5 ST900 ELV Main Processor Card & PHS Daughter Card The ST900 ELV main processor card is paired with the PHS daughter card. The two are bolted together and should not be separated. In case of failure, both cards should be replaced as a single unit (in order to ensure compatibility between the firmwares fitted to each card).
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The main processor card is the heart of the controller. It holds the controller configuration and performs the function of configuration, control and management. The primary external data interfaces of the main processor card are an Extended System Bus interface to SDE and OTU cards, interface to the Manual Panel and a front-panel serial interface to handset or Gemini2.
The PHS daughter card accepts parallel control data from the main processor card and converts this into high speed serial data. The PHS also acts as a second processor, providing independent safety monitoring of the controller functions. Three high-speed serial channels are available on 3 separate RJ-45 sockets on the PHs. The RJ-45 socket marked “LSLS” on the PHs must be connected to the LSLS cards. The two remaining RJ-45 sockets are identical and both marked “IO” One of these is connected to the IO cards and the other, to Intelligent Detector Backplanes. It is not important which connector is used for the IO and which is used for the Intelligent Detector Backplanes.
Figure 17 – ST900 ELV Processor Card and PHS Card (front and rear views)
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Figure 18 shows the location of the configuration PROM, firmware PROM(s) and selection switches on the main processor board.
1 32
16 17
Phase Bus Firmware (PB815)
PHS Connector
RAM Chips
PP
WD
SE BEStatus LEDs
Phase Bus Processor
(PB820) EPLD1
(PB821) EPLD2 Main Processor
Firmware (PB801)
Configuration PROM socket
Main Processor
Ram Back-Up battery
FRONT
Handset Fuse (500ma)
Phase Bus Connector
Extended System Bus Connector
Manual Panel Connector
Power Connector RS232 Handset
port
Modem Port
Hardware fail flash selection
Power fail signal source
32 pin
Figure 18 – Main Processor Card
Note: The shaded area shows the location of the PHS daughter card, which is shown in Figure 20 – PHS Daughter card Note that the LEDs and RJ45 connectors are mounted on the component side of the card.
Position of the Configuration PROM in the Configuration PROM Socket
Pins 1, 2, 31 & 32 of socket not used
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4.5.1 Processor LEDs There are four LED indicators on the front of the Main Processor card and six LEDs on the PHS card as shown below.
PP - Power Present (Heartbeat)
SE - System Error
BE - Bus Error
WD - Watchdog
LP4 - Green
LP3 - Red
LP2 - Red
LP1 - Red
MAIN PROCESSOR CARD
Figure 19 – Processor Card LEDs
LED Function No Fault State Fault Indicated State
PP - Green
Power Present
Flashes twice per sec (approx)
Off. No power to the Main Processor card. Check that the controller is powered and that the power connector is inserted into the back of the Processor card.
SE - Red System Error
Off On. Faults present in fault log. Illuminates during the power-up sequence and then extinguishes when the controller is running normally.
BE - Red Bus Error Off Illuminates when the Processor has problems executing the firmware, e.g. when the firmware PROM is missing.
WD - Red Watchdog Off Illuminates when the hardware watchdog circuit times-out. Note that when the firmware detects a serious fault, it extinguishes the signals and deliberately stops ‘kicking’ the hardware watchdog so that it times-out and reinforces the signals’ off condition, or HFF if configured on non UK Controllers.
Table 6 – Main Processor Card LEDs
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Figure 20 – PHS Daughter card
HB - Heartbeat
FF – Fail Flash
SW – Software Fault
HW – Hardware Watchdog Fail Latched
LP4 - Red
LP3 - Red
LP2 - Red
LP1 - Green PHS CARD
LP5 - Yellow
LP6 - Green
SE – System Error
PP – Power Present
Figure 21 – PHS Card LEDs
LED Function No Fault State Fault Indicated State
HB Green Heartbeat
Flashes giving an indication that the PHS software is
running normally.
Off
FF Yellow Fail Flash Off.
If FF is enabled, flashes when the Hardware Fail Flash signal from the
Main Processor card is active, i.e. on power up and when the Controller is
shut down. SW Red
Software Fault Off On
10-way header for LSLS comms in ‘cuckoo’ installations
PP SE HW SW FF HB
Status LEDs
RJ-45 High-Speed serial comms to LSLS cards
RJ-45 High-Speed serial comms to I/O and Backplane cards
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LED Function No Fault State Fault Indicated State
HW Red
Hardware Watchdog
Fail Latched
Off On
SE Red
System Error Off On
PP Green
Power Present On
If this LED is not illuminated but LEDs on the Main Processor card are (see
Table 6), check the connections between the two cards and consider
replacing both. Table 7 – PHS Card LEDs
Note While the Controller is shut down or while the Main Processor card is held reset due to (for example) a problem with the power supply, the PHS card will be held reset. In this state, all LEDs except FF will be illuminated and will not flash.
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4.5.2 Switches, Links and Firmware Before the controller is switched on, the set-up switches and links on the Main Processor card must be checked to ensure they are set correctly. Also the firmware should be checked to ensure that the correct version (as specified on the IC4 printout) is fitted. The switch and link settings are mainly related to the hardware fail flash facility; their locations and option selections are shown in Figure 22 below.
Note HFF only flashes signals on LSLS #1.
1 2
3 4
5 6 7 8
Flash rate depends on mains frequency
Power Fail Source
Link 2-3 Disabled Link 1-2 Enabled +160ms if Off
To ‘add’, turn Off appropriate switch
X34
X31
3 2 1
3 2 1
Link 2-3 External Link 1-2 Internal(Link 2-3 must always be selected)
Fail Flash Enabled
(Link 2-3 must always be selected for UK use)
ON OFF
Flash ‘ON’ time 50Hz 60Hz
+320ms if Off
+267ms if Off +160ms if Off +133ms if Off +80ms if Off +66ms if Off +40ms if Off +33ms if Off
All 0n = 40ms All On = 33ms
ON OFF
Flash ‘OFF’ time 50Hz 60Hz
+320ms if Off +267ms if Off +133ms if Off
+80ms if Off +66ms if Off +40ms if Off +33ms if Off
All On = 40ms All On = 33ms
Flash Rate Selection
Minimum flash period is 40ms (50Hz) & 33ms (60Hz)
Figure 22 – Processor Card Switch Settings
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4.6 SDE/SA Card The Speed Discrimination Equipment/Speed Assessment (SDE/SA) card is only required where the Soundmark interface is specifically needed. Where the Soundmark interface is not needed, the main processor card of the ST900 ELV controller can support the SDE/SA functionality. The SDE/SA card obtains +24V DC from the LPU via the Power Adapter Kit.
The SDE/SA card is
supplied with two cable harnesses, each terminating in two terminal blocks. These are screwed to an appropriate place on the rear or side faces of the cabinet. The terminal blocks are then wired to Single Loop Detector Backplane(s) (Kit number 667/1/15990/003) and the SDE/SA loop detector cards (e.g. ST4S) are plugged into these backplanes. The Loop Detector cards connect to the road loops via the Detector Termination KOP. The SDE/SA loop detector cards are powered from the HPU via the Loop Detector Supply white terminal block adjacent to the HPU. Det Com is + (Orange wire) and Det Sup is - (Grey Wire).
4.7 OTU For information regarding the Tele12 OTU card, see: 667/HB/43100/000 - TC12 General Handbook
4.8 Gemini2
For information regarding the Gemini2 equipment, see: 667/HB/32600/000 - Gemini2 Traffic Outstation Handbook
4.9 IRM/IMU For information regarding the IRM/IMU equipment, see:
667/HB/22380/002 - TSCU/TfL IMU Handbook
The IRM/IMU card obtains +24V DC from the LPU via the Power Adapter Kit.
WARNING
The IRM/IMU card +24V DC MUST be supplied from the LPU and NOT from the HPU -24V DC. Failure to observe this will result in immediate damage to cards in the rack. If the IMU uses this to power its logic, then this reduces the number of I/O cards that can be fitted to the controller; see the ST900 Family General Handbook.
WARNING The SDE/SA card +24V DC MUST be supplied from the LPU and NOT from the HPU -24V DC. Failure to observe this will result in immediate damage to cards in the rack.
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4.10 I/O Cards The I/O card provides a rugged interface for up to 24 digital inputs and up to 16 changeover outputs for the connection of pushbuttons and above ground detectors, or to provide a free-standing UTC Interface or for linking between controllers. A sub-equipped variant of this card is also available, fitted with only 4 changeover outputs. If the IC4 Configuration requires the 24 in / 4 out variant but one is not available, then a 24 in / 16 out card can be fitted in its place. The I/O card connects to the PHS or previous I/O card via a high-speed serial cable through which the card also obtains its logic power supply. The first three I/O cards may be fitted in the primary cabinet. Additional I/O cards may be fitted in an adjacent expansion cabinet.
Note The number of I/O cards that may be fitted is subject to limitations. See the ST900 Family General Handbook for details.
Note The IO card is safety-protected by a fuse. Situated beneath the metal cover plate. Should the fuse fail, the card will indicate a major fault and the card should be replaced. Do not replace the fuse as the card will have been damaged and must be replaced.
Figure 23 – I/O Card (Showing 16-output variant)
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Figure 24 – I/O Card Address Switch and LEDs
4.10.1 I/O Card LEDs The I/O card has three tri-colour LEDs as shown in Figure 24, which are used to indicate various conditions, as follows:
Comms Active LED (LP1) Software Run LED (LP2)
Watchdog LED (LP3)
State
Yellow Yellow Off Processor Reset Yellow Yellow Red Watchdog Failure
Off Green Steady Off Performing Start Up Red Green Flash Off Awaiting Start
Green Toggle on Receipt of Message*
Green Flash Off Communications Active
Off Green / Red Alternating
Off Invalid Address
(As above depending on state)
Red Flash Off Major Fault Detected
* - May flash so fast it looks Green Steady. Table 8 – I/O Card LEDs
Conditions other than those identified above should not occur and can be treated as faults.
4.10.2 I/O Card Rotary Address Switch This screwdriver-adjustable switch is located on the I/O card(s) as shown in Figure 24 and is set up for the card address (before the controller is powered up) in accordance with the appropriate Works Specification. The valid address range is 1 through 15 (where A to F denote 10 to 15 respectively). Address 0 is the default address switch position for spare cards. The address range is shared with the Intelligent Detector Backplane cards and must be unique.
4.11 Intelligent Detector Backplane Cards There are currently two types of Intelligent detector backplanes they are similar and the differences will be shown below the features are the same unless specifically states as being on
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only one version. All ST950 production since the end of 2013 will use the enhanced Intelligent Detector Backplane. The enhanced IDB can in all cases be used to replace the original version. The Intelligent Detector Backplane provides an interface for up to 4 loop detector cards, each loop detector card connecting to 4 loops. The Intelligent Detector Backplane connects to the PHS or previous Intelligent Detector Backplane via a high-speed serial cable through which the card also obtains its logic power supply. The Loop Detector supply is cabled separately as shown in Figure 25. This supply is normally -24V DC from the HPU, but can be provided from a separate transformer. A twisted ribbon cable provides the connection between the loop detector cards and the road loops, via the loop termination card.
Figure 25 –Original Version Intelligent Detector Backplane (rear view)
In addition to the above features the enhanced Intelligent Detector Backplane allows the IR linking employed by the SLD4 detectors to be extended to additional racks or past partitions in the rack. It also has additional protection to allow high current cards such as the Wimag Interface card to be used in the same backplane.
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SLD4IN
SLD4OUT 1A Blade fuse
Figure 26 –Enhanced Intelligent Detector Backplane cards separated for clarity
Figure 27–Extending the IR link between Intelligent Detector Backplanes 667/1/32910/950
Short Cable 667/1/32994/001
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The SLD4 auto configuration facility utilises an infra-red dedicated communication link between SLD4 detectors cards. Some configurations of detector backplanes such as that utilised on the ST900ELV don’t allow all the detectors to communicate. A new Intelligent detector backplane allows this IR link to be extended between racks with a wired connections. The diagram above is the 667/1/32910/950 Variant of the IDB with the top card removed so that the position of the new connectors and fuseholder can be seen. In normal use it is not necessary to remove the card in order to fit the plugs as they are at right angled to the board facing up and down respectively. The 667/1/32910/950 IDB provides 2 additional connectors labelled SLD4IN and SLD4OUT. These connectors are on the Passive part of the IDB. In addition the new design incorporates a 1A blade style fuse to protect the backplane from faults on other linked backplanes. From the diagrams above the normal configurations can be seen. It is not necessary to wire link adjacent backplanes on the horizontal plane if there is no physical barrier between them and they have a no gap between them. Where more than one backplane exists in a row, then the left-hand backplane of the top row should be linked to the right-hand or lower backplane of the following row. There are available two cables for this purpose, 667/1/32994/001 (190mm long) and 667/1/32994/002 (590mm long). Only the 667/1/32994/002 variant will be will be carried as a maintenance spare. Where adjacent backplanes are to be linked because of a physical barrier between them, then the SLD4OUT of the left-hand backplane is linked to the SLD4IN (top connector) of the following backplane. It is recommended that SLD4 cards and WiMag detector replacement cards are not fitted into the same backplane. Under fault conditions it can cause damage to the SLD4 detector cards and the problem can be difficult to trace since the Wimag detector replacement cards will appear to be functional.
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4.11.1 Intelligent Detector Backplane Card LEDs The Intelligent Detector Backplane Card has three tri-colour LEDs, which are identical to the LEDs on the I/O card as described in section 4.10.1 above. It should be noted that these LEDs are viewed from above and are seen in reverse order (i.e. LP3, LP2 and LP1 from left to right). For this reason, the table below shows the LEDs in the order they are seen. Watchdog LED
(LP3) Software Run
LED (LP2) Comms Active LED
(LP1) State
Off Yellow Yellow Processor Reset Red Yellow Yellow Watchdog Failure Off Green Steady Off Performing Start Up Off Green Flash Red Awaiting Start
Off Green Flash Green Toggle on Receipt of Message*
Communications Active
Off Green / Red Alternating Off Invalid Address
Off Red Flash (As above depending on state)
Major Fault Detected
* - May flash so fast it looks Green Steady. Table 9 – Intelligent Detector Backplane Card LEDs
Conditions other than those identified above should not occur and can be treated as faults.
4.11.2 Intelligent Detector Backplane Card Rotary Address Switch This screwdriver-adjustable switch is located on the Intelligent Detector Backplane card(s) as shown in Figure 25 and is set up for the card address (before the controller is powered up) in accordance with the appropriate Works Specification. The valid address range is 1 through 15 (where A to F denote 10 to 15 respectively). Address 0 is the default address switch position for spare cards. The address range is shared with the I/O cards and must be unique.
4.11.3 Loop Detector Power The power for the Loop Detector cards is taken from the 12-way Loop Detector Supply Terminal Block, TBZ, on the side termination panel or from a separate -24V DC supply. See Figure for the power connections on the Intelligent Detector Backplane. The Loop Detector Supply Termination Block, TBZ, is powered from the HPU and is capable of supplying a maximum of 2.8A at -24V DC for AGDs and Loop Detector Cards.
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If the total current drawn by the Loop Detector Cards and AGDs exceeds 2.8A, then an additional power supply must be fitted into the cabinet. Both 50VA and 160VA DC kits are available; see the ST900 Family General Handbook.
Figure 28 – SK6 and SK7 Connections for Loop Detector Power
4.12 ST4S The Loop Detector cards pick up the Loop Detector Power from SK7 on the Intelligent Detector Backplane Card. that they are plugged into. Further information regarding ST4S Loop Detector Cards is available in the following document:
667/HB/27663/000 - ST4R Loop Detector Handbook
4.13 LSLS Card and Backplane The LSLS card provides 32 current and voltage monitored switched outputs to the ELV signal aspects. Each LSLS card is fitted into an LSLS backplane on the side panels of the cabinet. A maximum of 3 LSLS cards can be fitted into an ST900 ELV controller cabinet. A further 3 additional LSLS cards can be fitted in an adjacent expansion cabinet. The LSLS backplane terminates the street cabling, allowing connection of up to 4 wires for each of the 32 aspect drive outputs and gives a total of 64 return terminations. IC4 can be used to print self-adhesive labels for the LSLS backplane to identify the phase and colour of each street termination. In addition, the LSLS backplane provides a connection for the power supplied via the HPU; daisy-chained connections for the high-speed serial communications from
SK6
SK7
OUT
IN
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the PHS card or previous LSLS card; inputs for monitoring regulatory sign current and a means of setting the address of the LSLS card. Each of the 32 outputs has an associated LED showing the status of that output. The LED is tri-colour and should be the appropriate colour assigned to the output (except during Self Test when all LED’s illuminate yellow).
Figure 29 – LSLS Card and Backplane
4.13.1 LSLS Outputs The LSLS outputs can be configured to be lamp monitored. Typically, outputs that drive Aspects, Pedestrian Waits, Pedestrian Red and Green Nearsides and Demand/Wait Indicators can be lamp monitored. Outputs that drive Tactiles and/or
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Audibles cannot be lamp monitored due to the nature of the load that these devices present to the LSLS. Where an output is used to drive a combination of Pedestrian Nearside Green and Audible and/or Tactile units, it is NOT possible to enable lamp monitoring on this output. See the ST900 Family General Handbook for the number and combinations of devices that can be fitted to an LSLS output.
4.13.2 LSLS Addressing The LSLS card address is set by physically removing one or more of the resistors labelled R1 to R4 on the LSLS backplane. This is done during manufacture, but if an LSLS backplane is replaced in the field, it is important that the card address is configured correctly. The valid address range is 1 through 6. Figure below shows the address set to 1. Configuring the address simply requires that the resistors are completely removed by cutting through the component legs. The address range is NOT shared with the I/O cards or Intelligent Detector Backplanes. The address is set according to the following table:
Note If an address is incorrectly configured, the missing resistor(s) can be replaced with wire links soldered directly across the copper pads.
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Figure 30 – LSLS Card Addressin
Address set to 1
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4.13.3 LSLS Status LEDs The LSLS has two tri-colour status LEDs as shown in Figure which are used to indicate various conditions as follows. Conditions other than those identified should not occur and so can be treated as faults.
LED A LED B Meaning Possible Cause Yellow Yellow Reset Start up (if brief)
Comms lost to main processor (if brief) Hardware fault (otherwise)
Red continuous
any Major fault The LSLS has detected a major fault
Alternate green Peripheral download
LSLS powered up with peripheral download link present
Off Red flash
Awaiting start LSLS powered up Comms lost to main processor
Off Yellow flash
Downloading Main processor is downloading to LSLS
Off Green flash
Normal operation
Download complete and comms with main processor established.
Table 11 – LSLS LEDs
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4.14 Manual Panel The Manual Panel provides a direct means of manually controlling the junction in a safe manner. The card connects directly into the rear of the CPU as shown in Figure 17 on page 38.
SIEMENS
1 2
3 4 5
6 7
AUX 1 AUX 2 AUX 3
SW 1 SW 2 SW 3
MANUAL CONTROLS
CABINETALARM
ALLRED
PROHIBITEDMOVE
CABLELESSLINK
HIGHERPRIORITY
(AUX5)
HURRYCALL
(AUX4)
FIXEDTIME
LAMPTEST
MODESELECT
VA
MANUAL
SIGNALS OFF
ON
NORMAL
COMMANDAWAITING
Figure 31 – Manual Panel
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4.14.1 Manual Panel LEDs
The LEDs on the Manual Panel are used to identify which stage is active and to display status. Several versions of the Manual Panel are available and some of the indicators in the following summary may not be present in a particular example. MANUAL BUTTON INDICATORS
Indicate the stage (or combinations of stage for parallel stage streaming) that the controller has reached when in manual mode. While the controller is moving to the stage, the indicator flashes. When the stage is reached, the indicator stops flashing and remains illuminated.
MODE SELECT
Indicate what mode has been selected. If the mode is unavailable, then the indicator flashes. Note that during the start-up sequence, the indicator for the selected mode flashes, since the controller is in start-up mode, which is always the highest priority. When the start-up is complete, the indicator for the selected mode normally stops flashing and remains on steady. If ‘Normal’ mode is selected, then the controller also illuminates one of the other mode indicators if the controller is running that mode, e.g. VA.
AWAITING COMMAND LED
Under manual control only, this LED illuminates at the end of the minimum green period, signifying that a new stage may be selected by the stage select pushbuttons. Selection of a stage before the LED is lit is prevented and any such selection is ignored.
PROHIBITED MOVE LED
This LED illuminates if a prohibited stage to stage movement is attempted while under manual control. It remains illuminated until a permitted move is made.
HURRY CALL (AUX 4) LED
Illuminates during all modes of control when there is a hurry call being serviced, or can be configured for an auxiliary function.
HIGHER PRIORITY (AUX 5) LED
Illuminates when there is a mode with a higher priority than manual mode, such as UTC Control, or can be configured for an auxiliary function.
AUX 1 - AUX 3 LEDs
These LEDs can be configured to display auxiliary functions active such as Dim Override.
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4.14.2 Signals On/Off Switch
The lamp supply to the phase switch cards is removed immediately OFF is selected on the SIGNALS OFF/ON switch, extinguishing the signals.
WARNING Care should be taken to ensure safe traffic conditions before operating the switch.
With the OFF position selected, normal microprocessor control operations continue and the phase selections being implemented can be observed on the Lamp Switch indicators. When the switch is returned to the ON position, the signals turn on in the required switch on sequence.
4.14.3 Lamp Test Key
A key on the Manual Panel enables the indicators on the panel, including the Cabinet Alarm Lamp, to be checked. When the key is pressed, all LEDs on the Manual Panel should light. The lamp test is carried out under software control, and although correct results indicate that the processor is communicating with the Manual Panel, it does not guarantee that no faults are present.
4.14.4 Stage Select Pushbuttons (All Red, 1 - 7)
With Manual mode selected (Manual LED lit), the keys ALL RED, 1 - 7 select the configured stage (or combination of stages) provided the AWAITING COMMAND indicator is illuminated and a prohibited stage move is not requested.
4.14.5 Mode Select Pushbuttons (Manual, VA, Fixed Time, Etc)
These keys select the required mode for the controller. The controller can be configured so that manual mode is only available if a handset is plugged in. An alternative configuration is such that manual mode may only be selected following a specific handset command (see MND command).
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4.15 Audible Driver Module
4.15.1 Audible Driver Module - Single Output type (obsolete) The original style of Audible Driver Module (pictured in Figure below) was able to drive either loud or quiet audible indicators, but not both. This module has been superseded by an updated version (see section 4.15.2) which offers backwards compatibility, but also permits both loud and quiet audible indicators to be driven from a single module. Information on the original single-output module is retained here to allow servicing of the original module. In order to drive audible indicators, an Audible Driver Module Kit of Parts is required. The module is powered from the phase Green of the relevant pedestrian phase output of the LSLS card and provides a regulated 12V DC to the audible indicators. The module can be connected to an I/O card to allow operation to be inhibited (for example at night). The Audible Driver Module will operate at both dim and bright lamp voltages.
Figure 32 – Audible Driver Module – Single Output type
The Power Present (PP) LED on the module lights when the audibles are being driven. Each Audible Driver Module can drive up to 8 audibles. It is recommended that all audibles connected to an Audible Driver Module are the same type. Audible indicators recommended are:
The above indicators are functional equivalents. Any audible indicator that operates from a nominal 12V DC supply and takes a maximum of 18mA may be used as an alternative to the above.
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The Audible Driver Module is connected as shown in Figure 33 below and is mounted on the rear panel in the controller cabinet using the screws supplied in the KOP. Where more than 8 audible units need to be driven simultaneously, it is acceptable to connect up to 4 Audible Driver Modules in parallel to each LSLS output, giving up to 32 audible units per LSLS output. In order for the Audible Driver Module to operate, the two “Inhibit +” and “Inhibit –” connections on the Audible Driver Module must be shorted together. Where it is desired to switch off the Audible Driver at certain times of the day, the Inhibit connections can be connected to the ‘Common’ and ‘Normally Open’ connections of an I/O card. Where two Audible Driver Modules are connected in parallel, it is important that the “INH -” connections are paralleled and the “INH +” connections are paralleled. Do NOT connect “INH +” of one Audible Driver Module to “INH -” of another.
Note Tactiles and/or Audibles must not be paralleled with Pedestrian Greens if the Pedestrian Green is to be lamp-monitored.
A maximum of 4 Tactile Units and 1 Audible Driver Module (8 sounders) or 2 Tactile Units and 2 Audible Drivers (16 sounders) can be simultaneously driven from one LSLS output.
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Figure 33 – Audible Driver Module Connections – Single Output type
4.15.1.1 Monitored Audibles – Single Output type
The /002 variant of the Audible Driver Module has an opto-isolated Monitor Output that is open-circuit when the audible is voltage is less than 5V and short-circuit when the audible output has a voltage present of more than 5V. This allows independent monitoring of the voltage on the audible output. The Monitor Output can be wired directly to an input of the I/O card.
4.15.1.2 Dual Level Audibles – Single Output type
The recommended technique for connecting Dual Level Audibles (for the single-output type) is shown in Figure 34.
LSLS O/P
LSLS Return
Numbered signal output
Return
Audible +
Audible - -
+
Audible +
Audible - -
+
Audible 1
Audible 8
Audible Driver
Module(s) (4 max)
LSLS
I/O Card
INH -
INH +
Common
Normally Open Output
Input
Mon Ret * Mon O/P *
* Only on /002 variant of Module
Common
Input
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4.15.2 Audible Driver Module - Dual Output type In order to drive audible indicators, an Audible Driver Module Kit of Parts (KOP) is required – Siemens part number 667/1/32955/000. The module is powered from the phase Green of the relevant pedestrian phase output of the LSLS card and provides a regulated 12V DC to the audible indicators. The module can be connected to an I/O card to allow operation to be inhibited (for example at night), and to allow switching from Loud to Quiet audible indicators. The Audible Driver Module will operate at both dim and bright lamp voltages.
Figure 35 – Audible Driver Module The updated Audible Driver Module provides 4 outputs for Loud indicators and 4 outputs for Quiet indicators. A link position is normally fitted to connect these outputs together, giving 8 audible indicator outputs which are energised whether Loud or Quiet is selected (this gives full compatibility to the previous version of the Module). Cutting the output link allows separate control of Loud and Quiet outputs. Separate monitor circuits are provided for Loud and Quiet outputs, but note that Special Conditioning is required to perform the monitoring.
Quiet Audible +ve Loud Audible +ve
Audible -ve
Quiet PP LED Loud PP LED
CAUTION Do not touch components on the Module:
voltages of up to 81V peak could be present, and components could be hot.
Output link
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There are separate Power Present (PP) LEDs on the module, for Loud and Quiet outputs, which light when the audibles are being driven. It is recommended that all audibles connected to an Audible Driver Module are the same type. Audible indicators recommended are:
The above indicators are functional equivalents. Any audible indicator that operates from a nominal 12V DC supply and takes a maximum of 18mA may be used as an alternative to the above. The Audible Driver Module is mounted on the rear panel in the controller cabinet using the screws supplied in the KOP. When Loud/Quiet switching is not required, the Audible Driver Module is connected as shown in Figure 36 below. In order for the Audible Driver Module to operate, the EN (Enable) “+” and “COM” connections on the Audible Driver Module must be shorted together. Where it is desired to switch off the Audible Driver at certain times of the day, the Enable connections can be connected to the ‘Common’ and ‘Normally Open’ connections of an I/O card. When it is desired to switch audibles from Loud to Quiet operation (eg at different times of day), the Output Link (R40) must be cut, and Quiet audibles must be connected to Quiet Output + (QU O/P+) with Loud audibles connected to Loud Output + (LO O/P+). The LQ input “+” and “COM” must then be connected to the ‘Common’ and ‘Normally Open’ connections of an I/O card output, such that the LQ input is open circuit for Loud operation, and short circuit for Quiet operation. Where more than 8 audible units need to be driven simultaneously, it is acceptable to connect up to 4 Audible Driver Modules in parallel to each LSLS output, giving up to 32 audible units per LSLS output.
Note Tactiles and/or Audibles must not be paralleled with Pedestrian Greens if the Pedestrian Green is to be lamp-monitored.
Where two or more Audible Driver Modules are connected in parallel, it is important that the connections for EN and LQ are paralleled so that the “COM” connections both go to I/O card ‘Common’, and the “+” connections to I/O card ‘Normally Open’. Do NOT connect “COM” of one Audible Driver Module to “+” of another. See Figure 37. In systems with Audibles on more than one Green phase, there must be no connection of AUDIBLE COM or LQ/EN COM between the units. This requires that LQ and EN inputs are connected to separate I/O Card outputs. See Figure 38.
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Figure 36 – Audible Driver Module Connections – Loud only
4 Tactile Units and 1 Audible Driver Module (8 sounders) or 2 Tactile Units and 2 Audible Drivers (16 sounders) can be simultaneously driven from one LSLS output. Note 1: The MON COM connections are not connected to AUDIBLE COM or LQ/EN COM. AUDIBLE COM and LQ/EN COM are not the same as COMMON on I/O Card inputs: AUDIBLE COM and LQ/EN COM are connected to the LSLS I/P and are ‘energised’ when the green phase is active, whereas COMMON on the I/O Card input is grounded. Note 2: Output Monitoring is performed using Special Conditioning. If more than one Audible Module is connected, the Monitor outputs must be taken to separate digital inputs, with separate blocks of Special Conditioning code used to monitor each Audible Driver Module.
LSLS I/P
LSLS Return
Numbered signal output
Return
Loud O/P+
Audible COM -
+
Quiet O/P+
Audible COM -
+
Loud Audible 1
Loud Audible 8
Audible Driver
Module(s) (4 max)
LSLS
I/O Card
EN COM
EN +
Common
Normally Open Output
Input
Mon COM Mon ML
Common
Input
LQ COM
LQ + No connection
Mon COM
Mon MQ
No connection
R40 O/P+ LINK FITTED (8 Loud outputs)
Output monitoring Variant /002 with output monitoring is supplied as standard.
ST900 ELV Installation, Commissioning and Maintenance Handbook
(Monitoring not shown for simplicity – see Figure 36 )
LSLS I/P
LSLS Return
Numbered signal output 1
Return 1
O/P+
Audible COM -
+
O/P+
Audible COM
-
+
Phase 1 Audible 1
Audible 8
Audible Driver 1
LSLS
I/O Card
EN COM
EN +
Output Common 1
Normally Open 1
LSLS I/P
LSLS Return -
+
-
+ EN COM
EN +
Audible 8
Phase 2 Audible 1
Audible Driver 2
R40 O/P+ LINK FITTED
O/P+
Audible COM
O/P+
Audible COM
R40 O/P+ LINK FITTED
Numbered signal output 2
Return 2
Normally Open 2
Output Common 2
(Monitoring not shown for simplicity – see Figure 36 )
LSLS
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Figure 38 – Audible Driver Module Connections – Separate phases
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4.15.2.1 Connections for Dual Level Audibles - Dual Output type
The recommended technique for connecting Dual Level Audibles is shown in Figure 39. Link R40 must be cut. Although only 4 outputs are provided for each type of Audible, the Module is capable of driving up to 8 Audibles at Quiet or 8 Audibles at Loud (for example, using a white terminal strip to expand the wire connections). If it is not required to disable all audibles at any time, a local wire link from EN + to EN COM can be fitted instead of a connection to an I/O Card output. Separate monitoring of Loud and Quiet outputs is provided by the Audible Driver Module, but only one wire interconnecting the I/O Card ‘Input Common’ pins and the Audible Driver Module ‘Mon COM’ pins is required. Note that Special Conditioning is required to perform the monitoring.
LSLS I/P
LSLS Return
Numbered signal output
Return
Loud O/P +
Audible COM -
+
Loud O/P +
Audible COM -
+
Loud Audible 1
Loud Audible 4
Single Audible
Driver Module
LSLS
I/O Card
EN COM
EN +
Common
Normally Open (closed = enabled)
Quiet O/P +
Audible COM -
+
Quiet O/P +
Audible COM -
+ LQ COM
LQ +
Normally Open (open = Loud, closed = Quiet)
Quiet Audible 4
Quiet Audible 1
R40 O/P+ LINK NOT FITTED OR connect EN+
to EN COM with wire link (if inhibit function is not required)
Mon MQ
Mon COM
Mon ML
Mon COM
Outputs
Inputs
Input
Input
Common
Common
Common
Optional Variant /002 with output monitoring is supplied as standard.
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4.16 Pedestrian Tactile Indicators The ST900 ELV controller can be fitted with either switched or non-switched tactiles. Non-switched tactiles are wired directly across the pedestrian green. Whenever the pedestrian green is illuminated, the tactile rotates. These tactiles must not be used at crossings with a flashing green man period. The connections required for a non-switched tactile are shown in Figure 28 Switched tactiles are tactiles that can be disabled when required by use of an IO card output. The connections required for a switched tactile are shown in Figure 29 Some manufacturer’s tactiles (e.g. Radix Traffic ITE220) also have a fault output that can be wired back to an input of a digital IO card in the controller cabinet. This fault output has the following functionality: ITE220 Function Fault Output Tactile not powered Open-circuit Tactile powered and stalled (held or stuck) Open-circuit Tactile powered and motor open or short circuit Open-circuit Tactile powered and cone able to rotate Closed-circuit Special conditioning in the controller will discriminate between short-duration fault conditions (such as the tactile being temporarily held stalled) and a permanent fault that requires maintenance. The connections required for a switched tactile with fault output is shown in Figure 30 There are several mounting options for the tactile controller module;
When using tactiles with integrated motor and drive module, the assembly can be mounted in the pedestrian indicator.
When using tactiles with separate motor and drive module , the drive module can be mounted inside the nearest Helios signal head (the recommended position for mounting the tactile controller is at the top of the Amber aspect case – see Helios General Handbook 667/HB/30000/000) or the drive module can be mounted inside the traffic controller cabinet.
Figure 28, Figure 29 and Figure 30 show how tactiles can be connected to an ELV traffic controller.
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A maximum of 4 tactiles (either switched or non-switched types) can be driven in parallel from a single LSLS output.
Figure 28 – Pedestrian Green-Man drive and non-switched Tactile connections
Note Tactiles and/or Audibles must not be paralleled with Pedestrian Greens if the Pedestrian Green is to be lamp monitored.
Note
A non-switched tactile must not be used at a crossing with a flashing green man period. For crossings with a flashing green man period, a switched tactile must always be used and the tactile drive period limited to the solid-green period of the pedestrian green by means of the enable input of the tactile.
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Figure 29 – Pedestrian Green-Man drive and switched Tactile connections
Note The ITE220 should be installed in preference to the CU/TU100-48V
wherever possible
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Figure 30 – Pedestrian Green-Man drive and switched Tactile connections with fault output
WARNING Do not try to use a single common return between the tactile and the IO card (ie do not link the IO card “Input Common” to “Output Common”)
Note
If wiring tactiles in parallel: Connect Enable + of each tactile together and Enable – of each tactile together (if used) Similarly, connect the Fault Output + or each tactile together and Fault Output – of each tactile together (if used)
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4.17 ELV Solar Cell The ELV Solar Cell connects directly to the HPU connector SK2 as shown in Figure 31 below. The solar cell is powered from -24V DC from the HPU.
Note For the controller to be able to switch between dim and bright correctly, it is important that LSLS1 is connected to the PL4 of the HPU.
Figure 31 – Solar Cell Connections
Black
Red/Black
HPU
SK2
White
SOL +
SOL -
SOL SIG
ELV Solar Cell
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4.18 Above Ground Detectors Above-ground detectors provide detection for pedestrians and vehicles. The power for the detector is taken from the 12-way Loop Detector terminal block or, if more current is required than this supply can support (2.8A) a separate -24V DC supply (2A or 6A) can be fitted. The detector outputs connect directly to the I/O card inputs. See the documentation relevant to the particular detector devices being used.
Figure 32 – Above-Ground Detector Connections
4.19 Regulatory Signs Expansion Kit The regulatory sign expansion kit is required whenever the number of ELV regulatory signs exceeds the basic capacity of the ST900ELV (8 signs). It consists of a separate transformer and pcb module for powering a further 12 signs. Lamp monitoring is performed (if required) by two LSLS external monitor input channels. The wiring between the transformer and pcb module is detailed by drawing 667/GA/33070/000 (sheet 2) which is supplied with the ELV Regulatory Sign Extension Kit. The kit is installed above the HPU on the left hand wall of the controller cabinet with the additional transformer mounted above the pcb module.
Det Com
Det Sup (-24V DC)
+ - Detector
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Figure 33 Regulatory Expansion PCB Module
Care should be taken to avoid direct contact between the cabling and the heatsink at the rear of the expansion kit module. The module is secured to the cabinet with 4 screws (supplied with the kit). The transformer is attached to the cabinet directly above the pcb module. The street cabling to the regulatory signs is connected to the cage-clamp connector block located on the expansion kit pcb module. Up to twelve regulatory signs may be connected, arranged in two groups of six [These are labelled REG1..REG12 on the pcb ident. in the same manner as the HPU reg. sign connections]. The connection point closest to the p.c.b. is the common return connection. A common return may be utilised for regulatory signs. If using a common return, ensure the cable loading limits are not exceeded. Two twisted pair cables connect the LSLS module external (toroid) inputs to the current output connectors of the module. These are located at either end of the pcb module and use four way Molex style connectors.
Note Take care to observe the polarity of the connections when terminating the cable at the LSLS cage clamp connector. The blue wire must be closest to the pcb.
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Figure 34 LSLS Cable Terminations from Expansion Kit
Figure 35 Expansion Kit Installed The transformer has two independent secondary windings. These must be connected to the pcb module with full observance of the colour coding indicated on the wiring diagram. The secondary windings attach through the separate six way cage clamp connector. Do not earth either winding at the transformer. The earth connection should be made at the central connection point of the p.c.b. module power connector. Refer to drawing 667/GA/33070/000 for further details. Each regulatory sign consumes about 7 Watts; for six regulatory signs, the lamp load would be 7 x 6 = 42 Watts
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4.20 Detector Power Extension Kits (667/1/33075 (50VA) and 667/1/33074 (160VA))
The number of detectors which can be powered from the ST900 may be extended by the addition of a 50VA or 160VA additional power supply kit. The photograph shows a 50VA kit partially installed in a 40Amp controller (two HPU’s).
Figure 36 50VA Detector Extension Kit installed
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The detector power kits are mounted within the cabinet above the HPU units on the left hand side of the controller cabinet. Mains power is derived from the master control switch panel. The rectified DC supply is generated by a bridge rectifier which is also mounted to the cabinet. The output of the supply is available at a terminal block to the right of the transformer. This is labelled as shown below:
Full installation detail can be found in drawings 667/GA/33075/000 and 667/GA/33074/000. The secondary windings of the transformer should not be earthed directly.
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4.21 ELV Compatible Nearside, Wait and Demand Compatible units are clearly marked with ELV labels both externally and internally. However, PCB assemblies can become swapped during servicing which may then cause lamp monitoring failures. The Siemens Nearside and Wait/Demand units are only fully compatible with ELV controllers when fitted with PCB. issues as shown in the table below.
Nearside Unit PCB Assembly ELV Compatible Nearside Aspects 667/1/30695/001 Issue 9 and above. 667/1/30695/002 Issue 9 and above. 667/1/30695/003 Issue 9 and above. 667/1/30695/004 Issue 10 and above. 667/1/30695/005 Issue 9 and above. 667/1/30695/006 Issue 10 and above. LED Wait 667/1/30211/001 Issue 4 and above. LED Call Demand 667/1/30680/001 Issue 3 and above.
Visual identification of the ELV compatible assemblies is described within the Appendix – Visual Identification of ELV PCB. assemblies in the Helios General Handbook 667/HB/30000/000 revision 14 onwards.
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55.. FFIITTTTIINNGG TTHHEE CCOONNTTRROOLLLLEERR IINNTTOO AALLTTEERRNNAATTIIVVEE CCAABBIINNEETTSS The controller rack may be fitted into enclosures other than the single sided ST900 ELV cabinet. In the UK, the controller may only be fitted into an HA-approved enclosure. The procedure for fitting an ST900 ELV controller into an alternative enclosure is very dependent on the type of enclosure and the type and position of existing equipment. For this reason it is not possible to define in detail exactly what needs to be done but generally the procedure follows that described in sections 6 and 7.
Note Detailed installation instructions are included in the drawings contained in the kit relevant to the cabinet.
When fitting an ST900 ELV controller into an enclosure other than an ST900 ELV cabinet, a different type of 6U rack is required (a so-called ‘cuckoo’ rack). This rack houses up to three LSLS cards and has two 3U high bays which can be fitted with up to two Intelligent Detector Backplanes, supporting a maximum of eight Loop Detector cards.
Figure 37 – ST900 ELV Rack for fitting in Alternative Cabinets (front)
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Figure 38 – ST900 ELV Rack for fitting in Alternative Cabinets (rear)
In a ‘cuckoo’ rack, the RJ45 serial cables between the PHS card and the LSLS cards are replaced by 10-way ribbon cables connected in a daisy-chain between the PHS card and the LSLS cards across the front of the rack. The address of each LSLS card is set by connecting the appropriate ADDRESS pin to ADDR_RET on the rear connector as shown in Figure 39.
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d b z 2 Output 32 4 Output 31 6 Output 30 8 Output 29 from HPU
6.1 Service-Centre Cabinet Testing With reference to the Works Specification, check that:
- The cabinet is free from external physical damage - The correct cards have been supplied and fitted in the correct positions. - The PROMs and other socketed devices are securely fitted. - The correct configuration PROM is fitted to the main processor card - The links and address switches are correctly set on each card - All fuses are fitted securely and are of the correct rating - The primary connections to the Lamp Supply Transformer have been set to
the correct voltage - The connections between the Lamp Transformer secondary and the HPU are
correct and are secure - All plugs and sockets are securely mated - All fixings are tight – especially those securing cards to side or back panels of
the cabinet. Power the cabinet on and run the self-test (see Section 10) Using the handset command “CIC” ensure that the number reported agrees with the CIC printed on the IC4 printout Using the handset command “CRC” ensure that the CRC reported agrees with that printed on the IC4 printout. Finally, before the cabinet leaves the Service Centre:
- Tighten the screws on the swing-frame - Place the Junction Plan, the IC4 Printout and the Site Logbook into the
pocket inside the door of the controller - Close and lock the controller door with both key and T-bar locks - Re-package the cabinet with the protective packaging.
Note The key lock should not be operated unless the screw locks are tight, i.e. Unlock the case before undoing the screw lock and only lock the case after tightening the screw locks.
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6.2 Checking Site Suitability The controller outer case is installed to suit local conditions, but subject to the following limitations:
(i) The position of the controller is as shown on the relevant site-to-scale drawing, (STS)
(ii) No part of the controller is less than 457mm (18 inches) from the kerbside
unless agreed with the customer.
When it is necessary to site the controller less than 2 metres from the outer edge of the kerb, the access doors and panels should not open over or toward the carriageway. Where no pedestrian guard rails are fitted, then a clearance of at least 600mm shall be left between the outer case and kerb edge so that guard rails may be installed at a later date without the need to disturb the controller installation.
(iii) The controller door(s) should be easily accessible and not extend over the
roadway or obstruct the footpath when opened. The door describes an arc of approx. 710mm radius from the left-hand front corner. Note that the controller door swings open through 180 .
(iv) Any person having control over the junction, whether manual control or test
box simulation, MUST have a good view of the intersection. (v) When the controller is to be located on unmade ground (e.g. a grass verge)
it is recommended that paving slabs or a concrete standing be provided at ground level under all access doors and panels. The hard standing shall extend a minimum distance of 900mm away from the main doors, extending the full width of the case, and at least 800mm away from the side of the case with a flap, again extending the full width of that side.
Customers may specify particular requirements. The door of the controller must have ground clearance of at least 30mm over its whole opening arc.
6.2.1 Site Cable Installation If new site cabling is being installed, refer to the following:
667/DS/20664/048 - Traffic Signal Junction Cable Design & Certification for ELV Systems
If common neutral return connections are used it is possible for the failure of a return connection to cause unexpected signal displays, where one or more signals within a given signal head are incorrectly
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illuminated simultaneously. This lack of neutral return connection is not detectable by the controller because the signal voltage presented at the controller terminals does not exceed the required thresholds for conflict or correspondence monitoring. It is therefore essential that individual neutral returns are used for each green signal.
Note The signal connections in the pole cap MUST be kept physically apart from other connections (AGDs etc) in order to minimise the risk of short-circuits between the two.
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6.3 Cabinet Installation Prior to any installation works, firstly make sure that the cabinet has been delivered to site without external physical damage. The electronics should be removed from the controller and stored separately if:
- the controller cabinet cannot be made waterproof - the cabinet will be un-powered and may suffer from condensation,
moisture ingress and/or animal/insect infestation - there is a risk of the cabinet being damaged on-site - the cabinet will be left in an un-powered state for a prolonged period.
6.3.1 Order of Installation
Remove the electronics from the controller Remove the stool from the case, if not already separate Remove the CET bars from the stool Install the stool into the ground Run cables to the controller. Re-fit the CET bars to the stool Terminate the cable armouring to the CET bars Test the cables Re-fit the controller case to the stool In-fill the stool Seal the base Refit the electronics
6.3.1.1 Removal of Controller Electronics
Ensure the Master Switch is in the OFF position Remove all PCBs and the Mains Distribution Unit from the rack. Swing the rack forward and unscrew the retaining bolts for the back plate of the rack. Tie this plate to a convenient point on the rear face of the cabinet. Lift off the complete rack assembly from the hinge pins. The controller outer case is now ready for installation.
6.3.1.2 Removal of Stool from Outer case
This action may not be necessary as some controllers are delivered to site with the stool already separate from the outer case ready for installation. If they are assembled, separate the stool by removing its four nuts, bolts and washers and lift the rest of the assembly off the stool.
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The recommended method of installation is to install the stool without any CET bars or Master Switch Panel. As an alternative the outer case, stool and CET bar(s) only may be installed as a complete assembly. However, firstly the outer case and stool must be separated to fit the seal
6.3.1.3 Removal of CET bars
The CET bars are fitted to the outercase by nuts, bolts and washers, which should be removed and stored with the bars.
6.3.1.4 Installation of Stool
A hole should be dug and a flagstone at least 900mm x 600mm embedded securely at the bottom of the hole. Refer to Figure 41 for the general method of installation and dimensions. Ensure that enough clearance is left around the stool to enable the fitting of the CET bars and outercase fixings. If the controller is being installed on a slope, allowance must be made for the opening of the door adjacent to the uphill side. The controller stool is placed in the centre of the flagstone with the top surface between 50 and 75 mm above the final ground level. It is essential that the stool be fitted the correct way round with the holes to the front, as shown in Figure 41. Adjustment may be required to ensure that the outercase sides are vertical; this should be checked using a spirit level. Mix up a stiff mixture of concrete (mix: 1 cement, 3 sand, 4 coarse aggregate (20mm) with no excess water) and cover the flagstone to a height approximately 100mm (4") above the bottom of the stool. The concrete must be sloped to provide a run up for the cables. Any cables already entering the pit must be held away from the wet concrete. Where there is a risk of freezing, then a suitable antifreeze additive shall be incorporated in the concrete mix to ensure proper curing.
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Figure 41 - Stool Installation
6.3.1.5 Cable Installation to Controller
Wiring runs should be made neatly and routed to allow enough spare cables for possible changes/additions at a later date. Spare cores are to be bundled and routed to a convenient position clear of the mains. The ends are to be insulated to make the loom secured. Spare cores of ELV cables are to be loomed separately to the cores of LV cables. Note: normally spare cores are earthed at the controller end, as this makes Periodic Inspection Insulation Resistance testing much easier. If cable idents are required then these are fitted to cores before termination. All cables into the controller should be fed into the outer case as close to their termination positions as possible. This is to prevent unnecessary damage being caused should any cables need to be moved once they are in place. Care must be taken not to obstruct the Electricity Supply Company cut out with any cabling.
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6.3.1.6 Refitting CET bars
Re-fit the CET bars in the most suitable positions to suit the cable run.
6.3.1.7 Terminate the cable armouring
The outer sheathing must be stripped to expose the armouring. It is suggested that between 15mm and 30mm of the inner sheathing Is left above the CET bar. A further conductor length must also be allowed, sufficient to reach the terminal blocks via the proper routing. The cable is inserted in the CET ring and the armoured wires are bent outwards and down against the ring. A hose clip is then placed over the armoured wires and tightened up. The cable sleeve must be stripped from the armouring approx. 0 to 2mm below the level of the CET ring. See Figure 42 for details. The inner sheathing is removed to expose the individual leads, which are connected to associated terminals, leaving sufficient spare length for re-making off the ends should this become necessary. Unused leads should be left with sufficient length to enable them to be connected to any terminal should this subsequently become necessary. When the detector loop tails have been terminated, the connection to the Loop Detector Termination Board must be made with wires twisted together as pairs.
Cables must be identified as to their destinations. Additional cable idents may be required on specific contracts. After the site cabling has been terminated, additionally check:
- The cable connections to the CET bars are tight - The street cables are terminated correctly into the appropriate connectors.
6.3.1.8 Cable Testing
Site cabling must be tested against the requirements of the following: 667/HE/20664/000 – Installation and Commissioning Handbook – Installation Testing (General)
Note 667/HE/20664/000 (issue 12 or later) has been updated to include important information regarding the testing of cables on an ELV site. Do NOT test ELV site cabling without reference to this document!
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Cores
Ident
Stud
Nut
CET Bar
Inner Insulation
Ident(Alternative position)
Incoming Cable
SIDE VIEWMounted at CET Lower Fixing Position
Earthing Band667/2/02348/000
Wormdrive Hose Clip991/4/01375/028
PLAN VIEW
(Armouring not shown atfront of ring for clarity)Lower CET
Fixing Position
Higher CETFixing Position
55mm to65mm
CET Ring(Earthing Band)
Hose Clip
Figure 42 - Termination of Armoured Cable to CET bar
6.3.1.9 Re-fit the Cabinet to the Stool
If the controller cabinet was not installed with the mounting stool then it should be done as follows: Clean the top surface of the stool and the lower surface of the cabinet that will be in contact when the cabinet is fitted.
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The cabinet is installed by lowering it onto the stool and fitting the retaining bolts. When fitting the cabinet onto the stool, make sure that all the cables are in their correct position with regard to the CET bar. Once the cabinet has been secured, moving of the cables could cause damage.
6.3.1.10 Back-fill and In-fill the Stool
On completion of the cable tests the controller cabinet and stool can be back-filled by the civils team using the appropriate material for the site layout. Once the back-fill is completed in-fill with kiln dried sand , taking care that the compacted sand is at ground level when finished. If any of the cables were replaced or moved during the installation of the controller cabinet then the kiln dried sand in-filling must be made good before the sealing compound is introduced. NOTE: The back-fill must be brought to a level such that once the decorative top surface is completed that the finish is at the surrounding ground level, particularly paying attention to any hard standing around the controller base.
6.3.1.11 Sealing the Base
To prevent condensation and infestation in the controller cabinet the base MUST be sealed as soon as possible after the controller has been installed. If any of the cables were replaced or moved during the installation of the controller the kiln dried sand in-filling must be made good before the sealing compound is introduced. NOTE: - The in-filling, kiln dried sand, must be brought to ground level or above and compacted. Make sure that the kiln dried sand is level or slightly sloped down where it meets the cables so it will not prevent the sealant meeting the cable. The sealant should be poured all around the cables and to a height which, when the sealant is set, gives a total covering not less than 6.5mm thick over the base of the controller cabinet base. Use between 2.0 to 3.0 litres of approved epoxy resin for the large controller cabinet base and 2.0 Litres for the small controller cabinet base this will give an adequate and even cover. This will act as a preventative barrier against the ingress of moisture and animal/insect infestation. A concrete fillet around the outside of the stool may be completed before or after the epoxy sealing to suit site conditions.
Warning! Should the controller cabinet base/stool NOT be in-filled with kiln dried sand and sealed with an approved epoxy resin the controller electronics/electrical circuits may be damaged.
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6.3.1.12 Re-fit the Controller Electronics
Re-fit the electronics into the controller case, checking that:
- All cards are seated correctly in their sockets - The primary connections to the Lamp Supply Transformer have been set to
the correct voltage (Refer to section 4.1.1) - The connections between the Lamp Transformer secondary and the HPU are
correct and are secure - All plugs and sockets are securely mated - All fixings are tight – especially those securing cards to side or back panels of
the cabinet.
6.4 Controller Commissioning
6.4.1 Controller Setup Remove the CPU card from the controller and remove the Lithium battery on the main processor , discarding the plastic insulator strip. Reinstall the battery with care and replace the CPU card
6.4.2 Lamp Transformer Measure the incoming mains voltage and wire the transformer tappings as described in section 4.1.1
6.4.3 Setting Controller Time and Date
- Open the Manual Panel door and set the SIGNALS ON/OFF switch to OFF - Switch the controller on - Via the serial handset, using the TOD command, enter the current date and
time into the controller - Switch the Controller off.
6.4.4 Lamp Testing Ensure that the signals are switched OFF and run the controller self-test (see section 10). This illuminates each colour on each phase in turn for approximately 40 milliseconds. If there is any short in the cables the outputs are protected against damage. Following this test, use the LMP command to cause each colour on each phase to come up in turn whilst other persons are checking the aspects.
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WARNING All aspects under test must be covered Remove the power to the controller, switch the SIGNALS ON/OFF switch to ON and power the controller up normally.
6.4.5 Solar Cell Testing If the solar cell is fitted, carry out the following test:
Cover the solar cell for at least one minute to exclude any light and check that the signals are dimmed as requested. Remove the cover from the solar cell and the signals should revert to the bright condition.
6.4.6 Lamp Monitor Testing Use the handset commands “KLR=1” and KML=1” to force the controller to learn the lamp loads and force demands for all phases (including bright/dim changes) The handset will indicate “COMPLETE” once all lamp loads have been learned. Use the KEL command to display the learned lamp load in Watts and verify that the loads are as expected.
6.4.7 Junction System Testing Using the detect lights on the AGDs, ensure that all AGDs (Kerbside and On-Crossing) are functional and have the required zone of detection. Using the handset command “IOP” check that all road detector loops, AGD’s demand pushbuttons etc are correctly connected. Clear all faults in the log and allow the junction to run normally. Periodically check the log and ensure that no faults are raised. Verify that the controller has the correct date and is keeping correct time.
6.5 Customer Acceptance Run through the commissioning with the customer. Sign the Site Acceptance Test report.
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77.. LLEEAAVVIINNGG SSIITTEE Before leaving site: (a) Check the current plan. If CLF is configured, use handset command `CPL'. Is it
the one that is expected, bearing in mind the time of day? (b) CLF and timetable can be re-synchronised with the real time clock using handset
command `CCP'.
Reset any data that has been set up for testing, e.g. permanent demands or extensions PHD, PHE.
(c) If all inputs can be reset to normal operation, i.e. none have been set to provide
permanent signals due to faulty inputs, then use DET0 = 99 to reset all inputs to normal operation.
(d) Select ‘Normal’ on Manual Panel (unless there is a valid reason to leave it in
‘Fixed Time’, for example). (e) Should manual control be enabled, use handset command `MND' to enable or
disable manual. (f) If all faults have been investigated the fault log may be cleared using RFL = 1. (g) Ensure the visit is accurately recorded in the controller's `visit log book'. It should
contain reason for visit, action taken (i.e. card changed etc.) and any follow up action required or details of what actions are required should the fault re-occur.
(h) Place the Junction Plan, the IC4 Printout and the Site Logbook into the pocket
inside the door of the controller. (i) Lock the Manual Panel door, ensure that the main controller door is locked and
return the keys to the customer.
Note The key lock should not be operated unless the screw locks are tight, i.e. Unlock the case before undoing the screw lock and only lock the case after tightening the screw locks.
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88.. RROOUUTTIINNEE MMAAIINNTTEENNAANNCCEE PPRROOCCEEDDUURREESS This section contains a list of checks that must be performed at an ST900 ELV installation on a regular basis (normally annually). These instructions override any others that may exist. If a Site PI exists for the specific site, it may contain instructions that should be carried out in addition to those detailed below.
WARNING All power to the controller must be disconnected before any attempt is made to remove the internal components of the controller.
8.1 Routine Inspection of Signal Equipment Check all signal heads/aspects for damage and take any necessary corrective action. Check all signal heads for correct alignment with their respective approaches. Check all pole top cable connections; ensure that they are sound, secure and not seriously corroded. Check that all top caps are fitted and are not damaged. Check that all poles are secure in the ground and are not leaning or damaged.
8.2 Routine Inspection and Electrical Testing of Controller It is suggested that these procedures be performed in the order listed. Examine the outer case for serious damage. The outer case would normally only be replaced if it has been damaged to the extent that its security has been breached or that water or dirt is entering. Open the main door and the Manual Panel door, check that the screw-locks, lock and hinges operate freely. Inspect the door and lock, and check the lock and catch-plate for security. Replace or tighten as necessary. Lubricate as necessary with good quality penetrating type oil.
Note The key lock should not be operated unless the screw locks are tight, i.e. Unlock the case before undoing the screw lock and only lock the case after tightening the screw locks.
Inspect the main door seal and Manual Panel gasket, ensuring they are intact and in the correct position. Replace as necessary ensuring that the surface is clean before fitting.
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Check the Manual Panel for any damage and replace if necessary. Check that all functions operate correctly. Press the lamp test keypad and check that all LEDs are operational. Check the termination panel(s) and master switch panel within the controller and ensure that there are no loose fixings, or damage to these panels. Tighten any loose fixings and carry out any repairs that are necessary. Check the logic rack(s) and other assemblies within the controller are securely fixed. Retighten loose fixings as necessary. Ensure that no fault indications are showing. If any faults are revealed refer to the fault-finding procedures in section 9. WARNING The following tests will result in the signals extinguishing. Test the 300mA RCD (if fitted) by pressing the test button. The breaker should
operate immediately. Check that all fuses are secure in their holders. It is strongly recommended
that the controller supply is isolated before any fuses are checked. Check wiring and cable forms, particularly ribbon cables for damage. Repair or
replace if necessary. The battery on the Main Processor card must be replaced if it has failed. Any
replacement battery should be suitably marked with an appropriate date label. Having done this, the controller records should be updated accordingly.
Note The following tests require the controller to be powered and running normally.
With the handset, check that all inputs used are operating correctly.
Test the maintenance socket RCD by pressing the test button. The breaker
should operate immediately. The following checks should be carried out before leaving the site. Check the cabinet door seals are intact and in the correct positions. Replace as
necessary ensuring the surface is clean before fitting. Inspect the cabinet base seal. If damaged, the affected area should be filled with
sand and re-sealed. For details see the Controller Site Installation Handbook.
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8.3 Routine Setup Check Check that the real time clock is set correctly. If the controller is required to run CLF, use the time of day (TOD) command to check that the real time clock is running the correct time. A true measurement of the accuracy of the real time clock can only be gained if the clock with which it is compared has been accurately set up. It is essential that the time be compared with an adjacent controller using a clock that has been synchronised to that controller within the last 30 minutes.
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99.. FFAAUULLTT FFIINNDDIINNGG This section contains information to assist in location and diagnosis of faults.
9.1 Site Visits This section provides a reminder of considerations to be made before visiting a site, and actions to be taken on site and before leaving. For the tools and essential spares required when making a site visit, see sections 1.4.2 and Appendix A.2.
9.1.1 On Receipt of a Fault Report When a fault report is received it is recommended that the following are checked: (a) Is the fault a repeat one; i.e. is the fault and its cause known from previous visit.
Why was the controller left faulty? Can it now be cleared? I.e. are the resources now available to clear it; if so go to site. If not, make an appropriate note in the fault recording system, or on your fault report.
(b) If the report is DFM, i.e. detector fault, check to see if a fault is known to exist on
the site, especially if the fault is reported by an OMU as it may be a repeat alarm for a reported fault. Because, unlike the controller, most OMUs cannot be made to ignore faulty loops which have already been reported and, therefore, continue to raise the alarm.
(c) If the controller is under UTC control, check with UTC centre to ensure that the
fault report is not a result of any problem with the UTC, e.g. OTU may be out of action or faulty.
(d) If the Signal State is reported as being All Out, All Red or not giving right-of-way
to one approach try and check with the local authority/police as to whether they know of a requirement for the signals to be in this state.
(e) Check that after clearance of the fault the controller may be re-commissioned
and switched on again; in some cases the local authority may require the signals left off.
9.1.2 Before Going to a Site Before leaving for a site visit, it is recommended that the following be checked: (a) Check that you have the correct equipment and sufficient spares to do the job
you are going out to do. See the spares list in section A.2. (b) Check that all your spares are good; i.e. check that the replacement cards have
labels with test and inspection stamps on them. Ensure that none of the cards
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have labels on them that would indicate they are suspect or have been removed from a faulty site.
9.1.3 On Arrival at the Site If the visit is to install additional equipment or perform an annual inspection then proceed with the installation or inspection procedure. If the visit is to investigate a reported fault then on arrival at the site proceed as follows: Check all signal heads to see what signals are being shown to the road users, if any. Open the controller door. Make a visual inspection of all of the wiring and cards. Check the controller log book to see if any previous visits/faults are similar, as previous actions may have a bearing on this visit. Use handset to check for any entries in the Controller fault log. Now proceed with the fault diagnosis. If you wish to start fault finding using the symptoms as a basis, go to section 9.2.10. If you wish to start fault finding using the fault indications as a basis, go to section 9.2. NB: If there are fault indications it is recommended that that they be used as a basis for the fault finding and a start be made at section 9.2.
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9.2 Fault Finding Starting From the Fault Indications The following is a list of indicators in the ST900 ELV controller that assist in the location and diagnosis of a fault. The state of each of these indicators should be noted on arrival at a site before doing anything else.
9.2.1 Cabinet Alarm Indicator The LED (behind the manual access door) is normally lit when the controller has identified a detector fault, and flashes when the Controller has detected a red lamp fault. In some installations, the Cabinet Alarm may also be lit for other reasons - refer to the Works Specification.
9.2.2 Master Switch This removes the mains supply from the entire controller when opened, i.e. switched off. Depending on cabinet installation this is normally mounted on a panel at the bottom of the controller.
9.2.3 Controller Switch This is normally included in the Master Switch panel and removes power from the equipment rack and equipment powered from it. This is a single pole switch so does not provide safety isolation. Also note that the maintenance socket is still powered when the controller switch is off.
9.2.4 Main Processor Card LEDs Refer to Table 6 on page 40 When the controller is initially powered up, it performs various internal checks before starting normal operation. While these checks are being performed, the green heartbeat LED flickers and the red system error LED remains illuminated on the Main Processor card. If these tests fail, it would point to a serious fault on the Main Processor, and it should be replaced. The error message is repeatedly written to the handset display at 1200 baud, and no other handset operations can take place. See the ST900 Family Handset Handbook for full details. If the SE light is on, then the processor will have shut the system down and logged a fault – check the fault log. If the BE light is on, then the processor card has a major fault and cannot start. In this condition it is unlikely that the card will communicate with the service terminal. Power the system off, remove the card and check the firmware PROM is correctly seated in the socket and the PHS card is correctly assembled to the main processor.
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If the BE light lights when the processor is powered on again, replace the main processor and PHS.
9.2.5 PHS Card LEDs Refer to Table 7 on page 42. If the PP light on the card is off when the main processor card is powered, then the PHS card power supply has failed and the main processor and PHS should be replaced.
9.2.6 LSLS Card LEDs Refer to Table 11 on page 55. Each LSLS card is equipped with 32 multicolour LEDs indicating the state of each output. It should be remembered that for pedestrian phases, the amber channel is used for the pedestrian wait indicator, and hence may be lit for relatively long periods giving the false impression of being stuck red and amber.
9.2.7 I/O card LEDs Refer to Table 8 on page 46. If a major fault is indicated, check that the serial comms cable is correctly fitted and the card address is set correctly. If this does not solve the problem, replace the card. If all of the LEDs on the card are out, then check that the serial comms cable is correctly fitted. Also check other I/O cards in the system and the Intelligent Detector Backplanes. If all lights are off to all IDBs and I/O cards then suspect the +24V DC supply from the LPU has failed. With reference to Figure 16 – LPU Rear Connectors, measure the +24V DC output from the LPU. If it is not present, remove the power plug into the main processor card and re-test – if it is then present, then suspect a short-circuit between the LPU and the I/O cards. Remove the high-speed serial cables in the controller to isolate the short-circuit. Check that +24V is at the PHS, across pins 1 and 2 of PL7. If necessary, remove and re-terminate the +24V DC power cable from the main processor to the PHS card and re-test.
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If there is no +24V DC available at the LPU, the check the AC mains input to the LPU. If present, replace the LPU and re-test. If the lights are out on only one I/O card then the power supply on that card may have failed – replace the card and re-test.
9.2.8 Intelligent Backplane Controller Refer to Table 9 on page 50. If all LEDs on the card are out, then follow the same checking as for the I/O card.
9.2.9 Audible Driver Module – Single Output type The green PP LED on the Audible Driver Module will only illuminate when the audible indicators are being driven. This will only occur when the LSLS output is on (i.e. -48V DC) AND the inhibit+ and inhibit– connections on the module are shorted together AND the output is not short-circuited. If the green PP led is ON but the audibles are not sounding, check the polarity of the audible connections to the module and re-test. Measure across the “Audible +” and “Audible –” connections of the module - the module will present 12V DC when driving the audibles. If this is present, then suspect the connection between the module and the audibles and check that the audibles are not faulty by substituting a known working audible. Remove all audible connections to the module. If the PP LED on the module illuminates when the audibles should sound, check for a short-circuit on one of the audible connections either inside or outside the cabinet. Reconnect each audible one at a time to find the faulty one. The module is protected indefinitely against short-circuits on the output and will not be damaged. Short INH+ to INH- with wire. If the PP LED illuminates (and audibles sound) when the LSLS output is on, suspect a faulty connection between the audible module and the I/O card or a faulty controller configuration causing the I/O card to inhibit the audible module or a faulty I/O card. If the PP LED on the module does not illuminate and the audibles do not sound with INH+ and INH- shorted together, then measure the voltage across the “LSLS OP” and “LSLS RET” pins of the connector. This should be at lamp supply potential (-48V DC or -27.5V DC) when the module is being driven. If not, then suspect the connection between LSLS and the module or the controller configuration or faulty LSLS output. Finally, having shown that the module is getting power from the LSLS output AND that the inhibit is shorted to enable operation AND that there isn’t a short-circuit on the audible output, replace the module and re-test.
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9.2.10 Audible Driver Module – Dual Output type The green PP LED on the Audible Driver Module will only illuminate when the audible indicators are being driven. This will only occur when the LSLS output is on (i.e. -48V DC) AND the EN+ and EN COM connections on the module are shorted together AND the output is not short-circuited. If link R40 is fitted, both Loud and Quiet PP LEDs will illuminate, but if link R40 is cut, only one LED should light. This would be the Loud PP LED if LQ+ is open circuit, or Quiet if LQ+ is shorted to LQ COM. If link R40 is cut and a single green PP led is ON but the audibles are not sounding, check that audibles are connected to the correct outputs – loud or Quiet. If this is correct, or link R40 is still fitted, check the polarity of the audible connections to the module and re-test. Measure across the “O/P +” and “Audible COM” connections of the module - the module will present approximately 12V DC when driving the audibles. If this is present, then suspect the connection between the module and the audibles and check that the audibles are not faulty by substituting a known working audible. Note that when the Special Condition code for audible monitoring is included, the monitoring function must be enabled (typically using CFE6=1) in order to enable the audible output. If monitoring is not enabled, there will be no audible output and the green PP LEDs will not light. With monitoring enabled, faults in the circuit such as output short circuit will trigger a system error, which will extinguish all the signals (with fault ‘SCF1’ in the fault log). If this occurs, before conducting the fault tests described below, it would be necessary to temporarily short ‘EN+ to ‘EN COM’ with a wire link. Audible monitoring would then need to be disabled for the duration of the fault-finding tests below (e.g. CFE6=0). If the PP LED on the module fails to illuminate when the audibles should sound, short EN+ to EN COM with wire. If a PP LED illuminates (and audibles sound) when the LSLS output is on, suspect a faulty connection between the audible module and the I/O card or a faulty controller configuration causing the I/O card to inhibit the audible module or a faulty I/O card. If the PP LED on the module still did not illuminate with EN+ shorted to EN COM, remove all audible connections to the module. If the PP LED on the module now illuminates when the audibles should sound, check for a short-circuit on one of the audible connections either inside or outside the cabinet. Reconnect each audible one at a time to find the faulty one. The module is protected indefinitely against short-circuits on the output and will not be damaged. If the PP LED on the module still does not illuminate with EN+ shorted to EN COM and audible connections removed, then measure the voltage across the “LSLS I/P” and “LSLS RET” pins of the connector. This should be at lamp supply potential (-
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48V DC or -27.5V DC) when the module is being driven. If not, then suspect the connection between LSLS and the module or the controller configuration or faulty LSLS output. If link R40 is cut and the wrong PP LED lights, check whether the LQ+ input is open circuit or shorted to LQ COM. Open circuit should cause the Loud PP LED to light, and short circuit should cause the Quiet PP LED to light. If the module functions correctly (using a local wire link for this test if necessary) then suspect a faulty connection between the audible module and the I/O card or a faulty controller configuration causing the I/O card to request the wrong state or a faulty I/O card. Finally, having shown that the module is getting power from the LSLS output AND that the Enable input is shorted to enable operation AND that there isn’t a short-circuit on the audible output AND the loud/quiet input is driven correctly, replace the Audible Driver module and re-test.
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9.3 Fault Finding Starting from the Symptoms
WARNING Care must be taken when conducting tests on a controller with mains supply connected to it.
Having first recorded any fault indications in the controller visit log, proceed with the following. Below is a list of symptoms produced by controller faults. Against each one of them is the number of the subsection to which you must refer for the relevant fault finding procedure. Signals Lighting Incorrectly: See sub-section There no longer appears to be a fault 9.3.1 All traffic lights OFF 9.3.2 ) One lamp (or group of lamps) not lighting 9.3.3 ) One lamp (or group of lamps) always lit 9.3.4 ) see One lamp (or group of lamps) lighting at the ) also wrong time 9.3.5 ) 9.3.1 Signals not dimming during darkness 9.3.6 ) Signals dim during daylight 9.3.7 ) Signals cycling dim-bright-dim etc. 9.3.8 ) Signals Changing Incorrectly: Signals not changing at all, i.e. stuck 9.3.9 ) Signals not changing to green on one approach 9.3.10 ) see Signals changing too slowly 9.3.11 ) also Signals changing too quickly 9.3.12 ) 9.3.1 Others Faulty Input 9.3.13 ) see Faulty Output 9.3.14 ) also Cabinet Alarm/Detector Fault Monitor 9.3.15 ) 9.3.1 Controller not running required/expected mode 9.3.16 Intermittent Faults/Problem Sites 9.3.17 Controller Faults with Handset Plugged in/ Handset Port Faults 9.3.18
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9.3.1 Fault Symptoms No Longer Apparent
9.3.1.1 This procedure should be followed if, on arrival at the site, the fault symptoms described in the fault report are no longer apparent or no positive fault has been found after having followed another fault procedure.
Check the contents of the Historic Fault Log (LOG handset command) for faults that have been set and recently cleared. Refer to the ST900 Family Handset Handbook for further details.
9.3.1.2 Have you just followed another fault-finding procedure, which has resulted in no positive fault being found?
YES - Continue at 9.3.1.4 NO – Proceed to the next point
9.3.1.3 Are there any LEDs on the Main Processor or PHS cards illuminated which would indicate the controller has detected a fault?
YES - It is recommended that you move to section 9.2 and continue to fault find starting from the fault indications.
NO - Proceed to the next point
9.3.1.4 Check the signal sequence on the street and on the LSLS LEDs looking for irregularities.
9.3.1.5 Check that the controller operates correctly for the particular mode that it is in. If the controller is capable of working VA but is not currently in V.A. mode, then it is recommended that, if possible, it should be tested in the VA mode to check that it is responding to demands correctly and serving all phases.
9.3.1.6 Perform the electrical test specified in section 8.2.
9.3.1.7 Inspect the controller to ensure that all of the retrospective modifications required on the controller and facilities have been carried out.
Check all of the following: Racking LPU All Cards HPU
ELV Audible Module
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9.3.2 All Traffic Lights Off
9.3.2.1 Are there any of the LEDs on the Main Processor card illuminated?
YES - It is recommended that you move to section 9.2 and continue to fault find starting from fault indications.
NO - Proceed to the next point
9.3.2.2 Check to see if there are any indications of power on the controller. Are there any LEDs on (illuminated)? Press the lamp test button, do any of the Manual Panel indicators illuminate or does the cabinet alarm lamp illuminate?
YES - There is power/mains supply reaching the controller, move to 9.3.2.4 NO - There is no power, Proceed to the next point.
9.3.2.3 Locate reason for loss of supply
Check the following: (a) All DC supplies.
(b) Local area to see if there is a general power failure. (NB: This may have been checked before on receipt of the fault report). (c) Master switch and controller switch to see if either has been switched OFF. If either is OFF, then check as to why they are OFF. (d) If an RCD is fitted in series with the controller’s power supply, check to see if it has tripped. If it has then look for reason for trip, this may require an insulation test to be carried out with respect to earth. (e) Mains supply continuity throughout the controller referring to 667/DA/32900/000, and using a meter set to measure the relevant mains supply voltage. If any fuses are ruptured investigate the reason for their rupture in the following manner: Switch off the mains supply switch which immediately precedes the ruptured fuse. Using a meter set to measure resistance check for a low resistance between live and neutral or live and earth. If a low resistance is found then referring to 667/DA/32900/000, disconnect circuits until the elimination fault is found. If no low resistance can be found, check for signs of arcing within power supply and wiring on termination panel.
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9.3.2.4 Locate reason for signals off when mains supply on
Check the following:
(a) Lamp supply
NB: Normally if lamp supply has failed there is the fault log entry FLF17: If there is no entry in FLF17 it is unlikely that lamp supply is at fault. To check lamps supply further, do as follows. Using a meter set to measure mains supply voltage and Power Circuit Diagram 667/DA/32900/000, check for supply at various points. (b) See if the signals ON/OFF switch on the Manual Panel is in the OFF position. If it is, check to see if there is any reason for the signals to be OFF (e.g. road works, previous cable fault, local emergency). Do not switch the signals ON until any reason for them to be OFF is cleared or no reason can be found. When everything above has been checked, switch the signals ON and observe signal operation. (c) Is the controller part-time working? If it is, check to see if the conditions for switching to part time (signals OFF) are being satisfied. Example: Real time clock may be incorrect or loop detectors may not be working. (d) See if there is any special conditioning which can switch the signals OFF. (e) See if the conditions for switching the signals OFF are specified correctly and are being satisfied. (f) If signals are OFF and signals ON/OFF switch is requesting them to be ON, check using Self Test (see section 10). Then check for faulty switch or wiring (wiring from switch to Manual Panel card and Manual Panel to Main Processor card).
9.3.3 One Lamp (Or Lamp Group) Not Lighting
9.3.3.1 Are there any fault indications in the controller?
YES - It is recommended that you move to section 9.2 and continue to fault-find starting from fault indications.
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NO - Proceed to the next point.
9.3.3.2 Do LSLS LEDs indicate that the lamp(s) should be illuminated?
YES - Continue at 9.3.3.11. NO - Proceed to the next point. Check wiring to LSLS Backplane and signal heads.
9.3.3.3 Is the fault that all aspects of a certain colour are stuck `ON' or `OFF' (i.e. all ambers on or off) when they should not be, possibly whilst other aspects are switching normally
AND Is the controller configured for part time/standby mode. YES - See also 9.2. NO - Proceed to the next point
9.3.3.4 Do the lamp(s) require demands or special conditions to illuminate them?
YES - They require demands or special conditions - continue at 9.3.3.7. NO - The lamp(s) should be illuminating. Proceed to the next point.
9.3.3.5 The lamp(s) do not require any demands or special conditioning to illuminate so check the following:
(a) Replace the LSLS card and re-check, starting at 9.3.3.2. (b) Check configuration data/works specifications for any special lamp
sequence requirements.
9.3.3.6 Do lamps require only a demand to illuminate them?
YES - They only require a demand, continue at 9.3.3.8. NO - They require special conditioning, Proceed to the next point.
9.3.3.7 Special conditioning required
(a) See whether the special conditions required to illuminate the lamps are satisfied. If they are not then try and simulate the conditions. If/when the conditions are satisfied, check as to whether or not the LSLS is now indicating that the lamp should be on, if it is check that the signals on the street are also on. If they are not, continue at 9.3.2.
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(b) If, even when the conditions are satisfied, the LSLS does not indicate that the lamp(s) should be illuminated replace the LSLS and re-start at 9.3.3.2 again.
9.3.3.8 Are the necessary inputs being activated to generate the demands?
Using the handset and the command `IOP' check the relevant inputs. The inputs should be active when vehicles pass over the loops, or pushbuttons are pressed. YES - Continue at 9.3.3.10 NO - Proceed to the next point.
9.3.3.9 Inputs are not being activated.
Check: (a) Detector unit, detector wiring and detector loop (b) Pushbutton and its associated wiring (c) LEDs on I/O card (d) Reset the card (e) Replace card(s) and check to see if fault clears (start again at 9.3.3.1). (f) When demands are being inserted correctly, re-start at 9.3.3.2.
9.3.3.10 Inputs are being activated.
Check: (a) Using the handset, check that the required phase demand is being
inserted using `SPH' command. If a demand is being inserted do the following:
(i) Replace the LSLS and re-start at 9.3.3.2. (ii) Replace the I/O card
(b) If demands are not being inserted, check to see if the input(s) is
disabled by using handset and the `DET' command with the relevant DET number; DET should be = 2 for normal use. Another way of checking this is to use the `IOL’ handset command. If the values displayed by these codes do not change for the particular port and bit then it is either set permanently active or inactive.
(c) Check the configuration data/works specification to ensure that correct
input is being checked and demand that is expected is actually configured. Make sure that CRC is the same as the printed specification.
9.3.3.11 Lamp Switch cards indicate that lamp should be illuminated.
Check the following:
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(a) See if the LSLS card is working, e.g. using a meter set to measure DC
volts, measure across the LSLS output and RETURN. The voltage reading should be -44.6V (bright) or -25.4V (dim). If lower than this, check for shorts on aspect wiring.
(b) The continuity of the wiring from the output of the Lamp Switch card to
the signal heads. (c) The pole top connections. (d) The signal heads.
WARNING Care must be taken when conducting tests on a controller with mains supply connected to it. Where possible a test method should be used which does not require mains connected to the controller.
9.3.4 One Lamp (Or Group of Lamps) Always Lit
9.3.4.1 Are there any of the LEDs on the Main Processor card illuminated which would indicate the controller has detected a fault?
YES - It is recommended that you move to section 9.2 and continue to fault find starting from the fault indications. NO - Proceed to the next point
9.3.4.2 Do the LEDs on the relevant LSLS card(s) indicate that the lamp(s) should be on:
YES - Continue at 9.3.4.5. NO - Proceed to the next point
9.3.4.3 Is the fault all aspects of a certain colour stuck `ON' or `OFF' (i.e. all ambers ON or OFF) when they should not be, possibly whilst other aspects are switching normally?
AND Is the controller configured for part-time/Standby mode? NO - Proceed to the next point YES - See also 9.2.
9.3.4.4 Disconnect all external wires from the relevant phase output terminal(s), (care must be taken because, if it is a cable fault, then the cable cores may
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be at mains supply potential). Using a meter set to measure volts DC measure the voltage between the relevant phase output terminal(s) and RETURN. Does the voltage permanently exceed -15V (NB: 15V RMS is considered to be the voltage at which a signal is visible and deemed to be ON).
YES - Continue at 9.3.4.6. NO - Proceed to the next point
9.3.4.5 Possible cable fault
(a) Check pole top connections and external cables for short circuits and/or poor insulation. With the controller disconnected from the mains supply (i.e. master switch open), short circuits may be found using a meter set to measure resistance and checking core to core.
The insulation should be tested. (b) Also check the connectivity/continuity of the return cables for the
particular poles/signal heads. A visual inspection of pole top connections etc. is also worthwhile.
9.3.4.6 Replace the relevant LSLS card, reconnect the external cables and check that the lamp is no longer permanently lit and is lighting at the required point in the signal sequence.
9.3.4.7 The Lamp Switch card is showing that the lamp should be on.
Check the configuration data and works specification to see if there is a valid reason for the lamp(s) to be permanently lit, e.g. same phase in every stage, special conditioning requires it to be permanently illuminated, etc. If there is no valid reason for the lamp to be permanently illuminated then replace the LSLS card and check to see if the lamp(s) are still permanently lit.
9.3.5 Lamp (Or Lamp Group) Lighting at Wrong Time
9.3.5.1 Are there any of the LEDs on the Main Processor card illuminated which would indicate that the controller has detected a fault?
YES - It is recommended that you move to 9.2 and continue fault-finding starting from the fault indications.
NO - Proceed to the next point
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9.3.5.2 Do the LEDs on the relevant Lamp Switch card(s) show the correct signal sequence?
YES - Continue at 9.3.5.4. NO - Proceed to the next point
9.3.5.3 Check the configuration data and works specification. Is the sequence being shown the correct one and/or is it the required sequence?
YES - No fault NO - Proceed to the next point
9.3.5.4 Replace the LSLS card(s) and check as to whether or not the fault has been cleared.
9.3.5.5 Is the fault all aspects of a certain colour flashing (i.e. All ambers flashing) when they should not be, possibly whilst other aspects are switching normally?
AND Is the controller configured for part-time/standby mode? NO - Proceed to the next point YES - Continue at 9.2.
9.3.5.6 Disconnect all external wires from the relevant phase output terminal(s). (Care must be taken because if it is a cable fault, then the cable cores may be at mains supply potential). Using a meter set to measure volts DC measure the voltage between each of the disconnected cable cores and RETURN. Does the voltage ever exceed 15V RMS? (NB: 15V RMS is considered to be the voltage at which a signal is visible and deemed to be ON).
YES - Continue at 9.3.5.9. NO - Proceed to the next point
9.3.5.7 Using a meter set to measure DC voltage, measure the between the relevant phase output terminal(s) and RETURN.
Do any of the output terminals have a voltage of greater than 15V rms when they should not have? i.e. when the output(s) is not requested to be `ON' by the LSLS card. YES - Proceed to the next point
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NO - Fault symptoms are no longer apparent; continue at 9.3.1.
9.3.5.8 Replace the LSLS card and check to see if the fault has cleared.
9.3.5.9 The fault appears to be in the cable. Refer to the Cable Test Specification. Firstly check the continuity of the cable cores to and from solar cell
Then check for short circuits and/or poor insulation between cable cores to and from the solar cell and between cable cores associated with the solar cell and other cores in the same cable. An insulation test meter usually produces 500V or more. Ensure cable cores are disconnected from any devices/circuits that may be damaged by the high voltages used.
9.3.6 Signals Not Dimming During Darkness
9.3.6.1 Are there any of the LEDs on the Main Processor card illuminated which would indicate that the controller has detected a fault?
YES - It is recommended that you move to 9.2 and continue fault finding starting from the fault indications.
NO - Proceed to the next point.
9.3.6.2 Check handset commands ‘DOV’ and ‘KDP’. Check ‘MPA’ to see if dim override has been assigned a button on the Manual Panel.
9.3.6.3 Is dimming being overridden by UTC or Manual Panel dim override switch?
If a UTC facility is provided, check the works specification to see if a dim override facility is provided. If so check the state of the dim override bit using the handset and the `IOP' command to examine the appropriate input port. To determine if dimming is being overridden by the Manual Panel switch check condition of appropriate `dim/bright confirm' LED on Manual Panel. Is dimming being overridden by UTC or Manual Panel dim override switch? YES - Continue at 9.3.6.6. NO - Proceed to the next point.
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9.3.6.4 Run Self Test to check Dim/Bright relay.
A meter set to measure resistance may be used to prove continuity if controller is isolated from mains supply; check using circuit diagram 667/DA/32900/000.
9.3.6.5 Check the siting of the solar cell to ensure that light from street lighting does not prevent solar cell operating.
9.3.6.6 If dimming is being overridden by UTC, inform UTC centre (this may be a requirement of the UTC centre or an OTU fault).
To further check the UTC dim override input, see section 9.3.13. If dimming is being overridden by Manual Panel dim override switch then check the following to see if there is a reason: (a) Connections to the HPU. (b) Does controller permanently dim if override removed? If it does, see
section 9.3.7 for fault finding. Clear fault before returning Manual Panel dim override switch to normal position.
(c) Check controller visit log book to see if details of any previous visits
have a bearing on the situation. If no reason can be found for the dimming to be permanently overridden, return Manual Panel dim override switch to normal position and check that signals dim correctly and operate correctly. If all other tests prove fruitless, replace Main Processor card.
9.3.7 Signals Dim During Daylight
9.3.7.1 Are there any fault indications in the controller?
YES - It is recommended that you move to 9.2 and continue fault-finding starting from the fault indications.
NO - Proceed to the next point.
9.3.7.2 Is the controller dim at present?
YES - Continue at 9.3.7.6. NO - Proceed to the next point.
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9.3.7.3 Cover Solar Cell and check that controller dims within 60 seconds. If it dims then no fault; if it does not go to section 9.3.6.
9.3.7.4 Remove Solar Cell connections from HPU and Short-circuit Solar+ to Sol Signal – verify that the DIM relay operates
Is -24V DC available between SK2 Solar + and SK2 Solar - on HPU? YES - Continue at 9.3.7.6. NO - Proceed to the next point.
9.3.7.5 Do the following:
(a) Replace F3 (500mA) on HPU and re-check to see if dimming is now operating correctly.
(b) If fuse fails on replacement, check wiring from HPU SK2 to Solar Cell. If wiring is OK, replace Solar Cell. If all other tests prove fruitless, replace Main Processor card.
9.3.7.6 Check the connection between PL4 pin 9 on the HPU card and PL3 pin 9 on the first LSLS backplane.
Using a Multimeter set to Volts DC, put positive lead on SK2 Solar + on HPU and negative load on PL3 pin 9 on first LSLS. Verify that the Multimeter shows 0V when Solar Cell is dark and -5V when Solar Cell is bright. If not, recheck all wiring from the first LSLS PL3 pin 9 to HPU PL4 pin 9 and all wiring from HPU SK2 to Solar Cell. If no fault found, replace Solar Cell and re-check. If the voltages at PL3 pin 9 show the Solar Cell to be working correctly, replace the first LSLS and re-check. If replacing the first LSLS does not solve the problem, replace the Main Processor card.
9.3.8 Signals Cycling Dim-Bright-Dim Etc.
9.3.8.1 Are there any fault indications in the controller?
YES - It is recommended that you move to 9.2 and continue fault finding starting from the fault indications.
NO - Proceed to the next point.
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9.3.8.2 Is there an intermittent -24V DC supply voltage on the solar cell input (causing controller to alternate dim to bright)?
YES - Continue at 9.3.8.3. NO - Proceed to the next point.
9.3.8.3 There is no permanent dim request. Do the following:
(a) Replace the first LSLS card and re-check to see if dimming now operates correctly.
(b) Replace the Main Processor card and re-check to see if dimming now
operates correctly. (c) Check wiring to the HPU to ensure that there is no intermittent
connection. With the controller isolated from the power supply, i.e. controller switch in off position, a meter set to measure resistance may be used to provide continuity. Check using circuit diagram 667/DA/32900/000.
9.3.8.4 .Do the following:
(a) An intermittent dim override signal may be causing the problem. If the dim-bright-dim cycle is regular then check to see if a UTC facility is provided and whether it has a dim override `bit'. If it has a dim override bit check its operation using the handset and `IOP' command for the appropriate input port. For fault finding on an input, see section 9.3.13. If there is no UTC or no dim override bit then replace the Manual Panel card and re-check to see if the fault has cleared. If the dim-bright-dim cycle is irregular check the Manual Panel dim override switch to Main Processor card wiring. (b) Note that if permanent dim request should not be present then once
dim-bright cycling has been cleared, continue at 9.3.7.2. (c) Check that the solar switch has been wired correctly. (d) If fault still exists continue at 9.3.8.3.
9.3.8.5 Intermittent dim request from solar cell. Do the following:
(a) Replace solar cell and re-check to see if dimming now operates correctly.
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(b) If solar cell ok or replacement makes no difference, check all external wiring for the solar cell.
The controller must be isolated from the mains supply first, and the cable cores to and from the solar cell disconnected at the controller end. Using the Cable Test Specification, firstly check the continuity of the cable cores to and from solar cell. Then check for short circuits and/or poor insulation between cable cores to and from the solar cell and between cable cores associated with the solar cell and other cores in the same cable, using the procedure `Insulation testing of signal cabling'. An insulation test meter usually produces 500V or more. Ensure cable cores are disconnected from any devices/circuits, which may be damaged by the high voltages used, e.g. remove solar cell. If all other tests prove fruitless, replace Main Processor card.
9.3.9 Signals Not Changing At All, i.e. Stuck
9.3.9.1 Are there any fault indications in the controller?
YES - It is recommended that you move to 9.2 and continue fault-finding starting from the fault indications.
NO - Proceed to the next point.
9.3.9.2 Has the controller been left in manual mode? Check mode select switch on Manual Panel.
YES - Continue at 9.3.9.4. NO - Proceed to the next point.
9.3.9.3 Using a handset determine what mode the controller is in. Use the command `MOD?’ where ? is either 0, 1, 2 or 3 depending on which stream you wish to know the mode of operation.
What mode is the controller or particular stream in? Manual continue at 9.3.9.6 VA continue at 9.3.9.7 CLF continue at 9.3.9.10 UTC continue at 9.3.9.11 FT continue at 9.3.9.12 Priority hurry call continue at 9.3.9.13
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9.3.9.4 Switch mode select to `Normal'. Check again to see if controller is now operating normally.
9.3.9.5 This section details areas that should be investigated if checking the controller mode detailed in 9.3.9.3 does not reveal a fault.
(a) If a prohibited stage to stage move is being attempted the controller locks up unless an alternative move is given or the move is made an `IGNORE' move (for details on move constraints see the ST900 Family Controller General Handbook).
Check that any move being attempted is not just/only prohibited. Check Prohibited, Alternative and Ignore moves configured. A controller may get out of a potential lock-up if, between the stage that it is leaving and the one to which it wishes to go but cannot, there are other stages to which it can move when demands arise. However, it is recommended that wherever possible, either an `ignore' move or an `alternative' move be used. (b) Phases with appearance TYPE 1: If a phase which terminates when an associated phase gains right-of-way has an inter-green configured between itself and the associated phase, then when the controller comes to make a move where the phase should be terminated by the associated phase the controller locks up. Check for this situation. (c) Phases with appearance TYPES 1 & 3: If a phase has either an appearance type 1 or 3 then a demand can exist for the phase during the stage in which the phase appears without the phase appearing. Then because the controller cannot skip a demanded phase the controller cannot leave this current stage and the controller appears to lock up. If handset command PMV = 1 controller may lock up it should be set to 0, i.e. PMV = 0. Check for this situation. (d) Deleting phases: (Phases and stages may be deleted by master time clock or special conditioning). The controller does not allow a stage with a demanded phase to be skipped. Therefore, if a phase is deleted and a demand is subsequently received for it the demand cannot be honoured by the phase and the stage in which the phase would normally appear cannot be skipped. This may cause the controller to lock if it gets to a situation where it would want to skip the stage. Demands are normally cleared out and further demands
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prevented using special conditioning, if a phase is deleted. Check for this situation. (N.B. The above also applies to deleted stages if the stage being deleted has a phase in it, which appears in no other stage, or stage demands are being used.) (e) Replace the Manual Panel and re-check to see if fault has cleared. (f) Replace the I/O card and re-check to see if fault has cleared. (g) Replace the Main Processor card and re-check to see if fault cleared. (h) Replace the Intelligent Detector Backplane card and re-check to see if
fault cleared.
9.3.9.6 To arrive at this point the mode selection switch is not selecting manual, but the controller is operating in manual mode.
Do the following: (a) Check Manual Panel mode select inputs by confirming that the correct
LED lights when a mode button is pressed to determine if switch is faulty or the fault is in the wiring between the Manual Panel and the Main Processor card. Replace panel if necessary and re-check to see if controller is now cycling correctly.
(b) Replace Manual Panel and re-connect ribbon cable to Main Processor
card. Re-check to see if controller is now cycling correctly and in correct mode.
9.3.9.7 VA Mode:
Using the handset, check to see if demands are being entered for any of the phases. Use the `SPH' command, i.e. SPHA gives you the status of phase A. Are demands entered for any phases? YES - Continue at 9.3.9.9. NO - Proceed to the next point.
9.3.9.8 No demands for any phases
Do the following: (a) Check the addresses are set correctly on the Intelligent Detector
Backplane and I/O card.
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(b) Check inputs to see if they are operating correctly, using the procedure described in section 9.3.13 to diagnose faults with inputs.
(c) Replace I/O card and re-check to see if controller is now cycling. (d) If, after having checked (a) to (c) above the controller is still not
cycling, continue at 9.3.9.5.
9.3.9.9 Phases are being demanded but controller not cycling.
Do the following: (a) Check to ensure that those phases being demanded opposed the
phase currently at green. (NB Check especially carefully where one detector extends one phase
and demands another). If phases do not oppose each other, demands for one do not start the maximum timer of the phase with extensions; thus the max timer does not time out and the controller apparently locks-up.
(b) Continue at 9.3.9.5 if (a) above has not revealed a fault.
9.3.9.10 CLF Mode:
Do the following: (a) Using a handset, check group times for all plans to see if there are any
excessive group times which may make it appear that the signals are sticking or any group times which differ from the works specification. Any timings which differ from the works specification should be noted in the controllers `visits log book' if a visiting engineer changed them.
Any timings over which there is doubt should be checked with the
customer to ensure they are as required. (b) Check for ill advised sequences of group influences and/or very short
group times, either of which can cause the controller to lag behind the group changes and in certain situations make it appear that the controller has locked up. For example:
If a CLF plan were simply to move stage 1 to 2 to 3 and the minimum
times for each stage were 30 seconds, 15 seconds and 15 seconds respectively, then if the group times were
immediate move to Stage 1 30 seconds immediate move to Stage 2 10 seconds immediate move to Stage 3 10 seconds
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it is feasible that the immediate moves to 2 and 3 could be used up during the minimum green of Stage 1, thus for one cycle it would appear to stick in Stage 1.
(NB: It is recommended that group times be a minimum of the longest
minimum green in the stage to which the move is intended and the longest inter-green to that same stage).
Similarly, if the move 1 to 2 was prohibited and the alternative was 1 to
3 and the CLF plan was constructed to move 1 to 2 to 3, by the time the controller had moved 1 to 3 the move to 2 would have changed into a move to 3 and thus stage 2 would always be missed.
It is very rare that the above situations arise, once the controller has
been acceptance tested and installed. (c) If, after having checked (a) and (b) above, the controller is still not
cycling, continue at 9.3.9.5. Remember that CLF might only attempt an incorrect stage to stage move occasionally, this being dependant on group times, group influences and stage that controller is in at any one time.
9.3.9.11 UTC Mode:
Do the following: (a) If UTC interface is 106 then any one or all force bits being applied
permanently force and hold a stage causing controller to apparently lock up.
Check input port to which the UTC force bits are connected using the
handset and `IOP' command for the appropriate port. If an input bit appears to be faulty, fault-find using procedure 9.3.13.
(b) If UTC interface is 316 then the same as (a) applies, but a demand bit
must also be present permanently. Check input ports to which the UTC force bits and demand bits are
connected using the handset and `IOP' command for the appropriate port. If an input bit appears to be faulty, fault-find using procedure 9.3.13
(c) Replace I/O card and re-check to see if controller is now cycling. (d) If, after having checked (a) to (c) above, the controller is still not
cycling, continue at 9.3.9.5.
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9.3.9.12 FT Mode:
Do the following: (a) Check fixed time timings. Excessively long times may make the
controller appear to lock up. Any timings which differ from the works specification should be noted in the controllers `visit log book' if a visiting engineer changed them.
Any timings over which there is doubt should be checked with the
customer to ensure they are as required. (b) If, after having checked (a) above, the controller is still not cycling
continue at 9.3.9.5.
9.3.9.13 Priority/Emergency Vehicle and Hurry Call mode
Do the following: (a) Check timings associated with the particular mode. Excessively long
times may make the controller appear to lock up. Any timings which differ from the works specification should be noted
in the controller `visit log book' if a visiting engineer has changed them.
Any timings over which there is doubt should be checked with the
customer to ensure they are as required. Continue at 9.3.9.4.
9.3.9.14 Are permanent priority demands and/or permanent hurry calls being received?
YES: Continue at 9.3.13. Check to see if the input is faulty NO: Continue at 9.3.9.5. Check to see if there are any other reasons for the controller to lock.
9.3.10 Signals Not Changing to Green on an Approach
9.3.10.1 Are there any fault indications in the controller?
YES - It is recommended that you move to 9.2 and continue fault finding starting from the fault indications. NO - Proceed to the next point.
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9.3.10.2 Does the appropriate LSLS card indicate that phase is going to green?
YES - Continue at 9.3.10.5. Check for Lamp Switch or cable fault NO - Proceed to the next point.
9.3.10.3 Is the phase a fixed phase in a stage? Check in works specification.
YES - Continue at 9.3.10.5. NO - Proceed to the next point.
9.3.10.4 Using a handset and the `SPH' command, check to see if demands are being inserted for the phase.
Are demands being inserted for the phase? YES - Continue at 9.3.10.6. NO - Proceed to the next point.
9.3.10.5 Check appropriate input to see why demands are not being inserted.
Firstly, find the signal name that provides the demand for the phase. This is shown in the works specification, e.g. `AXYZ' demands phase A. Then find out which port and input bit the signal (e.g. AXYZ) has been allocated to. To fault-find on the input use procedure 9.3.13.
9.3.10.6 Is phase or stage in which it appears deleted or prevented for any reason?
To determine whether the phase or stage in which it appears is being deleted or prevented, the handset can be used along with the Engineering code ENG 15 (for the mnemonic `FZREST'). Refer to the ST900 Family Controller Handset Handbook for more details. Is phase deleted or prevented? YES - Continue at 9.3.10.9. NO - Proceed to the next point.
9.3.10.7 Is phase or stage in which it appears being skipped due to priority demands or hurry calls?
To determine if the stage in which the phase appears is being skipped due to Priority demands, Emergency demands or Hurry calls, firstly determine if stage is skipped. This can be done using the handset command `STS' which displays the current stage, where parallel stage streams are available the commands STS0 (for stream 0), STS1 (first stream 1), STS2 (for stream 2) and STS3 (for stream 3) etc.
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Watch the controller cycle through the stages. It should be evident if the stage is being skipped. When it can be seen that a stage is skipped use the handset to check what mode the controller/stage stream is in. See the ST900 Family Controller Handset Handbook for further details on handset commands. Is phase or stage in which it appears being skipped due to priority demands, Emergency vehicle demands or Hurry calls? YES - Proceed to the next point NO - Continue at 9.3.1
9.3.10.8 Check appropriate input to see if priority demands and/or hurry calls are valid.
Firstly, find the signal name that provides the priority demand, Emergency vehicle demand or Hurry call (shown in the works specification). Again referring to the works specification, find which port and input bit the signal has been allocated to. Then, to check the input, use procedure 9.3.13.
9.3.10.9 Check reason/conditions for deletion/prevention of phase.
Do the following: (a) A phase/stage can be deleted by timeswitch parameters, therefore,
check the works specification to see if controller has been configured with such a facility.
If the controller has such a facility check real time clock to see if phase/stage should be currently deleted, `TOD' command. If real time clock is incorrect, reset the real time clock. If real time clock is correct then check timetable using `TTB' command. (See the ST900 Family Controller Handset Handbook for further details on handset commands). (NB occasionally, a phase may also be deleted from special conditioning. Therefore, if timeswitch does not appear to be deleting phase/stage check special conditioning). (b) A phase/stage can be prevented from conditioning, therefore, check
the special conditioning and the reasons/conditions for prevention. Are the reasons/conditions for the phase/stage deletion/prevention valid (i.e. is real time clock correct, are conditions for special conditioning correct)?
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YES - Continue at 9.3.10.11. NO - Proceed to the next point.
9.3.10.10 Correct any invalid parameters, e.g. real time clock, input, etc. Check that phase now appears.
9.3.10.11 If possible, alter the conditions deleting/preventing the phase/stage and check that it can appear.
9.3.10.12 Is the stage in which the phase appears running?
To determine if the stage in which the phase appears is running use a handset and command `STS'; the handset displays the current stage number. (NB: Where parallel stage streams are available there is a `STS' command for each stream STS0, STS1, STS2, etc.). Watch the handset display for a couple of cycles of the controller; it is evident if the stage is running or not. Is the stage in which the phase appears running? YES - Continue at 9.3.10.14. NO - Proceed to the next point.
9.3.10.13 Check for reasons as to why stage is not running, i.e. following:
(a) Prohibited and alternative moves Check to see what prohibited, Ignore and alternative moves there are when going to the particular stage concerned. Check to see what the last stage is which precedes (in cyclic order) the non-running stage. Is the controller making a valid move when it skips the stage? If it is not then determine what needs to be changed to obtain correct operation. If it is then consult customer and question as to whether or not the prohibited, ignore, alternative moves are correct. (b) Check to see if stage is skipped due to priority demands, see section
9.3.10.7. (c) Check to see if stage is not running due to deletion or prevention, see
section 9.3.10.9.
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9.3.10.14 Stage in which phase appears is running but phase not going to green.
Replace associated LSLS card. Re-check to see if phase now cycling correctly.
9.3.10.15 Do the following:
(a) Replace LSLS card. Re-check to see if phase now cycling. (b) Check for cable fault. Perform `Insulation' test and `Loop resistance of
cable conductors post to controller' tests as specified in the Cable Test Specification. First isolate the controller from the mains supply (i.e. switch `off' controller switch) and disconnect the cables to be tested from the controller as necessary.
9.3.11 Signals Changing Too Slowly
9.3.11.1 Are there any fault indications in the controller?
YES - It is recommended that you move to 9.2 and continue fault-finding starting from the fault indications. NO - Proceed to the next point.
9.3.11.2 What mode is the controller running?
VA continue at 9.3.11.3 CLF continue at 9.3.11.4 FT continue at 9.3.11.5 Priority/Emergency Vehicle/Hurry Call continue at 9.3.11.6 If after having completed checks for the mode of operation, no fault can be found, check through the general reasons for slow signal response. Continue at 9.3.11.7.
9.3.11.3 VA Mode:
The controller is in the VA mode and cycling too slowly. Do the following: (a) Check to see if any phases have permanent extension, using the
handset command ‘SPH’. Note `SPH' only shows the extension timing whilst the phase is at green. If this is insufficient then determine from the works specification which signals provide extensions (e.g. AXYZ extends phase A) and to what input port and bit the signals have been allocated. The `IOP' command can then
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be used to view the status of the input ports to see if any of the inputs are permanently active. If any phases have permanent extensions, check appropriate input, see section 9.3.13. (b) Check to see if any phases are not receiving demands from the
appropriate call detectors. If a particular call detector is not inserting demands, check appropriate input, see section 9.3.13.
(c) Check extension and maximum green times. If any times seem
excessive or are different from the works specification, check in controller visit log book to see if timing has been changed and/or check with customer to see if timing is as required.
9.3.11.4 CLF Mode:
The controller is in CLF mode and cycling too slowly. Do the following: (a) Check to ensure that, for all stages to which there are demand
dependant moves, all phases in those stages are receiving demands from the appropriate detectors, using the handset command ‘SPH’.
However, if it is preferred, the input port which has the detector inputs
which create the demands can be examined using the ‘IOP’ command to check that the inputs are being operated when a vehicle crosses the demand loops.
If any demand dependant stages have phases that are not receiving
demands, check appropriate input. See section 9.3.13. (b) Check group times. If any seem excessive or are different from the
works specification, check in controller visit log book to see if timing has changed and/or check with customer to see if timing is as required.
9.3.11.5 FT Mode:
The controller is operating in FT mode and cycling too slowly. (a) Check fixed times. If any seem excessive or are different from the
works specification, check in controller visit log book to see if timing has changed and/or check with customer to see if timing is as required.
9.3.11.6 Priority/Hurry Call Mode:
The controller is in Priority or Hurry Call mode and cycling too slowly.
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(a) Are priority demands being received? If not check appropriate input,
see section 9.3.13. Checking to see if priority demands are being received is a difficult task as generally, a special unit is required to insert priority demands. If one such unit (usually attached to the underside of a vehicle) is available insertion of demands can be checked, by passing the unit over the loop of a priority detector unit and checking with the handset and command `PDS' that the demand/extension is being entered. (Note: The commands `PVU & PVP' may also be used, but these only give the status information for a single priority input/phase respectively and, therefore, the operation of all priority units cannot be seen all at once). (b) Is a priority inhibit timer running which is inhibiting priority unit? To check to see if any priority units are being inhibited by priority inhibit timers use a handset and the command `PIU'. This indicates what units are being inhibited. (c) Are hurry calls being received? If not check appropriate input. See
section 9.3.13. Firstly, determine if the hurry call input is operating correctly. Using the works specification, find out what input bit on what port the hurry call input is. Check to see if, when activated the input responds correctly. Use the appropriate `IOP' command to view the operation of the input. (NOTE: If the sender unit (e.g. push button) is too far away to make the testing of the input feasible, then the input should be forced to its active state, i.e. if input is active open circuit, disconnect input wire, if input is active, short circuit connect input to controller 0V). If after this the input appears faulty, go to section 9.3.13. (d) Is the hurry calls prevent timer running, thus preventing the hurry call? If the input is operating correctly, check the status of the hurry call, use a handset and the command `SHC' for the appropriate hurry call, i.e. 0 or 1. Below are the possible status displays and their meaning. 0 = Either input not going active or if input is going active, then hurry must be prevented by hurry call prevent timer. 3 = Timing hurry call delay period 1 = Requesting hurry call stage but not yet in hurry call stage.
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(Note: If hurry call status remains = 1 for a long time, the controller may be in a higher priority mode which the hurry call mode cannot override. Alternatively, a higher priority Hurry Call (Hurry Call 0) may be operational if Hurry Call status being viewed is for Hurry call 1 as Hurry Call 1 cannot override Hurry Call 0). 2 = Timing hurry call hold period Therefore, if input operates correctly but hurry call status remains at 0 then hurry call prevent timer active. (e) Check hurry call delay timers. If either delay times seem excessive or
are different from the works specification, check in controller `visit log book' to see if timing has been changed by an engineer and/or check with customer that timing is as required.
9.3.11.7 General Reasons for Slow Signal Changing:
(a) Check minimum green times and inter-green times. If any seen excessive or are different from the works specification, check in controller visit log book to see if timing has changed and/or confirm with customer that timing is as required.
(b) Extend all red: Check as to whether or not an extend all red facility is
provided on the controller. If it is then check to see if controller is always running to maximum all red and/or receiving permanent extensions which make it run to its maximum.
To check to see if there is a permanent hold inter-green request, use a handset and the engineering code for the mnemonic `HLDREQ'. This displays 255 or FF if a hold inter-green request is present. Refer to the ST900 Family Controller Handset Handbook for more details. Similar to above, the engineering code for the mnemonic `HLDON' can be used to determine if there are any hold inter-greens currently being applied. (c) Phase delays: Check to see if there are any phase delays during the
stage to stage move(s) which may explain delay in changing. Check timings for delays.
A check to see if there are phase delays occurring can be performed using a handset and the `SPH' command. (c) SDE/SA facility: Check as to whether or not an SDE or SA facility is
provided on the controller. If it is, check to see if extra clearance period is always being inserted.
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To check to see if an extra clearance period is being inserted, use a handset and the command `SCI'. There is also an `SCR' command that indicates if requests are present for the extra clearance period, and provides as display as above. (d) If possible try and determine what mode the controller was expected to
be in when fault was reported. It is possible that the slow response may be due to the controller being in a higher mode than that expected, e.g. if UTC was higher than VA a motorist may be reporting a slow response to their approaching the signals due to UTC sequence.
It is also possible that the reason for introducing the mode is not occurring, i.e. it is not reaching the expected mode because: UTC bits are not being actioned Hurry Calls are not being actioned Emergency vehicle demands are not being actioned Real Time Clock is not introducing CLF etc. If the intended mode is known, any reasons for not attaining the mode should be investigated.
9.3.12 Signals Changing Too Quickly
9.3.12.1 Are there any fault indications in the controller?
YES - It is recommended that you move to section 9.2 and continue fault-finding starting from the fault indications. NO - Proceed to the next point.
9.3.12.2 What mode is the controller running?
VA continue at 9.3.12.3 CLF continue at 9.3.12.4 FT continue at 9.3.12.5 Priority/Hurry Call continue at 9.3.12.6 If after having completed checks for the mode of operation no fault can be found, check through the general reason for quick signal changing continue at 9.3.12.7.
9.3.12.3 VA Mode:
The controller is operating in the VA mode and cycling too quickly. Do the following:
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(a) Check to see if any phases are not receiving extensions when their associated extension loops are occupied.
To check to see if any phases have extensions use the handset and the `SPH' command. Note `SPH' only shows the extension timing whilst the phase is at green. If this is insufficient, then determine from the works specification which signals provide extensions (e.g. AXYZ extends phase A) and to what input port and bit the signals have been allocated. The `IOP' command can then be used to view the status of the input ports to see if any of the inputs are not responding to vehicles crossing the loops. Continue at section 9.3.13 to fault-find an input. If any are not receiving extensions, check appropriate input. See
section 9.3.13. (b) Check extension times. If any times seem too short or are different
from works specification, check in controller `visit log book' to see if timing has been changed and/or check with customer to see if timing is as required.
9.3.12.4 CLF Mode:
The controller is operating in the CLF mode and cycling too quickly. Do the following: (a) Check Group times. If any seem too short or are different from the
works specification, check in the controller `visit log book' to see if timing has been changed and/or check with customer to see if timing is as required.
9.3.12.5 FT Mode:
The controller is operating in the FT mode and cycling too quickly. (a) Check fixed times. If any seem too short or are different from the works
specification, check in the controller `visit log book' to see if timing has been changed and/or check with customer to see if timing is as required.
9.3.12.6 Priority/Hurry Call mode:
The controller is in Priority or Hurry Call mode and cycling too quickly. (a) Are priority extensions being received? If not check appropriate input,
see section 9.3.13. To check to see if priority extensions are being received is a difficult
task as generally a special unit is required to insert priority demands or extensions. If one such unit (usually attached to the underside of a
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vehicle) is available insertion of extensions can be checked, by passing the unit over the loop of a priority detector unit and checking with the handset and command `PDS' that the demand/extension is being entered.
(Note: The commands `PVU & PVP' may also be used, but these only
give the status information for a single priority input/phase respectively and, therefore, the operation of all priority units cannot be seen all at once).
(b) Check priority extension times. If any seem too short or are different
from the works specification, check in the controller `visit log book' to see if timing has been changed and/or check with customer too if timing is as required.
(c) Check Hurry Call hold time, to ensure that it is running and is of
correct duration. If either hurry call hold period seems too short or is different from the works specification, check in the controller `visit log book' to see if timing has been changed and/or check with customer to see if timing is as required.
9.3.12.7 General reasons as to why signals might change too quickly:
(a) Check minimum green times and inter-green times. If any seem too short or are different from the works specification, check in the controller `visit log book' to see if timing has been changed and/or check with customer that timing is as required.
(b) Extend all red: Check as to whether or not an extend all red facility is
provided on the controller. If it is, check to see if extension requests are being received (e.g. when extension loops are occupied). If not check all red extension time and maximum time, also check appropriate input. See section 9.3.13.
To check to see if there are any inter-green hold requests use a
handset and the engineering code for the mnemonic `HLDREQ', this displays 255 or FF if a hold inter-green request is present.
Similar to above, the engineering code for the mnemonic `HLDON' can
be used to determine if there are any hold inter-greens currently being applied.
SDE/SA facility: Check as to whether or not an SDE or SA facility is
provided. If it is, check as to whether or not SDE/SA hardware is inserting speed extensions and extra clearance periods when necessary. If not, check the SDE/SA system.
To check to see if a speed extension is being inserted, use a handset
and the command `SEA'.
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(d) If possible, try and determine what mode the controller was expected
to be in when the fault was reported. It is possible that the quick response may be due to the controller being in a higher priority mode than that expected, e.g. If CLF is a higher priority than VA, a motorist may be reporting a fast response due to CLF force signals away from green and disregarding vehicle extensions.
9.3.13 Faulty Input
9.3.13.1 Check input using handset and `DET' command for appropriate input, if set to `1' or `0' then permanently activated or disabled, if set to `2' then normal operation.
Is input permanently activated or disabled? YES - Continue at 9.3.13.11. NO - Proceed to the next point.
9.3.13.2 Is the input permanently active?
YES - Continue at 9.3.13.9. NO - Proceed to the next point.
9.3.13.3 Is the input permanently inactive?
YES - Continue at 9.3.13.6. NO - Proceed to the next point.
9.3.13.4 Input is changing state but its action is still faulty.
YES - Proceed to the next point. NO – No fault.
9.3.13.5 Input is changing state but its action is still faulty.
Do the following: (a) Check the operation of the sending unit generating the input signal,
e.g. detector, etc. (b) Check that the active state of the sending unit’s output matches the
active state expected by the controllers input.
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9.3.13.6 The input is permanently inactive
Force input at controller to active state. Does controller I/O indicate that input is now active? YES - Continue at 9.3.13.10. NO - Proceed to the next point.
9.3.13.7 With input forced active I/O still does not indicate that it is active. Do the following:
(a) If input active state is short circuit (e.g. closed contacts), check that +24V supply is reaching Main Processor and cards.
(b) Again, if input active state is short circuit (e.g. closed contacts), check
continuity of 0V wiring. (c) Continue at 9.3.13.10.
9.3.13.8 The input is permanently active.
Force input at controller to inactive state. Does controller I/O indicate that input is now inactive? YES - Cable fault or sender Unit fault. NO - Proceed to the next point.
9.3.13.9 With input forced inactive I/O still does not indicate that it is inactive.
Do the following: (a) Check in works specification to see if any entries in the controller
timetable set any input(s) permanently active. If there are, check to see if real time clock is correct. If it is not, then
reset the real time clock. If real time clock is correct, check time against timetable to see if input
should be switched permanently active. If it should not then investigate timetable in controller using `TTB'
command. (b) If input active state is open circuit (e.g. open contact) check that +24V
supply is reaching Main Processor and I/O cards (c) Again, if input active state is open circuit (e.g. open contacts) check
continuity of 0V wiring.
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(d) Proceed to the next point.
9.3.13.10 Fault is external to the controller logic.
Do the following: (a) Check in works specification to see if any entries in the controller
timetable set any input(s) permanently inactive. If there are, check to see if real time clock is correct. If it is not then
reset the real time clock. If real time clock is correct check time against timetable to see if input
should be switched permanently inactive. If it should not, then investigate timetable in controller using `TTB'
command. (b) Check wiring between input and sender unit (e.g. detector, push
button, etc) checks for short circuit between cores and open circuit connections. Check also that appropriate cable cores are connected to the correct terminals on sender unit.
(c) Check operation of the sender unit. If faulty, replace and re-check to see if input operating correctly. (d) If sender unit is a vehicle detector, check loop.
Replace appropriate I/O card and re-check to see if input(s) are now operating correctly.
(e) If input is standard I/O then replace appropriate I/O card and re-check
to see if input(s) now operating correctly.
9.3.13.11 Input is either permanently disabled or enabled.
Check to see if there is a reason for input to be permanently enabled or disabled. Check in controller visit log book. (NB: If input is a detector input and input is set = `1' then there may be a loop fault as this is a method of getting the controller to function normally if a detector is inoperative). If reasons for input being permanently disabled or enabled is no longer valid, e.g. loop has been repaired, then set input to `Normal' operation and re-check to see if input is now operating correctly.
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9.3.14 Faulty Output
9.3.14.1 Disconnect wires from appropriate controller output terminals. Check output. Is it operating as expected?
YES - Continue at 9.3.14.12. NO - Proceed to the next point.
9.3.14.2 Check output using handset and `DET' command for appropriate output, if set to `1' or `0' then output is either permanently short circuit or open circuit respectively, if set to `2' then normal operation.
Is output permanently enabled or disabled? YES - Continue at 9.3.14.11 NO - Proceed to the next point.
9.3.14.3 Is the output permanently Open Circuit O/C (>100K ohms)? (DET = 0)
YES - Continue at 9.3.14.6 NO - Proceed to the next point.
9.3.14.4 Is the output permanently Short Circuit (180 ohms or less)? (DET = 1)
YES - Continue at 9.3.14.6 NO - Proceed to the next point.
9.3.14.5 Output is changing state but its action is still faulty:
(a) If output is controlled from special conditioning check that conditions for output to be inactive or active are being met correctly.
(b) If output is controlled by controller functions/process, e.g. UTC reply
bits check operation of controller. (c) Check for intermittent connections all associated cables and their
attendant joints by gently flexing cables and connectors.. (d) Replace I/O card and re-check to see if output is now working
correctly.
9.3.14.6 Output is either permanently open circuit or short circuit. Force the output of the controller into the opposite state to the one in which it is stuck.
Is the output now in the opposite state to the one in which it was stuck?
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YES - Continue at 9.3.14.10 NO - Proceed to the next point.
9.3.14.7 Fault is in I/O System
Are all outputs of controller affected or all outputs on one card? YES - Continue at 9.3.14.9 NO - Proceed to the next point.
9.3.14.8 Check faulty output(s)
Do the following: (a) Check in works specification to see if any entries in the controller time
table set any output(s) permanently active or inactive. If there are, check to see if real time clock is correct, if it is not then reset the real time clock.
If real time clock is correct, check time against timetable to see if input
should be switched permanently active or inactive. If it should not, then investigate timetable in controller using `TTB'
command. (c) Replace the I/O card and re-check to see if the output is now in forced
state. (d) Check for intermittent connections all associated cables and their
attendant joints by gently flexing cables and connectors..
9.3.14.9 All outputs on controller faulty or all on one I/O card faulty.
Do the following:
(a) Replace the I/O card and re-check to see if the output is now in forced state.
(b) Check for intermittent connections all associated cables and their
attendant joints by gently flexing cables and connectors..
9.3.14.10 Output can be forced to operate correctly so fault must be in function driving it.
Do the following:
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(a) If output is driven from special conditioning, check conditioning to see if conditions are met. If conditions are not true, try to make the conditions true and check that output operates as required.
(b) If output is driven by a controller function, e.g. UTC green confirm
reply bits check controller functions which operates the output.
9.3.14.11 Outputs have been set either permanently short circuit or open circuit using handset command `DET'.
This is unusual and it should be checked that there is no valid reason for this situation. If no valid reason can be found set output to `Normal' operation (appropriate `DET' command = 2) and check that output performs as required.
9.3.14.12 Fault is between controller output terminal and receiving unit.
Check cabling between controller and receiving unit for short circuits and intermittent connections.
9.3.15 Cabinet Alarm/Detector Fault Monitor
9.3.15.1 Is the Cabinet alarm lamp flashing?
YES - Continue at 9.3.15.5 NO - Proceed to the next point.
9.3.15.2 Was DFM fault reported by an OMU?
YES - Continue at 9.3.15.4 NO - Proceed to the next point.
9.3.15.3 Check fault log to determine what detectors are at fault. If detector fault cannot be rectified immediately use `accept detector fault' facility on the controller. Do not reset DFM as this causes a repeat alarm.
If fault log does not indicate that any loops are at fault or accepting detector fault does not clear cabinet alarm, check special conditioning to see if cabinet alarm lamp is used to indicate any special conditions.
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9.3.15.4 If detector fault was reported by an OMU the engineer attending site should be familiar with OMU operation. It is possible that the fault is a repeat of an already existing fault, and to prevent fault reports being repeated until the fault is fixed requires knowledge of the OMU.
9.3.15.5 If cabinet alarm lamp is flashing.
Do the following: (a) Check to see if LMU facility is configured. If LMU is configured then
replace failed lamps and clear fault. (b) If LMU facility not configured check special conditioning to see if
cabinet alarm lamp is used to indicate any special conditions. If it is check conditions which illuminate cabinet alarm lamp.
9.3.16 Controller Not Running Required/Expected Mode
9.3.16.1 Are there any fault indications in the controller?
YES - Continue at 9.2 NO - Proceed to the next point.
9.3.16.2 What mode is the controller running? Below are reasons as to why a mode may be overriding another and why a mode may not be running when it should.
Before proceeding check as to where the relevant modes over which there is doubt are in the mode priority table, in the configuration data/works specification. By studying where the modes are in relation to each other in this table, it can be decided if one is overriding the other or that one is not running because the conditions that introduce it are not correct. Reasons for being in a particular mode are given in 9.3.16.3 (i.e. reasons for overriding another mode). Reasons for not being in a mode are given in 9.3.16.4.
9.3.16.3 (a) If the controller is in the VA mode check mode indicated on Manual Panel.
(b) If the controller is in the FT mode check mode indicated on Manual Panel.
(c) If the controller is in CLF mode, check time of day, i.e. real time clock.
If incorrect reset the real time clock.
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(d) If the controller is in UTC mode, check for force bits present. Check inputs (see 9.3.13).
(NB Force bits may be applied from special conditioning. Therefore, checks conditioning if no force bits are being applied from OTU etc).
(e) If the controller is in priority mode, check for priority demands present.
Check inputs (see 9.3.13). (NB Priority demands may be applied from special conditioning.
Therefore, checks conditioning if no priority demands are being applied from external source).
(f) If the controller is in Emergency Vehicle mode, check for emergency
vehicle demands present. Check inputs (see 9.3.13). (NB Emergency vehicle demands may be applied from special
conditioning. Therefore, checks conditioning if no priority demands are being applied from external source).
(g) If the controller is in hurry call mode, check for hurry call request
present. Check inputs (see 9.3.13). (NB Hurry call requests may be applied from special conditioning.
Therefore check conditioning if no hurry call requests are being applied from external source).
(h) If the controller is in the Part time mode, check real time clock. If it is
incorrect reset the real time clock. If part time is controlled by special conditioning (e.g. flow and queue detectors) check condition required to switch to part time (Signals OFF).
9.3.16.4 (a) If the controller is not in the VA mode then:
Check the operation of the mode select buttons if using them.
Check to see if VA is being overridden, i.e. that current mode of operation has a higher priority than VA.
(b) If the controller is not in FT mode then: Check operation of the mode select switch, if using mode select
switch. Check to see if FT mode is being overridden, i.e. that current mode of
operation has a higher priority than FT. (c) If the controller is not in CLF mode then: check to see if CLF is being overridden, i.e. that current mode of
operation has a higher priority than CLF. check to see if real time clock is correct, if not reset the real time clock.
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check to see if plan being called is valid, because if plan is invalid, e.g.
no group timings, CLF will not be operative. (d) If controller is not in UTC mode then: check to see if any force bits are present, i.e. check inputs. See 9.3.13
. check to see if UTC is being overridden, i.e. that current mode of
operation has a higher priority than UTC. (e) If the controller is not in Priority mode then: check to see if any priority demands are present, i.e. check inputs.
See.9.3.13. check to see if priority is being overridden, i.e. that current mode of
operation has a higher priority than priority mode. check to see if any priority inhibit timers are active. (f) If the controller is not in Emergency mode then: check to see if any Emergency vehicle demands are present, i.e.
check inputs. See 9.3.13. check to see if Emergency vehicle mode is being overridden, i.e. that
current mode of operation has a higher priority than Emergency vehicle mode.
check to see if any Emergency vehicle inhibit timers are active. (g) If the controller is not in Hurry call mode then: check to see if any Hurry call requests are present, i.e. check inputs
9.3.13. check to see if Hurry call mode is being overridden, i.e. that current
mode of operation has a higher priority than Hurry call mode. check to see if either Hurry call prevent timers are running. (h) If the controller is not in part time mode then: check real time clock. If it is incorrect reset the real time clock. If part time is controlled by special conditioning (e.g. flow and queue
detectors) then:
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check that conditions required to switch to part time are present, if they
are not, take any necessary corrective actions.
9.3.17 Intermittent Faults/Problem Sites
If a site has an intermittent fault or a fault which keeps repeating then first the appropriate procedure for the fault should be followed as most paths have more than one suggested area to check for the fault. If the fault is still intermittent, do the following:
(a) Gently - try and move/flex each card whilst in situ to check for any
intermittent connections. If any intermittent connections are found, replace appropriate card. (b) Gently move cables and wiring looms to check for any intermittent
connections. (c) Switch controller ‘off’ and withdraw all cards. Check security of any ICs
mounted in sockets; namely firmware PROM and configuration PROM on the Main Processor card.
Re-fit cards and re-check operation of controller.
9.3.18 Faults with Handset
9.3.18.1 If the handset does not operate correctly when plugged into the handset port on Main Processor card, do the following:
(a) Check that there is a +5V supply on pins 9 and 10 of the handset socket (0V is on pins 1, 7, 18 and 19). With the handset plugged in check the ripple voltage on 5V supply.
(This supply powers those handsets that do not have their own
supplies.) To fully investigate may require the use of an oscilloscope. (b) Switch off controller and withdraw Main Processor card. Check
security of ICs mounted in sockets of the above card. If no loose ICs are found, replace Main Processor card.
(b) Replace Main Processor card and re-check to see if handset now
operates correctly.
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9.4 Replacement of Cards This section covers removal and fitting of cards in the ST900 ELV cabinet. Also described are procedures to ensure that the card functions correctly when fitted (e.g. PROM fitting).
9.4.1 Safety Requirements
WARNING
Before replacing any fuses, cards etc., IT IS ESSENTIAL THAT THE POWER TO THE CONTROLLER IS ISOLATED. See the Safety Warning on page 2 for details. Failure to isolate the supply before changing parts may result in damage to the Controller.
9.4.2 General Requirements When replacing cards, the original card should be inspected and the following points checked: (a) Check the connectors on the card. Are any pins bent, broken or damaged in any
way? If there are, make a note of the card and pin number in the Controller Visit Logbook as the backplane may have been damaged.
(b) Check any ICs that are mounted in sockets and ensure they are the correct ones
for the position and are securely fitted. Refer to the works specification for the correct version and type of firmware and configuration PROM. Refer to Figure 18 for the PROM location.
A problem with a loose fitting IC or use of an incorrect one can usually be rectified easily without having to fit a replacement card.
(c) Do not forget to record the replacement in the Controller Visit Logbook. (d) Complete a fault label and return the faulty card for repair.
9.4.3 Access to Cards in ST900 ELV 19” Controller Rack The cards in the rack have connectors at their rear edge linked to various parts of the system and most need disconnecting at the rear as well as the front of the card. In order to gain access to the rear of the cards, it is first necessary to swing out the ST900 ELV Rack Assembly. Release this by undoing two screws at the right hand edge of the frame and swinging out the assembly. Having done this there is room to reach the back of the cards to deal with the cables. The cards are held in the rack by retaining strips at the front, which must be moved clear after first loosening the strip clamping screws.
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Exercise care when withdrawing cards so as not to damage the ribbon cables as they pass across the rear edge of the rack. I/O cards are located at the back of the controller. Move the swing frame out of the way, then the I/O cards can be reached. See section 9.4.8 for details.
9.4.4 Replacement of HPU
WARNING See the Safety Information on pages 2-4 before proceeding.
When an HPU card needs to be replaced, remove the HPU card, metal brackets and heat transfer pad. Handle the heat transfer pad with care, as it can be damaged by sharp blows. Fit the new heat transfer pad to the side panel, as shown on 667/GA/33040/ETC. Align the HPU and metal brackets to the panel, and screw the brackets to the panel, gradually compressing the heat transfer pad.
9.4.5 Replacement of LPU The LPU is removed by unscrewing the 4 retaining screws at the front of the LPU and pulling the LPU forward. The replacement LPU is fitted in the reverse order, taking care to align the LPU into the card guides when inserting,
9.4.6 Replacement of Main Processor Card In case of failure, the entire unit, consisting of the main Processor AND PHS cards, should be replaced. The type and position of the configuration PROM and the software identification number printed on the PROM label should be checked. Refer to the Works Order Specification for details.
9.4.7 Replacement of LSLS Card Pull the spring clip under the LSLS card and pull the card part way towards you using the front handle. Tilt the top of the card away from the side of the cabinet, lining up a notch on the card with the projection on the card holder, then pull the card right out. Replace with the new LSLS card by reversing the above procedure. Note that LSLS 3 is reverse orientation; the spring clip is on top.
9.4.8 Replacement of I/O Card
The controller should be powered down before disconnecting any RJ45 connector.
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I/O cards are situated on the back panel of the controller cabinet. Disconnect the cables which are held in place with two screws each, then the serial cables and the six mounting screws. Remove the card and replace with the new one. Reverse the procedure to connect the new card.
9.4.9 Replacement of Intelligent Detector Backplane Card
The controller should be powered down before disconnecting any RJ45 connector. The Detector Backplane card(s) is/are situated at the rear of the rack. Generally speaking, only the Intelligent Detector Backplane card will need replacing, although the replacement kit includes the passive Detector Backplane. They are supplied together to protect delicate components and connections. Remove the three nuts holding the card in place and pull away from the passive backplane. Replace with the new card and tighten the nuts. Reassemble and return the kit including the defective card to Siemens Poole.
9.4.10 Replacement of the Manual Panel Card First unplug the cable connecting the panel to the Main Processor card (Rear connector). The panel is retained by a number of screws to the main cabinet assembly. (Mounting methods may vary in different cabinets). After removal of these screws the panel may remain stuck in place by the gasket. Ease the panel away from the housing, gradually working from one corner taking care not to scratch or otherwise damage it. The replacement panel should be mounted with a new gasket to prevent water ingress. After fitting, reconnect the cable to the Main Processor card. An Internal Manual panel (where fitted) can be removed directly by removal of the screws holding it to the 19 inch panel; it may be easier to remove the 19 inch panel from the rack first. As there is no gasket on an internal Manual Panel, no sealing is required on refitting.
9.4.11 Replacement of SDE/SA Card and/or IRM/IMU Card Removal of these cards may be done individually after disconnection of the rear expansion bus ribbon cable from the Processor Card and the Berg input/output connectors.
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9.4.12 Replacing Components Other Than Cards When replacing any components (including cards) only approved spares may be used. Use of any other components may invalidate the Type Approval of the equipment. See APPENDIX A for details of approved spares.
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9.5 Logging/Recording Faults and Visits Every controller should have a Controller Visit Log Book. It should be a small book, usually stored in the document pocket inside the controller door. On every visit the visiting Engineer should write down in the log book the date, his/her name, reason for visit and actions taken. For example, the reasons for the visit may be a fault report, routine inspection, fitting of new equipment, adjustment of timings, etc. The actions taken may be card or unit replaced, timing adjusted, new equipment fitted, etc. This information is essential for the next Engineer who may visit the site so that he/she can see what has happened previously and helps to reduce duplication of effort. The requirement to fill in the visit log book also applies to Local Authority Staff. The maintenance organisation cannot be held responsible for any problems arising from neglect of this responsibility.
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1100.. TTHHEE SSEELLFF--TTEESSTT FFAACCIILLIITTYY
10.1 Introduction The Self-Test facility can be used to check the hardware fitted to the controller, even without a configuration loaded. It has been designed for use in production and on the street by installation / maintenance engineers. Self-Test is initiated by holding down the level 3 access button while switching the controller’s power on. The button should be released once the green heartbeat LED starts to flash. The green heartbeat LED continues to flash during the Self-Test unless a fault is detected, when the red system error LED illuminates. A 20 character by 4 line handset connected displays information about the checks it is performing, such as the firmware issue and the lamp supply voltage, both dim and bright, and details any faults found. Self-Test performs the checks detailed on the following pages and reports the error messages shown if faults have been detected. While the Self-Test is running, the Manual Panel can be checked. Pressing each button on the panel should illuminate the associated LED. To distinguish this from normal operation, the LED flashes at a fast rate while the button is pressed. Note that the ‘Lamp Test’ button flashes all the LEDs on the Manual Panel. To test the signals ON/off switch and the cabinet alarm LED, switching the switch to the signals ‘ON’ position flashes the cabinet alarm LED. Switching it to the ‘off’ position extinguishes the cabinet alarm indicator. The Signals On/Off Switch does not affect the Self-Test in any other way.
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10.2 Self-Test Part One The following shows typical information output by Self Test during Part One, and summarises the tests it performs:
Controller SelfTest =================== Q: Pause Display After 4 Lines? [YN] PIC:PB801 ISS 2 PLD:000 LMU RAM Size.....512KB CPU Speed....16MHz PHS CPU......Found PHS:32931 ISS 2 LSLS Cards...----21 2 LSLS Cards VLS 1:32941 ISS 1 VLS 2:32941 ISS 1 VLS 3:- VLS 4:- VLS 5:- VLS 6:- P/Bus CPU....None ZXO From.....PHS Mains Freq...50.0Hz PHS Init.....Passed L/Supply Off=0V V/Mons Off...Passed All Cards Working?
On power-up, the Self-Test facility checks the integrity of the Main
All the above faults point to problems internally on the Main Processor card. Checks communications with the Phase Bus Processor:
PHS CPU......
If the Processor cannot be detected, the Self-Test waits indefinitely at this point with the red system error LED illuminated. Check that the PHS Card is fitted correctly.
P/Bus CPU....None Note: An ST900 ELV Controller will indicate that the Mains Phase Bus Processor (known as ‘P/Bus’ or ‘PHP’) has not been found, even if that processor is fitted and has started correctly. However, without a ZXO Signal from the Mains Lamp Switch Cards, communications with that processor will not be established.
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Examines the LSLS Cards to see how many are fitted:
No LSC or LSLS! No cards were detected; check the connections from the PHS to each LSLS and that all the LSLS Cards appear powered (i.e. their status LEDs are flashing).
If it appears that an LSLS Card is missing, e.g. if the first and third cards are detected, but not the second, then the error message “Missing LSLS?” is displayed. It should be clear from the information displayed prior to this error message (shown above in grey) as to which card or cards appear missing. Check the connections from the PHS to each LSLS and that all the LSLS Cards appeared powered (i.e. their status LEDs are flashing). Note: If the last fitted card is not found, the Self-Test will not detect the problem at this point. For example, it will continue if LSLS#1 and LSLS#2 are found, but LSLS#3 is not powered. It is therefore essential that the user checks (at the start of Part Two, see section 10.3) that all the LSLS Cards have been correctly identified. Waits for ZXO synchronisation and checks the mains frequency:
ZXO From.....
If the Phase Bus Processor cannot synchronise to the mains zero cross-over signal, then Self-Test waits indefinitely at this point with the red system error LED illuminated. Check/replace the connection between LSLS#1 and the PHS. Then try replacing LSLS#1, the PHS or the Main Processor Card.
Mains Freq Error If the mains frequency is more than 5% out from either 50Hz or 60Hz. Initialises the Phase Bus Processor:
PHS Init.....
Once initialised, the Phase Bus Processor and LSLS Cards perform more thorough checks and may detect faults. This could result in some of the general error message (as shown in section 10.5) being displayed.
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Checks that the lamp supply is OFF:
L/Supply Off=48V L/Supply Stuck On
If a lamp supply is being detected, then this implies that the lamp supply relays are all switched ON or are being by-passed by a wiring fault for example.
If any of the voltage monitors appear to be detecting a voltage, even though the lamp supply is switched off, then this implies a problem with the hardware on one or more of the LSLS cards. See section 10.4 for details of this format of error message. Checks the monitor validation signal:
M/V Test.....Failed Mon Val Failed
The monitor validation signal is generated by the Main Processor and travels down the phase bus cables (via the PHS Card) to each of the LSLS cards, so a failure is probably due to a faulty LSLS Card, PHS Card or interconnecting cable. If, after checking and/or replacing these items, the problem persists, there is the possibility that the logic supply phasing may be incorrect – contact Siemens Engineering in Poole for further information. Step 1 Complete, Start Step 2:
At this point, the Self-Test has successfully checked-out the logic side of all the LSLS cards that it has found. It then displays a scrolling pattern on the amber LEDs on these LSLS cards to prove that it can address all the cards correctly and to show that the first part of the Self-Test is complete.
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10.3 Self-Test Part Two
WARNING
It is essential that the correct number of LSLS cards have been detected at this point as, following this, the Self-Test starts applying the lamp supply to the LSLS Cards.
Therefore, check that the pattern illuminates the correct number of LEDs on the card for that card’s address, e.g. the pattern will just contain one illuminated LED on LSLS#1, but will contain two illuminated LEDs on LSLS #2. Also check that the scrolling pattern illuminates all the amber LEDs in turn on all the LSLS cards fitted. After the level 3 button is pressed, Self-Test switches ON the lamp supply and will test each LSLS output and monitor circuit by switching each one ON in turn for just two mains cycles (40mS). This may visible on the traffic signals as a bright flash, particularly with LED Signals. Therefore:
WARNING All LED Signal Heads should be covered before proceeding any further with the Self-Test.
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The following shows a typical information output by Self Test during Part Two, and summarises the tests it performs:
All Cards Working? **** IMPORTANT **** All LED Signals to be covered before continuing... Starting Pass 0001 V/Mons Off...Passed Lamp Supply..48V M/V Test.....Passed Dim L/Supply=27V LSLS Outputs:1-10 Relay A Test=Ok LSLS Outputs:11-20 Relay B Test=Ok LSLS Outputs:21-32 LSLS Outputs:Passed Checking Lamp Supply Arrangement: RelayB:All Sigs Off RelayA:All Sigs Off Controller Set-Up: 'Fail To Black-Out' Exp'n Cards..Found IOx1 =================== Pass 0001 Complete. =================== Run Time = 00:00:30
Self-Test switches ON the lamp supply and then checks that the voltage
monitors still indicate that the signals are switched off:
If any of the voltage monitors appear to be detecting voltages, it would imply that those LSLS Outputs are stuck ON (short circuit) and thus that LSLS card should be replaced. See section 10.4 for details of this format of error message. In the above example, LSLS #2 should be replaced because the eight digits after the card number are not all zeroes; one or more outputs ON. LSLS #1 appears ok because the eight digits are all zeroes; all outputs OFF.
L/Supply Failure LSLS not on..----21
No lamp supply has been detected on the LSLS Cards identified. Check the lamp supply circuit’s relays, fuses, etc., in and around the HPU.
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Checks that each lamp supply relay can switch off the lamp supply
independently:
Relay A Fault Relay B Fault
Failure of any of these tests implies that the relay is not switching off, i.e. that it is either stuck closed or the control signals from the Main Processor card are stuck active.
Relay A HFF Fault This fault indicates a problem with the Hardware Fail Flash set-up of the controller:
Only one LSLS Card has been found, but the link on the HPU appears to be set-up for HFF, i.e. Relay A did not switch off the lamp supply to LSLS#1.
More than one LSLS Card has been found and the link of the HPU appeared to be set-up for HFF, but Relay A has switched off the lamp supply to LSLS#1.
Checks that the dimming relay is functioning:
Dimming Fault
A fault is only detected with the dimming relay if the dim lamp supply is more than 75% of the normal lamp supply, i.e. that the dimming relay seems to have no effect on the lamp supply. If dimming is not required, then the dim and bright lamp supplies must not be connected together. If dimming is configured as not present, i.e. KDP is set to zero, then the controller simply never attempts to switch to dim. Note that this test does not fail if there is no dim lamp supply. Therefore, the dim voltage should be checked manually, e.g.
Dim L/Supply=28V Checks all of the LSLS Outputs by pulsing each one ON in turn:
1/32:Extra Sigs On 180000000 4-------- 200000001 5-------- 3-------- 6--------
A fault is logged if extra signals are detected as ON when one particular aspect is pulsed. This would normally imply a short-circuit in the street cabling or an open return connection. See section 10.4 for details of this format of error message. The example above shows the following information. The test pulsed LSLS#1 Output 32 (“1/32”) and found extra signals appeared to be illuminated (“Extra Sigs On”). It found that LSLS #1 Output 32 appeared ON (“1” followed by “80000000”) and LSLS #2 Output 1 appeared ON (“2” followed by “00000001”). LSLS #3 through to LSLS#6 were not fitted (“--------”). This would imply a short circuit between LSLS#1 Output 32 and LSLS#2 Output 1.
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No Voltages On... 180000000 4-------- 200000000 5-------- 3-------- 6--------
A fault is also logged if no voltages were detected, e.g. when the output switch on the LSLS Card will not switch ON. Checks the Lamp Supply arrangement:
The Self-Test checks the lamp supply arrangement of the controller after checking each lamp supply relay and each output and monitor circuit. With Relay B switched OFF but with Relay A switched ON, it pulses a selection of outputs to check that the lamp supply to all of the cards has been removed:
Checking Lamp Supply Arrangement: RelayB:All Sigs Off
If any voltage monitors detect lamp supply during this test then the Self-Test shuts down and displays the fault on the handset since this relay should remove the lamp supply from all the LSLS Cards, e.g. if LSLS#1 still appears to be powered:
Relay B Off But... 100000001 4-------- 200000000 5-------- 3-------- 6--------
With Relay B switched ON and Relay A switched OFF, it again pulses a selection of outputs and checks which cards, if any, still have lamp supply present. From this, the controller can determine whether the link on the HPU is set-up for ‘fail to black-out’ or for ‘fail to flashing’. If the Controller is set-up for ‘fail to black-out’ then Relay A also switches off the lamp supply to all the LSLS Cards, i.e. only the ‘green supply’ from the HPU (which can be switched off by either of the lamp supply relays) is passed to all of LSLS cards. If this is the case, then this result is displayed on the handset and the Self-Test continues:
Checking Lamp Supply Arrangement: RelayB:All Sigs Off RelayA:All Sigs Off Controller Set-Up: 'Fail To Black-Out'
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If the link on the CPU Card is set to ‘Fail to Flashing’, then Self-Test aborts and displays the following error message since the set-up of the controller appears inconsistent.
Fail to Black-out wiring but CPU card link is set for 'Fail to Flashing'.
If this test detected that Relay A removed the lamp supply from all LSLS Cards, but the Relay A test performed earlier detected that the lamp supply was not removed from LSLS#1, then Self-Test displays the following error message since it implies that Relay A may not be operating consistently.
Fail flash result does not agree with earlier test of Relay A.
If the Controller is set-up for ‘fail to flashing’ then the red/amber lamp supply on the HPU which is not switched OFF by Relay A is used to power the outputs on LSLS#1. The lamp supply to all the other LSLS Cards is still switched off. Self-Test will display the result of the testing (LSLS#1 supply still ON) and thus that Hardware Fail Flashing is available, then whether or not it has been selected by the link on the CPU Card:
Checking Lamp Supply Arrangement: RelayB:All Sigs Off RelayA:LSLS 1 On FailFlash Available And Selected.
... FailFlash Available But Not Selected.
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If Self-Test detects that the lamp supply on a different LSLS remains ON, it displays the results and aborts. Check that the power connections from LSLS#1 are connected to the first LSLS position on the HPU.
Checking Lamp Supply Arrangement: RelayB:All Sigs Off RelayA:LSLS 2 On
Only LSLS#1 should be connected to the fail flash lamp supply!
If the lamp supply to more than one LSLS Card appears to remain ON, then it aborts and displays either of the following error messages. These imply a serious problem with the wiring of the controller or that the Relays have now failed.
All LSLS connected to fail flash lamp supply?
More than one LSLS connected to the fail flash lamp supply?
If the test detected voltages present on LSLS Outputs it did not pulse, then it aborts and displays the following error message identifying the Outputs that appeared ON:
Bad BO/FL Result: 100000101 4-------- 200000000 5-------- 3-------- 6--------
Regardless of whether the link on the CPU card is set to ‘fail to black-out’ or ‘fail to flashing’, if the Controller set-up allows the ‘fail to flashing’ option then the controller flashes all of the outputs on LSLS#1 for five seconds to confirm that set-up. At the end of the test, the Self-Test switches OFF the lamp supply and displays a scrolling pattern on the LSLS card LEDs to show that all the tests have passed successfully. It also illuminates a number of amber LEDs on the first lamp switch card to show some of the expansion cards detected by the Self-Test. See the following picture.
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LSLS Card #1 – Expansion Card Indications
... 27
SDE/SA Card 26 - 25 24 23
TfL IRM/IMU Card 22 - 21 20 19
Integral TC12 OTU Card 18 - 17 16 15
Serial I/O Card or Detector Backplane Address 3 14 - 13 12 11
Serial I/O Card or Detector Backplane Address 2 10 - 9 8 7
Serial I/O Card or Detector Backplane Address 1 6 - 5 4 3
CPU Card 2 - 1
If I/O cards (Serial I/O Cards or Detector Backplanes) with addresses higher than 3 are fitted, use the handset to confirm how many I/O cards have been detected, e.g:
Exp'n Cards..Found IOx5, OTU
It is also clear on the I/O cards themselves whether or not they have been recognised by the Controller because their status LED’s will indicate that they have been configured. After a few seconds, Self-Test repeats Part Two, allowing the controller to be soak-tested. If one or more expansion cards detected during Pass 1 are not detected on a subsequent pass, the self-test aborts and displays the following error message:
Exp'n Cards Failed! Found this time: IOx4, OTU
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10.4 LSLS Card Faults
Resolving problems with LSLS Cards and LSLS Outputs: When various tests fail, the handset may display information such as shown below:
If only one LSLS Card is fitted: 1/05:Extra Sigs On identifies the test which has failed 32:1000000000000000 LSLS outputs 32 through to 17 16:0000000000010000 LSLS outputs 16 through to 1 ........87654321 (Helpful information)
The display shows the status of all 32 LSLS Outputs on that card. The display is in ‘binary’, with each digit / bit showing ‘1’ to identify that output as faulty. The status of the 32 LSLS Outputs (1-32) is shown on the second and third lines.
The first line identifies the test that has failed (see section 10.3). The second line shows the status of LSLS Outputs 17 to 32, starting with 32 on the left, just after the text “32:”. The third line shows the status of LSLS Outputs 1 to 16, starting with 16 on the left, just after the text “16:” and finishes with LSLS Output 1 on the right. The fourth line is added to clarify the position of the digits / bits for LSLS Outputs 8 through to 1. In this example, the LSLS Outputs 5 and 32 appear to be ON.
If more than one LSLS Card is fitted: No Voltages On... identifies the test which has failed 180000000 4-------- outputs on LSLS#1 and LSLS#4 200000000 5-------- outputs on LSLS#2 and LSLS#5 3-------- 6-------- outputs on LSLS#3 and LSLS#6
The numbers are in hexadecimal notation with each of the eight digits encoding four LSLS outputs, so the status of the 32 LSLS Output numbered 1-32 (from right to left) is shown by the eight digits. Each possible combination of the LSLS outputs is encoded to a value as follows. In the above example, the voltage monitor for LSLS Output 32 is indicated as faulty, implying that the output switch (or the monitor) is faulty.
32 - 29
28 - 25
24 - 21
20 - 17
16 - 13
12 - 9 8 - 5 4 - 1
3 3 3 2
2 2 2 2
2 2 2 2
2 1 1 1
1 1 1 1
1 1 1
2 1 0 9
8 7 6 5
4 3 2 1
0 9 8 7
6 5 4 3
2 1 0 9
8 7 6 5
4 3 2 1
0= - - - -
0= - - - -
0= - - - -
0= - - - -
0= - - - -
0= - - - -
0= - - - -
0= - - - -
1= - - - X
1= - - - X
1= - - - X
1= - - - X
1= - - - X
1= - - - X
1= - - - X
1= - - - X
2= - - X -
2= - - X -
2= - - X -
2= - - X -
2= - - X -
2= - - X -
2= - - X -
2= - - X -
3= - - X X
3= - - X X
3= - - X X
3= - - X X
3= - - X X
3= - - X X
3= - - X X
3= - - X X
4= - X - -
4= - X - -
4= - X - -
4= - X - -
4= - X - -
4= - X - -
4= - X - -
4= - X - -
5= - X – X
5= - X – X
5= - X – X
5= - X – X
5= - X – X
5= - X – X
5= - X – X
5= - X – X
6= - X X -
6= - X X -
6= - X X -
6= - X X -
6= - X X -
6= - X X -
6= - X X -
6= - X X -
7= - X X X
7= - X X X
7= - X X X
7= - X X X
7= - X X X
7= - X X X
7= - X X X
7= - X X X
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8= X - - -
8= X - - -
8= X - - -
8= X - - -
8= X - - -
8= X - - -
8= X - - -
8= X - - -
9= X - - X
9= X - - X
9= X - - X
9= X - - X
9= X - - X
9= X - - X
9= X - - X
9= X - - X
A= X – X -
A= X – X -
A= X – X -
A= X – X -
A= X – X -
A= X – X -
A= X – X -
A= X – X -
B= X – X X
B= X – X X
B= X – X X
B= X – X X
B= X – X X
B= X – X X
B= X – X X
B= X – X X
C= X X - -
C= X X - -
C= X X - -
C= X X - -
C= X X - -
C= X X - -
C= X X - -
C= X X - -
D= X X – X
D= X X – X
D= X X – X
D= X X – X
D= X X – X
D= X X – X
D= X X – X
D= X X – X
E= X X X -
E= X X X -
E= X X X -
E= X X X -
E= X X X -
E= X X X -
E= X X X -
E= X X X -
F= X X X X
F= X X X X
F= X X X X
F= X X X X
F= X X X X
F= X X X X
F= X X X X
F= X X X X
8 0 0 0 0 0 0 0
10.5 Other Error Messages The following error messages can be displayed at any time during the Self Test. Other error messages not shown here may be displayed shortly after power-up and before Self-Test begins if there is a fundamental problem with the Main Processor Card. See the details of the start-up sequence in the Handset Handbook for details. ZXO Synchronisation
If the Controller loses synchronisation with the zero-crossing points of the mains supply, the following error message will be displayed and Self-Test will abort.
ZXO Sync Lost
This fault is displayed when the mains power to the controller is switched OFF or there has been a short interruption to the mains supply. If the problem persists and the mains supply is thought to be good, check the connections between LSLS#1 and the PHS. Then try replacing LSLS#1, the PHS and the Main Processor Card. PHS Faults
If communications between the Main Processor and the PHS fail, the following error messages can be displayed:
PHS Msg Timeout
PHS Stopped!
Replace the Main Processor Card if the problem persists.
PHS Fault Code N
The PHS has confirmed a serious fault and shutdown the controller. The code number ‘N’ displayed is the same as that shown in the FLF 2 fault flag; see the ST900 Handset Handbook for details.
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Unexpected Correspondence Faults If the LSLS Cards indicate that signals appear ON at times when the Self-Test is not expecting any signals to be illuminated, then either of the following error messages will be displayed:
Unexp Corr Fault
Unexp PHS Corr Flt
If the fault occurs within a few seconds of the “PHS Init…” step in part one of the Self-Test (see section 10.2), then it implies that outputs appear to be ON even though the lamp supply is still OFF. This can be caused by faulty voltage monitors on the LSLS Cards. Try removing all but LSLS#1 and repeating the Self-Test. If it still fails, then replace LSLS#1. If it passes, remove LSLS#1 and replace it with just one of the other LSLS Cards and repeat the test. Repeat this to test each LSLS Card in turn. It can also be caused by stray voltages on the street cables. Carefully check all the street cables to ensure that no voltages are present from external sources. Configuration Download Sequence
If the configuration download sequence to the PHS, or an LSLS or Serial I/O Card fails, then one of the following error messages is displayed. The ‘*’ will be replaced by the card address.
Check the connections to the card and if the fault persists, replace the card. LSLS Card Failures
If low power is confirmed by one or more LSLS Cards, then the following error message is displayed. The ‘*’ will be replaced by the address of the first card to report it.
LSLS* POWER LOW
Carefully check the mains supply voltage to the Controller and the taps on the lamp supply transformer (which also provides the logic power to the LSLS Cards). If the fault persists, change the LSLS Card. Also see the description of “FLF 9:255 LSPF” in the handset handbook.
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If communication to one or more LSLS cards has been lost, then the following error message is displayed. The ‘*’ will be replaced by the address of the first card that disappears.
LSLS* COMMS FAIL
Check the cable connections between the PHS and that LSLS Card. Also see the description of “FLF 43:255 LSLS” in the handset handbook. If a ‘Major Fault’ is reported by an LSLS Cards, then the following error message is displayed. The ‘*’ will be replaced by the address of the LSLS Card.
LSLS* MAJOR FAULT
The LSLS Card will probably need to be replaced. For more information, see the description of “FLF 42:255 LSMF” in the handset handbook.
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AAPPPPEENNDDIIXX AA -- PPAARRTT NNUUMMBBEERRSS AANNDD SSPPAARREESS LLIISSTT
WARNING Use of components other than those listed, or modifications or enhancements that have not been authorised by Siemens Traffic Controls may invalidate the warranty and/or safety of this product.
AA..11 PPaarrtt NNuummbbeerrss Listed below are all the currently available main parts common to all ST900 ELV Controllers. Sections A.1.1 and A.1.2 give part numbers for those parts that are exclusive to either UK only or non-UK Controllers. For an up to date list see the ST900 ELV Family Tree (667/DZ/32900/000). Description STC Part Number ST900 ELV Additional LSLS Rack Wiring kit 667/1/32945/000 20A Transformer kit 667/1/32980/020 ELV Lamp Switch (LSLS) Kit 667/1/32943/001 ELV Lamp Switch (LSLS) Backplane Kit 667/1/32960/000 ST900 I/O Card Kit (16 outputs) 667/1/32995/001 ST900 I/O Card Kit (4 outputs) 667/1/32995/002 ST900 ELV CPU card assembly 667/1/32920/001 ST800/ST900 Controller Configuration PROM kit 667/1/27057/000 Intelligent Detector Serial Backplane kit 667/1/32910/000 Enhanced Intelligent Detector Backplane Kit 667/1/32910/000 Enhanced IDB Linking Cable 190mm 667/1/32994/000 Enhanced IDB Linking Cable 590mm 667/1/32994/002 ELV 24V DC Detector Supply kit (6.6A) 667/1/33074/000 ELV 24V DC Detector Supply kit (2A) 667/1/33075/000 Detector 6U Rack Expansion kit 667/1/33002/000 Manual Panel RS232 Kit 667/1/27110/000 SDE Facility Kit (SDE/SA Card) 667/1/27005/000 ELV Audible Driver Kit (Dual Output type) 667/1/32955/000 Mounting Stool (Grey) 667/2/27096/000 300mA RCD kit 667/1/27117/000 20A-40A Upgrade kit 667/1/32980/040 Regulatory Signs Expansion kit 667/1/33070/000 Rear Additional Panel kit 667/1/33001/000 Isolator Locking kit 667/1/33073/000 Cabinet mounted Cut-out Connection kit 667/1/33072/000 Expansion Cabinet kit 667/1/32900/000 Expansion Cabinet kit ELV Master Switch 667/1/33080/000 LSLS Expansion Cabinet Kit 667/1/33007/000 Screw Lock Key 667/2/20234/000 Manual Panel (Intersection Controller) 667/1/27056/001 DFM Lens Kit 667/1/27104/000 ELV Solar Cell Kit 667/1/10039/024 Tactile kit (ELV, non-switched;combined motor and drive unit) 667/7/17390/048
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Tactile Kit (ELV, switched;separate motor and drive unit) 667/7/17390/148 Tactile Kit (ELV, switched;fault o/p;combined motor and drive unit) 667/7/17390/248 ST900 ELV SDE/SA and IRM/IMU Power adapter Kit 667/1/33006/000 ST900ELV Low Inrush Transformer Assembly (20A only) 667/1/32980/500
AA..11..11 UUKK OOnnllyy ST900 ELV Controller Cabinet UK 20A Single LSLS Grey 667/1/32900/020 ST900 ELV Controller Cabinet UK 40A Single LSLS Grey 667/1/32900/040 ST900 ELV Controller Cabinet UK 20A Single LSLS Black 667/1/32900/021 ST900 ELV Controller Cabinet UK 40A Single LSLS Black 667/1/32900/041 ST900 ELV Controller Cab UK 20A Single LSLS Low Inrush Grey 667/1/32900/520 ST900 ELV Controller Cab UK 20A Single LSLS Low Inrush Black 667/1/32900/521 Gas Plinth 667/1/21150/002
AA..11..22 NNoonn--UUKK OOnnllyy ST900 ELV Controller Cabinet Non UK 20A Single LSLS Grey 667/1/32900/120 ST900 ELV Controller Cabinet Non UK 40A Single LSLS Grey 667/1/32900/140 ST900 ELV Controller Cabinet Non UK 20A Single LSLS Black 667/1/32900/121 ST900 ELV Controller Cabinet Non UK 40A Single LSLS Black 667/1/32900/141 ST900 ELV Non UK Rack Kit 20A Single LSLS 667/1/32900/900 Lightning Protection Kit – Mains Surge Arrester (Non UK) 667/1/27118/000 Lightning Protection Kit – Telephone (Non UK) 667/1/26271/000 Manual Panel Signals On/Off and DFM Assembly (Non UK) 667/1/27056/301
AA..11..33 OOppttiioonnaall PPaarrttss Integral TC12 OTU Kit 667/1/27004/000 Gemini2 667/1/32600/000 SDE/SA 667/1/27005/000 Only required if SDE/SA Card fitted:
Loop Detector Backplane 667/1/15990/003 Detector Termination KOP 667/1/15854/000
IRM/IMU Facility 667/1/27007/000
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AA..22 SSppaarreess LLiisstt In addition to the spares listed below, many of the parts listed in section A.1 may be ordered as replacement items. Contact Siemens Poole for details.
AA..22..11 CCoonnttrroolllleerr FFuusseess The following table lists the fuses fitted in the controller. Fuses should only be replaced with ones of similar rating and type.
Electricity Company Cut-out (Standard ST900ELV)
The Max size of this fuse should not exceed 100A (without reference to STC Poole). Maximum prospective short circuit current must not exceed 16,000A. Rating depends on application but 45A minimum is recommended up to 20A load
Electricity Company Cut-out (ST900ELV Low Inrush)
Max size and Maximum prospective short circuit current as above. Recommended rating is 25A ELV load
