LED Signal - Ansaldo STS
Contents
1. l Battery A l 7 L l l l l Figure 2 1 LED System Diagram 2 1 LED Signals The LED signals are available in red amber yellow cyan green and lunar white in 6 3 8 diameter N4620440X and 8 3 8 diameter N4621280X The LED signal is a sealed unit NEMA type 4 enclosure The 6 3 8 diameter unit contains 10 high power LEDs wired in series The 8 3 8 diameter red green and lunar white signals contain 12 high power LEDs The 8 3 8 diameter yellow signal contains 14 high power LEDs These signals are powered by a constant current source Because the signals are designed to operate with an external constant current source no DC DC converters or other active electronics are included The LED module only includes LEDs and other passive components for diagnostics and surge protection The unit conforms to AREMA standards 7 1 5 and 11 5 1 Class B for signals The outer cover of the light is UV stabilized and can be used in areas where it will be exposed to intense sunlight Microlok is a registered trademark of Union Switch amp Signal SM 7A1 0001 Rev 2 March 2010 2 1 ec LED System Description AnsaldoSTS 2 2 Driver Protection PCB The Driver Protection PCB N4620520X Figure 2 2 is an entrance panel mounted board It is used in combination with ASTS USA lightning arrestors to provide a high level of surge protection The Driver Protection PCB N46205201 which is mounted in th2. 4 2 SM 7A1 0001 Rev 2 March 2010 AnsaldoSTS LED Signal System Troubleshooting Figure 4 2 LED Protection Board Orientation 4 1 4 Troubleshooting LED Signals e Because of the constant current regulator the electrical readings taken at the LED signal load will be different from typical signals Where the load voltage of an ON state incandescent signal is typically at battery level i e 12V or lower due to line drop the load voltage of a ON state ASTS USA LED signal is typically 35V to 42V SM 7A1 0001 Rev 2 March 2010 4 3 i LED Signal System Troubleshooting AnsaldoSTS e The LED signal cannot be checked for operation energized by applying battery voltage directly to its terminals A constant current regulator or equivalent current source is required to light the signal Also an ohmmeter across the terminals of the signal will not provide an indication of the signal s integrity e The LED signal has five terminals which are clearly marked three require a field connection two have no external connection Ensure that the connections are made to the proper terminals e The LED signal field terminals have a polarity that must be observed where incandescent signals typically do not A signal hooked up with reversed polarity will not operate and could eventually damage the signal e Slide wire resistors are not required for use with the LED signals and should never be installed Also the LED signal cannot be dimm
3. Figure 2 3 Constant Current Regulator N34801401 e eee LLA HEL LLAF E LL RL FEL LLY nnLnuou 2 3 Figure 2 4 ASTS USA LED Signal System Block Diagramm 2 4 Figure 3 1 Rear View of the 6 amp 3 8 Inch LED Gong 3 2 Figure 3 2 Rear View of the 8 3 8 Inch LED Gional CLLH LEL LLALL CYLL HEL LL nA EFLn Hon 3 2 Figure 3 3 Nut and Washer Arrangement on the Grounding Studie 3 3 Figure 3 4 Nut and Washer Arrangement on the Terminals inner YY sese L LLY HF nnion 3 4 Figure 4 1 Pins on the Constant Current Regulator CYLLYLL LLI HLR ELLY Y HEL LL RHYL noon 4 2 Figure 4 2 LED Protection Board Orientaton CYLLYLL LLY LLE EL LLALL EL LL REC L LL nn FnnHnoN 4 3 List of Tables Table 3 1 Maximum Signal Distance from the Signal House 3 5 Table 4 1 Constant Current Regulator Readings 4 1 Table 6 1 Part Numbers for the ASTS USA LED Signal System Component 6 1 iv SM 7A1 0001 Rev 2 March 2010 Ei EZ AnsaldoSTS Introduction 1 INTRODUCTION The ASTS USA LED light Signal System consists of the LED signals in four distinct colors a 6 3 8 inch diameter unit N4620440X and a 8 3 8 inch diameter unit N4221280X complete with the LED Protection Board N46205001 a Constant Current Regulator N34801401 and a Driver Protection PCB N4620520X Each LED signal contains several high intensity LEDs which operate on a constant current provided
4. March 2010 3 1 LED Signal System Troubleshooting AnsaldoSTS EARTH GROUND TERMINAL Figure 3 1 Rear View of the 6 8 3 8 Inch LED Signal EARTH GROUND TERMINAL Figure 3 2 Rear View of the 8 3 8 Inch LED Signal 3 2 SM 7A1 0001 Rev 2 March 2010 oh i S AnsaldoSTS LED Signal System Troubleshooting 3 2 Replacing the LED Protection Board Only The LED protection board can be replaced without having to remove the LED signal Proceed as follows to replace only the LED protection board 1 Remove power to the signal assembly 2 Open the rear door on the signal assembly case 3 Disconnect the positive negative and earth ground leads from the LED signal 4 Remove the nuts and washers from the four terminals that hold the LED protection board to the LED signal 5 Pull the LED protection board off of the LED signal 6 Remove the ground stud from the defective LED protection board by removing the three nuts and three washers that secure the ground stud to the board Figure 3 3 NUT H NUT caj COPPER WASHER Kaes NUT y COPPER WASHER maT TERMINAL POST Figure 3 3 Nut and Washer Arrangement on the Grounding Stud 7 Insert the ground stud and a washer into the ground stud hole on the new LED protection board and secure it to the board with the three nuts and three washers removed in Step 6 Be sure they are in the proper arrangemen
5. account every eventuality that may arise with technical equipment in service Please consult an ASTS USA local sales representative in the event of any irregularities with our product ASTS USA expressly disclaims liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved ASTS USA spare parts are used as replacements SM 7A1 0001 Rev 2 March 2010 i GI Revision History d AnsaldoSTS Revision History Ser Date Nature of Revision September 2008 Initial Release 2 March 2010 Revised Figure 1 1 Figure 2 3 and Figure 4 1 Revised Section 2 3 ii SM 7A1 0001 Rev 2 March 2010 uw AnsaldoSTS Table of Contents Table of Contents 1 INTRODUCTION x meer este krno YF HNN Rekonas RHYN YH HYN Vema ii atero sio kiba sianietikavo 1 1 2 DESCRIPTO N WEE 2 1 ERR RRE el 2 1 2 27 Driver Proteetlon PCB Le As A A a A LO as ae 2 2 2 3 Constant Current Reoulator ieee cece ee enne CYLL LEL erent eset tates LLALL LLL NHY YEE LLY HEL LLL HE LLDD annnka 2 2 2 4 SUpplyingiPOWer eiu ennu o yny YY EL YG Ddy Cyn YND Dd ETA o Cynn nn TO a a 2 4 3 LED SYSTEM NSTALLATIONU uii r i zer ecen nec enio uza o oc ojnsoinosuunfegtegnar nnacen ascezkseensadenniazenan uninakaj 3 1 3 1 Installing an LED Signal with LED Protection DCH 3 1 3 2 Replacing the LED Protection Board Only seessssess
6. will occur to the system if an output is inadvertently shorted to ground Fuses can be installed on the SM 7A1 0001 Rev 2 March 2010 3 5 i LED Signal System Troubleshooting AnsaldoSTS system battery connections to the system as required These fuses can be installed in the circuit between the VCOR I and terminal B12 e Slide wire resistors are not required for use with the LED signals and should never be installed Also the LED signals cannot be dimmed by wiring in a series resistance e The LED signal has five terminals which are clearly marked two require a field connection one is for ground surge protection and two have no external connection Ensure that the connections are made to the proper terminals e The LED signal field terminals have a polarity that must be observed where incandescent signals typically do not A signal hooked up with reversed polarity will not operate and could eventually damage the signal 3 6 SM 7A1 0001 Rev 2 March 2010 AnsaldoSTS LED Signal System Troubleshooting 4 LED SIGNAL SYSTEM TROUBLESHOOTING 4 1 Typical System Measurements This section provides a list of voltage and or current measurement for a good system and for a faulty system 4 1 1 Constant Current Regulator Table 4 1 summarizes the expected measurements that can be observed from a functional constant current regulator operating off of a 9 8 to 16 2 volt source Any readings outside the stated rang
7. OST ln TERMINAL POST ni WASHERS WASHERS Figure 3 4 Nut and Washer Arrangementon the Terminals 3 3 Signal and Protection Board Wiring Table 3 1 summarizes the maximum distance a signal can be located from the signal house based on the wire gauge selected for the application As noted in the table the distances already include the series resistance of all the lightning surge protection circuitry However the series resistance of additional components such as house wiring relay contacts and terminal connections will reduce the maximum distance for a signal they will need to be included in the 3 ohm limit for each leg 3 4 SM 7A1 0001 Rev 2 March 2010 i x AnsaldoSTS LED Signal System Troubleshooting Table 3 1 Maximum Signal Distance from the Signal House Wire Gauge Maximum signal distance or wire length for each leg 8 103951 7500 ft 8 0 6282 4700 ft O92 OAL Note 1 Distances are based on maximum line resistance of 3 ohms per leg 6 ohms total Note 2 Distances include series resistance of all lightning surge protection circuits Note 3 Additional series resistance of house wiring relay contacts terminal connections etc will reduce the maximum distances allowed The following is a list of wiring specific requirements notes for the ASTS USA LED Signal System e For all applications the use of the lightning surge protection components of the LED signal system is recommended e ASTS USA recommends t
8. aN AnsaldoSTS ei Dive Pitsbugh PA 18219 SM 7A1 0001 LED Colorlight Signal ASTS USA Part No N4620440X 6 3 8 inch unit N4621280X 8 3 8 inch unit WW Installation E Operation m Maintenance Copyright 2010 SM 7A1 0001 Rev 2 Ansaldo STS USA Inc March 2010 NN y AnsaldoSTS Notices Proprietary Notice This document and its contents are the property of Ansaldo STS USA Inc formerly known as Union Switch amp Signal Inc and hereinafter referred to as ASTS USA This document is furnished to you on the following conditions 1 That no proprietary or intellectual property right or interest of ASTS USA is given or waived in supplying this document and its contents to you and 2 That this document and its contents are not to be used or treated in any manner inconsistent with the rights of ASTS USA or to its detriment and are not to be copied reproduced disclosed or transferred to others or improperly disposed of without the prior written consent of ASTS USA Important Notice ASTS USA constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it is impossible to take into
9. by the constant current regulator The Driver Protection PCB is in series with the signal and provides surge protection for the signal The components of the system are ordered separately and installed as a system based on the specific application of the signals All of the components of the system are shown in Figure 1 1 SM 7A1 0001 Rev 2 March 2010 1 1 Introduction 6 3 8 Inch LED Signal Front View 8 3 8 Inch LED Signal Front View 8 FJELD 30 WIRING s Driver Protection Board Constant Current Regulator Figure 1 1 LED Signal System Components 1 2 SM 7A1 0001 Rev 2 March 2010 N AnsaldoSTS System Description 2 DESCRIPTION This section contains a brief description of the LED System components and their function in relation to the overall system A block diagram of the LED System is shown in Figure 2 1 The Constant Current Regulator is DIN rail mounted in the house The LED12 board is installed as part of the MicroLok II system see SM6800N for information on the LED 12 PCB The LED Driver PCB Protection Board is mounted on the AAR terminals at the entrance rack FIELD E l WAYSIDE SIGNAL HEAD G96 BUS to CPU I WIRING I l VCOR l l Contact l l Constant Current LED 12 Regulator PCB LED Driver L N34801401 N17066101 PCB l l LED Signal LED Signal l Protection Board l iro e e DN Output N4620520x
10. e house is designed to terminate house wiring on the left hand side of the board and field wiring on the right hand side of the board An optional version of the Driver Protection PCB N46205202 allows terminating the house wiring on the right hand side of the board and field wiring on the left hand side of the board Both versions of the board use the same components and allow the components to be viewed for inspection when mounted in the house HOUSE 38 FIELO FIELD 38 HOUSE WIRING s WIRING Cc i i e IR e WIRING got WIRING r w oer HO j SS DRIVER BOARD PROTECTION PCB DRIVER BOARD PROTECTION PCB N46205201 N46205202 HOUSE WIRING ON LEFT SIDE OF BOARD HOUSE WIRING ON RIGHT SIDE OF BOARD Figure 2 2 Driver Protection PCB N4620520X 2 3 Constant Current Regulator CAUTION The constant current regulator is designed to be installed on a standard DIN rail When installed with other regulators there should be at least a 1 2 separation between the regulators The Constant Current Regulator CCR N34801401 Figure 2 3 provides a constant 350mA regulated current output for driving the LED signals The output of the regulator includes both open and short circuit protection 2 2 SM 7A1 0001 Rev 2 March 2010 AnsaldoSTS System Description The CCR has a non vital output that is derived from the internal monitoring function of the CCR It is not required that the non vital outp
11. ecommended that the complete assembly be replaced The LED signal requires no focusing Maintenance primarily consists of periodically cleaning the face of the LED signal and replacing any non functional LED signal 5 2 Cleaning The front surface of the LED signal should be cleaned with a Lexan cleaner using a soft nonabrasive cloth The exterior of the case may be cleaned with a soft dry cloth paper towel or brush NOTE Dirt and dust that collect on the exposed surface of the outside of the LED signal should be removed periodically to maintain the normal range of the signal 5 3 LED Signal Replacement The optical system of the LED signal contains no field replaceable parts It must be replaced as a unit when it is defective Replace the LED signal per Section 3 1 Caution When replacing the LED signals ensure that the LED signal being replaced is replaced by an LED signal of the same color If a red LED signal is being replaced ensure that a red LED signal is used to replace it and not one of another color SM 7A1 0001 Rev 2 March 2010 5 1 LED Signal System Troubleshooting AnsaldoSTS SN 4 AnsaldoSTS 5 2 SM 7A1 0001 Rev 2 March 2010 Parts List d AnsaldoSTS 6 PARTS LIST This section provides the part numbers for all system components Table 6 1 Part Numbers for the ASTS USA LED Signal System Components LED Signal Red 6 3 8 EE includes LED Pr
12. ed by switching in a series resistance as can typically be done with an incandescent signal e When used in combination with the Vital Output LED12 PCB an OFF state ASTS USA LED signal will have a load voltage of approximately 2 5V This voltage level 1s normal and is present because OFF state diagnostics are being performed by the control system e The diagnostic and light out detection functions of the Vital Output LED12 PCB do not use external check pulses For both ON and OFF state LED signals a check pulse will never be seen at the load e The LED12 PCB will detect shorts between signals that cause an incorrect signal state If the return leads of any two or more signals are shorted together the system will not indicate an error because this is a legal wiring option If the controlled lead of two or more signals are shorted together the system will not indicate an error if all of the signals are in the same state all on or all off If a wiring short causes an off state signal to turn on then a critical error will occur and the Microlok II system will reset 4 4 SM 7A1 0001 Rev 2 March 2010 i AnsaldoSTS LED Signal System Troubleshooting 5 MAINTENANCE 5 1 General Maintenance Maintenance consists of performing routine cleaning and replacing the non functional LED signals Repair of damaged units is limited to replacing component parts in the field Should the signal assembly sustain any damage it is r
13. es indicate a possible faulty regulator Figure 4 1 gives the pinout of the CCR Table 4 1 Constant Current Regulator Readings CONDITION EXPECTED READING Voltage at output with no load connected V 58V pin 4 referenced to pin1 Voltage at output with resistive load connected pin V 9 35 R 10 where 4 referenced to pin1 R 140ohms Voltage at output with a known good LED Signal connected signal ON condition pin 4 referenced 29V V 50V to pin1 u output with valid load signal ON condition I 350mA 10 See Figure 4 1 4 1 2 LED Signal The expected voltage readings taken across the LED Signal field wiring terminals will be the same or slightly less due to resistance in the wiring than the readings taken across the driver protection board field terminals as given in Table 4 1 Any readings outside of the stated ranges indicate a possible faulty LED signal 4 1 3 LED Protection Board Inspect the components for signs of stress or damage If present replace the board with a spare and return the faulty board to ASTS USA for repair Figure 4 2 illustrates the proper orientation of the protection board on the back of the LED signal SM 7A1 0001 Rev 2 March 2010 4 1 i LED Signal System Troubleshooting AnsaldoSTS NOT USED B12 LED OUTPUT CONSTANT CURRENT REGULATOR MODULE NON VITAL NOT USED OUTPUT Figure 4 1 Pins on the Constant Current Regulator
14. gnal load is powered by an external regulated current source rather than a voltage source which is applied and removed from the signal load via a software controlled switch US amp S 350mA CONSTANT CURRENT l REGULATOR SOFTWARE CONTROLLED SWITCH US amp S LED SIGNAL OR RELAY CONTACT o El BATTERY 9 8 16 2V Figure 2 4 ASTS USA LED Signal System Block Diagram 2 4 SM 7A1 0001 Rev 2 March 2010 i AnsaldoSTS LED Signal System Troubleshooting 3 LED SYSTEM INSTALLATION 3 1 Installing an LED Signal with LED Protection PCB When an individual LED signal complete with the LED Protection PCB N46205001 needs to be installed follow this procedure 1 Remove power to the signal 2 Open the rear door of the signal assembly Ifthe old LED signal has not been removed remove it in accordance with the procedure found in Section 3 2 3 Place the new LED signal into the case and position it in the opening in the front of the case The LED signal should be oriented with the text on the LED protection board right reading Figure 3 1 and Figure 3 2 4 Secure the LED signal to the case 5 Connect the positive lead to TL2 and negative lead to the TL1 on the LED signal 6 Connect the ground wire to the Earth Ground terminal on the LED signal 7 Apply power to the signal assembly and verify that the LED signal is lit 8 Close the signal case door SM 7A1 0001 Rev 2
15. he use of twisted pair wiring two to three turns per foot to minimize possible noise This should be done wherever possible on all I O wiring e ASTS USA recommends the physical separation of clean and noise generating wiring Ideally all outputs are gathered in one bundle inputs are gathered in another bundle and power wiring is gathered in a third bundle Each of these bundles is physically separated from each other 6 preferred and all bundles are physically separated from other house wiring It is particularly important to maintain this physical separation from high current noise generating wiring e All field wiring should be configured to minimize cross talk between wires Cables and wires should be kept as short as possible to minimize induced line noise Case house wiring layouts should also be arranged to minimize noise Battery leads should be as short as possible and must be isolated as much as possible from noisy wiring e Additional loads such as local indicators cannot be connected across the signal leads of the LED signal e Multiple signals cannot be wired in series or parallel i e color position lights must be separately wired to individual constant current sources e The outputs of multiple constant current sources should not be connected in parallel or series e Fuses are not needed recommended on the signal outputs the ASTS USA constant current regulator output includes short circuit protection and no damage
16. otection Board N46205001 LED Signal Cyan Green 6 3 8 MM includes LED Protection Board N46205001 LED Signal Amber Yellow 6 3 8 includes LED Protection Board N46205001 LED Signal Lunar White 6 3 8 includes LED Protection Board N46205001 LED Signal Red 8 3 8 146212801 includes LED Protection Board N46205001 LED Signal Cyan Green 8 3 8 e includes LED Protection Board N46205001 LED Signal Amber Yellow 8 3 8 nape sat includes LED Protection Board N46205001 N46204403 N46204404 N46212804 LED Signal Lunar White 8 3 8 includes LED Protection Board N46205001 SM 7A1 0001 Rev 2 March 2010 6 1 LED Signal System Troubleshooting AnsaldoSTS SN 4 AnsaldoSTS 6 2 SM 7A1 0001 Rev 2 March 2010 Ay Parts List a AnsaldoSTS 7 RAIL TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link Team RAIL Team is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product Contact the RAIL Team in the United States at 1 800 652 7276 or by e mail at railteam ansaldo sts us SM 7A1 0001 Rev 2 March 2010 7 1 E wi D RAIL Team and Technical Support AnsaldoSTS SN 4 AnsaldoSTS End of Manual 7 2 SM 7A1 0001 Rev 2 March 2010
17. siesesrsesrsrnssrrnsesersrnesrnnaaarennearnnndetinndsneennaant 3 3 3 3 Signal and Protection Board VWimg eee ee esenee LLY LLE L LLARY LEL LLALL EL LL HYNA LLDD EE Fnnn o 3 4 4 LED SIGNAL SYSTEM TROUBLESHOOTING sssesnennesnnnneannnnnnnnannnnnaannnnannnnnnnnatno 4 1 4 1 Typical System Measurements nn RHY LLY ALL LEL ALL LLE ALLE LLALL LLALL EL RF FFF FnnnLu 4 1 4 1 1 Constant Current Regulator i YYYLLLLYLLL iea raana EEEa Aena AAEE eraai 4 1 41 2 E D Signa Y 4 1 4 133 LED Protection Board 5 i A uge 4 1 4 1 4 Troubleshooting LED Signals eeeessseeeeeseenneeesnannnettaannnkntanknkktaanknkntao 4 3 S MANTE NAN OE ir o peuo orto eno uu Sore OI festan ikto CN FLYNN Cod DYT dE 5 1 9 1 General Maintenance eet Eu ENA MAMA OOJ 5 1 D 2 E WT 5 1 9 3 LED Sighal Replacement sss A ar dn ka a in anla niao 5 1 PARTS LIST sc sss bo e ka atte e rere ne akr enen kej 6 1 RAIL TEAM AND TECHNICAL SUPPORT sssessessnnnnnnnnonnnnnennnnnnnnnnnnnneennnnnnnnnnnnnnnrtnnn 7 1 SM 7A1 0001 Rev 2 March 2010 iii v Table of Contents AnsaldoSTS List of Figures Figure 1 1 LED Signal System Components nd nnr LLY LLY ee EAEE EAEE FEE LLYR LEL LL RAR ia 1 2 Figure 2 1 EED Systerm Diagraiuueiu iu FT IY I A Y FY Aine 2 1 Figure 2 2 Driver Protection PCB N4620520X dnn LL YL HYLL LLE LLYR LEL LY HL ANTRAN EIEEE K EKAA EYLnno 2 2
18. t on the grounding stud and tighten them to the board 8 Slide the LED protection board onto the terminals on the LED signal Be sure the lettering on the board is right reading and the directional arrow Figure 3 1 and Figure 3 2 on the LED signal is pointed to the top of the signal assembly 9 Secure the board on the LED signal using the nuts and washers removed in Step 4 See Figure 3 4 for the proper arrangement of the nuts and washers SM 7A1 0001 Rev 2 March 2010 3 3 wi E LED Signal System Troubleshooting AnsaldoSTS 10 Connect the positive and negative leads to the top terminals of the LED signal Be sure to observe the proper polarity when connecting the wires to the LED signal The positive terminal is on the left and the negative terminal is on the right The proper polarity is printed on the LED protection board 11 Apply power to the signal assembly and verify that the LED signal is lit 12 Close the signal case door WASHERS WASHERS NUTS NUTS TERMINAL o T TERMINAL FS 8 J ID NUTS NUTS PORD OWOW H a AI NUTS NUD NUTS OND TERMINAL P
19. ut circuit be used The non vital output is capable of driving 400 ohm relay coils If the output voltage of the CCR goes below 33 volts 2 volts the non vital output of the CCR will go to 0 volts If the output voltage of the CCR is above 33 volts 2 volts the non vital output of the CCR will be approximately equal to the battery voltage depending upon load impedance Note Only ASTS USA Constant Current Regulators are to be used with the ASTS USA LEDs A regulator is required for each ON LED signal in a system however a regulator can be shared between signals that will never be on at the same time Figure 2 3 Constant Current Regulator N34801401 The power consumption of the constant current regulator is With the Regulator Powered and the LED signal ON 20W With the Regulator Powered and the LED signal OFF 0 6W SM 7A1 0001 Rev 2 March 2010 2 3 5 LED System Description AnsaldoSTS 2 4 Supplying Power The ASTS USA LED Signal System is designed for use with a Microlok II unit or an Object Controller Series 4000 See Service Manual SM 6800N for application information with a Microlok II unit The ASTS USA LED Signal operates from an external constant current source This design allows for accurate monitoring of the operational state of the LED devices in the signal Figure 2 4 illustrates the ASTS USA LED Signal System This system differs from the typical existing system in that the si
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