automatic level crossing system spa-5/lva...

TECHNICAL DOCUMENTATION No:

DTRen-2008/ SPA-5/LVA

Total Page:

B AUTOMATIC LEVEL CROSSING SYSTEM SPA-5/LVA

pages: 44 1

All rights reserved. Copying and publishing without prior permission of Bombardier Transportation (ZWUS) Polska is prohibited

AUTOMATIC LEVEL CROSSING SYSTEM

SPA-5/LVA

December 16th, 2008

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B DTRen-2008/SPA-5/LVA Rev.: a

Bombardier Transportation (ZWUS) Polska Sp. z o.o.

TABLE OF CONTENTS:

1 DOCUMENT REVISION 3

2 ABBREVIATIONS AND DEFINITIONS 3

3 APPLICATION 4

3.1 PRODUCT DESTINATION...................................................................................................................... 4 3.2 PRODUCT DESCRIPTION ..................................................................................................................... 4 3.3 APPLICATION SCOPE.......................................................................................................................... 4

4 TECHNICAL DESCRIPTION 5

4.1 TECHNICAL DATA............................................................................................................................... 5 4.2 CONSTRUCTION AND CONFIGURATION................................................................................................. 8

4.2.1 System configuration ....................................................................................................................... 8 4.2.2 ERR-20 – LX shelter construction ................................................................................................... 9 4.2.3 Power supply rack ......................................................................................................................... 10 4.2.4 Control rack ................................................................................................................................... 11 4.2.5 LX start procedure ......................................................................................................................... 12

4.3 LX SYSTEM STRUCTURE................................................................................................................... 13 4.3.1 System structure............................................................................................................................ 13 4.3.2 Power supply system..................................................................................................................... 15 4.3.3 Interface between SPA-5/LVA and interlocking system................................................................ 16 4.3.4 EHZ-8 – LED Road Signal............................................................................................................. 22 4.3.5 Electrical Gate Machines............................................................................................................... 24 4.3.6 EAR-1 – Control Panel (CP).......................................................................................................... 26

4.4 SYSTEM ELEMENTS.......................................................................................................................... 27 4.4.1 Programmable Logic Controllers (PLC) ........................................................................................ 27 4.4.2 EMF-6 stabilized DC/DC power converter module....................................................................... 28 4.4.3 EDL-5 DC/AC converter ............................................................................................................... 29 4.4.4 EMK-2 Battery voltage control module.......................................................................................... 30 4.4.5 EMB-10 Safety Breaker Module................................................................................................... 31 4.4.6 EMH-2 Manual Control Unit.......................................................................................................... 33 4.4.7 EDG-4 Audible alarm generator .................................................................................................... 35 4.4.8 EZE-2 Event Logger ...................................................................................................................... 36 4.4.9 EDZ-30 module ............................................................................................................................. 37 4.4.10 Auxiliary elements ......................................................................................................................... 38

4.5 ENVIRONMENTAL CONDITIONS .......................................................................................................... 39 4.6 PRODUCT SYMBOL........................................................................................................................... 40

5 SAFETY OPERATION RULES 42

6 PACKAGING, STORAGE AND TRANSPORT 42

6.1 ERR-2 SHELTER.............................................................................................................................. 42 6.2 OTHER ELEMENTS............................................................................................................................ 42

7 REMOVAL AND RECYCLING 43

8 RELATED DOCUMENTS 44

9 MANUFACTURER 44

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1 DOCUMENT REVISION

Revision Date Author Remarks Change No.

2008.12.16 Bartłomiej Pawełek Document created

0 2009.06.17 Tomasz Pisarek Document verification E150/2009

a 2009.11.02 Bartłomiej Pawełek Update CP chapter, figures update E317/2009

2 ABBREVIATIONS AND DEFINITIONS

LX Automatic Level Crossing System. Set of devices that automatically warn road users about approaching trains.

LX disengagement (released state)

LX status when warning devices are active and don’t forbid road users to enter the crossing.

LX engagement LX status when warning devices are active and forbid road users to enter the crossing.

LX safe state LX state when normal operation of the system is stopped, road signals forbid road users to enter the crossing (as long as batteries are full).The only way-out of the safe state is manual system restart.

Critical failure Failure that causes loss of the system operation credibility and causes that system falls to the safe state, i.e. loss of communication between control channels, no PLC power supply, software operation failure detection.

PLC Programmable Logic Controller

CP Control Panel

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3 APPLICATION

3.1 Product destination

Automatic Level Crossing System is destined to assure safety on crossings of railway tracks and public roads. It automatically warns road users about trains approaching to the crossings. It can be installed on level crossings with barriers or half barriers situated on one- or more-track railway lines equipped with electrical traction or having no traction at all. Railway line can be equipped with line block of any technology or it can have no such system.

SPA-5/LVA system must be able to ensure safe rail and road traffic operation at following crossing types:

a) Unguarded level crossings equipped with automatic light signalling (train-operated or operated from the station interlocking system)

b) Guarded level crossings equipped with automatic warning light signalling and with automatic or semiautomatic barrier booms of electrical gate machines (barrier booms close automatically but open by means of button pressing by gate keeper)

c) Unguarded level crossing equipped with automatic light signalling with automatic barrier booms of electrical gate machines, which may have a supervisory monitoring at the nearest station and C.T.C control office.

3.2 Product description

Automatic Level Crossing System SPA-5/LVA is designed in accordance with requirement specification defined by Latvian Railways.

Technical data of the system is presented in paragraph 4.1.

SPA-5/LVA is connected with Ebilock interlocking system. Ebilock is responsible to send engagement and disengagement commands to LX. Depending on the system state (engagement or disengagement) warning devices perform their tasks according to the requirements. In case of guarded crossings a control panel is used to enable operations of the gate keeper.

Information about LX status is sent to the remote control device that is placed in the dispatcher’s room. Remote control device enables supervision of the LX system operation and logging of events and faults.

3.3 Application scope

The number and type of equipment applied in the LX system can be defined for each specific application. The version of a control unit as well as all the facilities of the LX system can be adapted according to the specific requirements and configuration of any crossing. Product symbol (4.6) defines the most important configuration parameters of the system.

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4 TECHNICAL DESCRIPTION

4.1 Technical data

Parameter Data

Remarks

Power supply

Primary power supply voltage

230V (+10%, -15%) / 50 Hz

Power consumption: Maximum

Average

1500W

300W

Stabilised power supply DC/DC converters to charge batteries

EMF-65 26-31 V DC ManufacturerBT ZWUS

Buffered power supply of LX devices

Types of batteries

24 V DC, 2-4 batteries

24V/85Ah,

24V/115Ah,

24V/150Ah

e.g.

A512/85A

Time of normal system operation in case of no supply 230V/50Hz

min. 8h / 100 pairs of trains

Warning devices

LED Road signal:

- Flashing frequency - LED unit

- Power consumption

EHZ-8

0,67Hz

EHE-2

4W per one LED unit

ManufacturerBT ZWUS

Audible alarm:

- Supply voltage - Pulse frequency - Sound intensity

Sound generator EDG-40 and loudspeaker EDE-1000

12V or 24V DC 1Hz ±20% 60÷80dB in the distance of 7m

ManufacturerBT ZWUS

Electrical gate machine:

- Barrier boom length - Supply voltage - Type

EEG-1

<= 12m 24VDC no self-falling

ManufacturerBT ZWUS

Barrier boom:

- Length

ESD-8

3,5 – 6,5m

ManufacturerBT ZWUS

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- Braking boom detector circuits

- Brake-away protection

Yes

multiple use (with ball safety device)

Interlocking interface

Interlocking (Ebilock) interface

EDJ-5 (electronic interface)

ManufacturerBT ZWUS

Control System

Control and power supply unit

ERR-20 – LX shelter

ERR-24 – LX rack

ManufacturerBT ZWUS

Control system:

- CPU

- RAM

- Program Memory

- Program cycle

2 x PLC series 2003

7CP476

750Kbyte SRAM,

1,5Mbyte Flash PROM

50ms

ManufacturerB&R (Austria)

Automatic/manual operation

Automatic operation System engagement / disengagement from the interlocking system

Manual operation Manual system engagement / disengagement from the shelter/rack and from the Control Panel

Monitoring and diagnostics

Remote Control Device:

- Visualization of 1-8 LXs

- Registration time

ERP-7

Panel PC with 12”LCD touch-screen 2 x 8 LED 2 x Audible alarm

at least 1 month

ManufacturerBT ZWUS

Local Diagnostic Panel:

- Visualization - Operation

EZG-17

LCD display 2x40 digits 5-key keyboard

Manufacturer BT ZWUS

Event Logging Unit

- Data access - Registration

EZE-2

PC application 65000 records

ManufacturerBT ZWUS

Safety

Hardware - 2 independent PLC controlled channels A and B

- 2 independent power supply

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channels

- Both channel realising the same functional requirements

Software - A and B channel,

- 2 different compilers,

- 2 programming languages,

- error detecting codes, CRCs

- program sequence check

LX engagement

LX disengagement

1 out of 2

2 out of 2

Cyclic on-line testing - Testing of detectors and warning devices

- Testing of intermediate modules

Environmental parameters

Temperature range for track-side equipment placed directly on field or in cabinets

-40°C ÷ +70°C

Relative humidity 0 ÷ 95% without water vapour condensation

Protection degree at least IP44 for shelters

Protection against electric shocks

P 302 25-30-AC

Residual-Current Circuit Breaker 30mA Power supply –24V DC

Fire protection Constructional elements of the racks non-flammable; electronic modules designed with excess assuring that their surface temperature does not exceed the ambient temperature more than 15%

Burglary protection LX system control unit receives signal indicating that the ERR-20 shelter door is open and sends information about this to the Remote Control Device.

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4.2 Construction and configuration

4.2.1 System configuration

SPA-5/LVA consists of the control and supply devices ERR-2 (in shelter or as a rack to be placed in the interlocking shelter) and external devices. Application configuration is defined by a product symbol (see 4.6).

Following external devices can be connected to the SPA-5/LVA:

Device Quantity

EHZ-8 LED Road Signal with two or three aspects

max 6

EEG-1 Gate Machine with ESD-8 boom max 8

EDG-4 Audible Alarm max 4

EDJ-50 Interlocking Interface 1

Control Panel 1

EZE-2 Event Logger 1 (option)

EZG-17 Local Diagnostic Panel 1

ERP-7 Remote Control Device 1

EAR-1 Control Panel 1 (option)

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4.2.2 ERR-20 – LX shelter construction

SPA-5/LVA in ERR-20 variant is based on a standard shelter type EST-6022/LVA. Control and power supply modules of LX SPA5/LVA are mounted inside this shelter. Control racks (A and B) are mounted on the left side of the shelter, power supply rack is installed on the right side.

All the cables from external devices go inside the shelter through respective cable inlets located in the shelter’s floor and then they are connected to the terminal strips. Further the cables are distributed, via terminal strips, to particular modules of the control unit.

1604 1764

2452

Dimensions of the shelter ERR-20 (housing type EST-6022/LVA)

Figure 1

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4.2.3 Power supply rack

Power supply rack

Figure 2

List of elements placed on power supply rack.

1. Rack frame.

2. Terminal strip with outputs of channel A power source circuits and voltage control circuits of channel A.

3. Terminal strip with outputs of channel B power source circuits and voltage control circuits of channel B.

4. DC/DC converters EMF-65 for battery charging for A and B channel.

5. Power distribution terminal with fuses.

6. Mains control circuits.

7. Terminal strips of first mains.

8. Terminal strips of second mains (optional).

9. N/A.

10. Separation transformer.

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11. Electrolytic capacitor.

12. Rectifier.

13. Grounding terminal strip.

14. Battery.

4.2.4 Control rack

Control racks are configured according to the specific requirements of the application. The example of the rack is presented below.

Example of Control Rack -channel A (KANAŁ A) and channel B (KANAŁ B)

Figure 3

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The most important elements placed on Control Rack.

5. EMB-10 Safety breaker module

6. EDJ-50 Ebilock interface

7. Power distribution terminal with over-current fuses (channel A)

8. Power distribution terminal with over-current fuses (channel B)

11. PLC A and PLC input, output modules

12. PLC B and PLC input, output modules

23. EMH-2 Manual Control Unit and StkA, StN1, StN3 Contactors

24. EDJ-50 Ebilock interface or EDL-51 module (configuration dependant)

25. RS-485 repeaters (galvanic isolation) for road signals and EDG-40 module (channel A)

26 RS-485 repeaters (galvanic isolation) for road signals and EDG-40 module (channel B)

27 Lighting protection and EDZ-3 modules set (channel A)

28 Lighting protection and EDZ-3 modules set (channel B)

49 RAD ASM-20 modem for interface Ebilock

4.2.5 LX start procedure

Because of safety reasons SPA-5/LVA can be started (restarted) only manually at the crossing.

Procedure of SPA-5/LVA system start/restart:

a) Switch-off LA and LB fuses on terminal strips LAB on Control Rack A and LBB on Control Rack B.

b) Switch-on LA and LB fuses (at the same time).

c) Wait until green LEDs “RUN” of CP476 PLC cards are on.

d) Turn left START switch (EMH-2 module) and pull it.

e) After at least 2 seconds push START switch.

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4.3 LX system structure

4.3.1 System structure

A Typical layout of the SPA-5/LVA LX is presented at the Figure 4. Types and number of devices at LX, as well as the presence and types of the interfaces are individually defined for the specific system localization.

ERR-2 (SPA-5/LVA control and power supply unit) is connected via serial transmission link with the Ebilock interlocking system. Separate transmission link connects ERR-2 with Remote Control Device (ERP-7).

Ebilock sends orders (e.g. engagement and disengagement commands) to LX and receives statuses and simplified diagnostic messages from LX.

Control Room

ERR-2

TRACK2

TRACK1

N2 N4

N1N3

S1

S2

S3

S4

Dz1

Dz2

EZG -17

RS485

MODEM

MODEM

PC

EBILOCK

ERP-7

ControlPanel

(optionally)

Typical layout of LX

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Local Diagnostic Panel EZG-17 and Event Logger EZE-2 are foreseen to be used directly at the crossing – in the LX shelter.

ERP-7 remote control device should be installed in the dispatcher’s room. In case of the standard transmission cable the distance form ERP-7 to LX should not exceed 5km. For longer distances amplifying units or modems must be used.

Connections of elements of SPA-5/LVA (ERR-2) are shown at Figure 5 and Figure 6.

SPA-5/LVA structure - example.

Figure 5

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4.3.2 Power supply system

SPA-5/LVA power supply system is located on a dedicated rack. Power supply is divided into two parts – 230V AC and 24V DC part.

ERR-2 - power supply structure.

Figure 6

230V AC voltage part

230V AC voltage part is responsible for the supply of the system batteries, fun, heater, lighting and also electric socket inside shelter. TRA and TRB transformers assure a galvanic insulation of the system supply from the 230V AC input power supply.

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24V DC voltage part

Low voltage part is responsible for the constant batteries’ charging and for the power supply distribution for all the devices of ERR-2. Batteries (24V DC) are main power supply of the whole LX equipment (modules on the racks and external devices).

Voltage from transformers (about 29V AC) is to be rectified and stabilized. EMF-65 suppliers ZsA and ZsB are destined to charge the batteries. Information about performance of ZsA is passed to the PLC A and information about performance of ZsB is passed to the PLC B. EMK-2 module checks the value of the battery voltage from which is powered. Output 5 of EMK-2 is used to pass the information about the voltage level of the battery to PLC. Threshold value is about 21V. Output 7 of EMK-2 controls the coil of StA (StB) contactor (depending on the control channel). StA (StB) switches-off the load when the battery voltage is too low.

4.3.3 Interface between SPA-5/LVA and interlocking system

Interlocking system is responsible for sending to SPA-5/LVA engagement and disengagement commands during normal automatic operation. SPA-5/LVA operation is based on the electronic interface with the interlocking system Ebilock. Ebilock sends commands to LX and receives back confirmations and simplified diagnostic messages.

Different variants of the connection between LX and Ebilock can be prepared depending on the design requirements (distance between LX rack and interlocking rack, number of LXs connected to the same station, etc.). Generally 3 types of devices are necessary to realize interface between SPA-5/LVA and Ebilock: electronic interface EDJ-5, Protocol Converter Unit PCU and modem (e.g. RAD ASM-20).

PCU (Protocol Converter Unit)

PCU performs a bidirectional conversion of HDLC data streams into Ethernet data streams used at the main level of the Ebilock communication. HDLC (High Level Data Link Control) is a bit-oriented synchronous data link layer protocol developed by the International Organization for Standardization used in transmission between Ebilock and its object controllers.

EDJ-5 (transmission converter).

EDJ-5 is a bidirectional converter of HDLC data streams (maximally two streams) required by Ebilock into one RS-232 data stream used by the object controller. SPA-5/LVA works as an object controller.

Modem (e.g. RAD ASM-20)

Modems are required in case of long distances between elements of the SPA-5/LVA – Ebilock interface. Modems are connected with four wire cable and work in full duplex mode. Modem from one side has a digital interface (HDLC or V.24/RS232) and on the other side diphase modulated signal (EUROCOM Std. D1) to provide immunity from background noise, eliminate a normal line distortion and enable efficient transmission and reception of serial data over a twisted pair cable for assurance long distance transmission. Modems can be placed between

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SPA-5/LVA PLCs and EDJ-5 modules or between EDJ-5 modules and PCU modules depending on the application design requirements.

Variants of the interface between SPA-5/LVA and Ebilock are specified below.

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4.3.3.1 SPA-5/LVA – Ebilock interface - variant 1

a) Distance – ERR-2 located far from station container

b) LX configuration – without barrier machines

c) Modem connection – one channel connection (no redundancy)

d) Digital interfaces of modems - V.24/RS-232

e) Example – interface between station Mezare (km154.4) and LX km 153.991

ERR-2

MODEM

Type: ASM-20

EDJ-5

PCU

PCU

SW

ITC

H

SW

ITC

H

MODEM

Type: ASM-20

NETWORK

STATION INTERLOCKINGlocated at station, or another container

PLC BCA

N

RS232

PLC A

CA

N

SPA-5/LVA – Ebilock interface - variant 1.

Figure 7

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a) Distance – ERR-2 located far from station container

b) LX configuration – with barrier machines

c) Modem connection – two channel connection (transmission channel redundancy)

d) Digital interfaces of modems - HDLC

e) Example – N/A


Figure 8

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a) Distance – ERR-2 located in the station container

b) LX configuration – with or without barrier machines

c) Modem connection – N/A

d) Digital interfaces of modems – N/A

e) Example – interface between interlocking SER (km 136.27) and LX km 135.966


Figure 9

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a) distance–

- ERR-2 is located in the station container (first LX)

- ERR-2 is located far from the station container (second LX)

b) LX configuration –

- with or without barrier machines for the first LX

- without barrier machines for the second LX

c) modem connection –

- one channel connection (no redundancy) for the first (distant) LX

- no modems necessary for the second LX

d) digital interfaces of modems –

- V.24/RS-232 for the first LX

- no modems for the second LX

e) example – interface between interlocking SER (km 136.27) and LX km 135.966 and LX km 132.72

NOTE: The same PCUs are used for both LXs

ERR-2

MODEM

Type: ASM-20

PLC BCA

N

RS232

PLC A

CA

N

ERR-2 RACK

SW

ITC

H

SW

ITC

H

EDJ-5PCU

PCU

PLC B

CA

N

RS232

PLC ACA

N

MODEM

Type: ASM-20

EDJ-5

STATION INTERLOCKINGlocated at station or container

ETHERNET NETWORK


Figure 10

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4.3.4 EHZ-8 – LED Road Signal

The signal has a modular design. The steel mast is a bearer. The mast should be mounted on the concrete foundation.

It is possible to install the following signal units on the mast:

a) Signal lamps equipped with EHE-2 LED optical unit

b) Audible warning unit

c) Road signs: „St.Andrew’s cross” and other as appropriate

EHZ-8 is intended for emitting light and audible signals for the purpose of controlling the road traffic and ensuring safety at the level crossing. SPA-5/LVA is capable of controlling of maximally 6 EHZ-8 road signals with two or three aspects. SPA-5/LVA is able to control up to 4 audible alarms (bells).

EHZ-8 road signal can be equipped with:

a) Two red light chambers (always)

b) One white light chamber (option)

c) One audible alarm (option)

Detailed information about EHZ-8 can be found in [2].

Below an example of EHZ-8 application is shown (road signals marked as S1-S4).

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Example of LX system with 4 EHZ-8 road signals with 2 bells (audible alarms).

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4.3.5 Electrical Gate Machines

SPA-5/LVA system can be equipped with up to 8 electrical gate machines (EEG) equipped with barrier boom ESD-8 [3].

Figure 12 shows scheme of the control circuits of the four gate machines N1, N2, N3, and N4. Gate machines N1, N3, N5 and N7 are powered by A channel and gate machines N2, N4, N6 and N8 are powered by B channel.

In LX disengagement state the barrier movement direction is set to “down”. Barriers remain in the upper position because individual movement contactors are off. Motors of barrier machines are not powered and voltage is present on breaker.

When LX is engaged then after configured time delay, PLCs will switch on respective contactors of the individual movement. That causes the breaker to be released and voltage is connected to the motor. Barriers go down.

When barrier machine reaches down position then PLC switches off individual contactor that controls barrier’s movement. Information about down position is received from the limiter switch.

Change of the LX state to disengagement causes that PLCs generate rectangular waveform to “contactor of the movement direction” (EDL-51), and movement direction is set to up. Breakers are released and barrier machines start to rise.

Barrier machines’ control signals

Figure 12

NOTE!

Both PLCs must generate a correct rectangular wave to change the direction of the gate machines to “rising” (decided by EDL-51).

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When all barriers reach the upper position then the whole circuit is prepared to close barriers.

Continuity of the barrier is checked. If lack of the barrier continuity is detected then respective barrier machine will not move any more.

Related documents:

DTRen-2009/EEG-1 [3], DTRen-2009/EEG-3 [4], DTRen-2003/ESD-8 [5]

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4.3.6 EAR-1 – Control Panel (CP)

Control Panel (CP) is a device used for manual control of the LX system. It is installed outside ERR-2 and operated by the cross-keeper. CP presence in LX system configuration is optional and depends on the specific LX requirements.

Orders set by operator of the Control Panel have higher priority than those sent from EBILOCK or worked out in PLCs. CP is equipped with: Mono-stable and bi-stable switches, LEDs indicating state of the controlled signalling equipment, Bell (optional).

Example of orders that can be executed from the Control Panel: Turn bell off Engage LX Emergency gate machines open Emergence gate machine blocking in upper position Engage LX and switch-on barrage signals Permission for automatic open LX Test CP LEDs NOTE! CP functionality depends on the specific requirements of the application.

Shelter

ERR-2

Control Panel

Bell - inside

CP - Front PanelSwitchesDiodes

Connection

General view of Control Panel

Figure 13

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4.4 System elements

4.4.1 Programmable Logic Controllers (PLC)

Two PLC controllers of 2003 series manufactured by Bernecker & Rainer (Austria) are placed at the control rack. PLCs’ main task is generation of output signals, which control signalling and executive devices on a basis of values of current logic input signals. Programs in A and B channel are performed independently but for the system normal operation both PLCs have to work properly. The controllers are connected with each other via CAN standard transmission link. This link enables synchronisation of the operation of some LX devices and allows detecting any possible A/B synchronisation faults which is identified as one of the LX system critical failures.

Both programs have been designed in different programming languages by two separate groups of programmers.

CPU 7CP476.60-1

1 interface RS232 1 interface CANbus sub-modules -1÷4

I/O module 7DM435.7

8 inputs, 24VDC,1ms 8 outputs, 24VDC, 05A

Module 7DI439.7

6 inputs, 24VDC, 1ms

I/O module 7DM465.7

16 inputs, 24VDC, 1ms

16 outputs, 24VDC, 0.5A

Module 7IF321.7

Interface RS422/RS485

PLC modules

Figure 14

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4.4.2 EMF-6 stabilized DC/DC power converter module

EMF-6 stabilised power DC/DC voltage converter lowers non-stabilised input voltage to the stabilised and adjustable in a certain range output voltage. In SPA-5/LVA EMF-65 module is used to charge batteries

- Uout=25÷29V

- Maximal output current Iout max=10A.

EMF-65 - block diagram.

Figure 15

There are two separated control circuits of the output current of the EMF-6 module. They are galvanically separated from the EMF-6 output current. Each of the control circuits is supplied from the independent DC voltage and generates two logic output signals Ip1_A(B) and Ip2_A(B) which are interpreted by the PLC program. Logical value of Ip1_A(B) and Ip2_A(B) depends on the value of the output current of EMF-6 in comparison to two threshold values (Ip1 and Ip2; Ip2 > Ip1). Ip1_A(B) and Ip2_A(B) are in low state (L) if EMF-6 output current does not exceed Ip1 threshold value. Ip1_A(B) is in high state (H) and Ip2_A(B) is in low state if EMF-6 output current value (I) is in the range Ip1 < I < Ip2. Ip1_A(B) and Ip2_A(B) are in high state when I > Ip2.

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EMF-6 connections

Figure 16

NOTE

EMF-65 applied in SPA5/LVA utilizes only first current threshold level Ip1.

PLC A

PLC BIp1_B

Ip2_AIp1_A

Ip2_B

EMF-6

+Uin

+Uout

4.4.3 EDL-5 DC/AC converter

EDL-5 converter, supplied from the battery, is used to control contactors responsible for the direction of the movement of barrier machines (up or down). 24V/50Hz rectangular wave is obtained on EDL-5 output. Output signal of EDL-5 converter can be achieved only if control signals from PLC outputs are correct.

EDL-5 - block diagram.

Figure 17

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4.4.4 EMK-2 Battery voltage control module

EMK-2 module checks the value of the battery voltage from which is powered. The output 5 of EMK-2 is used to pass the information about the voltage level of the battery to PLC. Output 7 of EMK-2 controls the coil of power supply contactor. The contactor switches off the load when the battery voltage is too low.

If the output voltage of a battery will lower below threshold voltage (typically 21,6V ± 0.5V) then after defined time delay ( typically 30-60 seconds ) main contactor will be switched off and by this way batteries will be disconnected from the rest of the system. If the battery voltage will lower below low threshold value (typically about 17 V ± 0.5V) then disconnection of batteries will be done without any delay. Batteries will be connected again if battery voltage will be charged up to top voltage threshold (typically 26V).

EMK-2 - block diagram.

Figure 18

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4.4.5 EMB-10 Safety Breaker Module

The safety circuit-breaker module is responsible for reliable cutting off the signals which control the safety critical devices if any critical failure in the LX system control unit occurs.

The safety circuit-breaker is activated from both control channels by the rectangular wave (OutGen1A and OutGen1B) generated by the PLC A and PLC B. Signals generated in PLC A (OutGen1A) pass through the whole hardware structure of the EMB-1 module and are directed as a feedback (InGen1B) to the digital inputs of the adjacent PLC B. The same is done with rectangular wave generated by PLC B.

If EMB-10 works correctly then as long as both controllers operate correctly and rectangular waves are transmitted to the EMB-10 the output signals from EMB-10 (galvanically separated UA and UB voltage) supply input/output modules of PLCs responsible for the operation of the safety critical functions. In case of any EMB-10 hardware failure or in case of any PLC software critical failure rectangular waves will be distorted and it will result in cutting-off of the EMB-10 output signals Ua and Ub and cutting-off feedback signals to PLCs. Lack of power supply of the PLCs input/output cards causes that warning devices go the strictly defined status which is treated as safe. Normal program operation of PLCs will be stopped. As a result LX system will fall to the safe state from which the only way-out is via manual restart of the system.

EMB-10 Safety Breaker module and its location in the whole LX system architecture.

Figure 19

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In the safe state of LX all road signals are switched-on with a steady light, barrier machines remain in the position from the moment of the critical failure appearance.

Normal operation of SPA-5/LVA is possible after removal of the failure and after system restart. System restart procedure requires to restart both PLCs and to depress and afterwards to press the START key of EMH-2 module (see chapter 4.2.5).

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4.4.6 EMH-2 Manual Control Unit

EMH-2 module consists of switches used for restart and manual operation of the LX system.

EMH-2 module - front view.

Figure 20

START switch

START switch is used to perform LX system restart (PLCs program activation).

O/Z switch

O/Z switch is used to engage (Z) or disengage (O) the system manually. O/Z switches are doubled – they are placed not only in EMH-2 module but also in a small case for manual LX operation outside LX shelter (O/Zz switch). That enables to control LX system without opening of the shelter.

NOTE!

There is a logical “OR” between order “LX engage” sent from Ebilock and “manual engage” order (Z position of O/Z or O/Zz switch). That means that as long as O/Z or O/Zz switch is in Z position Ebilock will be not able to disengage LX.

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Z/L switch

Z/L switch enables to choose the master of the transmission between LX and external devices (remote control device ERP-7 and local diagnostic panel EZG-17). In Z position ERP-7 remote control device is a transmission master and EZG-17 listens to the telegrams and informs about LX status. Choosing L position of the switch causes that transmission to remote control device ERP-7 is broken (local diagnostic panel EZG-17 is a transmission master in such situation; event logging is still possible if EZE-2 module is used). Z/L switch can be equipped with blocking key.

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4.4.7 EDG-4 Audible alarm generator

EDG-4 sound generator is a programmable source of the acoustic signal that is delivered to the loudspeaker EDE-1. Feedback signals (current control circuit) from the generator can be used to check if audible alarm works properly.

EDG-4 module circuit

Figure 21

Activation and deactivation of the audible alarm is realised by digital PLC output OutA. If OutA is in high state then audible alarm is active. If OutA is in low state then audible alarm is not active.

EDE-1

GENERATOR(EDG-4)

+VA

PLC A

Ip1 A

Ip2 A

Out A

Out L

Ip1 B

Ip2 BPLC B

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4.4.8 EZE-2 Event Logger

EZE-2 event logger can store the data about events and failures in records with the date and time. EZE-2 is connected to the CANBUS transmission link between PLC A and PLC B. Event logging is possible independently on the status of the transmission to the remote control device. Time used by EZE-2 is synchronised with the time used by ERP-7.

Event logger EZE-2 – block diagram.

Figure 22

EZE-2 event logger uses FLASH memory with capacity for at least 65000 events or failures to be logged in the buffer. 8 LED indicators inform about EZE-2 performance. Meaning of LEDs is as follows:

D1 (green) - power supply,

D2 (yellow) - not used

D3 (yellow) - not used

D4 (yellow) - CAN transmission from PLC to EZE-2 (Z2 connection),

D5 (yellow) - CAN transmission from EZE-2 to PLC (Z2 connection),

D6 (yellow) - RS232 transmission from PC to EZE-2 (Z3 connection),

D7 (yellow) - RS232 transmission from EZE-2 to PC (Z3 connection),

D8 (red) - fault.

If D1 is on constantly and D8 is off then EZE-2 works properly. During normal operation of EZE-2 D5 should flash (100ms for every few seconds) – that means that EZE-2 communicates with PLCs.

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4.4.9 EDZ-30 module

EDZ is a power module to control lamps of the control panel CP. One EDZ-30 module consists of two independent circuits. Each of circuits is responsible for the activation of the lamp (green LED on means lamp activated from PLC) and checking of the lamp circuit’s current (red LED on; not used in SPA-5/LVA).

The front panel of EDZ-30 module is shown below.

AMPLIFIER 1Output 1

8

4

+U1

-U1

5

7

EDZ-30

Input 1

D1V

D1C

AMPLIFIER 2Output 2

2

10

+U2

-U2

11

9

Input 2

D2V

D2C

1

3

EDZ-30 - internal scheme.

Figure 23

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4.4.10 Auxiliary elements

Door switches

Figure below shows a connection diagram of door’s switches, mechanically coupled with locks. Position of upper and lower lock is monitored by controller PLC A, and position of middle lock by PLC B.

13 14

13 14 +UA

+UB InDrzwi B

13 14 InDrzwi A

Control box door switch

Upper door switch

Lower door switch

PLC A

PLC B

Connection of hut door switches.

Figure 24

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4.5 Environmental conditions

SPA-5/LVA is able to operate in the following environmental conditions:

a) Temperature range from – 40°C to +70°C for track-side equipment placed directly on field or in cubicle

b) Temperature range from 0°C to +70°C for in-door equipment placed inside buildings and shelters

As a protection against electrical shocks all devices of ERR-2 are connected to the equipotential surface, residual-current breaker is used and shields for circuits with high voltage are used.

Smoke detector with fun circuit breaker and fire extinguisher are placed inside ERR-2 shelter for fire protection purposes.

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4.6 Product symbol

The product symbol (ERR-2xxxxxxx) depends on the application design and documentation. Table below presents the information about application variants of SPA-5/LVA and comprises possible product symbols.

Product symbol consists of several digits with unique meaning of every digit.

Product symbol Meaning

digit 2 control and power supply unit type

ERR-20xxxxxxx control and power supply unit in the shelter EST-6022

ERR-21xxxxxxx control and power supply unit in the shelter EST-6107

ERR-22xxxxxxx reserved

ERR-23xxxxxxx reserved

ERR-24xxxxxxx control and power supply unit as one-sided racks to be placed in buildings, containers

ERR-25xxxxxxx control and power supply unit as two-sided racks to be placed in buildings, containers

digit 3 tracks and detectors

ERR-2x0xxxxxx system without detectors

ERR-2x1xxxxxx reserved


ERR-2x3xxxxxx Non-standard number of detectors of EOC-1 or EOC-3 type



ERR-2x6xxxxxx Non-standard number of detectors of ELS-95 type

ERR-2x9xxxxxx Non-standard crossing with different types of detectors

digit 4 road signals

ERR-2xx0xxxxx system without road signals

ERR-2xx1xxxxx 1 road signal

ERR-2xx2xxxxx 2 road signals

ERR-2xx3xxxxx 3 road signals (S1 + S2 + S3)

ERR-2xx4xxxxx 4 road signals

ERR-2xx5xxxxx 3 road signals (S1 + S2 + S4)

ERR-2xx9xxxxx Non-standard number of road signals

digit 5 barrier machines and control panels

ERR-2xxx0xxxx system without barrier machines

ERR-2xxx2xxxx 2 barrier machines and control panel

ERR-2xxx3xxxx 3 barrier machines (N1 + N2 + N3) and control panel

ERR-2xxx4xxxx 4 barrier machines and control panel

ERR-2xxx5xxxx 3 barrier machines (N1 + N2 + N4) and control panel

ERR-2xxx9xxxx Non-standard solution for barrier machines

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digit 6 train warning signals

ERR-2xxxx0xx system without train warning signals

digit 7 interlocking connection

ERR-2xxxxx0xx System without interlocking connection

ERR-2xxxxx1xx 1 track or more than 2 tracks, electronic interface to EBILOCK, open line type

ERR-2xxxxx2xx 2 tracks, electronic interface to EBILOCK, open line type

ERR-2xxxxx3xx 1 track or more than 2 tracks, electronic interface to EBILOCK, station type

ERR-2xxxxx4xx 2 tracks, electronic interface to EBILOCK, station type

ERR-2xxxxx9xx Non-standard interlocking connection

digit 8 white lamp for road signals

ERR-2xxxxxx0x System without white lamps

ERR-2xxxxxx1x White lamp for 1 road signal (S1)

ERR-2xxxxxx2x White lamp for 2 road signals (S1+S2)

ERR-2xxxxxx3x White lamp for 3 road signals (S1+S2+S3)

ERR-2xxxxxx4x White lamp for 4 road signals (S1+S2+S3+S4)

ERR-2xxxxxx5x White lamp for 3 road signals (S1+S2+S4)

ERR-2xxxxxx9x Non-standard number of white lamps on road signals

digit 9 optional equipment

ERR-2xxxxxxx0 One mains 230V AC

ERR-2xxxxxxx1 Two mains 230V AC

ERR-2xxxxxxx9 Non-standard equipment

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5 SAFETY OPERATION RULES

Staff responsible for SPA-5/LVA system maintenance needs to have qualifications and valid licenses to perform works at the railway infrastructure according to the rules of the railway authority.

All works should be done according to respective maintenance instructions and guidelines. “Operating Manual” [6] “Maintenance Instruction” [7]

The operation of SPA-5/LVA consists of the operation of the control shelter/rack ERR-2 and of the operation of the remote control device ERP-7 and local control device EZG-17. Respective operational and maintenance instructions should be followed.

6 PACKAGING, STORAGE AND TRANSPORT

6.1 ERR-2 shelter

There are no special requirements for the container packing. During transportation the container is pre-packed with a plastic bubble wrap and placed at an open pallet.

Inside buildings the container should be stored indoor where relative humidity level can be in the range of 25% to 75% and temperature can be in the range of -10°C to +50°C (263÷323K). It is allowed to store containers outside buildings.

Container must be transported vertically with any means of transport not causing strong shocks. Batteries have to be taken down from racks during transportation.

6.2 Other elements

Packaging, transportation and storage of all other elements of Automatic Level Crossing System SPA-5/LVA is described in respective technical documentations.

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7 REMOVAL AND RECYCLING

After finish of SPA-5/LVA normal operation all devices on site have to be disassembled. If they are not vandalized, work properly and are not older than 20 years, they can be stored to be used as spare parts for other installations.

Materials used in SPA-5/LVA can be divided into four groups:

a) Plastic,

b) Ferrous metals,

c) Non-ferrous metals,

d) Others.

Plastic, ferrous and non-ferrous metals should be recycled if possible and all other materials can be dumped at waste dumps for non-toxic materials because they are not dangerous to the environment.

In case of the removal of batteries it is necessary to proceed according to the rules defined by the producer of batteries.

In case of dismantling of ERR-2 container it is necessary to proceed according to the procedure bellow.

a) Turn off power supply

b) Disconnect power supply cables and transmission cables.

c) Cables that are used in others systems but pass through ERR-2 container have to be properly connected protected against damage and left.

d) Separate the container from the foundation and disassembly it.

e) Dig the container foundation out of the ground.

f) Level the ground.

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8 RELATED DOCUMENTS

[1] Railway applications – Environmental conditions for equipment. Part3: Equipment for signalling and telecommunications.

EN 50125-3:2003

[2] EHZ-8 Road signal DTRen-2008/EHZ-8/LVA

[3] EEG-1 Electrical gate machine DTRen-2009/EEG-1

[4] EEG-3 Electrical gate machine DTRen-2009/EEG-3

[5] ESD-8 Barrier boom DTRen-2003/ESD-8

[6] Operating Manual X-4-02658en

[7] Maintenance Instruction X-4-02657en

9 MANUFACTURER Bombardier Transportation (ZWUS) Polska Sp. z o.o. ul. Modelarska 12 40-142 Katowice tel.: (+48) 32 730 50 00 fax: (+48) 32 204 22 44

– THE END –

Prepared: Bartłomiej Pawełek

Verified: Tomasz Pisarek

Approved: Alfred Kurkowski

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