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C64.65201 Issue 1 May 2013

CLS LITE Signal

OPERATION AND MAINTENANCE MANUAL

Document Reference C64.65201 Issue 1 May 2013

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C64.65201 Issue 1 May 2013

Table of Contents Document Control ................................................................................................ 3

1 Introduction ...................................................................................................... 3

2 Compliance Matrix ............................................................................................. 3

3 Specifications .................................................................................................... 4

4 Storage ............................................................................................................ 4

5 Installation ....................................................................................................... 5

5.1 Safety ............................................................................................................ 5

5.2 Pre Installation Checks ................................................................................... 6

6 Installation Method ........................................................................................... 6

6.1 Safety ............................................................................................................ 6

7 Signal Mounting and Alignment .......................................................................... 7

7.1 Electrical Connection ...................................................................................... 9

8 Changing the Door Opening Side ..................................................................... 11

8.1 Door Preparation .......................................................................................... 11

8.1 Frame Preparation ........................................................................................ 11

8.1 Refitting the Door ......................................................................................... 12

9 Post Installation Checks ................................................................................... 12

10 Maintenance Activity ...................................................................................... 12

10.1 Signal Husbandry ....................................................................................... 12

10.2 Service and Repair ...................................................................................... 13

10.3 Module Replacement .................................................................................. 13

10.4 End of Life Disposal .................................................................................... 14

11 Contact Us .................................................................................................... 15

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Document Control

It is the reader’s responsibility to ensure they have the correct version of this document. If in doubt, please contact Unipart Dorman to verify the current issue status.

Issue Number Dated Reason 1 May 13 Initial Issue

1 Introduction Following the introduction of the Unipart Dorman Integrated Lightweight Signal (iLS) which is a versatile yet simple signalling solution for installation in a wide variety of applications, a requirement for the enhanced optics and better maintenance characteristics of the iLS module but housed in a classic Unipart Dorman Colour Light Signal frame was identified. The new signal is designed to retain the same interface with all standard modular route relay, geographical and solid state interlocking systems and infrastructure used in the UK; and the use of modular based construction with plug coupled electrical components reduces test and commissioning time to a minimum. The new lens/hood arrangement gives excellent protection against phantom aspects and is designed to be self-cleaning. This allows maintenance cost reductions to be made over the lifetime of the signal. The new module configuration also includes a Voltage Free Contact Proving capability where specified and the signals can be adapted to either single or double cut proving contacts.

Where Volt Free Contact Proving is used a less power hungry signal drawing just 45mA is available giving a consumption of just 5 Watts.

2 Compliance Matrix

The following table shows the Specifications and/or Regulations which the signal is compliant with.

Specification Title

Railway Group Standard GK/RT0045 (Lineside Signals, Indicators and Layout of Signals)

Network Rail Standard NR/L2/SIG 10062 (Requirement Specification for the Performance of Long Range Colour Light Signals)

Network Rail Approval Certificate PA05/04240

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3 Specifications

For all elements: Nominal Voltage 110Vac Operating Voltage Max 121Vac, Min 88Vac Operating Temperature Range -25OC to +40OC Flashing Aspects Flashing controlled by the

Interlocking Current Proving Variant Nominal Operating Current 300 mA @ 110Vac Relay Based Interlocking BR941A Solid State Interlocking (SSI) Current Path 1 or 4 110V Low Power Consumption (5 Watt CLS) Variant with Voltage Free Contacts Nominal Operating Current 45 mA @ 110Vac Relay Based Interlocking BR941A Solid State Interlocking (SSI) Current Path 1 or 4 Light Output Colour Classification Red BS1376 Class C (Restricted) Yellow BS1376 Class B Green BS1376 Class C Signal Performance Categories Colour Light Signal Category 1 & 4 (The signal is available in Wide and Narrow Beam variants in Medium Range)

4 Storage The signal is supplied complete on a large pallet with protective packaging which should not be removed prior to delivery to site. (All packaging materials should be disposed of in accordance with local regulations). The hardware used to secure the signal to the pallet should not be used to mount the signal onto the structure.

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The signal should be retained on the pallet until ready for installation and when removed should not be laid in such a way as the lenses are at risk of damage

5 Installation It is assumed that the mounting plate for the particular signal has been installed and has been accepted by the person responsible for structures prior to commencement of the installation.

5.1 Safety Before commencing assembly, any local safety requirements affecting the continued safe working environment of the signalling installation and/or the working railway, either directly or indirectly should be carried out. It is the user’s responsibility to ensure all necessary risk assessments, permissions to work and preparatory safety activities are correctly completed and adhered to throughout the installation and subsequent life of the signal. The all up weight of the signal is clearly marked and installers should ensure that they have sufficient measures in place to ensure a safe lift All activity on the CLS LITE, both mechanical and electrical, must only be carried out by staff deemed competent in these fields by their employer. It is the user’s sole responsibility to ensure that the CLS LITE is installed and/or maintained by certificated and competent staff. Activities identified as needing extra care are highlighted using the Caution Symbol

ACTIVITIES WHICH ARE OR HAVE THE POTENTIAL TO BE HAZARDOUS TO

PERSONNEL AND/OR EQUIPMENT ARE HIGHLIGHTED WITH THE WARNING SYMBOL

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5.2 Pre Installation Checks The signal should be checked for damage and any remaining transit packing materials should be removed and correctly disposed of. The lower backboard extension should be repositioned as detailed in Section 7 and the warning notices should also be removed and correctly disposed of. The signal modules can be removed to lighten the signal for lifting during installation and this is covered in Section 10.

6 Installation Method

6.1 Safety

Whilst it may be physically possible to install a signal using manual handling techniques, Unipart Dorman recommends that even with the module(s) removed, the use of mechanical lifting aids should be considered to reduce any risk of personal injury or physical damage to the signal. All signals are supplied with lifting eyes already installed to aid installation and these may be unscrewed and removed if additional clearance is needed after the signal has been lifted.

Before commencing installation, any local safety requirements affecting the continued safe working environment of the signalling installation and/or the working railway - either directly or indirectly should be carried out. It is the user’s responsibility to ensure all necessary risk assessments, permissions to work and preparatory safety activities are correctly completed, recorded as required and adhered to throughout the installation and subsequent life of the signal. The all up weight of the signal is clearly marked and installers should ensure that they have sufficient measures in place to ensure a safe lift. All activity on the CLS LITE should only be carried out by staff deemed competent in their fields by their employer. It is the user’s sole responsibility to ensure that the signal is installed, operated and/or maintained by certificated and competent staff.

BEFORE THE COMMENCEMENT OF ANY ACTIVITY, ARRANGEMENTS SHALL BE APPLIED TO PROTECT THE WORKING RAILWAY.

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7 Signal Mounting and Alignment

Once in the required position the CLS LITE is secured to the base platform using four Stainless Steel Nuts, Bolts and Washers. These should be left hand tight only until the sighting of the signal has been completed. Attach and test any bonding strips/earthing straps as required.

Remove the Lower Backboard plate from its stowage above the top aperture and refit the two Allen screws. Using the existing Allen screws mount the plate at the bottom of the backboard. The backing board must be removed prior to sighting the signal as it will obscure the hole in the upper backboard that the scope looks through.

The Signal Sighting Form will provide the signal specific sighting details and should always be consulted prior to commencement of work. The sighting target should be aligned within the scribed ring of the sighting scope lens.

The removable sighting scope unit should be fitted securely to the two mounting points by screwing the two knurled screws into the threaded holes (as shown arrowed in red). The mounting block can be moved to the corresponding position on the other side of the signal by undoing the two bolts (arrowed in blue).

Using the sighting scope to provide visual cues, the signal is adjusted in azimuth by rotating the base within the kidney slots in the bases and elevation by adjusting the angle of the signal head pivoting through the side slot as shown.

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Representative images only

When the signal is sighted as per the signal sighting form, ensure all the mounting nuts are correctly torque loaded and the sighting scope is removed and stored in its protective case.

This space Intentionally Blank

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7.1 Electrical Connection

To reduce the amount of spares that need to be held, all CLS LITE Modules have the splitter cable for the second Yellow module attached. If the signal only uses a single Red Yellow Green module the splitter cable will have a blanking cap fitted and it will be secured to the main plug coupler using a cable tie.

The main connector is plug coupled and connected by aligning the keyway and lug inside the connector shells with a slight push to get the worm drive to engage and then turning the locking collar by hand until an audible ‘click’ is detected and the two indicator spots are aligned. (The spots may be of different colours; this is simply the preference of the manufacturer and does not affect the plug coupler’s physical attributes).

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The Plug Couplers should connect easily and the use of handtools is discouraged. If the coupler cannot be fully engaged by hand, there may be a fault or mismatch in connection detail. This should be investigated as any attempt to force

the connection could result in bent or broken pins/sockets which may require complete replacement of either the infrastructure cable or the signal module and

cable assembly.

If the signal is a four aspect variant, connect the plug coupler which links the two modules together in exactly the same manner. The blanking plug is retained on a lanyard and should be stowed/removed as required

Once the connection is made the Plug Coupler should be stowed in the bracket on the back of the module ensuring the weight of the tail cable leading into the signal is supported by the bracket. Excess cable should be secured with cable ties and stowed in the back of the signal maintaining smooth bend radii.

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The signal should be bonded to earth if required by the use of standard bonding straps.

8 Changing the Door Opening Side

Note the assembly order of any fasteners removed in the instructions below, to ensure correct re-assembly sequence.

Undo the two dome nuts securing the door stay bracket to the door then undo the two button head screws securing the stay bracket to the frame. Remove the stay assembly as one complete unit.

Lift the door off its hinges.

8.1 Door Preparation

Remove the 4 rubber doorstops and refit them to the clinch studs on the opposite side of the door. Drive out the hinge pins and replace in the opposite end of the door hinges. Move the hinges to the opposite side of the door. (Do not fully tighten at this stage to allow later door / frame alignment).

Remove the earth/bonding straps from the base of the door and replace on the opposite side of the door.

8.1 Frame Preparation

Remove the frame earth strap and replace on the opposite side of the frame. Remove the 2 frame hinges. Drive out the end caps and replace in the opposite end of the frame hinges.

Drive out hinge pin. Replace pin in opposite end.

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Fit the hinges on the opposite side of the frame. Do not tighten at this stage to allow later door / frame alignment.

8.1 Refitting the Door

Rehang the door onto the frame. Adjust the hinges for satisfactory door operation and to give 1mm clearance between the inner face of the door and the top of the rolled edge on the frame. Tighten all hinge fasteners.

Turn the stay over and refit to the opposite side.

The door is closed and secured using the locking bolt and bar and a standard padlock

9 Post Installation Checks

The CLS LITE has been designed with Plug and Play installation in mind. Unipart Dorman recommends that the only test required is to have the signaller call on the aspects and ensure that the correct indications are displayed by the signal. This advice does not supersede any instructions issued by Network Rail.

10 Maintenance Activity

The signal design is such that it is maintenance free. However, Network Rail may mandate some maintenance activity and this will be promulgated through the normal channels.

The LED module(s) can be tilted back for access from the rear of the signal ensuring the worker stays in a position of safety.

10.1 Signal Husbandry

If the signals require any cleaning to be carried out, the only mediums approved are water and proprietary detergents.

Do not use any solvent based or abrasive cleaning material as this may irreparably damage the signal.

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10.2 Service and Repair

The LED modules have no user maintainable elements (apart from general husbandry requirements) and are intended to be replaced completely should they fail. A complete list of signal heads, spares and their catalogue numbers are shown on the Network Rail Approval Certificate.

10.3 Module Replacement

Before replacing the module remove any cable ties and disconnect the plug coupler.

Support the module to stop it swinging back and release the two locking levers as shown below

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The module can then be swung down and backwards and unhooked from the top bar for removal.

Refitting is a reversal of removal ensuring the plug couplers and cable ties are refitted.

If the module is simply to be tilted back to facilitate cleaning etc there is sufficient cable to allow the module to be tilted without disconnecting the plug coupler.

The plug coupler must be refitted into the support bracket as shown in Section 7 above before the door is closed and locked.

10.4 End of Life Disposal

Wherever possible the component parts and complete assemblies of the Unipart Dorman CLS LITE are designed to be disposed of in accordance with the requirements of the Waste Electronic and Electrical Equipment Regulations 2006. Please contact Unipart Dorman for full details of the procedure to be undertaken when a signal is permanently withdrawn from service for disposal.

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11 Contact Us

Unipart Dorman Wennington Road Southport Merseyside PR9 7TN

Tel 01704 518000 Fax 01704 518001 Email info@unipartdorman.co.uk Website www.unipartdorman.co.uk

Every effort has been made to ensure the accuracy of the information given in our Publications, but in accordance with our policy of continually improving our products we reserve the right to modify

designs and specifications whenever necessary.

The content of this document is the property of Unipart Dorman and information contained therein is confidential. This document either in whole or part, must not be reproduced, or disclosed to others, or used for any purpose other than that for which it is supplied without Unipart Dorman’s written

permission; or if any part is furnished by virtue of a contract with a third party, as expressly authorized under that contract.

The contents of this document are copyright © Unipart Rail 2013 - All rights reserved