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Siemens HB 43NB.20B Specifications

1. 2 4m min to 4 0m max see note 1 400 550mm 2 1m min to see note 5 2 6m max see note 2 2 1m min see note 3 1 0m min to 1 1m max see note 4 Ground level Cables entering via slot in pole Concrete Anti rotate rod Figure 10 Typical Signal Pole Assembly showing heights for compliance with Traffic Signs Regulations Notes 1 The dimensions on this drawing show the limits allowed where Light signals for control of vehicular traffic at road junctions at places where the headroom is permanently reduced or at places where pedestrians cross the road other than Pelican crossings See Traffic Signs Regulations 1994 and Schedule 8 2 The dimensions this drawing show the limits allowed for Light signals for pedestrians and animal crossings See Traffic Signs Regulations 1994 and Schedule 8 For cycle crossings see LTN 1 98 3 SAFETY NOTE Signals that are installed where pedestrians may cross the road must have no part of the signal head installation less than 2 1 m above ground level Where cyclists may be expected to use the crossing this dimension is 2 3 See section 2 3 3 for information on using cranked and formed poles at Toucan crossings 4 The height from the centre of the push button to the footway level see 667 HB 30000 000 Issue 24 Page 28 of 143
2. 200 mm Amber Cycle Lens 200 mm Green Cycle Lens Red Standing Man Lens LED Green Walking Man Lens LED Amber Cycle Lens LED Green Cycle Lens LED Amber Man LED Arrow Mask matt black finish fefe on eee el e omm A Peeke Tesen U Feefee U elle L eson Red Equestrian Lamp Lens Green Equestrian Lamp Lens Clear Equestrian LED Lens 200mm Bus CLS Lens 200mm Red Equestrian CLS Lens 200mm Red Man CLS Lens 200mm Green Man CLS Lens 200mm Amber Cycle CLS Lens 200mm Green CLS Lens 200mm Amber Man Standing CLS Lens Sacrificial toothed Cap Sacrificial smooth Cap Bracket to head fixing kit 1 aspect bracket 2 aspect bracket 3 aspect bracket 4 aspect bracket Extension bracket Single Body Four In line no doors Single Body Side Mounted no door Single body Four In line Reg Sign no doors Issue 24 Page 124 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Part Number 667 1 30200 807 667 1 30200 058 667 4 00977 000 667 1 30194 001 667 7 30632 000 667 1 02293 001 667 1 30200 411 667 1 30200 412 667 1 30200 413 667 1 30200 414 667 1 30200 415 667 1 30200 416 667 1 30200 417 667 1 30200 418 667 1 30200 419 667 1 30200 420 667 1 30200 421 667 1 3
3. 23 Figure 9 Three Aspect CLS with LMF Internal Fitting 24 Figure 10 Typical Signal Pole Assembly showing heights for compliance with Traffic ICIS uu us unu 28 Figure 11 Signal Pole Assembly showing useful dimensions for Pole Selection and DIANUN GOS 9 30 Figure 12 Wiring of the Neutral Terminal Block 35 Figure T9 Extension Bra CKE tee tena eco ca etae abaco papa to uua aeu ou Round 36 Figure 14 Side mounting bracket 36 Figure 15 Example Mounting Arrangements 37 Figure 16 Sacriicial Gap 38 Figure oacrilielal Gapdsselmbly map ce 39 Figure 18 Using screwdriver to open the door clip 39 19 Door CIID spa susah 40 Foure 20 GreemAEITOW MASK uuu u AA 40 Figure 21 CLS ELV B Anti rotation Clip 42 Figure 22 Mn 42 Figure 23 Side box showing fixing plate
4. 93 2 96 9 FIEBUIDS HIO GM 94 2 SOF sy E E N E A 94 Oe COMMISSIONING Q 96 3 1 Nearside Monitoring including pcb upgrade to MK2 LP 96 3 1 1 Replacing 667 1 30695 boards with 667 1 33655 97 4 MAINTENANCE xu MM 98 4 1 Routine Maintenance Visits 98 Z2 s celsus fos Ui efe fn dan otn Rufin ndi ne 98 4 2 1 Bulb Replacement Halogen 99 4 2 2 Bulb Holder Replacement Halogen 99 4 2 3 Transformer Replacement Halogen 99 4 2 4 LED or LED NLM PCB Replacement 100 4 2 5 PCB Fuse Replacement LED 102 4 2 6 PSU Replacement Linear 102 4 2 Transformer Replacement LED NLM 103 4 2 8 CLS Unit Futurit Type Replacement 104 4 2 9 CLS NLM Unit Dialight Type Replacement
5. 105 4 2 10 CLS ELV Type A 106 4 2 11 CLS ELV Type B Replacement 107 d 22 EME Te USS TRS ma kuwa kaqq 108 4 2 13 LMF Unit Replacement 108 42 14 TUDE Replacement fs uu uuu 109 4 2 15 Aspect Door Replacement 110 4 2 16 Aspect Door Assembly Replacement LED and LED 111 4 2 17 CLS with LMF CLS NLM Door Replacement 112 4 2 18 CLS ELV Door 113 4 2 19 Regulatory Sign Door Replacement 114 42 20 Door Clip Replacement u uuu k l aa 114 4 2 21 Hood 114 4 2 22 Lens or Reflector Replacement Halogen 114 4 2 23 Lens Replacement LED or LED NLM 115 4 2 24 Lens Replacement CLS with LMF or CLS 116 4 2 25 Lens Replacement CLS 117 4 2 26 Sacrificial Cap Replacement 117 4 2 27 Sacrif
6. 55 Solar 56 Figure 42 Pedestrian push button 5 Figure 43 LEDO Wall 59 Figure 44 LED Wait Door Assembly 1 61 667 HB 30000 000 Issue 24 Page 8 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Figure 45 Toucan Nearside Signal and Demand 62 Figure 46 Nearside Signal Shows the Two PCBs 1 63 Figure 47 Red Man PCB from Puffin Nearside Unit 1 63 Figure 48 Nearside Signal Shown with Red Man Cycle Equestrian PCB Removed Mk jr 64 49 2 Demand WON Em 65 Figure 50 Drilling guide for Nearside and Pedestrian WAIT range 67 Figure 51 U bolt and cable gland installation 2 68 Figure 52 Mounting of Nearside Pedestrian WAIT units to Pole 69 Figure 53 Standard Wait Mk2 Indicator unit 70 Figure 54 LED MK2Z Vall 72 Figure 55 CLS Wait Retrofit and MK2 74 Figure 56 CLS Wait Retrofit reverse side showing the D
7. ue n 4 4 4 n Figure 56 CLS Wait Retrofit reverse side showing the Driver PCB 667 HB 30000 000 Issue 24 Page 74 of 143 SI N S HELIOS GENERAL HANDBOOK 2 30 2 CLS Wait Production The CLS Wait has been designed as a production replacement for the LED Wait unit and as such shares the same part numbers his unit offers the benefit of CLS technology and provides a clear uniform display banner CLS Wait units are also lamp monitorable Figure 57 CLS Wait Unit There are four variants of the CLS Wait Box with Mechanical switch available for use in the United Kingdom These are Pedestrian Pushbutton Unit without Audible 667 1 33602 010 Pelican Pushbutton Unit without Audible 667 1 33602 011 Toucan Pushbutton Unit without Audible 667 1 33602 012 Equestrian Pushbutton Unit without Audible 667 1 33602 013 667 HB 30000 000 Issue 24 Page 75 of 143 SI E M E N S HELIOS GENERAL HANDBOOK The mechanical installation of the equipment is as defined for the LED Wait Mk2 Indicator Units see sections 2 25 2 26 2 27 2 29 Module Replacement Should it become necessary to replace the CLS Wait Module the part number is 667 1 47710 00 Disconnect the earth connection from the module 2 Gently prise the four plastic retaining clips and withdraw the module 3 Disconnect the red and black wires from the driver board terminal block noting their position 4 Connect
8. au a MER Sa A Ca ca 104 Bracket assembly 30 M Bracket TING 34 104 Bridge rectifier 45 Maintenance 77 103 First 80 uu u T 103 aa 80 Bulb holder replacement 81 Mandatory arrow 39 Bulb replacement 81 NL Kyu TEE TE 104 Mellor leg uuu sa 21 Module 98 MOUNTING Ula 105 19 e cee 46 CES P 15 P CLS Unit Replacement 86 87 Controller Part AUN DENS esce ee l 103 Neutral connection 29 Pedestia Me TIC 49 Pedestrian aspect 21 D Pole Neutral connections and terminations 28 te 103 ete crt 27 Door clip replacement 94 76 Door clips EEEE EO E 34 103 Pole length 25 Door replacement
9. 54 ras F Dr ae 55 P ele C PETER 55 2 21 Pedestrian Push Button 1 57 2 21 1 Optional Wiring Kits for Pedestrian Pushbutton 1 57 2 22 ED Walt BOXXNIK T 32 eo 58 2 22 1 Optional Wiring Kits for L E D Wait MK 1 59 2 22 2 LP D WaltBox DOOS 60 2 23Nearside Signal and Demand Unit 1 61 2 23 Nealside ighnmal htt VII 1 uuu u u u uu uu od edet oodd vp oM sies dudes 62 2 23 2 MK T 64 2 23 3 Optional Wiring Kits for Nearside Signal Unit and Demand Unit Mk 1 65 2 24Nearside Mk2 Range of units 66 2 25Nearside Mk2 Pedestrian Wait Mk2 Pole drilling positions 67 2 26Installation of Nearside and WAIT Mk fixing kits to pole 68 2 27 Installation of WAIT Demand Signal and Combined Mk2 units to pole 69 2 28Standard Wait Mk2 Indicator 70 2 28 1 Terminal Block Layout for STD Wait Mk2 Indicator units 71 2 2ILED Wait MKZ Indicator 71 2 29 1 Terminal Block Layout for LED Wait Mk2 Indicator units 72 2 90
10. N S HELIOS GENERAL HANDBOOK Push button Wait for signal 2 23 1 Nearside Signal Unit Mk 1 The three variants of Nearside Signal come with a door assembly which contain the following items a a PCB which contains all the Display Red LEDs arranged to illuminate either the Red Man Puffin Red Man and Red Cycle Toucan or a Red Horse Equestrian a PCB which contains all the Display Green LEDs arranged to illuminate either the Green Man Puffin Green Man and Green Cycle Toucan or a Green Horse Equestrian c a front panel the type which is dependant on the Nearside Signal 66 7 2 30690 000 Puffin 667 2 30690 001 Toucan 66 7 2 30690 002 Equestrian The following are the Nearside units that are available Puffin Signal Unit 667 1 30675 000 Toucan Signal Unit 667 1 30675 001 Equestrian Signal Unit 667 1 30675 002 The following are the Door Assemblies that are available Puffin Door 667 1 30686 000 Toucan Door 667 1 30686 001 Equestrian Door 667 1 30686 002 667 HB 30000 000 Issue 24 Page 62 of 143 S N S HELIOS GENERAL HANDBOOK i E ccr Figure 46 Nearside Signal Shows the Two 1 i E 2 4 HE 8 3 3 AK MEE SE DEE gt S o ka gt We n 5 O kd H Figu
11. 90 92 93 Pole mur musu 23 Door sas Ll 106 40 34 77 nu ua Su amsa ss 49 59 100 F eflective tape 71 Fibre optics 17 ae 103 Fir tree clips nn 106 Reflector replacement 95 96 mno oro unu E encores 77 Rec uu w ua masma aaa 106 NUS aut 106 Regulatory sign door 105 Four in line 1 37 Regulatory signs eee 23 37 Internal assembly 105 Replace G 81 Eo m 81 ce aN s unte ut o DOOF cette 90 92 93 6 meme eve toe ctc Eu se 94 H cH 95 LED POB 82 84 15 pee 95 FIC AIL 2 Mo dule 98 HOOG 46 105 Refleelor 95 uo X v Rr RE 97 TUO ost EM ME I 90 75 Installation eae 17 5 18 D 74 32 104 667 HB 30000 000 Issue 2
12. IZOd UNA TiLLOV1 TIVA3OOasS C HO31 SV 3 WING X UNN TILLOV NOULV IN3IPJO SINVRIVA Z 0018 VNINH3 L ZOd M SY 62 Md WNOL X VN s 1 ONLLLND CWSHHLL Od Sc HO31 SY ki WINOL X NE UNN TIVMGOQ3S LNN FHLOWL CNGHBL INHG 2094 SZ HOAL SV Id WNL X Yf UNN TIVAA3OQ3S E 4 i Sj 2 F Ei LLL NOLLVINSTINO HO31 SV 1d 120d NOS SZ HO3 L SV Td NSZ X i NOLLVINSR3O TWLINOZRIOH SAR 20d OVIH SLNYTHYA SMOO 8 TVNINHA3L 1435 3 301013 NOIS 933 SM BAR 209 QY3H SZ HO31 SV id X SNLL1 TO 3APHO 20 WIH SZ HOAL SV Id INST X ENF INADSAYON Li NSIS NOLLV IN3IJO TWOLLESA SANVTHVA 6 Y90708 ONLLLITO 3ARKI SZ HO31 SY Id WNOL X INAQ IZOd OVIH Mal3du 39d 78 209 IV3H 900 21600 7 199 H3NHOJSNVtL in INN 17008 INNS X SIN NOLLY LN3D4O TWOLLESA 3114 305 ONELLNO
13. ee ee LI LS T ZAR 09 E H e Mic 0 e i 796 zl ee _ 1 E LEE LI _ 667 HB 30000 000 Issue 24 Page 130 of 143 SI E M E N S HELIOS GENERAL HANDBOOK APPENDIX D Helios Signal Head Screw Fixing Procedure D 1 Introduction 1 2 3 The tightening of the single fixing between the bracket and the signal end caps is of crucial importance to the security of the signal and in the following appendix we cover four specific topics associated with this 1 The correct method of tightening the bolts end cap fixings These parts can be damaged by over tightening or vehicle impact Even if the damage is not immediately apparent it may reduce the life expectancy of the signal heads If the parts are not assembled with sufficient torque then the head may become loose breaking the mountings and potentially even fall off the post 2 Inspection of signal head fittings It is an essential of part of any periodic inspection to check the fixings that secure the signal to the pole and more specifically the fixings that secure the brackets to the signal head and in these sections we describe the recommendations for doing this 3 he different types of fixings that have been used As part of continuous improvement processes later signal products have updated parts in this area and care needs to be taken to ensure the correct
14. On long neutral runs during Red Amber the current can cause large voltage drops This contravenes the IEE Regulations which only allow a 2 5 voltage drop overall In addition the voltage drops can affect the operation of the green voltage monitor and or lamp monitors The length of the neutral feeds must not exceed the length shown below The number of bulbs is the total number of bulbs which can be illuminated at any one time e g phase A and phase AB will both have two bulbs lit during the Red Amber period Where two poles are fed on one cable the length of cable should be taken as the mid point between the two poles The cable inside a pole is approximately 3 25 metres So for normal runs the length of run shown on the STS should be approximately six metres shorter than the maximum allowable length of cable Where a cable run exceeds the figures shown two cores of the cable can be used as the neutral feeds then the distances shown can be increased by a factor of 1 5 Number of Current Total Length Typical Cable Lamps Lit of Cable Run on STS 1 0 27 370 364 2 0 54 185 179 3 0 81 123 117 4 1 08 93 87 5 1 35 74 68 6 1 62 62 54 7 1 89 53 43 8 2 16 46 40 9 2 43 41 35 10 2 70 37 31 11 2 97 34 28 12 3 24 31 25 13 3 51 28 22 14 3 78 26 20 15 4 05 25 19 16 4 32 23 17 667 HB 30000 000 Issue 24 Page 33 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 3 9 Number of Current TotalLength Typical Cable Lamps Lit of Cable R
15. SI N S HELIOS GENERAL HANDBOOK 4 2 25 Lens Replacement CLS ELV Note As the lens to door seal is difficult to align once removed this procedure should not be carried out on site complete replacement door assembly should be fitted as described in section 4 2 17 and the lens replacement done at the depot A damaged lens should only be replaced with one displaying the correct aspect Part numbers are given in APPENDIX B Undo the door loosening the anti vandal screws as described in section 4 2 if fitted and unplug the input cable Remove the door from the front of the module Working the ground CLS ELV Type A a If the CLS ELV unit type is Type A remove the 4 screws holding the unit to the front door b Replace the lens as required c Fit the lens on to the CLS ELV unit ensuring that the lens is positioned correctly Fit the seal around the new lens and place the door over the lens and seal Holding the door lens and CLS ELV unit turn the assembly over and replace the 4 screws holding the CLS ELV unit to the aspect door Working on the ground CLS ELV Type a Remove the 4 screws securing the retaining ring to the front door The retaining ring with aspect attached can now be removed from the door b Remove and replace the lens as required ensuring that the lens is positioned correctly c Fit the seal around the new lens and place the door over the lens and seal Turn the assembly over and
16. 667 HB 30000 000 Issue 24 Page 31 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 3 7 Measure off wires to length cut strip terminate necessary cores to terminal block and terminate two cables cores in earthing block for test purposes as described in Section 2 3 8 Once this operation is completed the excavation at the base of the pole may be back filled Note that lanterns are not terminated until after the cables have been tested On completion of all pole top terminations the tests described in the Installation and Testing Handbook see section 1 3 are to be completed Neutral Connections General For the purpose of the following text for ELV systems the ground return is considered in the same way as a neutral return for a LV system Introduction Street wiring faults can sometimes affect the display of traffic signals on street Poor connections for example in pole top termination blocks usually leads to the failure of signals to illuminate properly which may be detected by lamp monitoring where this is implemented Context Where common neutral connections are used it is possible for the failure of a neutral connection to cause unexpected signal displays where one or more signals within a given signal head are incorrectly illuminated simultaneously This lack of neutral connection is not detectable by the controller because the signal voltage presented at the controller terminals does not exceed the required thresho
17. Do up the four screws that hold the retaining ring lens to the door Note that there is no need for a seal between the lens and the lens retaining ring Refit the LED or LED NLM PCB onto the clips replace one side of the door refit the cable connector and clip the cables into place on the back of the PCB 667 HB 30000 000 Issue 24 Page 115 of 143 SI E M E N S HELIOS GENERAL HANDBOOK see Figure and Figure Make sure that the clear plastic shield covers the cable connector to give protection from the mains voltage present Do up the other door clips and any anti vandal screws 4 2 24 Lens Replacement CLS with LMF or CLS NLM Note As the lens to door seal is difficult to align once removed this procedure should not be carried out on site complete replacement door assembly should be fitted as described in section 4 2 17 and the lens replacement done at the depot A damaged lens should only be replaced with one displaying the correct aspect Part numbers are given in APPENDIX B Undo the door loosening the anti vandal screws as described in section 4 2 if fitted and unplug the lead from the phase power input PL1 to LMF unit and then the CLS Unit to the LMF unit SKT1 CLS with LMF or the Mains Input cable on a CLS NLM or CLS ELV and remove the door from the front of the module Working on the ground a if the CLS unit type is a Futurit remove the two screws holding the two CLS Retaining Clips and the two
18. Wire Colour for Signal Name 667 1 26942 000 998 4 88324 000 Green Yellow Green Yellow Earth Push button 1 Push button 2 Aud Signal 667 HB 30000 000 Issue 24 Page 59 of 143 S N S HELIOS GENERAL HANDBOOK 7 NOTE the Optional Audible Supply Kit 667 1 27006 000 is fitted wire Violet to Audio 2 and Yellow to Audio Common 2 NOTE If the Optional Audible Supply Kit 998 4 88324 000 is fitted wire Green to Audio 2 and Yellow to Audio Ov Common Ensure that the wiring at the controller is to 667 GA 27006 000 Sht 2 Issue 3 Optional Radix Tactile Equipment 667 7 17390 000 is available for all variants of L E D Wait Box 2 22 2 L E D Wait Box Doors Mk 1 All variants come with a Door Assembly which contains the following items a A PCB which contains all the display LEDs arranged to display the WAIT output and the LED control circuitry 667 1 3021 1 000 b Avandal resistant pushbutton This button has no moving parts and is touch sensitive 667 1 30210 505 C A polycarbonate front panel the type which is dependant on the LED Wait Box variant see 667 2 26302 ETC The following Door Assemblies are available Pedestrian Door 667 1 30210 200 Pelican Door 667 1 30210 205 Toucan Door 667 1 30210 210 Equestrian Door 667 1 30210 215 667 HB 30000 000 Issue 24 Page 60 of 143 S N S HELIOS GENERAL HANDBOOK 75m Pushbu
19. 2 2 4 4 CLS ELV 25 2 2 4 5 LV Regulatory 26 2 2 4 6 ELV Regulatory Signs 26 2 2 4 7 LV LED Regulatory Signs 26 2 3 Assembling and Terminating Signal Pole 27 2 9 do 27 zen PRENNENT 28 2 3 3 Cranked and Formed Poles at Toucan crossings 30 2 94 Ei Ci Ie T Ole uscite 31 2 9 9 INNO Pole DOT TOs ClO CHO uuu c ak rtu Gai Uie Fu Pen ea a bue D n c Roth otn 31 2 9 6 Wiring Pole after erecllOn nte 31 2 3 7 Neutral Connections 32 2 3 8 Pole Neutral Connections and Terminations Halogen 33 2 3 9 Pole Neutral Connections and Terminations for CLS ELV 34 2 4 Controller Neutral Connection 0 1 7 34 2 5 Helios Bracket Assemblies 35 25 1 Extension Bracket eve hu t Ne ri n ea ata 35 2 5 20 59106 MOUNINO Bracko s uacua
20. Cut the new transformer mains input leads about 25 30 cm from the transformer Using 2 off Red Butt Crimps 703 4 97182 000 TAG INLINE SPLICE 0 5 1 5MM2 RED and a calibrated crimping tool crimp these two leads using standard techniques to the leads that come from the pole top ensuring that colours are matched Reconnect the transformer connection to the LED NLM PCB and the Earth lead 667 HB 30000 000 Issue 24 Page 103 of 143 S N S HELIOS GENERAL HANDBOOK Figure 77 LED NLM Transformer 4 2 8 CLS Unit Futurit Type Replacement Disconnect the power lead of the CLS unit for the LMF unit by removing PL1 from the LMF unit or disconnecting PL1 of the CLS unit from SKT1 of the Mains power cable of a CLS NLM aspect Remove the two screws holding the CLS Retaining Clip in position and remove the CLS retaining clips Remove the CLS unit from the retaining ring by unclipping it from the four retaining clip of the retaining ring Fitting a new CLS unit is the reverse operation to that of removing it ensuring that the locating pip on the top of the CLS unit is engaged in the slot at the top of the retaining ring PL1 Figure 78 CLS Unit fitted into door 667 HB 30000 000 Issue 24 Page 104 of 143 S N S HELIOS GENERAL HANDBOOK Locating pip at the top of CLS unit Figure 80 Pip at the top of the Futurit CLS Unit CLS engaging slot Figure 81 Futurit
21. In the interests of health and safety when installing using or servicing this equipment the following instructions must be noted and adhered to 1 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 1 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 6 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 c Mains voltages are present in LED and LED NLM aspects Before any maintenance work is carried out the mains supply to the aspect must be isolated switched off WARNING the earth connections within the CLS with LMF signal head are daisy chained from the Red to Amber and then Green LMF Unit When removing either a Red or Amber LMF unit the aspects below will not be earthed and therefore should not be touched if the controller is powered on Ensure th
22. SI E M E N S HELIOS GENERAL HANDBOOK LTN 1 98 his dimension applies if the push button is a single housing or a separate housing Demand Display unit 5 height dimension of the pushbutton unit applies to single housing separate housing Demand Display unit see TR2181C The following information is provided to enable pole length requirements and planting depths to be determined This assumes a 667 2 01459 ETC pole and a 3 aspect signal Confirm dimensions using appropriate or latest drawings Note that a 3 75 m pole will only be used for amber centres below about 2 6 m Example 1 Obtaining heights to amber centre line with nominal pole lengths by varying planting depth m e 4000 2800 505 Planting depth in mm 695 mm Note see FIGURE and FIGURE for dimensions Example 2 Using common pole lengths and a planting depth of 700 mm the centre of the amber would be Pole Length m Planting Depth mm Amber centre line 4 700 2 80 m 5 700 3 80 m 5 9 700 4 30 6 700 4 80 m Example 3 obtain the pole length required for a given centre of the amber green or the clearance height e Pole length required Height to amber C L 505 mm planting depth e Pole length required Height to green C L 835 mm planting depth e Pole length required Clearance Height 1065 mm planting depth Therefore if the height of the green is to be 2 5 m the pole needs to be at least 2 5 m 0
23. ensure that it is erected properly and Is not liable to collapse or move using a ladder near a carriageway ensure that the area is properly coned and signed n Any personnel working on site must wear the appropriate protective clothing e g reflective vests etc Safety of Road Users 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 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 signal poles Warning Helios CLS signals are designed and proven to work with the monitoring and signal switching circuits of Siemens Traffic Solutions controller products Siemens are unable to guarantee their operation with third party supplied traffic control products and cannot accept liability in this respect In particular the Lamp Monitor Facility LMF fitted to monitor t
24. 24 Page 122 of 143 SI E M E N S HELIOS GENERAL HANDBOOK APPENDIX B SPARES LIST Listed below are the part numbers for approved Spares for the Helios signal head and associated equipment See the warning on page 4 regarding the use of parts other than those listed Part Number Description Hal only Red LED PCB Amber LED PCB Green LED PCB Up Green Arrow LED PCB 667 1 30198 005 Left Right Green Arrow LED PCB 518 4 90302 010 LED PCB 2 A slow blow 250 V Fuse 667 1 30321 001 Red LED NLM PCB 667 1 30321 002 Amber LED NLM PCB 667 1 30321 003 Green LED NLM PCB 667 1 30321 004 Up Green Arrow LED NLM PCB 667 1 30321 005 Left Right Green Arrow LED NLM PCB 667 7 28584 100 CLS Red Assembly LV 667 7 28584 101 CLS Amber Assembly LV 667 7 28584 102 CLS Green Assembly LV 667 7 28586 100 CLS Red Assembly ELV 667 7 28586 101 CLS Amber Assembly ELV 667 7 28586 102 CLS Green Assembly ELV 667 1 33157 006 ELV Tram Indicator 6 phase Module 667 1 31500 432 667 1 31500 434 667 1 30198 001 667 1 30198 002 667 1 30198 003 667 1 30198 004 Tram Lens assembly without hood Tram Lens assembly with demand indicator without hood Tram Cable loom assembly Tram demand indicator cable loom assembly LMF Assembly 230v Spares Use as Red or Amber Green 50 W Tungsten Halogen Lamp 667 1 33159 000 667 1 3317
25. 24 Page 136 of 143 S N S HELIOS GENERAL HANDBOOK plain rounder washer can be seen then a spring washer may also be included generally with the external or internal serrated washers the serrations will be visible Below you will see a plain and spring washer combination and it is this combination that we at present recommend upgrading to Nordlock washers using the method as described in section D 2 to remove and replace the bolts and washers Determining If a Spring Washer is fitted In this picture you can see 1 The bolt head 2 The plain washer 3 Another smaller diameter washer in between which show no signs of being serrated i e it is smooth in appearance This is a spring washer and should be replaced using the Nordlock replacement kit of parts 667 1 31505 000 There are other shakeproof washers that may be fitted both internal and external toothed serrated at present there is no recommendation to replace these Note Warning Due to a difference in boss lengths on end caps between those signals shipped with Nordlocks already fitted see section D 4 on compatibility of fixings The upgrade kit as noted above must be used on the older signals as it included the correct length bolt The correct bolt length for the shorter boss is 32mm and in the replacement kit these a coloured black to assist in identifying the correct ones to use 667 HB 30000 000 Issue 24 Page 137 of 143 SI E M E
26. CLS engaging slot 4 2 9 CLS NLM Unit Dialight Type Replacement see the note in section 4 2 regarding anti vandal screws Undo the door clips on one side open the door and remove the cable connector PL1 from the LMF unit this removes the phase power from the LMF Unit and then remove the cable connector of the CLS unit from the LMF Unit SKT1 if CLS with LMF or disconnect plug to the mains input lead if CLS NLM Remove the door assembly from the module and work on the ground Remove the 4 screws that holds the CLS Unit to the door Fit the lens on to the CLS unit ensuring that the lens is positioned correctly Fit the seal around the new lens and place the door over the lens and seal Holding the door lens and CLS unit turn the assembly over and replace the 4 screws holding the CLS unit to the aspect door NOTE ENSURE THAT THE CORRECT REPLACEMENT CLS TYPE i e CLS LV NOT CLS ELV 667 HB 30000 000 Issue 24 Page 105 of 143 S N S HELIOS GENERAL HANDBOOK Figure 82 Dialight CLS Unit CLS ELV units are identified by the label displayed in Figure below SIEMENS PART NO 667 7 28586 100 COLOUR RED VOLTAGE BRIGHT DIM 48V 27 5V POWER BRIGHT DIM 12W 4W Ce MODEL TYPE E LV Figure 83 ELV CLS LABEL 4 2 10 CLS ELV Type A Replacement see the note in section 4 2 regarding anti vandal screws Undo the door clips on one side open the door and disconnect the plug to the input lead Remov
27. Hoods and other fixings are supplied in a separate box Backing boards for a four in line assembly are attached to the outside of the box Figure 6 Figure 7 Figure 8 and Figure 9 show typical as delivered internal layouts for three aspect heads Figure 6 Three Aspect Halogen Internal Fitting 667 HB 30000 000 Issue 24 Page 22 of 143 S N S HELIOS GENERAL HANDBOOK Tw T T Lu N Bis Lent li Figure 8 Three Aspect LED NLM Internal Fitting 667 HB 30000 000 Issue 24 Page 23 of 143 S N S HELIOS GENERAL HANDBOOK Figure 9 Three Aspect CLS with LMF Internal Fitting The single aspect box will contain a single module with its side box mounting kit or the four in line fixing kit and all the hoods and fixings for the assembly All these elements should be assembled on the ground prior to fixing to the pole Lanterns are assembled in accordance with the requirements of the STS for primary and secondary signals Assembly and attachment of side boxes are described in section 2 7 2 2 4 Optical Units Helios only has 200 mm aspects with the exception of some regulatory signs that may be notionally 300 mm actual size approximately 270 mm The Mellor lens is not interchangeable with the Helios lens 200 mm Aspects for Vehicle Pedestrian and Green Arrow Signals 2 2 4 1 Halogen A pre focused 12 V 50 W Tungsten Halogen lamp is mounted in a parabolic reflector fi
28. N S HELIOS GENERAL HANDBOOK T T SECURITY CLASESEKCATKON 50 700 150 THIRD ANGLE PROJECTION Las HUMBER SHEET 1 667 51 30200 000 AND BOTTOM HELIOS 1 4 FIXING MODIFICATIONS raras wm important DO LIFT SIGNAL HEAD pra 1 NEW END WITH ALONGER STAINLESS STEEL INSERT IS NOW BEING USED i NEW FIXING ARRANGEMENT FOR MAIN PIVOT SCREWS i SQUARE NORD LOCK SEATING SIGNAL WASHER HEAD ii NORD LOCK ANT VIBRATION NEUEN WASHER 2 PARTS NON SACRIFICIAL CAP iii NEW M10x40mm CAP HEAD SCREW 3 NEW TORQUE SETTING OF 20Nm oo ond 25 d sv od o BEING APPLIED TO BOTH MAIN M10 A USING EITHER END BRACKET FIXINGS CAUSE DAMAGE m a SINGLE ASPECT ASSY ASPECT ASSY spinel SHOWING BOTTOM BRACKET SCREW STIST ASSEMBLY TORQUE TO 20Nm NEW END CAP BRACKET NORD LOCK NL10SS i ANTI VIBRATION d STAINLESS STEEL NS WASHER 2 2 PARTS is SACRIFICIAL i CAP ENSURE SQUARE STAINLESS E TEETH ENGAGE STEEL NORD LOCK F OF CORRECTLY SEATING WASHER SIGNAL qL 3 HEAD NOTE NEW FIXINGS USED ORDER OF ASSEMBLY 1 1 p IS VITALLY IMPORTANT ENLARGED VIEW SHOWING i BOTT
29. Puffin Nearside Signal Unit 667 1 33608 000 Toucan Nearside Signal Unit 667 1 33608 001 Equestrian Nearside Signal Unit 667 1 33608 002 Puffin Nearside Signal NFOV Unit 667 1 33608 500 Toucan Nearside Signal NFOV Unit 667 1 33608 501 Equestrian Nearside Signal NFOV Unit 667 1 33608 502 667 HB 30000 000 Issue 24 Page 77 of 143 S N S HELIOS GENERAL HANDBOOK Figure 58 Nearside Mk2 Signal Unit Each Nearside Signal Unit and Demand Unit comes complete with its fixing kit Each unit fastens to the Signal Pole using the U bolt provided When installing the Nearside Signal and Demand Unit the following must be observed a Centre of the Demand Unit Push button must be 1 0m 1 1m above the footway level b The distance between the bottom edge on the Demand Unit and the top edge of the Nearside Signal Unit must be less than 550mm but remember to leave sufficient room between the two units to allow the removal of the Nearside Unit Door The three variants of Nearside Signal come with a door assembly which contain the following items a a PCB which contains all the Display Red LEDs arranged to illuminate either the Red Man Puffin Red Man and Red Cycle Toucan or a Red Horse Equestrian b PCB which contains all the Display Green LEDs arranged to illuminate either the Green Man Puffin Green Man and Green Cycle Toucan or a Green Horse Equestrian c a front panel the type
30. Royce Thompson Electric Ltd type 5 55 Lux STCL part number 506 4 97891 000 or equivalent which plugs into a Rotaloc Socket The cell is mounted on the top of the 3 aspect case through a 20 mm diameter hole drilled using one of the two central guide indents on top of the case Around the central indent are eight other drill start points four of which should be used to secure the solar cell to the case pointing north using nuts and bolts and the cork washer See Figure The three terminals on the socket are connected as follows Socket terminal L Live Socket terminal N Neutral Socket terminal Lo to Controller dim input Each terminal is wired to the terminal block mounted on the top of the pole by 24 0 2 mm wire using the following colours Line Brown Neutral Blue Load White The solar switch is connected to its socket by locating the terminals in their slots and pushing down then twisting the unit clockwise when looking down on the socket This twist completes the circuit and if not done correctly the solar switch will not function During daylight the solar switch should give the signal bright condition test it cover the unit for approximately one minute and check that the signals go to the dim condition Uncovering the unit should then result in the signals going to the bright condition after approximately one minute 667 HB 30000 000 Issue 24 Page 56 of 143 SI N S HELI
31. ST700 Yes jN S STISO Yes 0000020 STOEV Sto N _ Table 1 CLS Wait Monitoring Options 1 Lamp monitoring is possible however the ST800 Controller firmware needs to be 667 TZ 12800 000 800 issue 31 or later and configuration changes may be necessary 2 Lamp monitoring is currently not possible with the ST900 LED This feature may be provided in the future by means of a firmware update Please contact Siemens Traffic Solutions sales department for further details Warning The CLS Wait is an ELV device designed for connection to 48V systems If the unit is to be used with an LV controller it will be necessary to fit a Wait Drive Transformer Kit 667 1 21029 001 Failure to do so will result in the permanent damage to the unit and possible damage to the controller 2 30 1 CLS Wait Retrofit The CLS Wait Retrofit kit is designed to allow the upgrade of existing MK1 and MK2 and Peek 48V incandescant Wait units to CLS technology Installation and maintenance details can be found in 667 47700 The following parts may be used during the retrofit process but see 667 47700 for more information 667 1 47711 000 CLS Wait Retrofit kit 667 HB 30000 000 Issue 24 Page 73 of 143 SI N S HELIOS GENERAL HANDBOOK 667 1 47701 000 Siemens MK2 Spacer Kit 667 1 12800 000 PB800 issue 31 or greater ST800 667 1 21029 001 Wait Drive Transformer 48V AC 160 VA
32. SZ HO31 SV13 NINOL X YN Jol T lol LINN CNLLOOS SARS IZOd SZ SV ld PANDI X BU 2 Ov 35H 3APHO YIH Wi E TIM 2902 900 2600 299 YINWNYOJSN YAL 00Q L2600 b 299 USWHOASNVELL N LL 0 57 77 7611 LOB ININGL X SN NOLLY1N3R3O TOUHA 31v aais O1 3415 ONLLLITO LZOd X3H 52 SV Yd X LUNN 3149491 TWAM3903S x E U 3 SILLOVL HNA STI 12V1 XICVH ONLLLDIO GWSUHL 209 QV3H DNULL ZOd YIH HOAL SV Id X Y SZ H2 31SV ld X YN 900 250047 299 H3WNHNOJSNVMHL 900 4600 199 USIOASNVALL 000 14600 v 99 HANMOASNVULL 2600 299 1 YIH MNIOSSHALNOCO 3WIS1INTIOS SNDtOVS 120 of 143 Figure 96 Front View Issue 24 667 HB 30000 000 SI E M E N S HELIOS GENERAL HANDBOOK g 4 4 iF 55 55 uo He E E BACKING BOARD M5 X 12MM PLAS TECH 25 HEX HEAD DRIVE 7 THREAD CLITTING Figure 97 Rear View 667 HB 30000 000 Issue 24 Page 121 of 143 SIEMENS ASPECT TO ASPECT M5 X 45MM HEAD DRIVE THREAD CU
33. and CLS ELV Helios options 667 1 31500 397 Clear Equestrian Lens LED Lens This lens is used in front of Red and Green CLS with LMF CLS NLM and CLS ELV units 2 6 7 Four Line A four in line configuration is delivered with three aspects assembled and the fourth in separate packaging The bottom bracket will be attached to the fourth aspect The fourth aspect should first have the O ring fitted included with the mounting kit to seal the join between the boxes It should then be clipped in place and secured using the two 5 x 45 mm screws supplied in the outer fitting positions see Figure and Figure 2 Side Boxes Side boxes are supplied with all the necessary fixings to fit them to the signal head One metal plate should be screwed vertically between the units the other fits horizontally for extra support See Figure and Figure for fixing details There is a conduit supplied to run the cables through The holes for the conduit should be drilled using an 18 mm or 20 mm drill bit in the forward drill start position on the signal head as shown in Figure witha corresponding hole in the side box Figure shows the conduit fitting from inside an aspect case If two side boxes are to be fitted on one side they should be connected together in the same way as the aspect boxes see section 2 6 7 before being fitted to the main signal head 667 HB 30000 000 Issue 24 Page 43 of 143 SI N S HELIOS GENERAL HAND
34. bolt is used with the correct fittings In the following sections we will inform you on how to identify compatible parts 4 Where upgrades are recommended We also recommend upgrades to existing installations under specific circumstances and in the following sections we will outline when and how this should be done Tools and Consumables Required 8 to 60 Newton metres torque wrench calibrated Halfords item code 200238 0 amm 3 8 drive hex bit Halfords item code 168039 0 Thule 6 metre securing straps Halfords item code 144139 0 Please refer to 9 118 for the correct way to use amp calibrate the Torque Wrench D 2 Tightening Procedure Hefer to drawing number 667 GL 30200 000 which can be found later in this section Ensure that the mating parts of the sacrificial bracket are joined I e toothed parts engaged and the whole bracket has engaged in its position correctly Tighten the securing bolt using a torque wrench set to 20 Newton Metres NB If they are excessively loose or turn continuously fail to tighten then the cap will need replacing 667 HB 30000 000 Issue 24 Page 131 of 143 S N S HELIOS GENERAL HANDBOOK D 3 Inspection Procedure With reference to the figure immediately below inspect the end cap fasteners on both ends of the Helios head Determine if the securing screws are tight The screw should be seated firmly in position securing the bracket head correctly There should be no e
35. con Se Loa e EN Le M oe RM od POM 36 2 6 Signal Head Arrangement 37 225 Gainea CaS ETE T 37 39 2022 PBemove DOOS 39 2 6 4 Green Arrow Halogen CLS with LMF CLS NLM and CLS ELV 40 667 HB 30000 000 Issue 24 Page 5 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 6 5 Green Arrow LED and LED NLM 42 2 6 6 Equestrian Halogen CLS with LMF CLS NLM CLS ELV LED and LED NEM ass 43 2 6 7 FOUI BIER TUM 43 2 c E NT 43 WIRING SIDS B0x861 45 2 7 2 Mandatory 45 2 0 Lransrormers 46 46 210 LEDNEM feto eae me nee 47 48 2 AZ OLS EEV UNS 9 49 2 13CLS ELV Type B Transformer Placement 50 2 14Lamp Monitoring Unit LMF 50 2 I 5ELV TRAM a 51 O Lo MIMI tM Ic MM UM 53 IO IIT 53 53 3100
36. fitted in one of the three recesses in the side of the module 3 Pedestrian signals may have the cable gland fitted in any position to reduce the length of the conduit Wherever the gland is fitted consideration should be given to the length of the transformer PSU wires and the amount of conduit tubing between the signal head and the pole A long length of tubing is unsightly and should be avoided wherever possible To fit the conduit tubing screw the conduit adapter into the cable gland Feed the locking ring onto the conduit tube and push the tubing firmly onto the end of the adapter Seal in place with the locking ring Note that the tubing does not form part of the signal head assembly but should be kept in quantity by installers and cut to fit as required 2 19 Hoods The signal is normally supplied with Helios moulded primary or secondary hoods but will also accommodate a wide range of hoods used with the previous Mellor style signals if required including most louvred and tunnelled hoods The new moulded hood is fitted with insertion slots for accurate positioning and is attached using fir tree clips See Figure for details The clips are just pushed in to hold the hood in place i Figure 39 Standard Hood fitting The moulded hoods may be fitted straight or turned up to 90 without modification If for any reason a hood needs to be attached at more than 90 to the vertical new holes will need to be drilled in t
37. input lead if CLS NLM or CLS ELV Remove the door assembly from the module and work on the ground 667 HB 30000 000 Issue 24 Page 112 of 143 S N S HELIOS GENERAL HANDBOOK If the existing hood is to be re used remove it as described in section 4 2 21 and retain it for re use Otherwise fit a new hood as described in section 2 19 Fit the replacement door back on to the aspect body connecting the lead from the CLS unit to either SKT1 on the LMF unit and then the phase power connector to PL1 CLS with LMF or the mains input plug if CLS NLM or CLS ELV Secure the door tightening the anti vandal screws if supplied If necessary re attach the hood NOTE Ensure that the correct type of door i e LV or ELV is used as the replacement II T n DE Figure 93 CLS Aspect Door 4 2 18 CLS ELV Door Replacement Normally a door lens assembly is replaced complete See the note in section 4 2 regarding anti vandal screws Undo the door clips on one side open the door and disconnect the plug to the input lead Remove the door assembly from the module and work on the ground If the existing hood is to be re used remove it as described in section 4 2 21 and retain it for re use Otherwise fit a new hood as described in section 2 19 Fit the replacement door back on to the aspect body see sections 4 2 10 and 4 2 11 re connecting the input lead Secure t
38. lamp holder fitted into a reflector assembly a red amber or green coloured lens and a lamp transformer fitted with sufficient cable on its input to reach the pole cap wherever the lantern is mounted on the pole LED Option An LED board is fitted behind a clear lens and connected to a PSU inductor assembly for each aspect The LEDs are linked in a number of strings around the board connected so that if a string fails it does not leave a dark area The Inductor continually measures the output current of the board and if that should fall below 80 the fuse blows and a fault is sent to the controller LED NLM Option An LED board is fitted behind a clear lens and connected to a dual winding transformer The LEDs are linked in a number of strings around the board connected so that if a string fails it does not leave a dark area This option does not allow any Lamp Monitoring CLS with LMF Option The Central Light Source CLS is fitted behind a clear lens and is connected to the Lamp Monitoring Facility assembly for each aspect The CLS Unit is a sealed unit that contain a number of high intensity LEDs There are three different types of CLS units a Red an Amber and a Green The LMF unit measures the output current of the CLS unit and if that should fall below 80 the fuse blows and a fault is detected by the controller The LMF unit is connected to the controller phase output CLS NLM OPTION The Central Light Source CLS is fit
39. maintain monitoring compatibility The controller firmware and monitoring profile remain the same It is only necessary to fit one dummy load unit per Nearside as it supports both the Red and Green aspects 667 HB 30000 000 Issue 24 Page 97 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 4 MAINTENANCE Before starting any maintenance work read the Safety Warning on page 2 of this Handbook 4 1 Routine Maintenance Visits Warning Mains voltages are present in LED and LED NLM aspects The mains supply to the signal head must be disconnected switched off before working on an LED or LED NLM aspect The interval between visits depends on local conditions but typically would be every six months Routine maintenance consists of the following The outside of the signal head should be cleaned The lens should only be cleaned using a proprietary window cleaner rest of the signal head may be cleaned with water The front and rear drainage slots in the top box should be cleared on each routine visit The drainage slot between the door and body of each aspect should be cleared on each routine visit Check that the seal between the body and door has its drainage slot in the centre of the bottom of the body especially on earlier models The fixings particularly for the hoods and backing boards should be checked tightened where required and replaced if necessary The securing screws for the Helios end caps may become loose i
40. means that during off peak hours when traffic volume is low the disruption to local residents is kept to a minimum The Bleep and Sweep Unit is to be fitted into Bleep and Sweep Signal Heads during site installation See Figure Figure and Figure The following are the Signal Head options for Bleep and Sweep 66 7 1 30200 840 Red Man Green Man Bleep amp Sweep STD halogen 667 1 30200 890 Red Man Green Man Bleep amp Sweep LED 667 1 30200 990 Red Man Green Man Bleep amp Sweep LED NLM 667 1 31500 890 Red Man Green Man Bleep amp Sweep CLS LMF 667 1 31500 990 Red Man Green Man Bleep amp Sweep CLS NLM Part Number for Sedgewall Bleep and Sweep Unit 11 TGR 212000 0 0 667 HB 30000 000 Issue 24 Page 89 of 143 S N S HELIOS GENERAL HANDBOOK Red Man Aspect Green Man Aspect Bleep amp Sweep Aspect Figure 65 Bleep and Sweep Signal Head Arrangement Bleep and Sweep Control Unit Standoffs provided in Bleep amp brush off Kit Figure 66 Bleep amp Sweep Unit Mounted in Signal Aspect 667 HB 30000 000 Issue 24 Page 90 of 143 S N S HELIOS GENERAL HANDBOOK Bleep and Sweep Microphone and speaker Figure 67 Bleep and Sweep Microphone and Speaker Mounting 2 36 Fitting Signal Head to Pole This section describes the recommended method ol installing the assembled signal head onto the pole To carry the signal head with
41. pointing upward Do up the four screws that hold the reflector lens to the door When correctly fitted the arrow pattern on the masking should point upwards EN thus Replace one side of the door and refit the bulb holder into the reflector Do up the other door clips and any anti vandal screws 4 2 23 Lens Replacement LED or LED NLM Warning Mains voltages are present The mains supply to the signal head must be disconnected switched off before working on an LED or LED NLM aspect Warning Anti static precautions must be taken when handling LED or LED NLM PCB Assemblies Note As the lens to door seal is difficult to align once removed this procedure should not be carried out on site complete replacement door assembly Should be fitted as described in section 4 2 16 and the lens replacement done at the depot Remove the door and work on the ground Detach the LED or LED NLM PCB from the door by squeezing the fir tree clips on the plastic pillars Unscrew the lens retaining ring tip out the lens and keep the seal to use again unless it also needs replacing Fit the seal around the new lens and place the door over the lens and seal aligning them very carefully When correctly fitted the pattern on the masking should point downwards thus Holding them together tip the door lens over replace the lens retaining ring and check that the small tag on the outside of the retaining ring is pointing upward
42. re fit the aspect by re fixing the 4 screws holding the retaining ring to the door When the lens is correctly fitted the arrow pattern on the masking should point upwards thus Replace one side of the door into the signal head enclosure and refit the input cable Close the door and do up the other door clips and any anti vandal screws 4 2 26 Sacrificial Cap Replacement Note Where the sacrificial cap is being replaced following an impact inspect the entire signal head carefully for associated damage To replace the sacrificial cap assembly remove the single hex cap bolt in the bottom bracket then slacken the lower bracket to pole fixings Swing the signal out just enough to give access to the broken sacrificial cap 667 HB 30000 000 Issue 24 Page 117 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Remove and replace the toothed sacrificial cap and refit the Allen bolt loosely Re align the signal head section 2 36 1 and re tighten all bolts and screws 4 2 27 Sacrifical Caps Screw Tightening Procedure It is possible for the Allen screws to become loosened after a collision with the signal head If the screws are found to be loose then it is recommended that they are removed and replaced using the procedure in Helios Signal Head Screw Fixing Procedure If it is found not possible to secure the cap screws then the cap should be replaced as described in the previous section 4 2 28 Modular Unit Replace
43. that are now recommended for use on the signal head end fixings are a Nordlock washer which consists of two parts and this must also be combined with a square washer The following are two different views of a Nordlock washer pair it should be noted that the two surfaces with the larger serrations are the two surfaces that should be mated together when the washer is assembled wr Waka ers The fixing currently The combination of a shipped is Nordlock plain washer and spring washer pair and a washer is no longer square washer recommended and However other earlier should be upgraded fixings may be found in Please refer to the the field using plain following section washers and ora combination of internal or external serrated shake proof washers or spring washers 667 HB 30000 000 Issue 24 Page 135 of 143 S N S HELIOS GENERAL HANDBOOK D 5 Upgrades Recommended If the fixing present is not a Nordlock then upgrading to Nordlock should be considered and the upgrade to Nordlock is recommended where either the washer combination includes a spring washer or where after having been tightened and torqued to the recommended 20 Nm a second inspection within 6 months has shown the fixing to have loosened again To determine if the present fixing has a spring washer check as follows Examine the fixings if a Square washer can be seen then it will be Nordlock 667 HB 30000 000 Issue
44. the unit to the right Fitting the new LMF Unit is the reverse operation to that of removing it If the replacement LMF Unit is a Spares Unit 667 1 31180 230SP it may be used as a replacement for either a Red LMF Unit or an Amber Green LMF Unit The LMF Spares Unit comes as a kit containing an LMF Unit and an LMF Spares Kit which allows it to be configured for either LMF Unit type If the LMF Unit is to be used to replace a Red LMF Unit all that is required is the Hed 230V Identification Label 667 2 31190 000 to be added to the Unit The Unit is now ready for fitting If the LMF Unit is to be used to replace an Amber or Green LMF Unit an internal jumper is required to be fitted First remove the Unit s cover by removing the 2 off 667 HB 30000 000 Issue 24 Page 108 of 143 S N S HELIOS GENERAL HANDBOOK M3 x 10mm screws Place the Jumper 508 4 21405 001 between pins 6 and 8 of PL2 as identified in Figure Replace the LMF Unit s cover and screws and add the Amber Green 230v Identification Label 667 2 31190 001 The Unit is now ready for fitting Place Identification Label Here O O Pin 8 O Pin 6 O OO O O PL2 Figure 86 LMF with Cover Removed Note the forming of the power cable into PL1 of the LMF unit This prevents any water ingress down this cable from dropping into the LMF unit ant N x SKT1 Formation of Earth Terminal Power Lead Pushbutton Ties Figure 87 LMF un
45. u uu cR doris den 95 le M 101 Figure 74 2 0 SS uu Q 101 FOUE 75 SEED INE PCOB TON uu nu nmana 101 Figure 76 PSU White Molex 103 Figure 77 LED NLM 104 Figure 78 CLS Unit fitted into 104 Figure 79 Futurit CLS Unit Retaining Ring and retaining Clips 105 Figure 80 Pip at the top of the Futurit CLS Unit 105 Figure 81 Futurit CLS engaging 101 105 Figure 82 106 Fig re 35 OLS LABE L 106 Figure 84 CLS ELV Type anti rotation clip 107 EIdure 95 108 Figure 86 LMF with Cover Removed 109 Figure 87 LMF unit within a signal aspect 109 FIg re 68 DOOF assembly FI8l 0Ger u u u uu u uyu yuy i uu 110 Figure 89 Lens with seal in place 110 Figure 90 Reflector
46. which is dependant on the Nearside Signal 66 7 2 30690 000 Puffin 667 HB 30000 000 Issue 24 Page 78 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 667 2 30690 001 Toucan 667 2 30690 002 Equestrian The following are the Mk2 Door Assembilies that are available Puffin Door Assembly 667 1 33661 000 Toucan Door Assembly 667 1 33661 001 Equestrian Door Assembly 667 1 33661 002 Puffin Door NFOV Assembly 667 1 33661 500 Toucan Door NFOV Assembly 667 1 33661 501 Equestrian Door NFOV Assembly 667 1 33661 502 For Nearside Mk2 LP replace 33661 with 33668 667 1 33668 010 2 31 2 Terminal Block Layout for Nearside Signal units shown below are the diagrams of the terminal block assembly used within the Nearside Mk2 Signal units RED 48VAC 1 RED 48VAC 2 48VAC 1 GREEN 48VAC 2 EARTH NEARSIDE MK2 SIGNAL 2 31 3 Nearside Mk2 Demand Unit There is currently two variants of the Nearside Demand Unit which are dual housed with the Nearside Signal Unit for use in UK Puffin Toucan and Equestrian Crossing applications The Nearside Demand unit uses a Mechanical or piezo touch switch This is illuminated by a circle of Red LEDs whenever a Demand is registered The UK Variants with mechanical switch are Nearside Demand Unit 667 1 33606 010 667 HB 30000 000 Issue 24 Page 79 of 143 S N S HELIOS GENERAL HANDBOOK The UK Variants with piezo switch
47. 0 000 667 1 31180 230SP 517 4 92787 000 667 1 30200 500 Lamp Holder with ceramic socket wires and screws Enhanced Optic Door Enhanced Optic Reflector Door sliding clips 200 mm Red Lens 667 2 30050 200 667 2 30056 200 667 2 30054 000 667 2 30200 200 LELELLL efef mm 0 ee ase 1 LESLEL eso O gt O N EB O O O Issue 24 Page 123 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Part Number 667 2 30200 201 667 2 30200 202 667 1 30200 300 667 1 31500 300 667 1 30200 310 667 2 31501 000 667 1 30200 400 667 1 30200 402 667 1 30200 403 667 1 30200 404 667 1 30200 405 667 1 30200 406 667 1 30200 407 667 1 30200 408 667 1 30200 409 667 2 30074 101 667 1 30200 399 667 1 30200 398 667 1 30200 397 667 1 31500 396 667 1 31500 397 667 1 31500 405 667 1 31500 406 667 1 31500 407 667 1 31500 408 667 1 31500 409 667 2 30052 002 667 2 30052 004 667 1 30200 104 667 2 30070 001 667 2 30070 002 667 2 30070 003 667 2 30070 004 667 1 02442 ETC 667 1 30200 806 667 1 30200 805 667 1 30200 808 667 HB 30000 000 Description 200 mm Amber Lens 200 mm Green Lens 200 mm Clear Lens 200mm Clear Lens for CLS Lens Retaining Ring CLS Retaining Clip 200 mm Red Standing Man Lens 200 mm Green Walking Man Lens
48. 0200 422 667 1 30200 423 667 1 30200 424 667 1 30200 425 667 1 30200 426 667 1 30200 427 667 1 30200 428 667 1 30200 429 667 1 30200 430 667 1 30200 040 667 1 30200 041 667 1 30200 061 667 1 30200 042 667 1 30200 043 667 1 30200 044 667 1 30200 045 667 1 30200 046 667 1 30077 000 667 2 30078 000 667 HB 30000 000 Description Single Body Side Mounted Reg Sign no doors Side mounting and AGD bracket Transformer Linear PSU Assembly Transformer for LED NLM Regulatory Sign Internal illumination assembly NRT Reg Sign amp Door NLT Reg Sign amp Door Except Buses Reg Sign amp Door Mandatory Arrow Reg Sign amp Door NUT Reg Sign amp Door No Entry Reg Sign amp Door Mandatory Cycle Reg Sign amp Door Buses Only Reg Sign amp Door Cycles Only Reg Sign amp Door Taxis Only Reg Sign amp Door Except Cycles Reg Sign amp Door Except Buses amp Taxis Reg Sign amp Door Except Buses Cycle amp Access Reg Sign amp Door NUT Reg Sign amp Door for export Except Trams Reg Sign amp Door Except Buses and Cycles Text amp Door Except Buses Taxis and Cycles Text amp Door Except Service Vehicles Text amp Door Mandatory Bus Only Graphic amp Door Except Mobility Scooters Text amp Door Primary hood kits Secondary hood kits Ped hood kits 2 in line backing boards 3 in line backing boards 4 in line backing boards 1 at side backing boards 2 at s
49. 1 1 Equestrian Door NFOV Mechanical Switch 667 1 33662 512 For Nearside Mk2 LP replace 833662 with 33667 4 667 1 3366 7 010 The following are the Mk2 LP piezo Door Assemblies that are available Puffin Door Active Piezo Switch 667 1 33662 000 Toucan Door Active Piezo Switch 667 1 33662 001 Equestrian Door Active Piezo Switch 667 1 33662 002 Puffin Door NFOV Active Piezo Switch 667 1 33662 500 Toucan Door NFOV Active Piezo Switch 667 1 33662 501 Equestrian Door NFOV Active Piezo Switch 667 1 33662 502 2 31 6 Terminal Block Layout for Nearside Combined units Shown below are the diagrams of the terminal block assembly used within the Nearside Mk2 Combined units 667 HB 30000 000 Issue 24 Page 85 of 143 SIEMENS TB2 cO NEARSIDE MK2 COMBINED 2 32 Radix Sedgwell Power Supply for Tactile RED 48VAC 1 RED 48VAC 2 GREEN 48VAC 1 GREEN 48VAC 2 TB1 EARTH HELIOS GENERAL HANDBOOK 48 V 48 V RET AUDIO 1 AUDIO 2 PUSH BUTTON PUSH BUTTON It is recommended that where used this unit be fitted in the amber aspect case in the upper position as shown in Figure otherwise the halogen reflector will stop the door closing Move the cables connecting the transformers and fit the power supply to the case as shown using the mounting positions shown in Figure NOTE There are two variants of the Radix Tactile Unit 667 7 17390 000 Radix ty
50. 1 S Will paces ter oes 73 230 VG s u u u Ls 73 98 75 2 31 Mk2 Signal and Demand Units 77 2 31 1 Nearside Mk2 and Mk2 LP Signal Unit 77 2 31 2 Terminal Block Layout for Nearside Signal units 79 2 31 3 Nearside Mkz Demand uyu ia mE 79 2 31 4 Terminal Block Layout for Nearside Demand units 80 2 31 5 Nearside Mk2 and Mk2 LP Combined Unit 82 2 31 6 Terminal Block Layout for Nearside Combined units 85 2 32Radix Sedgwell Power Supply for Tactile 86 29 BACKING OAKS 87 2 MI ADC uu yu S 88 667 HB 30000 000 Issue 24 Page 6 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 34Above Ground Detector AGD aa aa T 88 2 359Bleep ard 9SWeeb ees 89 2 906Fillingoighal Flead TO P Ole uuu L 91 2 36 1 Adjusting Tilt and Rotation 92 2 90 2 signal lead to Pole
51. 2 000 and 998 4 88324 000 are available for connection to the terminal block s inside the Nearside Signal Unit and Demand Unit to the terminal blocks in the pole cap assembly Note that each wire is 4 metres long Note a second terminal block requires fitting into the Demand Unit at the Right Hand Side of the Unit if 2 optional Audible Supply Kits 667 1 27006 000 are fitted The connections for these wires are as follows Wire Colour for Wire Colour for Signal Name Signal Name 667 1 26942 000 667 4 88324 000 Connection Connection Demand Nearside Unit Unit Green Yellow Green Yellow TB1 6 Earth TB2 Earth Connector 667 HB 30000 000 Issue 24 Page 65 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Orange Orange _ TB5 PushButons Orange White TB16 Push Button Red TB1 1 RED48VAC TB1 3 Audio 1 TB1 2 RED 40VAC2 TB1 4 Audio 2 Blue Blue TB1 4 GREEN TB1 2 48v RET 48VAC2 Brown Brown TB1 3 GREEN TB1 1 48v 48VAC1 Violet Green Wire Direct to Tactile Motor Yellow Yellow Wire Direct to Tactile Motor 1 NOTE If the Optional Audio Kit 667 1 27006 000 is fitted wire as follows a When using wiring kit 667 1 26942 000 i Fit an extra terminal block TB2 703 4 98500 016 to the Right Hand side Terminal Block position using screws 999 4 03302 012 li Wire Red to TB3 1 Wire Black to TB3 2 Wire Yellow to TB3 2 Wire Violet to TB3 3
52. 3 Remove Doors Two sliding clips on either side fix the door to its Aspect When signal heads and side boxes are delivered the doors are fitted To remove a door open all four clips and lift the door off If necessary use the point of a screwdriver as shown in Figure to push open the door clips Teflon based or similar dry type lubricant may be used to lubricate the clips Figure 18 Using a screwdriver to open the door clip Leave the lens and rellector in place on the rear of the door and unclip the bulb holder from the rear of the reflector 667 HB 30000 000 Issue 24 Page 39 of 143 S N S HELIOS GENERAL HANDBOOK Figure shows a door clip in the half open position with the door sitting above and unconnected The door 1 held in place by the door clip UM 2 lt ma 2 m T 4 r _ gt mo SSS Figure 19 Door clip detail 2 6 4 Green Arrow Halogen CLS with LMF CLS NLM and CLS ELV The green arrow optic includes a metal mask 667 2 30074 101 as shown in Figure This module 1 delivered with the mask positioned either vertically straight ahead or horizontally for left or right turn The mask has casilations that fit into indentations in the reflector lens retaining ring enabling it to point in any one of 16 directions depending on individual site requirements Figure 20 Green Arrow mask Any adjustment to the orientation of the green arro
53. 4 Page 142 of 143 SIEMENS Sacrificial cap replacement 97 Safety 2 106 ec MM TM PEOR 106 9196 0 aer EE 11 17 37 70 105 SIDS mounting 31 Signal head 32 Signal head to pole 74 DOAN COM MM S 48 103 T y 17 69 Terminal blocks 17 27 29 31 45 Tilt75 667 HB 30000 000 HELIOS GENERAL HANDBOOK Torque setting 19 75 Tirane Ol Tol 40 41 105 Tube replacement 90 V Vence 21 W DE 13 28 rx 29 cR 27 76 Issue 24 Page 143 of 143
54. 84 m 0 61 m 3 95 m Note see FiGURE and FIGURE for dimensions 667 HB 30000 000 Issue 24 Page 29 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 1051 1065 Ground level Cables entering l via slot in pole Planting Depth Concrete Anti rotate rod Figure 11 Signal Pole Assembly showing useful dimensions for Pole Selection and planting depth Note The planting depth must be a minimum of 610 mm to cover the cable entry slot Install under direction from the Civil Engineer dependent on the ground conditions 2 3 3 Cranked and Formed Poles at Toucan crossings Where cranked or formed poles are used at Toucan crossings the 4 32 m pole is recommended This has been specially designed to avoid the possibility of cyclists injuring themselves on the bend in the standard length poles These poles have a ma
55. Audio 1 Audio Sig Audio Sig Audio 2 nM b When using wiring kit 998 4 88324 000 i Fit an extra terminal block TB2 703 4 98500 016 to the Right Hand side Terminal Block position using screws 999 4 03302 012 ii Wire Red to TB3 1 Audio 1 Wire Black to TB3 2 Audio Sig Wire Yellow to TB3 2 Audio Sig Wire Green to TB3 3 Audio 2 Ensure that the wiring at the controller is to 667 GA 27006 000 Sht2 Issue 3 2 24 Nearside Mk2 Range of units The next sections detail the new Nearside Mk2 range of Wait Indicator Nearside Demand and Nearside Signal housings These provide a new contemporary design that is both aesthetically pleasing and able to provide product configuration that meet all of the latest customer needs amp requirements whilst reducing manufacturing costs 667 HB 30000 000 Issue 24 Page 66 of 143 HELIOS GENERAL HANDBOOK SIEMENS ing positions 2 25 Nearside Mk2 Pedestrian Wait Mk2 Pole drill SNOISN3WIG 9SNITIIiG 310d NVINLSAG3d 15 3 031 13A31 4 0014 0001 HOLIMS 99r oes 13 31 ONNOYD WON 078 0120 3 10H MVNO ZIG 70 1708 I 07096 SNOISN3WIG 9SNITTIHG 310d 8 TVNGIAIONI T 8 2 o 2 oG 25 Ac gt at VAU oh e 28 28 8 ape I m
56. BOOK Figure 24 Side box fitted on right of main signal head Both ends of any side fittings should have end caps fitted as shown in Figure There is an O ring supplied to seal the fittings to the body that should be placed In the groove inside the end cap Figure 25 End cap fitted to side box 667 HB 30000 000 Issue 24 Page 44 of 143 S N S HELIOS GENERAL HANDBOOK 2 7 1 Wiring Side Boxes Check that the internal illumination assembly is correctly fitted into each side box Green arrow and cycle side boxes have internal fittings similar to the main signal head regulatory signs are fitted as shown in Figure Feed the cable through the conduit up through the main signal head via the cable gland and wire to the top cap Figure 26 Regulatory Sign internal fitting 2 7 2 Mandatory Arrow Where a mandatory arrow sign is to be fitted it is delivered with the door un assembled for fitting on site to customer requirements The kit consists of the door a strip of mastic bead sealant and the optic The arrow should be lined up with one of the 16 points around the door aperture each of which represents an increment of 22 5 Figure 27 Signal Head with Mandatory Arrow fitted 667 HB 30000 000 Issue 24 Page 45 of 143 S N S HELIOS GENERAL HANDBOOK Clean the door aperture and outside of the lens carefully and ensure that both are completely dry before fitting the lens Place the strip
57. ED NLM options can have up ahead or left and right green arrows PCB s fitted as standard these utilise sub equipment green LED PCBs along with a green arrow mask but to have a green arrow in any other position a fully equipped green LED PCB assembly is required along with a green arrow mask The ELV TRAM indicator uses the same housing as other units within the HELIOS family and can be clipped onto standard aspects or used stand alone as required There is no room inside the housing however to fit any ancillary equipment The information below is therefore not applicable to the TRAM indicator module Various items may be added to the basic unit They are assembled to bosses moulded into the box These are e Tactile unit power supplies from Radix and Sedgwell e Additional 50 VA transformers for AGD drive low voltage wait etc e Additional terminal blocks e g STCL controller terminal HI pole cap terminal and MD 12 way brown blocks e Audio drive kit Fixing positions for these items are shown in Figure 96 Positions for fitting overhead detector sockets are provided in recesses three to each side These recesses may also be used for the side box mounted cable conduit See Figure and Figure oolar cell bosses are located on the top of the module Helios modular signals are compatible with existing pole drillings Note Fibre optic arrows cannot be fitted to Helios signs The new type of lens and mask renders fibre optics un
58. G The two pin plug from the CLS unit and the two pin mains socket from the controller output are fitted into the LMF Unit Note the Mains Input Wiring is formed so as to prevent any water ingress from the cables dropping in to the LMF Unit 66 7 HB 30000 000 Issue 24 Page 50 of 143 S N S HELIOS GENERAL HANDBOOK Note that the Mains wiring to other LMF Units is tied to the LMF chassis with two Pushbutton Ties which prevents any heat from the LMF unit from damaging any of the cable forms CLS Unit il 3 if Pushbutton 2 Cable Ties Mains Input Wiring LMF Unit Figure 34 CLS with LMF 2 15 ELV Indicator The TRAM indicator should only be replaced as a complete module The maintenance spares should always be fully equipped modules but the originally supplied equipment may be sub equipped The TRAM indicator uses the same LED driver module as other Helios ELV optics so is compatible with the ST900ELV lamp monitoring Care should be taken when removing the and refitting the unit to not tram the multi way cable and not to unscrew fixings that hold the module together Do not undo this nut Access to screws in keyhole slots through these cut outs Internal Chassis Plate Figure 35 TRAM Indicator with door open 667 HB 30000 000 Issue 24 Page 51 of 143 S N S HELIOS GENERAL HANDBOOK Keyhole slot Molex connector Figure 36 TRAM Indicato
59. Give way Prepare to Stop Blue Aspect B Return Green Aspect A Stop Yellow Aspect A Return White Proceed Ahead aA 2 a 5 _ _ Black Aspect C Return 7 Brown Aspect F Central Dot signal on Violet Aspect F Return 55355 Aspect Diagonal Left _ a Pink Aspect E Return Turquoise 1 2 3 4 5 7 10 11 Aspect D Diagonal Right 12 Grey Aspect D Return Green Yellow screen connect to Earth point This cable is supplied at a standard length of 3 5 metres To maintain the screening connection and the cable terminating crimp pins this cable must not be shortened Spare cable should be lost inside the pole or inside the assembly body Tram indicator cable Colour code shown in Table 1 above Multi way plug Termination crimp pins Screen sleeve Rear view of dot Lens Multi way Tram indicator plug Optional demand indicator plug 667 HB 30000 000 Issue 24 Page 140 of 143 SI N S HELIOS GENERAL HANDBOOK Below is a representation of the Aspects It should be noted that Aspect F is normally always lit whilst the optic is in use Thus it is shown lit in all the diagrams Aspect A Aspect B Aspect C Aspect D Aspect E Aspect F Where more than 3 aspects are driven special conditioning and drives for the Tram Aspects will be x Colour 1 card x Controller Common Ve digital x detector
60. HELIOS GENERAL HANDBOOK SIEMENS Siemens Traffic Controls Sopers Lane Poole Dorset 17 7ER HELIOS GENERAL HANDBOOK THIS DOCUMENT IS ELECTRONICALLY HELD AND APPROVED PREPARED Roy Bowen Dave Martin FUNCTION Senior Group Leader Issue Change Ref Date Issue Change Ref Date 1 Aug 2001 2 9001135 09 09 2002 3 TS001228 29 11 2002 4 15001310 29 04 2003 5 5001552 26 06 2003 6 15002019 28 05 2004 7 15002133 19 07 2004 8 15002438 30 03 2005 9 5002541 5 06 2005 10 15002832 28 09 2005 11 15003362 09 08 2006 12 75003948 11 09 2007 13 15004269 23 01 2008 14 1 004932 5004597 19 03 2009 15 1 004957 03 07 2009 16 15005436 13 04 2010 17 15005846 07 12 2010 18 15005953 11 02 2011 19 15006160 18 07 2011 20 TS006174 05 09 2011 21 75006640 26 07 2012 22 75006820 22 05 13 23 75006850 30 05 2013 24 75007161 08 08 13 Siemens 2001 2012 All rights reserved All trademarks are acknowledged The information contained herein is the property of Siemens plc and is supplied without liability for errors or omissions No part may be reproduced or used except as authorised by contract or other written permission The copyright and the foregoing restriction on reproduction and use extend to all media in which the information may be embodied 667 HB 30000 000 Issue 24 Page 1 of 143 SI E M E N S HELIOS GENERAL HANDBOOK SAFETY WARNING HEALTH AND SAFETY AT WORK Safety of Installation and Maintenance Personnel
61. OM BRACKETS ORDER OF FIXING ASSEMBLY SECTION OF NEW LAYOUT lt ICM Ne o 1 SIEMENS Ed dor SECURITY CLASSIFICATION MATERIAL VIE HELIOS THIS DRAWING HAS AN INVENTOR COMPUTER MASTER i STATED i TITLE _ Sela UNLESS OTHERWIBE STATED HELIOS MAIN FIXING LAYOUT CHANGE DRAWING NUMSER MTS 667 GL 30200 000 2 DIMENSIONS IN mm SHEET 1 667 HB 30000 000 Issue 24 Page 138 of 143 SI N S HELIOS GENERAL HANDBOOK Appendix E TRAM Indicator Cable connections and Aspects The Tram indicator unit is similar to the Regulatory Signs as the main optical assembly remains in the Lantern when the door assembly is opened The appearance of the Tram indicator is shown below Optional demand indicator Tram indicator door assembly showing dots Warning When the Door assembly is open and the unit powered the dots will be very bright do look directly into them To remove the optical assembly from the body a long pozidrive screwdriver is required Suitable tool Buck and Hickman 215093 250mm long shaft and PZ2 tip Do not under any Access Area for screws at circumstances undo the rear of the body These these nuts One of four allow removal of the optic shown assembly from the body Screw at rear of unit in Keyhole slot To remove the indicator undo the 4 screws in the back of the body through the slots provided by giving them 2 turns anticlockwi
62. OS GENERAL HANDBOOK 2 21 Pedestrian Push Button Mk 1 There are two variants of push button units currently in use in the United Kingdom Standard push button with no Sonalert 667 1 01478 000 2 man Pelican push button fitted with Sonalert 667 1 01478 001 3 man Figure 42 Pedestrian push button unit 2 21 1 Optional Wiring Kits for Pedestrian Pushbutton Mk 1 The pedestrian push button unit comes complete with its fixing kit Two optional wiring kits 667 1 26942 000 and 998 4 88324 000 are available for connection to the terminal block inside the PBU provided The connections to these wires are as follows Wire Colour for Wire Colour for Signal Name 667 1 26942 000 998 4 88324 000 Green Yellow Green Yellow Earth 667 HB 30000 000 Issue 24 Page 57 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 22 Red Aud Signal Aud Signal Wait Ind N Wait Ind L Green Tactile motor Tactile motor The wires within the Pedestrian push button should be arranged and cable tied so that the wiring cannot touch the push button micro switch housing Each wire is 4 metres long and connects to the terminal block in the pole cap assembly 7 NOTE If the Optional Audible Supply Kit 667 1 27006 000 is fitted wire Violet to Audio 2 and Yellow to Aud Signal 2 NOTE If the Optional Audible Supply Kit 998 4 88324 000 is fitted wire Green to Audio 2 and Yellow to Aud Signal En
63. RAL HANDBOOK TAE Ld Pie 9 E ml g 6 Figure 73 LED front Figure 74 LED PCB N a 4 b Connector Fuse SIEMENS amp Connector P 4 di iid LOL OL Jd dA Rl ETETE E DEE 39 98 99 as LORS IE La x c ru m 4 a gi ae Q 8 LA ETE 9 IUD T DIL S LP p qh 101 of 143 211777 Md Issue 24 1112111111771 111175 222 D py 223132552532 Q 47 Figure 75 LED NLM front 667 HB 30000 000 SI E M E N S HELIOS GENERAL HANDBOOK 4 2 5 4 2 6 PCB Fuse Replacement LED Warning Mains voltages are present The mains supply to the signal head must be disconnected switched off before working an LED aspect Warning X Anti static precautions must be taken when handling LED PCB Assemblies see the note in section 4 2 regarding anti vandal screws Undo the door clips on one side and open the door Unclip the cable connector from the LED board and remove the cables from the plastic cable clips on the rear of the board Remove the door assembly from the module and work on the ground The LED PCB 1 held in place with four plastic spacers with fir tree cl
64. TTING END M5 X 15MM PLAS TECH 25 HEX HEAD POZI DRIVE THREAD CUTTING END CAP M5 X 15MM PLAS TECH 25 HEX HEAD POZI DRIVE THRFAD CUTTING SOLAR CELL DRILL STARTS X 9 ASPECT ASPECI M5 X 45 MM HEX HEAD POZI DRIVE THREAD CUTTING ASPECT TO ASPECT M5 X 45MM HEX HEAD POZI DRIVE THREAD CUTTING END CAP 5 X 15MM PLAS TECH 25 HEX HEAD POZI DRIVE THREAD CUTTING END CAP M5 X 15MM PLAS TECH 25 HEX HEAD POZI DRIVE THREAD CUTTING ASPECT TO ASPECT 5 X 45MM HEX HEAD POZI DRIVE THREAD CUTTING 667 HB 30000 000 P ZEN uU HELIOS GENERAL HANDBOOK ASPECT TO ASPECT M5 X 45MM HEX HEAD POZI DRIVE THREAD CUTTING END CAP M5 X 15MM PLAS TECH 25 HEX HEAD POZI DRIVE THREAD CUTTING END CAP M5 X 15MM PLAS TECH 25 HEX HEAD POZI DRIVE THREAD CUTTING SOLAR CELL DRILL STARTS X 9 ee ONI pnma gt 4 poog pp ND TO ASPECT M5 X45MM HEX HEAD POZI DRIVE THREAD CUTTING Figure 98 Top View ASPECT TO ASPECT M5 X 45MM HEAD POZI DRIVE THREAD CUTTING END CAP 15 PLAS TECH 25 HEX HEAD POZI DRIVE THREAD CUTTING END CAP M5 X 15MM PLAS TECH 25 HEX HEAD POZI DRIVE THREAD CUTTING ASPECT TO ASPECT M5 X 45MM HEX HEAD DRIVE THREAD CUTTING Figure 99 Underside View Issue
65. a m lt E ns 020 310H GNV1S9 NO LLOS HSNd NOLLNG XVI 0 ZzLO x 2 S310H 1108 L 0 LZO 330H GNV19 310H THING AINO SI S310H WOLLOS OML SHL 40 H2IHM 123135 o ZLO INOWIXVIN 07065 020 31OH GNVTS 0210 XZ S310H 1308 gt I T3ASTONRONS O ZLO 13081 SNOISN3WIG 310d 3adISs v3N GANISWOD 1 asm gt lt e lt e lt ej 0520 819 0796 Stc 0 trr WAIT range ian de for Nearside and Pedestr ing gui Dr Figure 50 Issue 24 Page 67 of 143 667 HB 30000 000 SI N S HELIOS GENERAL HANDBOOK 2 26 Installation of Nearside and WAIT Mk2 fixing kits to pole PULL U BOLT THROUGH THIS HOLE USING A SUITABLE DRAW CORD ENSURE THE U BOLT IS FED THROUGH THE LOWER CABLE GLAND HOLE AS SHOWN HALF NUTS SUPPLIED WITH FIXING KIT DEMAND SIGNAL 9 WAIT U BOLTS CAN BE INSTALLED THROUGH FIXING HOLES BUT COMBINED U BOLTS MUST BE FITTED THROUGH GLAND HOLE ENSURE POLE GLAND IS FULLY INSERTED IN POLE SUPPLIED WITH FIXING KIT Figure 51 U bolt and cable gland installation Mk2 66 7 HB 30000 000 Issue 24 Page 68 of 143 SI N S HELIOS GENERAL HANDBOOK 2 27 Installation of WAIT Demand Signal and Combined M
66. acrificial Cap parts The sacrificial caps must be fitted correctly he smooth cap is fitted to the top of the signal head and the toothed cap is fitted to the bottom Assemble the parts as follows 1 Attach one end cap at each end of the signal head using five screws The sacrificial cap end cap fixes a similar position to the end cap fitted to side boxes shown in Figure Note For a four in line the bottom cap should be attached to the fourth module which will not be attached to the main signal head at this stage of the installation 2 Attach the smooth sacrificial cap and one bracket fixing to the top cap 3 Attach the toothed sacrificial cap and the other bracket fixing to the bottom end cap 4 The Allen bolts should be loosely screwed into place using the 8 mm Allen key Adjustment is needed later see section 2 36 1 667 HB 30000 000 Issue 24 Page 38 of 143 S N S HELIOS GENERAL HANDBOOK Figure 17 Sacrificial Cap assembly 2 6 2 Brackets Most signal head assemblies are delivered to site with the sacrificial caps and brackets ready attached to the signal head In those cases where the assembly has to be made on site follow the instructions given below The brackets should be attached to the signal head to bracket fixings at both ends of the signal head using the M10 screws and bolts supplied Do not fully tighten the screws as adjustment is required later See section 2 36 1 2 6
67. and replace with the new hood Hold in place using the five fir tree clips provided To replace another type of hood remove the fixings which could be fir tree clips bolts or rivets and remove the hood Replace with any compatible hood if necessary drilling as described in section 2 19 1 4 2 22 Lens or Reflector Replacement Halogen Note As the lens to door seal is difficult to align once removed this procedure should not be carried out on site A complete replacement door assembly should be fitted as described in section 4 2 15 and the lens replacement done at the depot 667 HB 30000 000 Issue 24 Page 114 of 143 SI E M E N S HELIOS GENERAL HANDBOOK A damaged lens should only be replaced with one displaying the correct aspect Part numbers are given in APPENDIX B Undo the door loosening the anti vandal screws as described in section 4 2 if fitted and unclip the bulb holder from the rear of the reflector Tuck the bulb holder securely in the module and remove the door from the front of the module Unscrew the reflector from the door and remove the lens Replace the lens or reflector as required A small lug on the rear of the lens fits into a cut out on the front of the reflector It is vital to ensure that the lens fits snugly into the reflector and cannot turn Replace the lens reflector onto the door making sure that the two seals are in place see Figure to Figure and the small tag on the outside of the reflector is
68. any attached side boxes safely remove all doors and place a hand inside the top module Do not carry the signal head by the top bracket Hang the signal head on the pole mountings Do up the two nuts and large bright washers and spring washers securely to hold the top bracket to the pole aligning the cable entry points on the bracket and pole spacer Then attach the bottom bracket with nuts and washers loosely leaving it at its lowest extent 667 HB 30000 000 Issue 24 Page 91 of 143 S N S HELIOS GENERAL HANDBOOK Figure 68 Bottom bracket fitted 2 36 1 Adjusting Tilt and Rotation Once the signal head has been fitted to the pole the angles of tilt and rotation see Figure and Figure need to be adjusted before finally tightening the Allen bolts and hex screws Helios may be tilted up to 6 from the upright and rotated up to 90 Note that it is not possible to tilt a signal head that is rotated over 45 without the use of side mounting brackets section 2 5 2 Adjust the distance between the pole and the signal head and the angle of tilt by sliding the signal head over the brackets Fully tighten the top and bottom hex nuts to the required torque setting see Appendix D for tightening procedure Fit the nut caps provided over the top and bottom nuts shown in Figure to stop reflections and to give weather protection The toothed sacrificial cap is designed so that in an impact the teeth will break and allo
69. are Nearside Demand Unit 667 1 33606 000 The Demand Unit comes with a door assembly that contains the following a A PCB which contains all the red LEDs arranged in a circle around the push button which illuminate when a Pedestrian Demand is Registered b A vandal resistant Stainless Steel mechanical switch or piezo touchswitch c A polycarbonate front panel 667 6 33652 000 in v Push button Wait for Signal rumen O SS 6 i HERRA F a x E d Figure 59 Nearside Mk2 Demand Unit Optional Audible Supply Kits 667 1 27006 000 and Optional Radix Tactile Equipment 667 7 17390 048 are available and can only be fitted into the Demand Unit 2 31 4 Terminal Block Layout for Nearside Demand units Shown below are the diagrams of the terminal block assembly used within the Nearside Mk2 Demand units 667 HB 30000 000 Issue 24 Page 80 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 48V 48 AUDIO 1 Gw AUDIO 2 PUSH BUTTON PUSH BUTTON NEARSIDE MK2 DEMAND 667 HB 30000 000 Issue 24 Page 81 of 143 SIEMENS 2 31 5 Nearside Mk2 and Mk2 LP Combined Unit HELIOS GENERAL HANDBOOK There are three variants of the Nearside Combined Unit which are single housed for use in UK Puffin Toucan and Equestrian Crossing applications Narrow Field of View NFOV option is also available on these assemblies The UK Variants with me
70. arside Mk1 Mk2 667 1 30695 006 ssue 10 and above Nearside Mk1 Mk2 Nearside Wait ELV Compatible PCB Assemblies 667 1 3021 1 001 Issue 4 and above Nearside Demand ELV Compatible PCB Assemblies 667 1 30680 001 Issue 3 and above 3 1 1 Replacing 667 1 30695 xxx boards with 667 1 33655 XXX Non ELV Controllers These controllers do not monitor Nearside units so it is possible to utilise the Nearside Mk2 LP p c b to replace the Nearside Mk1 or Mk 2 p c b Replace the 667 1 30695 XXX with the equivalent 667 1 33655 XXX board There is a reduction in power consumption as the new p c b is more efficient ELV Controllers Replacing all Nearside Boards For small installations it may be cheaper to replace all Nearside p c b s with the new version and convert the site to Nearside LP operation This is especially true where the number of Nearside units is small e g single pedestrian crossing It is also possible that customers may request all units to be replaced This will result in a reduction of running costs of the site In both cases the controller firmware must be upgraded to PB801 Issue 13 or later before monitoring of the Nearside units is enabled ELV Controllers Replacing a single board For larger installations or where the power saving is not required a single 667 1 30695 board may be replaced with the 667 1 33655 equivalent In this case the Nearside must also be fitted with a Nearside 2 LP dummy load unit to
71. at the Earth connections are reconnected after any remedial work has been carried out e WARNING The CLS ELV aspects must only be connected to ELV controllers or else irreparable damage will be caused to the CLS unit f These signals heads must only be connected to a signal controller that provides a readily accessible disconnect device e g double pole isolator controller switch or master switch to allow the signal heads to be isolated g All equipment of conductive material installed in these signal heads must be bonded to earth e g transformers tactile power supplies etc unless double insulated or access to it is restricted to use of a tool h Where Siemens signal head transformers are used a fuse not exceeding 16 amps must protect the wiring at the controller i Only trained competent persons should work on this equipment This includes persons who are employed to change bulbs All wiring has basic insulation and should be regarded as hazardous i e hazardous voltages are accessible if the insulation is damaged Surfaces within the signal get hot e g lamp lens and reflector Therefore care should be taken when working in such areas 667 HB 30000 000 Issue 24 Page 2 of 143 SI E M E N S HELIOS GENERAL HANDBOOK k Any power tools must be regularly inspected and tested Any ladders used must be inspected before use to ensure they are sound and not damaged m When using a ladder before climbing it
72. b holder removed by gently squeezing the bulb holder clips Pull the bulb free of the bulb holder and push the new bulb into place When fitting the new bulb make sure that it is not touched with the fingers as this shortens the life of the bulb and can affect its performance If the signal is not to be disconnected during this operation it is recommended that stout leather gloves be worn to protect the hands from the heat of a lit bulb Ensure that the bulb is positioned with its filament vertical and at right angles to the bulb holder Replace the bulb holder lugs on the bulb holder fit into the channels at the rear of the reflector and clip into place Secure the door tightening any anti vandal Screws Bulb Holder Replacement Halogen see the note in section 4 2 regarding anti vandal screws Open the door from either side and remove the bulb holder by gently squeezing the bulb holder clips Undo the wire that connects the bulb to the transformer Place the new bulb holder into the rear of the reflector and reconnect the wire to the transformer Secure the door tightening any anti vandal screws Transformer Replacement Halogen Warning Mains voltages are present The mains supply to the signal head must be disconnected switched off before working on Halogen Signal Aspect transformer oee the note in section 4 2 regarding anti vandal screws Open the door from either side and disconnect the bulb holder leads and the Earth lea
73. base aperture to the top of the pole using the draw rope if necessary to pull the cable up Unpack and dismantle the pole cap assembly and fit the terminal block assembly to the pole with the nuts bolts and washers supplied Connect the earth cable from the terminal block assembly to the earth connector in the pole secure all cable s to the slots on the terminal block assembly using the CET connector s and worm drive hose clip s Note that a suitable allowance must be made for the amount of cable at the bottom of the pole The pole is now ready for erection Once this operation is completed the excavation at the base of the pole may be back filled Note that Lanterns are not terminated until after the cables have been tested On completion of all pole top terminations the tests described in the Installation and Testing Handbook see section 1 3 are to be completed Wiring Pole after erection Each cable can be fed through the base aperture to the top of the pole using the draw rope if necessary to pull the cable up This operation is then repeated for each pole at the intersection Unpack and dismantle the pole cap assembly and fit the terminal block assembly to the pole with the nuts bolts and washers supplied Connect the earth cable from the terminal block assembly to the earth connector in the pole secure all cable s to the slots on the terminal block assembly using the CET connector s and worm drive hose clip s
74. bed in section 2 36 Note that it will be necessary to re align the signal head as described in section 2 36 1 667 HB 30000 000 Issue 24 Page 118 of 143 SI N S HELIOS GENERAL HANDBOOK Figure 95 Separated Modules 4 3Second Line Maintenance It is recommended that undamaged parts be reused where possible The following parts should be returned to Poole when replaced on site e Regulatory sign lamp mounting plate e LED LED NLM PCB door assembly e PSU e LMF Assembly e CLS Units LV and ELV Tram indicator complete module 667 HB 30000 000 Issue 24 Page 119 of 143 HELIOS GENERAL HANDBOOK APPENDIX A DRAWINGS The drawings given in this appendix are reproduced from 667 2 28968 000 sheets 1 to 3 issue 1 and are intended to assist with installation and maintenance They show fitting positions for the various components and the fixings to be used SIEMENS SNILLLfIO 7 SARC IZOd OVIH X3H Sc HDOAL SV Yd X FAN SV SISINSHO SNY HL CW3H SNOSYSLLNIOO MH HNOSS34NDIOO INN LOS X SN LAN L108 WASI X SN 9NDIOVS SNDOYE 1016 SNINIV 132 900 226007 299 1076 SNINY 900 2 600 299 107S SNINIV L St 000 2600 71 99 YANNOASNVALL LOTS SININIV 000 2600 7 199 YANYOISNVSLL SAO GWSH SZ MANO X SINLLLYO
75. chanical switch are Puffin Nearside Combined Unit Toucan Nearside Combined Unit Equestrian Nearside Combined Unit Puffin Nearside Combined NFOV Unit Toucan Nearside Combined NFOV Unit Equestrian Nearside Combined NFOV Unit The LP UK Variants with mechanical switch are Puffin Nearside Combined Unit Toucan Nearside Combined Unit Equestrian Nearside Combined Unit Puffin Nearside Combined NFOV Unit Toucan Nearside Combined NFOV Unit Equestrian Nearside Combined NFOV Unit The LP UK Variants with the piezo switch are Puffin Nearside Combined Unit Toucan Nearside Combined Unit Equestrian Nearside Combined Unit Puffin Nearside Combined NFOV Unit Toucan Nearside Combined NFOV Unit Equestrian Nearside Combined NFOV Unit 667 HB 30000 000 Issue 24 667 1 33601 010 667 1 33601 01 1 667 1 33601 012 667 1 33601 510 667 1 33601 51 1 667 1 33601 512 667 1 33604 010 667 1 33604 01 1 667 1 33604 012 667 1 33604 510 667 1 33604 51 1 667 1 33604 512 667 1 33604 000 667 1 33604 001 667 1 33604 002 667 1 33604 500 667 1 33604 501 667 1 33604 502 Page 82 of 143 S N S HELIOS GENERAL HANDBOOK Figure 60 Nearside Mk2 Combined Unit 667 HB 30000 000 Issue 24 Page 83 of 143 SI N S HELIOS GENERAL HANDBOOK Each Nearside Combined Unit comes complete with a fixing kit Each unit fastens to the Signal Pole using the U bolt prov
76. d from the aspect transformer Remove the door if necessary for ease of working placing it safely on the ground Either of the following procedures may now be used Disconnect the transformer mains input from the top of the Signal Pole and feed the cables back to the transformer that is to be replaced Hemove the two screws that are holding the transformer to the bottom of the Aspect and extract the transformer from the aspect Fitting the new transformer is the reverse operation to that of removing it Or 667 HB 30000 000 Issue 24 Page 99 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 4 2 4 Cut the mains leads to the transformer as close as possible to the transformer Remove and retain the two screws that are holding the transformer to the bottom of the Aspect and extract the transformer from the aspect Fit the new transformer into the same position as the one removed using the retained screws Cut the new transformer mains input leads about 25 30 cm from the transformer Using 2 off Red Butt Crimps 703 4 97182 000 TAG INLINE SPLICE 0 5 1 5MM2 RED and a calibrated crimping tool crimp these two leads using standard techniques to the leads that come from the pole top ensuring that colours are matched Replace the door on the aspect box and re connect the bulb holder leads and the Earth lead to the transformer Secure the door tightening any anti vandal screws if fitted LED or LED NLM PCB Replacement Warning Mai
77. d to the PSU chassis secure the door tightening the anti vandal screws if supplied NOTE for replacement of the Switch Mode PSU with the Linear PSU see document QAPROC 42 800 220 667 HB 30000 000 Issue 24 Page 102 of 143 SI N S HELIOS GENERAL HANDBOOK Figure 76 PSU White Molex Connectors 4 2 7 Transformer Replacement LED NLM Warning Mains voltages are present The mains supply to the signal head must be disconnected switched off before working on an LED NLM aspect Either of the following procedures may now be used Disconnect the transformer mains input from the top of the Signal Pole and feed the cables back to the transformer that is to be replaced Disconnect the transformer connection from the LED NLM PCB Remove the Earth lead connection from the transformer Remove the two screws that are holding the transformer from the bottom of the Aspect and extract the transformer from the aspect Fitting the new transformer is the reverse operation to that of removing it Or Disconnect the transformer connection from the LED NLM PCB Remove the Earth lead connection from the transformer Cut the mains leads to the transformer as close as possible to the transformer Remove and retain the two screws that are holding the transformer to the bottom of the Aspect and extract the transformer from the aspect Fit the new transformer into the same position as the one removed using the retained screws
78. d with tungsten halogen and LED aspects as the visible switching on and off of a CLS with LMF CLS NLM and LED NLM aspect Is instantaneous The CLS NLM and LED NLM is not compatible with the STC Controller lamp monitoring and should be driven from a separate output if the tungsten halogen lamps CLS with LMF and or LED are required to be monitored NLM LED signals can be monitored with the Retrofit LV controllers but the current capability for Halogen signals is reduced CLS ELV aspects should ONLY be connected to Siemens ST900 ELV and 51750 ELV controllers as the supply voltage to an aspect is 48V The CLS ELV is compatible with the lamp monitoring facility of the ST900 ELV and ST750 ELV controllers with each aspect having a visible switching on and off which is instantaneous NOTE The CLS ELV does not utilise a LMF Unit Within the ELV HELIOS family are LED regulatory signs and a TRAM indicator The design incorporates a sacrificial cap that is designed to break on impact absorbing part of the force and protecting the signal head from major damage Figure 1 Helios front view 667 HB 30000 000 Issue 24 Page 16 of 143 S N S HELIOS GENERAL HANDBOOK Figure 2 Helios TRAM indicator front view The basic three aspect lantern assembly is constructed on a modular principle Each aspect is self contained and consists of one of the following Halogen Option A high intensity tungsten halogen lamp and
79. door seal is in place Place the door over the lens tip the assembly over and screw the retaining ring back into position on the door Replace the CLS unit into the retaining clips in the lens retaining ring and then replace the retaining clips which hold the CLS in position b Dialight CLS the CLS unit and make sure that the lens door seal is in place Place the door over the lens tip the assembly over and screw the CLS unit back into position on the door CLS ELV Type B To alter the position of the mask a Gently press the anti rotation clip at the bottom of the CLS enclosure using a small screwdriver or other suitable tool see Figure 21 667 HB 30000 000 Issue 24 Page 41 of 143 SI N S HELIOS GENERAL HANDBOOK Figure 21 CLS ELV Type B Anti rotation Clip b Rotate the enclosure body anticlockwise and withdraw the enclosure from the door ring c Insert or adjust the mask as required Tm Figure 22 CLS ELV Arrow Mask d Re fit the enclosure to the door by inserting and rotating clockwise Ensure that the anti rotation clip has engaged and that the enclosure cannot be rotated anti clockwise 2 6 5 Green Arrow LED and LED NLM There are two variants of the green arrow LED and LED NLM up and left right If any other direction is needed the fully populated green LED or LED NLM must be used The green arrow metal mask 667 2 30074 101 is used with LED and LED NLM PCBs to preven
80. e the door assembly from the module and work on the ground Remove the 4 screws that holds the CLS Unit to the door Fit the lens on to the CLS unit ensuring that the lens is positioned correctly Fit the seal around the new lens and place the door over the lens and seal Holding the door lens and CLS unit turn the assembly over and replace the 4 screws holding the CLS unit to the aspect door NOTE ENSURE THAT THE CORRECT REPLACEMENT CLS TYPE i e CLS ELV NOT CLS LV 667 HB 30000 000 Issue 24 Page 106 of 143 S N S HELIOS GENERAL HANDBOOK Refit the door to the signal head and re connect the input lead 4 2 11 CLS ELV Type B Replacement See the note in section 4 2 regarding anti vandal screws Undo the door clips on side open the door and disconnect the plug to the input lead Remove the door assembly from the module and work on the ground Genily press the anti rotation clip at the bottom of the CLS enclosure using a small screwdriver or other suitable tool see Figure 84 Figure 84 CLS ELV Type B anti rotation clip Rotate the enclosure body anticlockwise and withdraw the enclosure from the door ring Fit the replacement aspect to the door by inserting and rotating clockwise Ensure that the anti rotation clip has engaged and that the aspect cannot be rotated anti clockwise Refit the door to the signal head and re connect the input lead Important Note If you are replacing a CLS ELV Type s
81. ed from the respective controller 230v phase output 2 24 3 CLS with LMF and CLS NLM A pre focussed CLS unit is held in position at a set distance from a specially designed medium wide angle lens made of clear acrylic material The CLS is a sealed unit which is available in Red Amber and Green and is designed to achieve the specified colour and brightness output The lens is screened with a specially designed mask to reduce the phantom effect The 230v supply voltage for the CLS with LMF is derived from the LMF unit The LMF unit monitors the load current of the CLS unit and is powered from the respective controllers 230v phase output The 230v supply voltage for the CLS NLM 1 derived from the respective controller 230v phase output 2 2 4 4 CLS ELV A pre focussed CLS ELV unit is held in position at a set distance from a specially designed medium wide angle lens made of clear acrylic material The CLS ELV is available in Red Amber and Green and 1 designed to achieve the specified colour and brightness output The lens is screened with a specially designed mask to reduce the phantom effect 667 HB 30000 000 Issue 24 Page 25 of 143 SI E M E N S HELIOS GENERAL HANDBOOK The 48V supply voltage for the CLS ELV is derived from the ST900 ELV or ST750 ELV controller phase outputs The Controller phase driver PCBs monitor the load current of the CLS ELV unit 2 2 4 5 LV Regulatory Signs Two 230 mm 9 6 W fluorescent t
82. f the head has been struck by a vehicle but not rendered in operative It is therefore recommended that the screws and main securing bolt are checked for tightness If either can be rotated more than turn then the procedure for tightening under Sacrifical Caps should be employed Bulbs LED or LED NLM boards and fluorescent tubes if fitted should be inspected and replaced if necessary Check that the CLS unit Futurit Type is seated correctly and the pip at the top of the CLS unit is aligned correctly within the Retaining Ring See Section 4 2 8 Teflon based or similar dry type lubricant may be used to lubricate the door clips if necessary 4 2 First Line Maintenance First line maintenance will be achieved on a modular replacement basis Wherever possible when carrying out maintenance remove the affected part and work on the ground When a door is removed and replaced make sure it is the right way up when refitting Note Where anti vandal screws are fitted to the door clips it is not necessary to remove them completely before opening the door Partially unscrew them 667 HB 30000 000 Issue 24 Page 98 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 4 2 1 4 2 2 4 2 3 so that the head is level with the outer edge of the clip his should enable the clip to slide without the door hitting the screw Bulb Replacement Halogen Where a bulb is to be replaced the door may be opened from either side and the bul
83. ffic signals They may also be used to fit an AGD section 2 34 if required Figure 14 Side mounting bracket 667 HB 30000 000 Issue 24 Page 36 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 6 Signal Head Arrangement 2 6 1 KEY May be green aspect green arrow pedestrian green man red man or regulatory sign e g No Left Turn No U Turn etc Figure 15 Example Mounting Arrangements Figure shows a selection of arrangements but it is not an exhaustive depiction of what is possible A maximum of eight modules may be incorporated on one assembly arranged as a four aspect lantern assembly with two side boxes on each side Sacrificial Caps Most signal head assemblies are delivered with the sacrificial caps and brackets fully assembled and attached to the signal head In those cases where the assembly has to be made on site follow the instructions given below Sacrificial cap assemblies are fitted to either end of the main signal head The assemblies are made up of an end cap the sacrificial cap the cap to bracket fitting and an 8 mm Allen bolt They differ only in the design of the cap one has a smooth lower surface and the other has teeth that engage in the end cap 667 HB 30000 000 Issue 24 Page 37 of 143 S N S HELIOS GENERAL HANDBOOK Plain cap teeth goes at the top of the signal head Toothed cap goes at the bottom of the signal head Figure 16 S
84. he operation of individual signals and remove the signal load switch off under fault conditions may operate inadvertently and extinguish the signal due to the nature of supplies lamp switching circuits of third party controllers It is strongly recommended that a separate neutral return or ground return in ELV systems is provided for each green signal See section 2 3 for full detail 667 HB 30000 000 Issue 24 Page 3 of 143 SI E M E N S HELIOS GENERAL HANDBOOK MAINTENANCE PROVISION NP 1 Product Reference Helios Traffic Signals 2 Specifications The Modular traffic signals are designed to meet the following specifications EN12368 H A TR2206 Draft 1 BS 7987 2000 HD 638 9 Installation and Commissioning Methods of Installation and Commissioning are detailed in the Siemens Traffic Controls document 667 HB 30000 000 Helios General Handbook 4 Spares and Maintenance All maintenance and repairs should be carried out in accordance with the siemens Traffic Controls documents 667 HB 30000 000 Helios General Handbook Modifications There are no approved modifications with the exception of those listed in the following Siemens Traffic Controls Document 667 HB 30000 000 Helios General Handbook 6 Warning Use of components other than those permitted above or modifications or enhancements that have not been authorised by Siemens Traffic Controls Limited will invalidate Type Approval of this produc
85. he door tightening the anti vandal screws if supplied If necessary re attach the hood NOTE Ensure that the correct type of door ELV is used as the replacement 667 HB 30000 000 Issue 24 Page 113 of 143 S N S HELIOS GENERAL HANDBOOK 4 2 19 Regulatory Sign Door Replacement Replacing any regulatory sign door except mandatory arrow simply involves removing the old door and replacing it with a new one replace a mandatory arrow door follow the additional fitting instructions in section 2 7 2 Alternatively it may be possible to remove a broken mandatory arrow lens and replace the sealant and lens without having to replace the door Secure the door tightening the anti vandal screws if supplied 4 2 20 Door Clip Replacement See the note in section 4 2 regarding anti vandal screws To remove a door clip hook the point of a screwdriver behind the retaining pip on the front of the door clip that holds it on the module and lift so that it will slide off The replacement door clip will just slide into place and be held by the pip Note that the upper door clips should have the retaining pip pointing up and the lower door clips should have it pointing down 4 2 21 Hood Replacement To replace a moulded hood clip off the protruding lengths of the fir tree clips inside the hood rim Figure to make it easier to remove the clips Figure 94 Fir tree clips Remove the hood by pulling it away from the door
86. he hood Also hoods used on previous signals may need on site drilling to fit Helios See section 2 19 1 for details 667 HB 30000 000 Issue 24 Page 54 of 143 S N S HELIOS GENERAL HANDBOOK Figure 40 Angled Hood fitting An optional Pedestrian Aspect Hood is available This hood is supplied with predrilled fixing holes but is of a non formed construction The hood is fitted to the aspect using fir tree clips 2 19 1 Drilling Hoods To fit hoods that do not have fixing holes that align with those on the Helios door including louvred and tunnel hoods the fitting positions have to be drilled using a 6 mm drill bit A moulded hood fitted at more than 90 also needs to be drilled Correctly position the hood to be drilled on the Helios door and then mark the appropriate positions that require drilling Remove the hood from the door and drill the marked fixing hole positions Where metal hoods which may be heavy have been drilled 5 mm bolts metal rivets or taptite screws may be more appropriate fixings than the plastic fir tree Clips 2 20 Solar Cell A solar cell is fitted when the customer requires the signals on the intersection to be dimmed at night It is mounted on the top of a 3 aspect case as shown in Figure where it will receive a non interrupted northern light 667 HB 30000 000 Issue 24 Page 55 of 143 S N S HELIOS GENERAL HANDBOOK Figure 41 Solar Cell The solar cell used 1 a
87. herwise mentioned lantern weight includes doors moulded hoods and brackets 3 Aspect 200mm lantern 15 Kg 667 HB 30000 000 Issue 24 Page 14 of 143 SIEMENS 3 Aspect 200mm lantern doors removed 2 Aspect 200mm lantern 1 Aspect regulatory sign 1 Aspect regulatory sign door removed 1 Aspect TRAM indicator fully equipped Pedestrian push button 4 0m Pole Pair of mounting brackets b Dimensions including backing 5 3 in line 4 in line 3 in line and side box 3 in line and side boxes at each side 667 HB 30000 000 Issue 24 HELIOS GENERAL HANDBOOK 9 Kg 11 Kg 3 Kg 2 25 Kg 9 5 Kg 3 6 Kg 68 Kg 3 2 Kg 1116 mm H x 468 mm W 1450 mm H x 468 mm W 1116 mm H x 841 W 1116 mm H x 1214 W Page 15 of 143 S N S HELIOS GENERAL HANDBOOK 2 SIGNALS AND POLES 2 1 General The Helios range of traffic signals has been developed to give optimum clarity reliability and longevity with a pleasing appearance It incorporates newly developed lens form and masking patterns which ensure that the signal is extremely clear and easy to see in all conditions There are tungsten halogen and LED aspects which may be mixed in one signal head For example the traffic signal at a pedestrian crossing could have red and amber halogen aspects with a green LED aspect since the green would be on most of the time CLS with LMF CLS NLM and LED NLM aspects should NOT be mixed ina signal hea
88. ht corner of the module although they may be placed in any of the four corners If the transformer is to be fitted in one of the upper positions four screws are required one in each corner For lower position fitting only two screws are needed to hold the unit to the floor of the case as the rear of the transformer fits into the retaining slots Figure 30 LED NLM Transformer Fitted to Aspect 667 HB 30000 000 Issue 24 Page 47 of 143 S N S HELIOS GENERAL HANDBOOK 2 11 CLS Unit The CLS units will normally be factory fitted into the appropriate door before delivery There are three variants of the CLS unit a Red CLS unit 667 7 28584 100 b Amber CLS unit 667 7 28584 101 c Green CLS unit 667 7 28584 102 The CLS unit is obtained from 2 manufacturers Futurit and Dialight The Futurit CLS unit is positioned into the lens retaining ring and held in place with two CLS retaining clips 667 2 31501 000 The lens retaining ring and CLS retaining clips are fitted into the door with four screws The Dialight CLS unit has the lens retaining ring built into the unit and is fitted to the aspect door with four screws Figure 31 Futurit CLS Unit 667 HB 30000 000 Issue 24 Page 48 of 143 S N S HELIOS GENERAL HANDBOOK Figure 32 Dialight CLS Unit 2 12 CLS ELV Units The CLS units will normally be factory fitted into the appropriate door before delivery There are two different type
89. ical Caps Screw Tightening Procedure 118 4 2 28 Modular Unit Replacement 118 4 3 Second Line Maintenance 119 APPENDIX DRAWINGS 120 APPENDIX B SPARES LIST 123 APPENDIX C Visual Identification of ELV Compatible PCB s 128 APPENDIX D Helios Signal Head Screw Fixing Procedure 131 Appendix E TRAM Indicator Cable connections and Aspects 139 667 HB 30000 000 Issue 24 Page 7 of 143 SI E M E N S HELIOS GENERAL HANDBOOK INDEX 142 FIGURES Fig re Helos TONE VIEW u u 16 Figure 2 Helios TRAM indicator front vlew 17 A mn er a 18 Foure EEV TYDS ER 18 1906 o Helos Sde VIEW bo I ois ue D e d 19 Figure 6 Three Aspect Halogen Internal Fitting 22 Figure 7 Three Aspect LED Internal Fitting 23 Figure 8 Three Aspect LED NLM Internal Fitting
90. ide backing boards Main body to side box conduit kit LLLELELLELLELELLELELLELELLEL fet mo P P ETT ET asen lID II Il EP Side to side mounting plate Issue 24 Page 125 of 143 SIEMENS Part Number 999 4 44188 000 999 4 44189 000 Seal Black expanded EPD foam mm x 5 mm x 1110 mm Seal Black expanded EPD foam 4 mm x 4 mm x 220 mm Seal Black neoprene ring 5 mm dia x 140 mm Seal Black neoprene ring 3 mm dia x 659 mm Seal Black neoprene ring 3 mm dia x 669 mm M5 x 15mm S S Hex head bolt M5 x 12 mm S S screws PLAS TECH 25 S S screws PLAS TECH 25 3 mm x 10 mm pan head Pozi HEYCO 066 6013 518 4 98068 000 667 2 10094 000 Anti Rotate Rod for Signal Poles 999 4 44316 000 Washer Nordlock M10 Stainless Steel A4 Description M4 x 10 mm S S screws Pan head Pozidriv PLAS TECH 25 Screws to fix transformer PSU assembly S S hex head Pozidriv M5 x 12 mm screws for fixing 1 Backing board 2 Endcap 3 Reflector lens holder to door oeal between body and door Seal end cap to body Seal between bodies Seal between lens and reflector Seal between lens and door 9 9 self tap screw To fix front edge of one body to next pan head M5 x 45 mm To secure Side to Side plate to front edges of two main bodies M5 Nut S S Used with M5 x 15 mm bolts M5 Washer S S Used with M5 x 15 mm bolts To secure Side to Side plate across back of two main bodies Fixing
91. ided When installing the Nearside Combined Unit the following must be observed a Centre of the Demand Push button must be 1 0m 1 1m above the footway level Figure 61 Nearside Mk2 Combined Unit Shows the Three PCBs The three variants of Nearside Combined Signal come with a door assembly which contains the following items a a PCB which contains all the Display Red LEDs arranged to illuminate either the Red Man Puffin Red Man and Red Cycle Toucan or a Red Horse Equestrian b a PCB which contains all the Display Green LEDs arranged to illuminate either the Green Man Puffin Green Man and Green Cycle Toucan or a Green Horse Equestrian c a PCB which contains all the Red LEDs arranged in a circle around the push button which illuminate when a Pedestrian Demand is Registered d a front panel the type which is dependant on the Nearside Signal 667 2 33651 000 Puffin 667 2 33651 001 Toucan 667 2 33651 002 Equestrian 667 HB 30000 000 Issue 24 Page 84 of 143 SI E M E N S HELIOS GENERAL HANDBOOK e A vandal resistant Stainless Steel switch or piezo switch The following are the standard Mk2 Door Assemblies that are available Puffin Door Mechanical Switch 667 1 33662 010 Toucan Door Mechanical Switch 667 1 33662 011 Equestrian Door Mechanical Switch 667 1 33662 012 Puffin Door NFOV Mechanical Switch 667 1 33662 510 Toucan Door NFOV Mechanical Switch 667 1 33662 5
92. ignal with a CLS ELV A signal please refer to section 4 2 10 667 HB 30000 000 Issue 24 Page 107 of 143 S N S HELIOS GENERAL HANDBOOK 4 2 12 LMF Fuse Replacement Remove power to the LMF unit by removing the connector in PL1 of the LMF unit Remove the fuse by unscrewing the fuse cap from the fuse holder Replace the fuse 518 4 97068 000 Ceramic 20 x 5 1A 240v in the fuse cap and screw the cap back into the fuse holder Note care needs to be exercised when removing the fuse as it is possible to drop and trap the fuse between the LMF PCB and the rear metal panel of the LMF unit Fuse Hold use nolaer suRFAC Figure 85 view of a LMF unit 2 w E amp 1 4 2 13 LMF Unit Replacement WARNING the earth connections within the CLS with LMF signal head is daisy chained from the Red to Amber and then Green LMF Unit When removing either a Red or Amber LMF unit the aspects below will not be earthed and therefore should not be touched if the controller is powered on Remove power to the LMF unit by removing the connector in PL1 of the LMF unit Remove the connector from the CLS unit connected to the LMF unit SKT1 Disconnect the earth cables by pulling the spade connectors from the earth terminals Remove the cable loom from the two Pushbutton ties 915 4 10307 000 The LMF unit can now be removed by loosening the four retaining screws and sliding
93. ilable for use in the United Kingdom These are Pedestrian Pushbutton Unit without Audible 667 1 33602 010 Pelican Pushbutton Unit without Audible 667 1 33602 011 Toucan Pushbutton Unit without Audible 667 1 33602 012 Equestrian Pushbutton Unit without Audible 667 1 33602 013 667 HB 30000 000 Issue 24 Page 71 of 143 S N S HELIOS GENERAL HANDBOOK TRIANc Y 2ush button and wait for signal opposite Figure 54 LED Mk2 Wait Box The L E D Wait Box comes complete with its fixing kit The unit fastens to the pole using the U bolt provided When installing a pushbutton box the centre of the pushbutton should be between 1 0m 1 1m above the footway level 2 29 1 Terminal Block Layout for LED Wait Mk2 Indicator units Shown below are the diagrams of the terminal block assembly used within both of the Nearside Mk2 LED Wait Indicator units LED LAMP SAFETY SUPPLY EARTH LED LAMP AUDIO _ RETURN TACTILE 2 AUDIO 0V COMMON AUDIO TACTILE 1 PUSH BUTTON PUSH BUTTON NEARSIDE MK2 WAIT 667 HB 30000 000 Issue 24 Page 72 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 30 CLS Wait Two versions of CLS Wait are available a retrofit solution and a production replacement for the existing LED Wait Both versions offer the benefit of CLS technology and the possibility of lamp monitoring depending on the controller type Table 1 shows the lamp monitoring options
94. ils Ensure that the mating parts of the sacrificial bracket are joined and the whole bracket has engaged In its position correctly Tighten the securing bolt using a torque wrench set to 20 Newton Metres S Torque to 20Nm c Remove the 6 metre hule securing straps Make a general inspection of the signal head to ensure that it is secure 0 4 Different Fixings In the field As a process of continuous improvement designs change and where possible compatibility is maintained between old and new parts however when this is not possible the compatibility issues that you must consider are noted in the documentation What follows is a description of the two types of end cap that you may come across on product in the field how to identify which are which and the compatibility issues that must be considered Currently supplied end cap with longer boss with which a longer bolt is used _ y End Caps viewed from inside the signal Previously supplied end cap with shorter boss for which a shorter bolt is required 667 HB 30000 000 Issue 24 Page 134 of 143 SI N S HELIOS GENERAL HANDBOOK For the shorter bossed end cap use a 32mm bolt part number 999 4 44333 532 or kit 667 1 31505 000 which includes nordlock washers To aid identification of the correct 32mm length bolt as supplied by Siemens is coloured black For the longer bossed end cap use a 40mm bolt part number 999 4 44333 040 The only washers
95. ips These should be squeezed to release the clip mechanism and the board lifted off the door assembly See Figure for the position of the fuse Remove it and replace with one of a similar size and rating see APPENDIX B for the part number Clip the PCB back into place on the door assembly Replace the door on the aspect box and refit the cable connector Clip the cables back into place on the rear of the PCB using the cable clips Make sure that the plastic safety guard tucks over the cable connector before closing the door secure the door tightening the anti vandal screws if supplied PSU Replacement Linear LED Warning Mains voltages are present The mains supply to the signal head must be disconnected switched off before working on an LED aspect Warning Earth connections are daisy chained from the red to the amber and then to green This means either the red or amber PSU s are removed the aspects below will not be earthed see the note in section 4 2 regarding anti vandal screws Undo the door clips on one side and open the door Disconnect the 2 white molex connectors from the PSU see Figure Remove the earth wires from the earth stud on the PSU case Cut the cable tie holding the Inductor to the PSU chassis Loosen the 3 screws holding the PSU chassis to the backplate and lift out the PSU chassis Fitting the new PSU 1 the reverse operation to that of removing it ensuring that the inductor is re tie
96. it within a signal aspect 4 2 14 Tube Replacement See the note in section 4 2 regarding anti vandal screws Open the door from either side and remove the fluorescent tube s to be replaced Replace with a tube of similar size 230 mm and wattage 6 W and refit the door Tighten any anti vandal screws 667 HB 30000 000 Issue 24 Page 109 of 143 SI N S HELIOS GENERAL HANDBOOK 4 2 15 Aspect Door Replacement Halogen Normally a door lens assembly is replaced complete When the appropriate variant is not available any undamaged lens reflector and hood may be re used see the note in section 4 2 regarding anti vandal screws Undo the door clips on one side open the door and remove the halogen lamp holder from the reflector Undo the remaining door clips and remove the door from the module and work on the ground If the existing hood is to be re used remove it as described in section 4 2 21 and retain it for re use Otherwise fit the new hood as described in section 2 19 Seal qu Lens Reflector Seal Ground Figure 88 Door assembly Halogen When bringing the door assembly together place them as shown in Figure noting the orientation of lens and reflector as described in section 4 2 22 Holding the reflector and door together flip the assembly over so that the door is face down on the ground and insert the four screws Note The lens to door seal can be very difficult to align once removed Therefore
97. its correct module and slide the clips into place to hold the door If necessary use the point of a screwdriver as shown in Figure to help close the door clip Where specified screw the door clips in place with an anti vandal screw Figure shows the screw position in the middle of the clip Screws may be fitted to all door clips although the door will be secure if two are used on diagonally opposite sides of the door 667 HB 30000 000 Issue 24 Page 94 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Figure 72 Door Clip closed 667 HB 30000 000 Issue 24 Page 95 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 3 COMMISSIONING Adjust the angles of tilt rotation and arrow directions to customer satisfaction In the absence of alternative instructions from the customer the primary signals should be focussed to 40 m from the stop line and secondary signals should be focussed to the centre of the stop line Inspect every aspect before power is applied and check that all aspect components are correctly seated aligned and firmly fixed particularly transformers PSUs LED PCBs CLS Units LMF Units and OEM equipment and CLS ELV units are only connected to a ST900 ELV Controller Note 1 The CLS ELV signal head is identified by a label marked ELV on the bottom surface of the signal head along with a label marked ELV on each CLS unit used in each aspect Note 2 The ELV compliant Nearside units are clearly marked
98. k2 units to pole CAREFULLY SLIT THE REQUIRED U BOLT GLANDS AS SHOWN TO ALLOW THE U BOLT TO PASS THROUGH ENSURE LARGE DIAMETER WASHERS SUPPLIED WITH FIXING ARE USED Figure 52 Mounting of Nearside Pedestrian WAIT units to Pole Typical to all assemblies Combined unit shown 667 HB 30000 000 Issue 24 Page 69 of 143 SI N S HELIOS GENERAL HANDBOOK 2 28 Standard Wait Mk2 Indicator Units Ae dE oe lt Figure 53 Standard Wait 2 Indicator unit There are four main variants of Standard Wait Indicator units with Mechanical Switch available for use in the United Kingdom Pedestrian WAIT push button without Audio 667 1 33603 010 Pelican WAIT push button without Audio 667 1 33603 011 Equestrian WAIT push button without Audio 667 1 33603 012 Toucan WAIT push button without Audio 667 1 33603 013 667 HB 30000 000 Issue 24 Page 70 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 28 1 Terminal Block Layout for STD Wait Mk2 Indicator units Shown below are the diagrams of the terminal block assembly used within both of the Nearside Mk2 STD Wait Indicator units _ LEDILAMP SAFETY SUPPLY EARTH rrrr LED LAMP AUDIO _ RETURN TACTILE 2 AUDIO 0V COMMON AUDIO TACTILE 1 PUSH BUTTON PUSH BUTTON TB1 NEARSIDE MK2 WAIT 2 29 LED Wait Mk2 indicator Units There are four variants of the 48 Volt L E D Wait Box with Mechanical switch ava
99. lamp socket to lamp holder Fir tree clips 14 98 long fixing hood to aspect oor Fuse Ceramic 20 x 5 1A 240v 667 2 22895 000 Square Washer Stainless Steel used in conjunction with Nordlock above 667 HB 30000 000 Issue 24 HELIOS GENERAL HANDBOOK 1 126 143 SI E M E N S HELIOS GENERAL HANDBOOK Part Number Description 667 1 31505 000 Helios Fixing Upgrade kit used on earlier versions of signals refer to Appendix D four guidance on determining signal version gt l N l 667 HB 30000 000 Issue 24 Page 127 of 143 SI N S HELIOS GENERAL HANDBOOK APPENDIX C Visual Identification of ELV Compatible PCB s LED WAIT Identification Components to left hand side of W as shown in this photograph Indicate that the unit is ELV compliant PCB Assembly Issue 667 1 30211 Issue 4onwards The issue number is the last two digits on the serial number label q hese components are only present T on controller compatible boards 667 HB 30000 000 Issue 24 Page 128 of 143 SI N S HELIOS GENERAL HANDBOOK CALL DEMAND Identification Additional capacitor on the rear of the p c b Indicates that this board is ELV compliant PCB Assembly Number 667 1 30680 Issue 3 onwards The issue number is the last two digits on the serial number label This area of the Seboard is on
100. lds for conflict or correspondence monitoring When incandescent signals are used a cable fault of this type usually causes the signals to be illuminated at a low level and is not particularly noticeable For LED signals however it is possible for the signals to flash at least at their dim level Although the rate of signal flashing is such that they are only typically illuminated for a very short time less than the conflict correspondence time defined in TR2500 it can be more noticeable than the display seen with incandescent lamps Procedure Normally this type of fault only affects a single signal head or pole and due to other signals displaying correctly is unlikely to cause signalisations that could be considered dangerous so retrospective action is not essential Therefore we are not mandating retrospective action on existing sites however if the customer wishes to re wire then we can do this on a chargeable basis 667 HB 30000 000 Issue 24 Page 32 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 3 8 However for new LED sites where it is desired to reduce the likelihood of Incorrect displays particularly involving green signals it is recommended that Individual neutral returns are used for each green signal For existing incandescent sites where LED signals are being now fitted and spare cables cores are available these may be used to provide additional neutral connections Pole Neutral Connections and Terminations Halogen
101. lic sheet upon which any of the mandatory signs may be printed in full colour Most regulatory signs are delivered with the lenses fitted into the door of the module using a mastic bead sealant Mandatory arrow signs come as a kit with separate sealant to allow fitting on site to customer requirements Note At this time Siemens type controllers are unable to lamp monitor the LV LED Regulatory Sign 667 HB 30000 000 Issue 24 Page 26 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 3 Assembling and Terminating a Signal Pole 2 3 1 Pole Types General PVC covered Poles 667 2 01459 ETC Galvanised Poles 667 2 03686 Cranked Pole 66 7 2 30230 000 001 667 2 30231 000 001 Formed Pole 667 2 28107 001 003 NOTE If the Pole is a Formed or Cranked Type the Pole has an Extension Arm fitted an Anti Rotate Rod must be fitted to the Pole See Figure 10 Part Number for Anti Rotate Rod 667 2 10094 000 667 HB 30000 000 Issue 24 Page 27 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 3 2 Pole Selection Centre Line of Amber Lower edge of container
102. ly present 2 Scontroller compatible p c b s 667 HB 30000 000 Issue 24 Page 129 of 143 SI N S HELIOS GENERAL HANDBOOK NEARSIDE ASPECT Identification TUN E Capacitor the rear of the board Indicates that this I se i LAN b e 4 2 e I MINNIE compliant ee e ee fee ee ee Ix INE 06 29 ee 7 This feature is 24 78 7 ee Tee ee ee also present for ee 799 7 667 1 33655 boards which are all ELV compliant from Issue 1 PCB Assembly Number 667 1 30695 Issue 9 onwards The issue number is the last two digits on the serial number label A Ma gt lt A 97 I 4 ot A c 2 gt 2395 Ma y e 4 i 2 Et Fee V 96 _ ec ee ce 790 ee 796 799 9 ME Y MEE Y Boards with this component on the back 99 are controller compliant 5 29 EI 1 LI 06 gt P L E
103. m bracket Three aspect signal heads are generally delivered with the brackets attached For a four in line case the long top bracket is attached to the top of the signal head and the bottom bracket is attached to the separately delivered bottom aspect 2 5 1 Extension Bracket Assembly Signal heads can be mounted away from the pole using extension arms To ensure that the arms are mounted the correct way up the mounting plate on the arm should be examined It will be apparent that the lip is longer in one direction and the longer lip must be mounted toward the top of the pole Make up on the ground by laying out the two horizontal arms and attaching the vertical bar between them using the fixings provided Hang the extension bracket on the pole and fix using the nuts provided 667 HB 30000 000 Issue 24 Page 35 of 143 S N S HELIOS GENERAL HANDBOOK Add bolts and spacers to the extension bracket on which to hang the signal head All bolts should be securely tightened 4 7 Figure 13 Extension Bracket Connections from the signal head to the pole are enabled by the use of a terminal block in the top aspect case 2 5 2 Side Mounting Bracket Where signal heads are to be fitted at an angle of rotation greater than 45 and also need to be tilted side mounting brackets part no 667 1 30200 058 should be installed as shown in Figure 14 to assist in final adjustment This usually only applies to road tra
104. m long with bare ends for 10 mm can be used to loop around to other terminal block positions Terminal blocks may be used for both neutral looping and phase live output looping that may require more than the single screw terminal provided See Figure Note that no bare strands should be exposed when the looping is complete Consult the appropriate controller installation manual for details of the terminal blocks designated for such use It is important that all of these connections are checked for tightness during periodic inspections 667 HB 30000 000 Issue 24 Page 34 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Phase drive R A G VAM AMAJN F OOO OOOO OOOO 0600000009 OCIO OCOOOQCCO e O O O OOOO OOOOOOQOO Controller neutral Figure 12 Wiring of the Neutral Terminal Block 2 5 Helios Bracket Assemblies There are four types of bracket for Helios 1 The standard bracket that is used top and bottom on a three aspect case 667 2 30070 003 and the bottom bracket on the four in line two in line and single aspect assemblies 2 A four in line assembly has a long top bracket 667 2 30070 004 and a standard bottom bracket 3 A two in line pedestrian assembly uses a longer top bracket 667 2 30070 002 fitted as shown in Figure and a standard bottom bracket 4 A single aspect assembly uses one aspect top bracket 667 2 30070 001 and a standard botto
105. ment Warning Mains voltages are present The mains supply to the signal head must be disconnected switched off before working on an LED aspect Where a modular unit has been damaged the head has to be removed Proceed as follows the pole cap disconnect wiring to the signal head and feed cables back through the cable entry point in the pole Remove the nuts holding first the bottom bracket and then the top bracket Lift the entire signal head free of the pole fittings and lower to the ground When the signal head has been removed slacken the hex bolts holding the sacrificial caps in place and then loosen the two screws at each end that hold the brackets to the signal head The faulty unit may then be changed by removing the internal wiring removing any side boxes attached to the damaged module removing the internal inter module screws and unclipping the units Do this by lifting the two tabs holding the fronts of the units and applying force on the back of the module It is recommended that the screws 4 8 mm x 45 mm self tapping used to hold the modules together are not replaced in their original position more than 10 times Each module has four small indents provided at the front Figure and Figure in Appendix A so that when a new module has been clipped into place previously unused screw positions may be used if required He connect the wiring between the modules and instal the signal head on the pole as descri
106. necessary and the 200 mm arrow takes the place of the old fibre optic Installation at a new site Where there are no existing signals to be replaced it is possible to specify the combination of modules required and have them delivered in a largely pre assembled state This method is suitable where the STS drawing is available Upgrading an existing site Helios signals are a significant improvement on the Mellor and HITS type of signals Due to the visual differences it is not recommended that different types be mixed on the same signal pole oub assemblies are available to expand a signal head e g to add a side box It is important to ensure that the correct backing boards e g four in line hoods and brackets are called for 667 HB 30000 000 Issue 24 Page 20 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 2 Helios Signals 2 2 1 2 2 2 Order of Installation The recommended order in which installation should take place is as follows Read the Safety Warning on page 2 of this Handbook Unpack items from packaging section 2 2 3 Install pole section 2 3 Add mounting kit to pole section 2 3 Wire pole section 2 3 5 2 3 6 Fit extension arm s section 2 5 1 Remove doors section 2 6 3 OF iV Mex ee Adjust green arrow mask section 2 6 4 9 Complete four in line assembly section 2 6 7 10 Connect side boxes to main signal head sections 2 7 and 2 7 1 11 Attach mandato
107. ns voltages are present The mains supply to the signal head must be disconnected switched off before working on an LED aspect Warning Anti static precautions must be taken when handling LED and LED NLM PCB Assemblies oee the note in section 4 2 regarding anti vandal screws Undo the door clips on one side and open the door Unclip the cable connector from the LED or LED NLM board and remove the cables from the plastic cable clips on the rear of the board Remove the door assembly from the module and work on the ground The LED and LED NLM PCB is held in place with four plastic spacers with fir tree clips These should be squeezed to release the clip mechanism and the board lifted off the door assembly the clear plastic safety guard and its retaining clips from the board and fit it onto the new PCB Remove the plastic cable clips from the board and refit onto the new PCB Push down firmly until they clip into place Both these can be seen in Figure Clip the new PCB into place on the door assembly Replace the door on the aspect box and replace the cable connector Clip the cables back into place on the rear of the PCB using the cable clips Make sure that the clear plastic guard tucks over the cable connector before closing the door Secure the door tightening the anti vandal screws if supplied NOTE LED and LED NLM PCBs are NOT interchangeable 667 HB 30000 000 Issue 24 Page 100 of 143 HELIOS GENE
108. of sealant around the Inside of the door aperture carefully align the lens and press both parts together Remove any surplus seal from the face of the lens 2 8 Transformers Halogen The transformers will normally be factory fitted before delivery The usual position is in the bottom right corner of the module although they may be placed in any of the four corners If the transformer is to be fitted in one of the upper positions four screws are required one in each corner For lower position fitting only two screws are needed to hold the unit to the floor of the case as the rear of the transformer fits into the retaining slots as shown in Figure Figure 28 Transformer fitted to floor of case 2 9PSUs LED The PSU assembly will normally be factory fitted before delivery The usual position is centrally near the floor of the case one in each LED aspect The assembly consists of a metal backplate with an inductor tie wrapped to one side a metal PSU cover with an earth point and keyhole fixings holding the PSU and associated wiring The backplate may be fitted with the inductor on either side the PSU is always fitted with the earth point at the top 667 HB 30000 000 Issue 24 Page 46 of 143 S N S HELIOS GENERAL HANDBOOK Figure 29 PSU assembly fitted into case 2 10 Transformers LED NLM The transformers will normally be factory fitted before delivery The usual position is in the bottom rig
109. ons listed below Safety Warning Maintenance Provision MP Section 1 Introduction Section 2 Signals and Poles section3 Commissioning Section 4 Maintenance Appendix Drawings Appendix B Spares List Index 667 HB 30000 000 Issue 24 Page 11 of 143 HELIOS GENERAL HANDBOOK SIEMENS 1 3 Related Documents 667 HE 20661 000 General Principles 667 HE 20662 000 Signals and Poles for reference only 667 HE 20663 000 Detectors and Cable Terminations 667 HE 20664 000 Installation and Testing 667 HE 20665 000 Above Ground Detectors 1 4 Definitions AGD Above Ground Detector CET Cable Earth Terminal CLS Central Light Source ELV Extra Low Voltage HI High Intensity IEE Institute of Electrical Engineers LED Light Emitting Diode LMF Lamp Monitoring Facility LSLS Low Voltage Serial Lamp Switch LV Low Voltage MVD Microwave Vehicle Detector NLM Non Lamp Monitored PBU Push Button Unit PI Periodic Inspections RAG Red Amber Green 3 Aspect signal head S S Stainless steel STC Siemens Traffic Controls STS Site to Scale drawing 1 5 Tools Required As well as a standard Installers tool kit the following are required when installing and maintaining Helios Pozidriv screwdriver no 2 or 3 13 mm and 17 mm spanners or sockets and an 8 mm Allen key are necessary to install and adjust the lanterns Where side boxes are to be fitted 19 mm drill bit is needed to fit the conduit Where a solar cell is to be fi
110. oses is the same as other ELV HELIOS optical units If the unit becomes faulty no attempt should be made to replace individual drivers within the optic the whole sub assembly must be replaced More information see Appendix E Helios all types The aspects are clipped to each other Holes in the mouldings provide a passage between aspects for the cables Each moulding contains drill start indentations to allow for cable conduit AGD detector sockets solar cell etc Figure 5 Helios side view The door to each aspect is fixed by two sliding clips on either side enabling left or right opening and easy removal of the door As an anti vandal measure screws may hold the door clips shut Hoods and their fittings will also be supplied but need to be attached to the doors prior to installation Helios has its own moulded hood but may use most existing louvred and tunnelled hoods although some may need to be drilled If a green arrow box sign aspect or four aspect lantern assembly is specified the extra module or modules required can be added to the basic signal head in combinations as shown in section 2 6 Fittings to secure each module to the basic lantern will be supplied with each single aspect 667 HB 30000 000 Issue 24 Page 19 of 143 SI E M E N S HELIOS GENERAL HANDBOOK The halogen CLS with LMF CLS NLM and CLS ELV green arrow may have a green arrow mask placed in a number of positions in 22 5 increments The LED and L
111. pair process Dismantling of the indicator module must not be attempted Under no circumstances should the 4 nuts on the front of the module be undone as this will result in the module falling apart This could result in short circuits and the signals extinguishing It could also result in damage to the LED s and the driver modules 667 HB 30000 000 Issue 24 Page 52 of 143 SI N S HELIOS GENERAL HANDBOOK Do not undo this nut Keyhole slot Individual LED dot LENS Figure 37 TRAM Indicator showing keyhole slot from the front 2 16 Terminal Blocks Fixing positions have been provided for terminal blocks which are generally only fitted in aspects where an extension bracket has been used Figure shows terminal block fitted in one of the positions provided and Figure gives all the possible fixing positions 2 17 Bridge Rectifier see Figure and Figure for the fixing position Note if the cable P clip is fitted in this position either fit the bridge to another unused pillar position or move the P clip Figure 38 Bridge Rectifier 2 18 Cable Gland The cable gland is normally fitted in the knockout on the back of the top red aspect but it may be fitted where required with the following provisos 1 For a four in line assembly the gland must be fitted to the second box 66 7 HB 30000 000 Issue 24 Page 53 of 143 SI N S HELIOS GENERAL HANDBOOK 2 Side mounted signals may have the cable gland
112. pe CU100 230v operation this requires the power supply unit to be fitted as described above 667 7 17390 048 Radix type IT E200 48v operation this unit is totally self contained and is powered directly from the 48v Green Man output 667 HB 30000 000 Page 86 of 143 S N S HELIOS GENERAL HANDBOOK 4 gt gt l lt t lt D 4 lt p I 4 Figure 62 Radix power supply This equipment comes with its own fitting instructions Note that Sedgwell may include rivnuts remove them for best fixing to Helios 2 33 Backing Boards Where specified these are delivered with the main packaging for the signal head Where side boxes form part of the installation these should be assembled before fitting backing boards See section 2 7 for details The boards fit into place behind the front face of the case and attach using the positions and fixings as shown in Figure 667 HB 30000 000 Issue 24 Page 87 of 143 S N S HELIOS GENERAL HANDBOOK Figure 63 Backing board fixings 2 33 1 Reflective Tape 2 34 Some installations require the use of reflective tape over the backing boards Backing boards with the tape already fitted are avallable If retro fitted reflective tape is required then this glues into position before fitting the boards as described in section 2 33 Ensure the surface
113. r rear view showing Keyhole slots To remove the Tram indicator from its housing The Tram indicator is a complete module and must be replaced as a complete assembly The LED and power supply assembly is fitted into a standard Helios aspect box This assembly remains in the rear part of the box when the door lens assembly is opened Care must be exercised whilst the door lens assembly is open as the LED dots are extremely bright and may dazzle the viewer The assembly is kept in the rear part of the box by screws attaching it to the rear of the box A screwdriver with a 150mm crosshead blade is required to reach the screws To aid replacement the fixings are located in keyhole slots Once the screws are slackened a few turns the assembly can be lifted and withdrawn from the box Once the assembly is clear of the box the 12 way Molex connector can be unplugged The Molex connector 1 a tight fit and there are release leavers that must be squeezed to enable the connector to part It is essential that the operative is stable with both hands free when attempting this operation Re fitting is the reverse of removal The operative must ensure that the cable does not become trapped when refitting the assembly The entire assembly can then be returned for repair Although there are 3 variants of the TRAM indicator module only the fully equipped version will be kept as a spare The faulty unit will be upgraded to the fully equipped version as part of the re
114. re 47 Red Man Puffin Nearside Unit Mk 1 667 HB 30000 000 Issue 24 Page 63 of 143 S N S HELIOS GENERAL HANDBOOK Red Man Cycle Equestrian PCB Position of Red Man Cycle Equestrian PCB Position of Green Man Cycle Equestrian PCB x Figure 48 Nearside Signal Shown with Red Man Cycle Equestrian PCB Removed Mk 1 The Following PCB variants are available for the Nearside Signal 1 Green Puffin 667 1 30695 001 2 Red Puffin 667 1 30695 002 3 Green Toucan 667 1 30695 003 4 667 1 30695 004 5 Green Equestrian 667 1 30695 005 6 Red Equestrian 667 1 30695 006 2 23 2 Demand Unit Mk 1 The Demand Unit 667 1 30675 100 comes with a Door 667 1 30685 000 that contains the following a a PCB which contains all the LEDs arranged in a circle around the push button which illuminate when a Pedestrian Demand is Registered 667 1 30680 000 b A vandal resistant pushbutton This button has no moving parts and is touch sensitive 667 1 30210 505 c polycarbonate front panel 667 2 30676 000 667 HB 30000 000 Issue 24 Page 64 of 143 S N S HELIOS GENERAL HANDBOOK Push button Wait for signal Vandal Resistant Pushbutton S 9 EL LED Figure 49 Demand Unit 2 23 3 Optional Wiring Kits for Nearside Signal Unit and Demand Unit Mk 1 Two wiring kits 667 1 2694
115. remaining screws holding the Lens Retaining Ring the front door b If the CLS unit type is Dialight remove the 4 screws holding the unit to the front door Replace the lens as required Fit the new lens as follows a if the CLS unit is a Futurit type fit the lens retaining ring ensuring the small lug on the rear of the lens fits into a cut out on the front of the lens retaining ring It is vital to ensure that the lens fits snugly into the Lens Retaining Ring and cannot turn Fit the seal around the new lens and place the door over the lens and seal Holding the door lens and lens retaining ring in place turn the assembly over and replace the two screws that hold the Lens retaining ring to the aspect door Fit the CLS unit and the two CLS retaining clips Refer to Section 4 2 8 for CLS replacement procedure b If the CLS unit is a Dialight type fit the lens on to the CLS unit ensuring that the lens is positioned correctly Fit the seal around the new lens and place the door over the lens and seal Holding the door lens and CLS unit turn the assembly over and replace the 4 screws holding the CLS unit to the aspect door When the lens 1 correctly fitted the arrow pattern on the masking should point EN upwards thus Replace one side of the door into the aspect body and refit the CLS unit lead Close the door and do up the other door clips and any anti vandal screws 667 HB 30000 000 Issue 24 Page 116 of 143
116. river 74 gx 75 Figure 58 Nearside Mk2 Signal Unit 78 Figure 59 Nearside Mk2 Demand Unit 80 Figure 60 Nearside Mk2 Combined Unit 83 Figure 61 Nearside Mk2 Combined Unit Shows the Three PCBs 84 Figure 62 Radix 87 Figure 63 TIXITIgS vd 88 Figure 64 AGD fitted to signal head bracket 89 Figure 65 and Sweep Signal Head 90 Figure 66 amp Sweep Unit Mounted in Signal 90 Figure 67 and Sweep Microphone and Speaker Mounting 91 Figure 69 dca a aa su Medeam cu uma ua E Eus 92 FOUG GJS ANIES Ol illu y usu Rex Genuine Oras den est Videte UE Sl exu CI HMM nayawa 92 FIGUKG 7 O ANGIe or ROION e 93 Figure Pole Cap tie Cte uuu u uu M 94 Foure 7 2 DOOF CIO CIOS CO
117. ry arrow lens to door section 2 7 2 12 Attach terminal blocks and or bridge rectifier sections 2 15 and 2 17 13 Attach cable gland section 2 18 14 Attach hoods to doors section 2 19 15 Fit solar cell section 2 20 16 Fit pedestrian push button section 2 21 17 Fit tactile power supply section 2 32 18 Attach reflective tape section 2 33 1 19 Fit backing boards section 2 33 20 Fit AGD section 2 34 21 Fit signal head to pole section 2 36 22 Adjust angles of tilt and rotation section 2 36 1 23 Connect wiring between pole and signal head section 2 36 2 24 Fit pole cap section 2 36 2 25 Fit bulbs and doors sections 2 36 3 and 2 36 4 New installations only Optional depending on specification Halogen only Torque Settings The recommended torque settings are as follows Plas Tech 25 screws 0 8 Nm These are factory set and should not need adjusting setting or testing 667 HB 30000 000 Issue 24 Page 21 of 143 S N S HELIOS GENERAL HANDBOOK 2 2 3 M10 screws and bolts 20 Nm As signal heads rely on the security of their mounting fixings these fixings must be torqued up and the recommended procedure for this is found in appendix D Signal Head packaging Helios modular signals are supplied boxed in two forms The three aspect box can contain a one two or three aspect head with attached brackets with the backing boards loose in the box
118. s or tug gently on a wire to find its origin Note Wires from all transformers are the same length Therefore when wires come out of the signal head on a three aspect halogen the longest leads will be from the red aspect the next longest from the amber aspect and the shortest from the green aspect Take care when making connections to the top connector that the cables will not be crushed or damaged by the pole cap screw If there could be a problem put extra insulation around the connections Once the connections have been made screw the pole cap onto the terminal block assembly ensuring that the thread is engaged Do not overtighten 667 HB 30000 000 Issue 24 Page 93 of 143 SI N S HELIOS GENERAL HANDBOOK THEVA Figure 71 Pole Cap fitted 2 36 3 Fit Bulbs Halogen Note that bulbs are not delivered with the signal head assembly they are kept by STCL Services department Fit a tungsten halogen bulb into each of the bulb holders using the sleeve in which the bulb is supplied to push the bulb into place It should not be touched with the fingers Before fitting the bulb holder into the reflector ensure that the bulb is positioned with its filament vertical and at right angles to the bulb holder Fit the bulb holder into place in the reflector Lugs on the bulb holder fit into channels at the rear of the reflector and clip into place 2 36 4 Fit Doors Making sure they are the right way up fit each door over
119. s and conduil 44 Figure 24 Side box fitted on right of main signal 44 Figure 25 E deap fitted TO SIOG u u u D uu Iberi ier prd Pee eed 44 Figure 26 Regulatory Sign internal fitting 45 Figure 27 Signal Head with Mandatory Arrow fitted 45 Figure 28 Transformer fitted to floor of case 46 Figure 29 PSU assembly fitted into case 47 Figure 30 LED NLM Transformer Fitted to 47 Figure 3 1 Eul anti6OLES Uhiluuuu uu uuu 48 Figure 32 DialiGnt 49 FOUG 33 LFaAnSlOnMer MOUNUNG u ast dava 50 Figure GPS With EE 51 Figure 35 TRAM Indicator with door open 51 Figure 36 TRAM Indicator rear view showing Keyhole slots 52 Figure 37 TRAM Indicator showing keyhole slot from the front 53 Foure Se 6 53 Figure 39 Hood MUNG 54 Figure 40 Angled FIOOG TUNO
120. s are clean and dry Using the glue supplied take the roll of tape and stick it over the existing ink border in accordance with the Supplier s instructions trimming it to follow the rounded corners of the backing boards Above Ground Detector AGD AGD can be mounted in the slot on the top bracket as shown in Figure Alternatively a side mounting bracket section 2 5 2 may be fitted on top of the head to bracket fixings This bracket then provides a slot and two holes that may be used to fix the AGD 667 HB 30000 000 Issue 24 Page 88 of 143 SI N S HELIOS GENERAL HANDBOOK Nut caps fitted over top and bottom bracket nuts and bolts 2 35 Figure 64 AGD fitted to signal head bracket The AGD connector cable is generally fitted to the toomost indent on the red Aspect either side The hole should be drilled using the rear drill start point Connect the cable in accordance with the Supplier s instructions See the Above Ground Detector handbook see section 1 3 for further details Bleep and Sweep Unit The Bleep and Sweep Unit which is fitted into a Helios Signal Head has been developed by Sedgewall Communications Ltd for use as a Pedestrian Crossing Alarm It has a sound that is quite distinctive from other traffic noises and has the ability to adjust its volume according to ambient noise levels such that in busy city streets it will be much louder than for example in quiet residential area This
121. s of CLS ELV units each type has a Red Amber and a Green variant CLS ELV Type A Red 667 7 28586 100 Amber 667 7 28586 101 Green 667 7 28586 102 CLS ELV Type B Red 667 1 46700 100 Amber 667 1 46700 101 Green 667 1 46700 102 The CLS ELV Type A unit has the lens retaining ring built into the unit and is fitted to the aspect door with four screws The CLS ELV Type B unit has a separate retaining ring which is secured to the door with four screws The aspect body attaches to the retaining ring by a simple twist fit mechanism 667 HB 30000 000 Issue 24 Page 49 of 143 SI N S HELIOS GENERAL HANDBOOK 2 13 CLS ELV Type B Transformer Placement If CLS ELV Type B units are to be retro fitted to an existing installation it may be necessary to relocate transformers fitted within the signal head enclosure to avoid a clash with the aspect enclosure body Lamp transformers tend to offer sufficient clearance however 24V transformers with top mounted fused terminal blocks as used for AGD units must be mounted on the rear of the signal head enclosure NOT on the bottom see Figure 33 Transformer mounting points Figure 33 Transformer mounting points 2 14 Lamp Monitoring Unit LMF The LMF units will normally be factory fitted into the appropriate aspect body before delivery The are two variants of the LMF unit a LMF for Red Aspect 667 1 31180 230R b LMF for Amber or Green Aspect 667 1 31180 230A
122. se with the long handled pozidrive screwdriver The whole assembly should then be pushed upwards in the keyhole slots until the assembly can be partially withdrawn The multi way cable must now be unplugged and the optional demand indicator cable if fitted so that the unit can be totally withdrawn from the body The multi way connector is a tight fit and the operative must be stable and secure prior to attempting removal With the Tram indicator removed there will be full access to the back of the assembly body This will enable access to the cable entry gland position for both installation and maintenance 667 HB 30000 000 Issue 24 Page 139 of 143 S N S HELIOS GENERAL HANDBOOK The optical assembly must NOT be further dismantled and care should be taken not to damage the unit or to get any contaminants on the lenses The optic has a multi way cable that needs to be terminated usually to the pole cap assembly in the normal way The Cable Colour code is shown in Table 1 below It should be noted that not all aspects dots are used in every installation and the controller specification should be studied to enable the correct aspects to be connected Unused connections should be terminated in spare terminal block positions to prevent accidental contact with other wiring Table 1 Wiring Table For Helios ELV Tram Indicator cable 667 1 33159 000 Connector Pin Wire Colour number PL1 Wire Colour at Free end B Stop
123. supply outputs Common Demand 2 Y Controller 24V EN detector Supply Tram Demand indicators 1 signal heads General arrangement for demand Indicators used on Helios ELV Tram signal heads Caution must be taken to ensure the correct polarity is observed The Demand indicators must be driven from the 24V detector supply on an ELV controller ELV TRAM indicator 6 aspect internal assembly 667 1 33157 006 TRAM Lens Door without hood 667 1 31500 432 TRAM Lens Door with Demand indicator without hood 667 1 31500 434 ELV TRAM Dem Cable 667 1 331 70 000 Cable Loom Assembly 667 1 33159 000 Part numbers for Tram indicator assemblies 667 HB 30000 000 Issue 24 Page 141 of 143 SI E M E N S HELIOS GENERAL HANDBOOK INDEX TODIS ciis uo u ee ie 11 A Upgrade e TNR 18 Adjusting angle 75 L 71 ACID NUNG Dei Desa 31 Tem 103 BED eiat 15 B LED PCB replacement 82 84 Loll RTT 103 Backing board ee 70 105 Lens replacement aa 95 96 Bleep and Sweep s ERE SES 72 leno c u u 106 RR 104 LMF Fuse 88 BOISE 106 LMF Unit 89
124. sure that the wiring at the controller is to 667 GA 27006 000 Sht 2 Issue 3 The unit fastens to the pole using the U bolt provided When installing a pushbutton box the centre of the pushbutton should be between 1 0m 1 1m above the footway level L E D Wait Box Mk 1 There are four variants of the 48 Volt L E D Wait Box available for use in the United Kingdom These are Pedestrian Pushbutton Unit without Audible No Lamp Monitoring 667 1 30210 000 Pelican Pushbutton Unit with Audible No Lamp Monitoring 667 1 30210 01 1 Pelican Pushbutton Unit without Audible No Lamp Monitoring 667 1 30210 001 Toucan Pushbutton Unit without Audible No Lamp Monitoring 667 1 30210 002 667 HB 30000 000 Issue 24 Page 58 of 143 S N S HELIOS GENERAL HANDBOOK 2 Surf Eb HR 156 Figure 43 LED Wait L E D Wait comes complete wilh its fixing kit The unit fastens to the pole using the U bolt provided When installing a pushbutton box the centre of the pushbutton should be between 1 0m 1 1m above the footway level 2 22 1 Optional Wiring Kits for L E D Wait Box Mk 1 Two wiring kits 667 1 26942 000 and 998 4 88324 000 are available for connection to the terminal block inside the LED Wait Box to the terminal block in the pole cap assembly Note that each wire is 4 metres long The connections to these wires are as follows Wire Colour for
125. t 667 HB 30000 000 Issue 24 Page 4 of 143 SI E M E N S HELIOS GENERAL HANDBOOK TABLE OF CONTENTS SAFETY WARNINGQG 2 MAINTENANCE PROVISION MP 4 te NTRODU O TO N m 11 UD 11 COLDS 11 to Related u 12 E MID Rem 12 159 uuu asal EE 12 1 6 Signal Specification 12 1 7 Weights and Dimensions Signal Heads 14 2o SSIGNALSAND POEES 16 16 2 1 1 Installation at a new sitle 20 2 1 2 Upgrading an existing site 20 Felos u Lu ide ned ent oneal ee 21 2 2 1 Orderof Installali0fi u u u u u u Et etes os 21 2 2 2 21 2 2 9 DIGMAlIME AG packaging 22 224 OPIC UN er 24 2 24 1 98 uuu annua DE 24 2 2 4 2 LED and LED NLNM 25 2 2 4 3 CLS with LMF and CLS NLN 25
126. t any shadowing from the board electronics and to hide the superfluous LEDs on the left right arrow or fully populated PCB Any adjustment to the orientation of the green arrow mask should be carried out on a flat surface to help in positioning the lens seal To alter the position of the mask unscrew the retaining ring from the rear of the door and remove it Tip the mask out from behind the lens and place it in the position required in the retaining ring Replace the lens back in its original position on the retaining ring and make sure that the lens door seal is in place Place the door over the lens tip the assembly over and screw the retaining ring back into position on the door secure the door tightening the anti vandal screws if supplied 667 HB 30000 000 Issue 24 Page 42 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 6 6 Equestrian Halogen CLS with LMF CLS NLM CLS ELV LED and LED Lens are available for displaying equestrian figures These lens have the equestrian figure silk screened on to them a Red and Green Equestrian Lens for the Halogen Helios options 667 1 30200 399 Red Equestrian Lamp Lens 667 1 30200 398 Green Equestrian Lamp Lens b Clear Equestrian Lens for the LED and LED NLM Helios options 667 1 30200 397 Clear Equestrian Lens LED Lens This lens is used in front of Red and Green LED and LED NLM PCB option c Clear Equestrian Lens for the CLS with LMF CLS NLM
127. t faults may be displayed depending on the combination of lamps illuminated Refer to the handset handbook 667 HH 27000 000 Ensure that all lamp loads are learned using the KLR and KML commands Follow usual commissioning procedures for completion of site installation Nearside Mk2 Signal and Demand Units With the new Nearside Mk 2 range there is now a choice between having separate Nearside Signal and Demand units and having a Nearside Combined Unit The following sections detail the new housing and part numbers for each option There is also a lower power version of this designated Mk2 LP which is mechanically identical but incorporates an alternative p c b design and has a different lamp monitoring profile 2 31 1 Nearside Mk2 and Mk2 LP Signal Unit There are three variants of the Nearside Signal Unit which are dual housed with the Nearside Demand Unit for use in UK Puffin Toucan and Equestrian Crossing applications The Nearside Signal is illuminated using either Red or Green LEDs A Narrow Field of View NFOV option is also available on these assemblies The Mk2 UK Variants Puffin Nearside Signal Unit 667 1 33605 000 Toucan Nearside Signal Unit 667 1 33605 001 Equestrian Nearside Signal Unit 667 1 33605 002 Puffin Nearside Signal NFOV Unit 667 1 33605 500 Toucan Nearside Signal NFOV Unit 667 1 33605 501 Equestrian Nearside Signal NFOV Unit 667 1 33605 502 The Mk2 LP UK Variants are
128. ted behind a clear lens and is connected directly to the controller phase output The CLS Unit is a sealed unit that contain a number of high intensity LEDs There are three different types of CLS units a Red an Amber and a Green This option may be monitored by the ST800 900 700 and 750 retrofit controller facilities 667 HB 30000 000 Issue 24 Page 17 of 143 SI N S HELIOS GENERAL HANDBOOK CLS ELV OPTION The Central Light Source CLS is fitted behind a clear lens and is connected directly to the ST900 ELV or ST750 ELV controller phase output The output from the controller is 48V bright with the controller capable of performing Lamp Monitoring of each aspect The CLS ELV unit contains a number of high intensity LEDs There are two different types of CLS ELV units each type has a Red Amber and a Green variant CLS ELV Figure 3 CLS ELV Type A CLS ELV Type B Figure 4 CLS ELV Type B 667 HB 30000 000 Issue 24 Page 18 of 143 S N S HELIOS GENERAL HANDBOOK WARNING The CLS ELV OPTION CAN ONLY BE USED WITH SIEMENS 51900 ELV and ST750 ELV CONTROLLERS ELV TRAM indicator OPTION This ELV Helios unit is designed specifically for use with light rail and TRAMS The Light colour is white and the aspects take the form of a bar of discrete lights The central dot is normally constantly illuminated to indicate the optic as on The same LED driver is used so the profile for monitoring purp
129. the red and black wires to the driver terminal block on the replacement module 5 Align the module to the retaining clips and apply pressure until the retaining clips are fully engaged 6 Re connect the earth connection to the module metalwork Lamp Monitoring ELV For ELV controllers the CLS Wait will be monitored as if it were an ELV CLS signal aspect It will be necessary to change the load type for the sensors monitoring the Wait indicators This can be done in the IC4 configuration or with the following handset command KLT Sensor Number 1 Lamp Monitoring LV Refer to section 2 30 for a description of available lamp monitoring options If the controller is an ST800 LED the firmware needs to be 667 TZ 12800 000 800 issue 31 or later If necessary change the configuration PROM Confirm that the Controller configuration has been generated by acompetent person in accordance with the required procedures in place for the county and region NOTE A site can usually be upgraded to CLS without changing the configuration PROM depending on the signals types fitted and monitoring required The KRW command can be used to enable Lamp monitoring of the CLS Wait units on an LV CLS LED system The Format of the KRW command is as follows KRW Sensor Number 1 667 HB 30000 000 Issue 24 Page 76 of 143 2 31 SI E M E N S HELIOS GENERAL HANDBOOK This will enable Wait indicator monitoring on the internal sensor Differen
130. this procedure should be avoided wherever possible Figure and Figure show the seals correctly fitted Figure 89 Lens with seal in place 667 HB 30000 000 Issue 24 Page 110 of 143 S N S HELIOS GENERAL HANDBOOK Figure 90 Reflector with seal in place Secure the door tightening the anti vandal screws if supplied 4 2 16 Aspect Door Assembly Replacement LED and LED NLM Warning Mains voltages are present The mains supply to the signal head must be disconnected switched off before working an LED or LED NLM aspect Warning Anti static precautions must be taken when handling LED and LED NLM PCB Assemblies Normally a door lens assembly is replaced complete When the appropriate variant is not available any undamaged lens PCB and hood of the correct variant may be re used see the note in section 4 2 regarding anti vandal screws Undo the door clips on one side open the door and remove the cable connector from the PCB Remove the cables from the harness clips on the LED or LED NLM board Remove the door assembly from the module and work on the ground If the existing hood is to be re used remove it as described in section 4 2 21 and retain it for re use Otherwise fit a new hood as described in section 2 19 Remove the LED or LED NLM PCB by releasing the four fir tree clips holding it onto the door and siore it carefully Reattach the LED or LED NLM PCB to the new door b
131. tted a 20 mm drill bit is needed 1 6Signal Specification Model Description Current Consumption 230 V 50Hz 667 1 30200 ETC Tungsten Halogen 0 23 A per optical unit 667 1 30198 001 Hed LED 0 105 A per optical unit 667 1 30198 002 Amber LED 0 121 A per optical unit 667 1 30198 003 Green LED 0 09 A per optical unit 667 HB 30000 000 Issue 24 Page 12 of 143 SIEMENS 667 1 30198 004 667 1 30198 005 667 1 30200 907 667 1 30200 908 667 1 30200 906 HELIOS GENERAL HANDBOOK 667 HB 30000 000 POWER CONSUMPTION LED SIGNALS Red Aspect Amber Aspect Green Aspect Green Arrow POWER CONSUMPTION NLM LED Red Aspect Amber Aspect Green Aspect Power Consumption CLS LMF Red Aspect Amber Aspect Green Aspect Power Consumption CLS NLM Red Aspect Amber Aspect Green Aspect BRIGHT 230v 24 watts 20 watts 20 watts 16 watts BRIGHT 230v 24 watts 20 watts 24 watts Bright 230v 28 watts 28 watts 28 watts Bright 230v 13 watts 13 watts 16 watts Up Arrow Green LED 0 06 A per optical unit L R Arrow Green LED 0 08 A per optical unit Red NLM LED 0 102 per optical unit Amber NLM LED 0 1174 per optical unit Green NLM LED 0 1034 per optical unit Dim 160v 6 watts watts 9 watts 4 watts Dim 160v watts 8 watts watts Dim 160v 12 watts 12 watts 13 watts Dim 160v 3 watts 3 watts 4 watts NOTE CLS with LMF must not have a Dim or Bright voltage be
132. tted behind a specially designed medium wide angle lens of self coloured acrylic material Rear access is provided to the lamp holder to facilitate 667 HB 30000 000 Issue 24 Page 24 of 143 SI E M E N S HELIOS GENERAL HANDBOOK lamp changing without exposing the reflector to the elements and possible surface damage The lens is screened with a specially designed mask to reduce the phantom effect The lamp voltage is derived from a small step down transformer one per signal aspect mounted in the lamp body 2 2 4 2 LED and LED NLM The 247 pre focussed LEDs on the standard red amber and green aspects are mounted on a PCB that is held at a set distance from a specially designed medium wide angle lens made of clear acrylic material The LEDs have the correct colour wavelength intensity and viewing angle to achieve the specified colour brightness and medium wide beam The lens is screened with a specially designed mask to reduce the phantom effect Rear access is provided to the PCB to allow it to be replaced easily Note that mains voltages are present in LED aspects and the supply to the aspect must be isolated or switched off before any work is carried out The supply voltages to the LED PCB are derived from a small switch mode PSU mounted in the aspect case and powered from the respective controller output The supply voltages to the LED NLM PCB are derived from a dual winding transformer mounted in the aspect case and power
133. tton Assembly WAIT PCB Assembly Figure 44 LED Wait Box Door Assembly Mk 1 2 23 Nearside Signal and Demand Unit Mk 1 There are three variants of the Nearside Signal and Demand Unit which are dual housed for use in UK Puffin Toucan and Equestrian Crossing applications The Nearside Signal is illuminated using either Red or Green LEDs whilst the Demand unit uses a Touch Sensitive switch around which is illuminated by Red LEDs when a Demand is registered The UK Variants are Puffin Nearside Signal and Demand Unit 667 1 30670 000 Toucan Nearside Signal and Demand Unit 667 1 30670 001 Equestrian Nearside Signal and Demand Unit 667 1 30670 002 Each Nearside Signal Unit and Demand Unit comes complete with its fixing kit Each unit fastens to the Signal Pole using the U bolt provided When installing the Nearside Signal and Demand Unit the following must be observed a Centre of the Demand Unit Push button must be 1 0m 1 1m above the footway level b The distance between the bottom edge on the Demand Unit and the top edge of the Nearside Signal Unit must be less than 550mm but remember to leave sufficient room between the two units to allow the removal of the Nearside Unit Door Optional Audible Supply Kits 667 1 27006 000 and Optional Radix Tactile Equipment 667 7 17390 048 are available and will normally be fitted into the Demand Unit 667 HB 30000 000 Issue 24 Page 61 of 143 S
134. tween 180V and 200V NOTE CLS with LMF only supports 160V Dimming Power Consumption CLS ELV Type A and CLS ELV Type B Hed Aspect Amber Aspect Green Aspect Power Consumption Tram Indicator ELV Centre Dot Always on Issue 24 Bright 48v 12 watts 12 watts 12 watts 11 watts Bright 48v Dim 27 5v 4 watts 4 watts 4 watts Dim 27 5v 3 watts Page 13 of 143 SIEMENS HELIOS GENERAL HANDBOOK All other states 11 watts 3 watts Reference EN12368 Performance level class 2 Luminous intensity distribution M Phantom class 5 Symbol class S1 Impact resistance IR2 IR3 Ingress protection IP55 Environmental class A B Power Consumption Reg Sign LV Current Power Measured at 230 volts Power Consumption Measure at 48 volts Power Consumption Measure at 230VAC Power Consumption Retrofit MK2 Wait Box Power Consumption Measured at 48 volts Power Consumption 320 75 Watts LED Reg Sign ELV 7 Watts LED Reg Sign LV 8 Watts CLS Wait Bright 48v Dim 27 5v 12 watts 4 watts 12 watts 4 watts LED Wait Box Current Power 100mA 4 8 Watts Nearside Signal Demand Unit Current Power Measured at 48 volts Red Man Cycle Equestrian 300mA 16 Watts Measured at 48 volts Green Man Cycle Equestrian 300mA 16 Watts Measured at 48 volts Call Accept 100mA 6 Watts 1 7 Weights and Dimensions Signal Heads a Weights Note Except where ot
135. ubes are mounted in front of a metal reflector The tubes are connected in such a way as to provide protection against total signal failure The lens is formed from a flat acrylic sheet upon which any of the mandatory signs may be printed in full colour Most regulatory signs are delivered with the lenses fitted into the door of the module using a mastic bead sealant Mandatory arrow signs come as a kit with separate sealant to allow fitting on site to customer requirements 2 2 4 6 ELV Regulatory Signs Two 6 LED arrays are mounted onto a plate along with a control module and connection terminal block This ELV Module 667 1 33510 000 is then mounted into a body using 3 off M4 x 10mm Plastech 25 pan head pozi screws The required door lens is fitted to the body The lens is formed from a flat acrylic sheet upon which any of the mandatory signs may be printed in full colour Most regulatory signs are delivered with the lenses fitted into the door of the module using a mastic bead sealant Mandatory arrow signs come as a kit with separate sealant to allow fitting on site to customer requirements 2 2 4 7 LV LED Regulatory Signs Two 6 LED arrays are mounted onto a plate along with a control module mains transformer and connection terminal block This LV Module 667 1 33510 230 is then mounted into a body using 3 off M4 x 10mm Plastech 25 pan head pozi screws The required door lens is fitted to the body The lens is formed from a flat acry
136. un on STS 17 4 58 22 16 18 4 86 21 15 19 5 13 19 13 20 5 40 18 12 If there is a danger of neutral connectors being disconnected it is recommended that separate neutrals be used for 1 Signals and green arrows 2 Wait indicators 3 Box Signs Solar Cell and MVDs 4 Sonalert on Pelican Controllers If more than one armoured cable conductor with the same function needs to be terminated into the post terminal block they should be connected into one side of the connector The other side should be left clear for the connection of lantern conductors Pole Neutral Connections and Terminations for CLS ELV See 667 DS 20664 048 Traffic Signal Junction Cabling Design Certification for ELV Systems Latest Issue 2 4 Controller Neutral Connection Neutral kits are available for the ST800 and ST400 controllers The part numbers are 667 1 27068 000 and 667 1 20679 000 or 001 with terminal block respectively Where these are not available proceed as described below Minimum wire size to be 24 0 2 mm 1 5 sq mm and colour to be black for neutrals Length required approximately 1 5 metres maximum Cut lengths of wire 60 mm long and bare each end for 10 mm Starting at the appropriate terminal block insert two separate ends into the block and screw down tightly Take each loose end and loop around to the next position Continue in this fashion for as many neutral terminal points as are required Two lengths of wire approximately 250 m
137. vidence that the screws have been over tightened for example the threads should not have been stripped out of the screw hole If screws found to be loose tighten appropriately and annotate on a Periodic Inspection report sheet Five securing screws each end Helios head end cap screws 2 Inspect the Helios head main fasteners see below Determine if the fasteners are loose or if spring washers are fitted If soring washers are fitted complete procedure detailed below see also section D 5 Upgrades If soring washers are not fitted check tightness of screw bolt using torque wrench set to 20NM if there is a requirement for tightening annotate this requirement on a Periodic Inspection report Main fastener one at each end Helios Head 667 HB 30000 000 Issue 24 Page 132 of 143 S N S HELIOS GENERAL HANDBOOK Important Note Where If necessary the main fasteners should be removed or replaced using the recommended process method noted below 1 Replacement of Main bolts and or washers a Secure the signal head bracket which requires the fasteners replaced using a 6 metre Thule securing strap as shown in the figures Immediately below for the appropriate brackets top and bottom Thule securing Strap 667 HB 30000 000 Issue 24 Page 133 of 143 SI N S HELIOS GENERAL HANDBOOK b Replace the bolt and washer with items appropriate to the type of end cap in use see section D 4 for deta
138. w should be carried out with the optic door removed from its aspect and placed on a flat surface to help in positioning the lens seal The Type B CLS ELV module is designed such that the Arrow Mask can be replaced adjusted with the door ring in situ This removes the potential of disturbing the lens seal as the clear lens is retained by the door ring 667 HB 30000 000 Issue 24 Page 40 of 143 S N S HELIOS GENERAL HANDBOOK Helios Halogen To alter the position of the mask unscrew the reflector from the rear of the door and remove it Tip the mask out from behind the lens replacing the lens in its Original position if necessary and replace in the position required Make sure that the two seals lens door and lens reflector are in place and screw the reflector back into position See section 4 2 15 and Figure for details CLS with LMF CLS NLM and CLS ELV Type A To alter the position of the mask remove the CLS unit by a Futurit CLS Removing the two CLS retaining clips and release it from the remaining clips in the lens retaining ring and then unscrew the lens retaining ring from the rear of the door and remove it b Dialight CLS Remove the 4 screws holding the unit to the rear of the door Tip the mask out from behind the lens and replace it in the position required in the retaining ring Replace the lens back in its original position on a Futurit CLS the retaining ring and make sure that the lens
139. w the signal head to swing absorbing part of the force and minimising damage to the signal head Figure 69 Angles of Tilt 667 HB 30000 000 Issue 24 Page 92 of 143 SI N S HELIOS GENERAL HANDBOOK Figure 70 Angle of Rotation Make sure that the Allen bolts are loose enough so that the toothed sacrificial cap on the bottom bracket is not engaged before rotating the signal head Adjust as required tighten the Allen bolts top bottom to the required torque setting refer to Appendix D for tightening procedure Note As a final adjustment the nuts holding the bottom bracket to the pole should be loosened slightly the signal head and bracket pushed up as far as possible and the nuts re tightened securely Fit nut caps over the four pole mounting nuts to stop reflections If the bolt protrudes too far to allow the nut caps to fit over the nuts add the extra washers provided in the pole mounting kit Remove and replace the nuts one at a time so that the mounting brackets are not disturbed from their final positions 2 36 2 Signal Head to Pole Connection Adjust the amount of conduit tube to ensure there is sufficient to project into the pole Pass the conduit and cables through the cable entry point in the pole and draw the cables up through the top of the pole Generally red and green ident sleeves identify the wires but where this is not apparent see the following note for a way of identifying the appropriate lead
140. with ELV labels inside the case The p c b assemblies within must only be replaced with ELV compliant assemblies The visual identification of these assemblies is described in the Appendix C Visual Identification of ELV Compatible PCB s 3 1 Nearside Monitoring including pcb upgrade to MK2 LP The following p c b assemblies are compatible with Nearside monitoring facilities of an ELV controller These versions include slight modifications to the circuitry which allow fully monitorable operation with an ELV controller Visual identification of compatible circuit boards is described in appendix C Nearside Signal Mk2 LP ELV Compatible PCB Assemblies 667 1 33655 001 Issue 1 and above Nearside Mk2 LP 667 1 33655 002 Issue 1 and above Nearside Mk2 LP 667 1 33655 003 Issue 1 and above Nearside Mk2 LP 667 1 33655 004 Issue 1 and above Nearside Mk2 LP 667 1 33655 005 Issue 1 and above Nearside Mk2 LP 667 1 33655 006 Issue 1 and above Nearside Mk2 LP Note ELV controllers will require PB801 Issue 13 firmware 667 HB 30000 000 Issue 24 Page 96 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Nearside Signal ELV Compatible PCB Assemblies 667 1 30695 001 Issue 9 and above Nearside Mk1 Mk2 667 1 30695 002 lIssue9 and above Nearside Mk1 Mk2 667 1 30695 003 9 and above Nearside Mk1 Mk2 667 1 30695 004 Issue 10 and above Nearside Mk1 Mk2 667 1 30695 005 1 9 and above Ne
141. with seal in place 111 FOUS Ol SLED ASPEC DOON a 112 Figure 92 LED NLM 6 DOO ss ur xu iba uae 112 L S ASDCCL DOOR uu A ss gasas 113 Foue Fir CMDS 114 667 HB 30000 000 Issue 24 Page 9 of 143 SI E M E N S HELIOS GENERAL HANDBOOK Fidlile 95 e eparated 119 Foure FONC VICW TX 120 FOUE Rear VIEW araser 121 190 TOD VIEW ranerne ECTE EETA EEr 122 Gr C WCW aune E 122 667 HB 30000 000 Issue 24 Page 10 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 1 INTRODUCTION 1 1 Purpose This handbook gives a general description and specification along with the procedures for installation commissioning and maintenance for the following versions of Helios Signal Head CLS with LMF Signal Aspect CLS NLM Signal Aspect CLS ELV Signal Aspect LED LED NLM LED TRAM Indicator ELV Tungsten Halogen In addition the manual also gives a general description and specification along with the procedures for installation commissioning and maintenance for various other equipment including Wait Indicator LED Wait Indicator CLS Wait Indicator Nearside Indicator Demand unit 1 2Scope This handbook is written for the Helios Signal Head and is made up of the secti
142. ximum planting depth of 830 mm to adhere to all regulations The standard minimum planting depth of 610 mm applies To allow for a level clearance height of all signals at a Toucan straight poles are also available in 4 32 m length 667 HB 30000 000 Issue 24 Page 30 of 143 SI E M E N S HELIOS GENERAL HANDBOOK 2 3 4 Erecting the Pole 2 3 5 2 3 6 The pole assembly may be completed to the point of having drawn up the cables and fitted at least the pole cap prior to erection in which case see Section 2 3 5 Alternatively assembly may follow erection in which case go to Section 2 3 6 Transport lantern bracket assemblies pole cap assembly pole draw rope ladders and all necessary tools to the first pole location The mounting kit delivered separately includes U bolt and two 8 bolts that are used to attach pole spacers and then the signal head to the pole The U bolt is fixed in the lower position attach a nut loosely to one end to prevent the bolt being lost inside the pole feed the other end in through one hole and out of the other Remove the nut place the pole spacer over the bolt ends and attach firmly to the pole using plain M8 washers and M8 nuts The upper pole spacer is held in place with two M8 bolts washers and nuts that can be held in place with a hand inside the pole whilst fixing to the pole These bolts should be securely tightened Wiring Pole prior to erection Each cable can be fed through the
143. y clipping the board onto the fir tree clips Replace the new door assembly onto the case and reconnect the cables clipping them into place as shown in Figure NOTE LED and LED NLM PCBs are NOT interchangeable When bringing the door assembly together note the orientation of lens and lens holder as described in section 4 2 22 Holding the lens holder and door together flip the assembly over so that the door is face down and insert the four screws Note The lens to door seal can be very difficult to align once removed Therefore this procedure should be avoided wherever possible Figure shows the seal correctly fitted 667 HB 30000 000 Issue 24 111 of 143 S N S HELIOS GENERAL HANDBOOK 2 E 9 4 522 Figure 92 LED NLM Aspect Door Secure the door tightening the anti vandal screws if supplied If necessary re attach the hood 4 2 17 CLS with LMF CLS NLM Door Replacement Normally a door lens assembly is replaced complete When the appropriate variant is not available any undamaged lens CLS unit and hood of the correct variant may be re used oee the note in section 4 2 regarding anti vandal screws Undo the door clips on one side open the door and remove the cable connector PL1 from the LMF unit this removes the phase power from the LMF Unit and then remove the cable connector of the CLS unit from the LMF Unit SKT1 if CLS with LMF or disconnect plug to the mains

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