Operation Manual ZP D 43 13-01-2010 - Doc
Operation Manual ZP D 43 13-01-2010 - Doc
Operation Manual ZP D 43 13-01-2010 - Doc
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Confidentiality:
None
Issuing department:
I MO RA OP IED 5
Author of
German
document
Pohl
I MO RA PC IED 5
Translation
released by
Argiel
I MO RA R&D DOC 5
31.05.2010
See EDM
Translation
prepared by
Dawson
I MO RA R&D DOC 5
2009-11-16
See EDM
Name
Org. unit
Date
Signature
The contents of this translation correspond to the German document with the number
A6Z08110491156
Document history
Version
Release
date
Sections
changed
Reason,
Change Notice if applicable
2007-08-14
All
First issue
2008-03-18
4.3.4; 7.1.1;
7.1.6; 7.1.8;
7.1.11; 7.2.2;
7.5.4; 7.5.5;
8.2; 10.3.2.3,
9.5.5, 9.6
2008-04-01
5.1, 7.5.4
2008-05-16
6.4.2, 6.4.4,
8.3, 10.1
2009-03-01
All
Various additions
2009-08-03
Cover page
2009-08-20
Cover page
5, 6.4.5,
7.2.2, 7.2.3,
7.5.4, 10.3.3,
Insertion of a photograph
Warning modified
Addition in footer
Note deleted (contained in Section 5)
Addition of dimensions
Addition of Siemens code numbers
2009-11-09
Kap. 7.1.11
Note specified
Kap. 7.4.3.2
Kap. 7.5.4
Note added
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Contents
1
1.1
10
Safety information
11
3.1
11
3.2
12
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
Safe state
Usable axle counting systems
Fusing
Qualified personnel
Preparation for work
Performance of work
Completion of work
Storage of ZP D 43
12
13
13
13
14
15
17
17
3.3
18
3.4
18
3.5
19
21
4.1
21
4.2
Electrical function
22
4.3
24
4.3.1
4.3.2
4.3.3
4.3.4
25
25
25
26
32
5.1
33
5.1.1
5.1.1.1
5.1.1.2
5.1.2
33
33
33
33
5.2
34
5.2.1
5.2.2
5.2.3
5.2.4
Cable capacitance
DC resistance of feeder cable
Interference voltages
Attenuation specifications
34
35
35
36
37
6.1
37
6.2
Connecting cables
37
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6.3
38
6.4
38
6.4.1
6.4.2
6.4.3
6.4.3.1
6.4.3.2
6.4.4
6.4.5
39
39
39
39
39
40
41
43
7.1
43
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6
44
45
46
48
49
7.1.15.1
7.1.15.2
7.2
58
7.2.1
7.2.2
Standard application
Vertical arrangement of trackside connection box
58
59
7.3
Tools required
60
7.4
60
7.4.1
7.4.2
7.4.3
7.4.3.1
7.4.3.2
7.4.3.3
7.4.3.4
7.4.3.5
7.4.3.6
60
63
63
63
65
67
68
69
7.4.4
7.5
73
7.5.1
7.5.2
7.5.2.1
7.5.2.2
7.5.3
7.5.4
7.5.5
73
74
74
75
75
76
77
7.1.7
7.1.8
7.1.9
7.1.10
7.1.11
7.1.12
7.1.13
7.1.14
7.1.15
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50
51
52
53
53
54
55
55
56
56
56
56
70
71
Mobility
7.5.6
7.5.7
7.5.7.1
7.5.8
7.5.8.1
80
81
81
82
83
7.6
84
85
8.1
85
8.1.1
8.1.2
85
86
8.2
Electrical connection
87
8.3
87
8.4
90
91
9.1
Required tools
91
9.2
Preliminary testing
92
9.3
Calibration of ZP D 43
94
9.4
95
9.5
Electrical testing
96
9.5.1
9.5.2
9.5.3
9.5.4
9.5.5
9.6
101
10
Maintenance
102
10.1
Inspection
102
10.2
104
10.2.1
10.2.2
10.2.2.1
10.2.2.2
10.2.2.3
Fault location
Single faults
Wheel detection equipment supply voltage U60
Transmitter frequency fs
Receiver voltages UE1 and UE2
97
98
99
99
100
104
106
106
106
107
10.3
10.3.1
10.3.2
10.3.3
10.3.4
10.3.5
10.3.6
11
Technical data
115
11.1
ZP D 43
115
11.2
Multimeter requirements
116
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108
108
109
110
111
112
113
Mobility
11.3
PEGA 1211
11.3.1
11.3.2
General
ZP 43 operating mode
117
117
117
Declaration of conformity
118
List of abbreviations
119
List of figures
120
List of tables
122
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1
a description of configurations
The first section contains essential information on the safety of personnel, system safety
and the problem of interference of the electronic wheel detection equipment. If danger to
persons and material cannot be ruled out, these hazards are indicated by means of
pictograms. Technical data of the wheel detection equipment is described.
Note
If you have any tips, comments or suggestions for improvement regarding this
Operating and Service Manual or have discovered any mistakes, please
contact us directly. All your ideas will be gratefully received.
Siemens AG
P.O. Box 33 27
38023 Brunswick
Germany
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1.1
Referenced Document
SSN
Modification Instruction
ZP 43 E to ZP D 43
A25552-T4100-A1-*-7651
A25552-T701-C1-*-31
A25552-M43-A1-*-31
Installation Instructions for mounting a trackside connection box onto a slim or lattice
post
A25165-A42-B111-*-31
Table 1
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2
Siemens AG
Ackerstrasse 22
38126 Brunswick, Germany
Tel. +49 (0) 5 31 2 26-0
Fax +49 (0) 5 31 2 26-43 98
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3
3.1
Safety information
Symbols and pictograms
If hazards for persons and material cannot be ruled out in the work described, specially
highlighted safety notes draw attention to these hazards. The safety notes used are
classified according to the severity of the hazard involved and have the following
meanings:
Death or severe injury will occur if you do not take the precautions described.
Death or severe injury may occur if you do not take the precautions described.
CAUTION
"CAUTION" and a hazard warning sign indicate that minor injury may occur if
you do not take the precautions described.
Caution
"Caution" without a hazard warning sign indicates that damage to property
may occur if you do not take the precautions described.
Notice
An undesirable event or state may occur if you do not observe the relevant
note.
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CAUTION
This indicates electrostatic sensitive devices.
Before touching a board bearing this sign, always equalize charge.
3.2
The following instructions must be followed in order to avoid personal injury and damage
to property. Personnel must be familiar with the sections of this Operating and Service
Manual in order to ensure safe and correct work on the ZP D 43 wheel detection
equipment.
3.2.1
Safe state
Risk of accident
The wheel detection equipment does not guarantee a safe state. Maintaining a
safe state when a wheel detection equipment failure is detected is the
responsibility of the higher-level evaluation unit.
If evaluation computers are used which cannot distinguish the faulty state from
the occupied state, counting errors may arise (valid wheel) in the event of a
failure (e.g. dual-channel hardware reset with jitter).
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3.2.2
Risk of accident
The ZP D 43 wheel detection equipment may only be operated in conjunction
with the following axle counting systems:
- Az S M (E), (PB), (R)
- Az S 350 U
- Az S (M) 350, Versions B, M, T
- Az S 350
- Az S 350 B1, B5
- Az S M 350
Applications extending beyond this should be checked with the specialist
department on a case-by-case basis.
3.2.3
Fusing
Caution
The power supply of the wheel detection equipment must be limited to 250 mA
by the higher-level supply unit.
3.2.4
Qualified personnel
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3.2.5
Risk of accident
Hazards to the installation and maintenance personnel
Only perform maintenance work during intervals between trains.
Safety measures stipulated by the respective railway regulations must be
carried out before commencing work on the track. All measures must be
agreed upon with the signalman.
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3.2.6
Performance of work
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3.2.7
Completion of work
Notice
3.2.8
Storage of ZP D 43
Notice
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3.3
3.4
Every circuit board is marked with the symbol "Electrostatic sensitive devices" and is to be
handled with care.
CAUTION
This indicates electrostatic sensitive devices.
Before touching a board bearing this sign, always equalize charge.
Only place the board on bases that are or have been made conductive (e.g.
carbonized foam mats).
If you hand over boards from one person to another with no packaging, equalize
charge before handover by touching the hands of the other persons involved.
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Notice
Failure of the wheel detection equipment
Do not attempt to repair defective boards.
Replace defective boards and send them to Siemens AG for repairs. Secure
the collar screws of the mounting rack with Loctite.
3.5
Risk of accident
After dismantling a double wheel detector from the rail, the relevant track
section may be inadvertently indicated as clear.
After dismantling a double wheel detector, loosely bolt together the transmitter
and receiver using the associated bolts and nuts.
The railway operator must ensure by suitable measures that there are no
effects on further operation.
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Notice
Damage
Work on the track bed (packing) may damage the double wheel detector and
its associated cables.
Before commencing this work, dismantle the double wheel detector from the
rail and remove it and its cables from the ballasted area.
After reinstalling the double wheel detector, check the electrical parameters
and adjust them if necessary (see Section 9).
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4
4.1
Signaling cable,
star quad
Signaling cable,
star quad
Evaluation computer
EC
CH 1/2 Counting head
DEK 43 double wheel detector
Trackside connection box
Figure 1
Overview of ZP D 43 components
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4.2
Electrical function
The electrical functions during traversal of the wheel detection equipment are described
more precisely by the block diagram below:
Figure 2
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Note
The ZP D 43 has been optimized in terms of wheel profile and axle spacing
according to the German Railway Building and Operation Regulations (EBO).
Deviations may be caused by substantially modified rolling stock. In particular
wheel profiles and axle spacings that do not correspond to EBO and special
block-type magnetic rail brakes may result in limitations. Particularly when
converting a network from a heavy rail system to a light rail system, the
special features of the rolling stock must be observed.
Two resonant circuits installed in the double wheel detector transmitter generate a
magnetic alternating field with a frequency of 43 kHz. This alternating field inducts a
receive signal in two resonant circuits installed in the double wheel detector receiver.
When a wheel enters the effective range of the double wheel detector, the magnetic
coupling between the transmitter and receiver increases. Consequently, the induced
voltage in the receiving coils increases. The received voltages pass via the connecting
cable to the two receiving amplifiers in the trackside connection box. Following filtration,
the amplitude of the received signals freed from interference is rectified and increased to
an appropriate level in the subsequent amplifier.
The received voltage of the double wheel detector in its quiescent state, i.e. when there is
no passing wheel, is recorded on the wheel detection equipment board in the trackside
connection box within the context of calibration and converted into two AC voltage signals
with the quiescent frequencies of f1 = 3.60 kHz and f2 = 6.52 kHz.
When a wheel enters the effective range of the double wheel detector, the increased
magnetic coupling between the transmitter and receiver causes the received voltage to
increase beyond the defined quiescent voltage. The wheel detection equipment board
reacts by increasing the frequency of the AC voltage signals. At the same time, the
amplitude of these signals is decreased. This corresponds to the occupied state of the
double wheel detector.
The downstream transformer (Tr) combines the AC voltage signals of the two channels
and feeds them into the signaling cable. The transformer also separates the supply
voltage from the interlocking from the signals to be transmitted to the evaluation computer.
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4.3
Trackside
connection box
plastic cover
Standard
S25552-T4100-A3
S25554-A6100-A300
S25554-A6150-A300
Standard with
overvoltage protection
S25552-T4110-A3
S25554-A6110-A300
S25554-A6160-A300
Double usage
S25552-T4100-A2
S25554-A6100-A200
S25554-A6150-A200
S25552-T4110-A2
S25554-A6110-A200
S25554-A6160-A200
S25552-T4100-A1
S25554-A6100-A100
S25554-A6150-A100
S25552-T4110-A1
S25554-A6110-A100
S25554-A6160-A100
Application variant
Table 2
Application variants
Note
The wheel detection equipment can also be supplied pre-assembled ex works
(completely equipped and with an already connected double wheel detector).
The code numbers are listed in Table 17 on page 109.
Note
Overvoltage protection includes protecting the core to earth.
Note
Reducing plates have to be ordered separately depending on the rail type.
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The switch-on threshold is specified by coding as 1.58 times the basic level. When the
wheel detection equipment is fully fitted, a 500-mm-long pipe support and a wheel
detector with a 5-m-long connecting cable is included. Reducing plates have to be ordered
separately depending on the rail type.
4.3.1
The ZP D 43 wheel detection equipment can also interoperate with two evaluation
computers installed at different locations, i.e. it can be operated as double-usage wheel
detection equipment.
4.3.2
The ZP D 43 wheel detection equipment can also be supplied externally with DC voltage
or AC voltage. An external supply is necessary if long distances are to be covered
between the evaluation computer and the wheel detection equipment (further details in
Section 5.2). In this case, power for the wheel detection equipment cannot be supplied via
the same core pair on which the wheel detection equipment signals are transmitted.
Power must be supplied via a second core pair or another cable. It must be
uninterruptible.
Note
An isolating transformer must be used if transient interference voltages
exceed 1.5 kVrms and continuous interference voltages exceed 250 Vrms on the
supply line.
Only an AC external supply is possible in this case. Application variant
S25552-T41**-A1 must be used.
4.3.3
Broadband transformers (BBT) are required for electrical isolation when transmitting
wheel detection equipment signals if the cable capacitance of a continuous cable or
the interference voltage is too high.
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In accordance with EN 50121-4, transient interference voltages of 1.5 kVrms and
continuous interference voltages of 250 Vrms must not be exceeded in cable systems and
the connected signaling and safety equipment.
In addition, the cable capacitance of an electrically connected telecommunications line
must not exceed 325 nF. In the event of sporadic intercore short circuits in the trackside
cable, there is the danger that, if the cable capacitance is too high, counting pulses may
be incorrectly simulated as a result of skews between the two wheel detection equipment
information channels. With a maximum cable capacitance of 325 nF, a typical cable
capacitance of 50 nF/km results in a cable length of 6.5 km.
Consequently, for all axle counting systems specified in Section 3.2.2, it is necessary to
isolate the trackside cable between the wheel detection equipment and the evaluation
computer if the maximum permissible cable capacitance is exceeded. A broadband
transformer is used for isolating wheel detection equipment signal transmission.
In this case, power for the wheel detection equipment cannot be supplied via the same
core pair on which the wheel detection equipment signals are transmitted. Power must be
supplied via a second core pair. This external power can be supplied from a DC voltage
situated in the vicinity or by an AC voltage. It must be uninterruptible.
Also for the supply line, the transient interference voltage must not exceed 1.5 kVrms, and
the continuous interference voltage must not exceed 250 Vrms. If necessary, an isolating
transformer is also to be inserted there. In this case, only AC supply is possible.
4.3.4
Typical configurations
Risk of accident
Wheels are not detected.
The signaling cable described in Section 5 must be used for the transfer of
information.
Cables with any stranding can be used for external supply (supply line). If required, two
cores of the supply line each are to be connected in parallel in order to reduce the direct
current resistance.
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Configuration example 1:
Standard application
Transient interference voltage 1.5 kVrms and continuous interference voltage 250
Vrms
Configuration example 2:
Interference voltage too high, external supply
The cable capacitance of each section of the information line must be 325 nF.
Further BBTs are to be inserted if required.
In each section, the transient interference voltage must be 1.5 kVrms and the
continuous interference voltage must be 250 Vrms.
Further BBTs and ITs are to be inserted if required.
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Configuration example 3:
Cable capacitance or interference voltage too high, external supply from adjacent
interlocking
Cable capacitance of the information line > 325 nF or transient interference voltage
on the information line > 1.5 kVrms or continuous interference voltage on the
information line > 250 Vrms
On each section of the information line, the cable capacitance must be 325 nF, the
transient interference voltage 1.5 kVrms and the continuous interference voltage
250 kVrms. If required, further broadband transformers must be inserted there.
On the entire line length between the wheel detection equipment and interlocking B,
the transient interference voltage must be 1.5 kVrms and the continuous interference
voltage 250 kVrms.
If required, the supply line is to be divided into two or more sections by means of
isolating transformers. The restriction with regard to transient and continuous
interference voltages applies for each section. In this case, only an AC supply is
possible.
Configuration example 4:
Double usage
The two outputs of the wheel detection equipment are isolated from each other with a
dielectric strength of 4 kVrms AC.
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Configuration example 5:
Double usage and external supply
The cable capacitance of the information line to interlocking A is > 325 nF; after
inserting the necessary BBT(s) into the information line to interlocking A, the cable
capacitance of each section must be 325 nF.
The cable capacitance of each section of the information line to interlocking B must
be 325 nF, the transient interference voltage 1.5 kVrms and the continuous
interference voltage 250 Vrms. If required, one or more BBTs must be inserted there.
Configuration example 6:
Double usage and external supply
Transient interference voltage on the information line to interlocking A > 1.5 kVrms or
continuous interference voltage on the information line to interlocking A > 250 Vrms
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The cable capacitance of each section of the information line to interlocking A must
be 325 nF, the transient interference voltage 1.5 kVrms and the continuous
interference voltage 250 kVrms. Further BBTs are to be inserted if required.
On the entire length of the supply line to interlocking A, the transient interference voltage must be 1.5 kVrms and the continuous interference voltage 250 Vrms. If required, further isolating transformers are to be inserted.
The cable capacitance of each section of the information line to interlocking B must
be 325 nF, the transient interference voltage 1.5 kVrms and the continuous interference voltage 250 Vrms. If required, further BBTs must be inserted.
Configuration example 7:
Interference voltage between wheel detection equipment units too high
Transient interference voltage on each information and supply line 1.5 kVrms and
continuous interference voltage on each information and supply line 250 Vrms
Transient interference voltage between the wheel detection equipment units between
1.5 kVrms and 3 kVrms
Electrically isolated DC supply for each wheel detection equipment unit: a separate
SV5715C power supply board for each wheel detection equipment unit
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Notice
Interference voltage
When mounting the wheel detection equipment to the right and left of the
interlocking and the evaluation computer respectively (configuration example
7), the permissible total interference voltage between the two wheel detection
equipment units must not be exceeded.
For this reason, isolation of the power supply is necessary for the wheel
detection equipment concerned. This is effected by connecting each wheel
detection equipment unit to be isolated to separate 70 V DC power supply
boards (SV5715C), which are installed in groups in the Az S M cabinets.
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Different aspects to be noted for the cabling between the evaluation computer and the
wheel detection equipment are described below.
Risk of accident
Wheels are not detected.
Star-quad signaling cables must be used for transmitting information from the
wheel detection equipment to the evaluation computer.
Taking into account other services that do not exceed a maximum interference
level of 9 mVrms, a paired signaling cable may also be used.
The connecting cable of the wheel detection equipment must not be laid
together with cables that carry traction current or traction return current in a
cable route or cable trough.
A 400 Vrms heavy-current supply must not be routed together with the signal
cores of the ZP D 43 in one and the same cable, unless the cable design ensures sufficient electrical isolation.
The conditions specified in Section 6.4.5 are to be observed for routing signal
cores together with cores carrying a voltage of 230 Vrms.
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5.1
In cable distribution cabinets, cable distribution boxes and trackside connection boxes for
isolating transformer boards (if present), the cable shields must be electrically joined
together in a conductive manner.
Please refer to Section 7.5.5 for notes on the design of the earth conductor.
5.1.1
5.1.1.1
The cable shield and cable armoring (if present) are isolated from the trackside
connection box.
5.1.1.2
The cable shield must be connected to the earthing terminal of the trackside connection
box in a highly conductive manner. If the wheel detection equipment is fitted with extra
overvoltage protection elements, the notes in Section 8 must be observed.
5.1.2
The cable shield and cable armoring (if present) are isolated from the trackside
connection box.
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5.2
The cable length between the evaluation computer and the wheel detection equipment is
limited for the reasons set out in Sections 5.2.1 to 5.2.4 below (see also Section 4.3). The
level of the signal frequencies is predominantly attenuated by the cable capacitance,
whereas the range of the wheel detection equipment supply is restricted by the core
cross-section (direct current resistance).
With the paired and star-quad signaling cables used, a control distance of 6.5 km is
typically possible with a direct supply (standard scenario) and a nominal core diameter of
1.4 mm.
In individual cases, the maximum possible control distance must be determined taking into
consideration the reasons set out in Sections 5.2.1 to 5.2.4 below. Under certain
conditions, control distances of up to 21 km can be attained if the cable is segmented into
electrically isolated sections (insertion of transformers, see Sections 4.3.3 and 4.3.4) and
the necessary external power supply is available. This must also be taken into
consideration when relocating wheel detection equipment and / or changing the cable
routing.
The maximum possible cable length is always attained when one of the limiting values
described below is attained.
5.2.1
Cable capacitance
Risk of accident
Wheels are not detected.
The cable capacitance (core to core) of an electrically connected
telecommunications line must not exceed 325 nF. Star-quad signaling cable
according to Dlk 1.013.110 has, for example, a cable capacitance of approx.
50 nF/km. In this case, the length of an electrically connected cable must not
exceed 6.5 km.
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5.2.2
5.2.3
Interference voltages
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5.2.4
Attenuation specifications
As the individual cable types have different electrical properties, it is not possible to state
a distance that applies to all cable types. The attenuation values listed in the following
table apply.
Wheel detection
equipment
application
Set transmission
level (Vrms)
dB
Standard application
and double usage
1.75
2.31
20.10
External supply
2.60
2.71
23.57
Table 3
Note
The values in the table refer to application on evaluation computers of types
Az S 350 and Az S M.
The data sheet value for the frequency of 6.5 kHz must be used for determining the cable
attenuation. Star-quad signaling cable according to Dlk 1.013.110 has, for example, an
attenuation of 1.05 dB/km (core diameter 1.4 mm) or 1.6 dB/km (core diameter 0.9 mm) at
6.5 kHz. If no data is available for this frequency, the attenuation must be interpolated
from the data for adjacent frequencies. No coil-loaded cables must be used, because their
attenuation is too high at 6.5 kHz.
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The ZP D 43 wheel detection equipment is installed at the track section limits. It consists
of a double wheel detector and a trackside connection box, which together form a single
functional unit (wheel detection equipment unit). The two are linked by a pair of
connecting cables approx. 5 m long (alternatively 10 m or 15 m), permanently attached to
the double wheel detector.
Details on their arrangement on the track are provided in Section 7.2.
6.1
The DEK 43 double wheel detector (called double wheel detector below, and also called
detector unit, electronic double wheel detector or electronic wheel detector in other
documents) consists of two electronic detector systems. Each system has a transmitting
part and a receiving part. The transmitter and receiver of both detector systems are each
fitted in a common plastic housing. The transmitter housing is situated on the outer side
and the receiver housing on the gage side of the rail. In order to reduce interference from
the rail, e.g. by traction return currents, the transmitter and receiver are each provided
with a reducing plate on the side facing the rail. The reducing plate is matched to the rail
profile and reaches from the rail base across the web to underneath the rail head.
Reducing plates are available for all conventional rail profiles (see Table 22). The double
wheel detector is fixed in the neutral zone of the rail web by two mushroom-head bolts
through drill holes.
6.2
Connecting cables
Shielded connecting cables are used to connect the double wheel detector and the
trackside connection box. The connecting cables have a unilateral permanent connection
with the parts of the double wheel detector and form a unit. They are approx. 5 m, 10 m or
15 m long. This results in maximum distances of approx. 4.2 m, 9.2 m and 14.2 m
between the double wheel detector and the trackside connection box respectively.
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6.3
Figure 3
6.4
Diagnostics, channel 2
Diagnostics, channel 1
ZP D 43 board layout
Once the maximum permissible interference voltage or the maximum permissible cable
capacitance is reached, it is necessary to electrically isolate the line between the wheel
detection equipment and the evaluation computer. A broadband transformer is used for
electrically isolating the wheel detection equipment transmission line. For this reason, the
wheel detection equipment must be supplied via a second core pair in this case. This
external supply must be uninterruptible and can originate from a DC voltage situated in
the vicinity or an AC voltage. On the supply line, too, a transient interference voltage may
not exceed 1.5 kVrms and a continuous interference voltage may not exceed 250 Vrms. If
necessary, an isolating transformer must also be used there. In this case only an AC
power supply is possible.
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6.4.1
The SCN V25319-Z1-A9 broadband transformer is used for electrically isolating the cable
for wheel detection equipment signal transmission.
6.4.2
The SCN V25319-Z1-A14 isolating transformer must be used in new systems. It can
power up to three ZP D 43 wheel detection equipment units in the ambient temperature
range of -40C to +80C. The isolating transformer supplies the two output voltages of
230 V and 42 V.
The isolating transformer is to be protected by a 100 mA slow-acting fuse on the interlocking side (in the cable termination cabinet).
6.4.3
6.4.3.1
The SCN C25320-A37-A1 mounting equipment is used for mounting. This unit has two
slots for broadband transformers or isolating transformers. The mechanical construction of
the mounting equipment, subject to corresponding adjustments, also allows for
accommodation in other cable termination racks or cabinets.
6.4.3.2
The connection box for the isolating transformer board can be installed directly on the
cable route in the open on a pipe support.
The dimensions of the connection box (without pipe support and cable bushings) are 241
mm x 241 mm x 174 mm (w x d x h). The different board arrangement variants are set out
in Table 20 in Section 10.3.4.
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Note
The terminal assignment of the isolating transformer boards can be found in
the associated circuit diagrams SCN A25552-T701-C11-*-11 to ...C15-*-11.
Instructions for mounting can be found in the Connection Box for Isolating
Transformer Boards Installation Instructions, SCN A25552-T701-C1-*-31.
The variants of the isolating transformer boards can also be used
independently of the connection box and mounted at an appropriate location,
e.g. in racks or cabinets.
6.4.4
Note
The external supply must be uninterruptible.
If the 230 V AC external supply is from the interlocking, it has to be nonearthed. This can be done by using a 230 / 230 V isolating transformer, SCN
V25319-Z1-A14, in the cable termination rack if an earthed voltage is used or by
using the non-earthed signal voltage supply network.
If isolating transformers are used, it is to be noted that, for power reasons, max.
three such transformers may be connected in series.
The permissible supply voltage range, measured at the trackside connection
box, is between 26 Vrms AC and 50 Vrms AC or 30 V DC and 72 V DC with max.
3% ripple.
The voltage for the external power supply must be connected to the FS terminals in the
trackside connection box. For details, see Figure 3.
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Risk of accident
Wheels are not detected.
In the event of use with the Az S 350 or Az S (M) 350 systems, remove the
200 mA fuse in the evaluation computer mounting frame on the corresponding
bandpass filter board (Bapas), SCN S25552-B637-A2 or B1, or on the
amplifier, trigger and bandpass filter board (Vesba), SCN S25552-B604-C1.
In the event of use with the Az S M (E) or Az S M (PB) systems, remove the
corresponding 200 mA fuse for wheel detection equipment supply on the
terminal strips in the Az S M cabinet or on the ZAN board.
In the event of use with the Az S M (R) system, remove the corresponding
fuse on the Zan board, SCN S25552-B701-A1.
6.4.5
The signaling cable must fulfil the following conditions in the event of external supply with
230 Vrms:
The cable must be suitable for 230 Vrms with regard to its parameters.
In its regulations, the railway operator must allow the joint transmission of 230 Vrms
and low-level signal voltages on one cable.
For supply, a different star-quad to that used for wheel detection equipment signal
transmission must be used.
The rms value of the interference voltages caused by other signals (including the 230 V external supply) in
the same cable must not exceed 9 mV. This corresponds to a harmonic distortion of 3%. For the purpose of
measuring the interference voltage, the wheel detection equipment is to be de-energized (remove the fuse
from the evaluation computer).
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Note
Equipment for uninterruptible power supply often generates voltages that
deviate from the sinusoidal shape. In this case, interference with wheel
detection equipment signal transmission must be expected. In such cases, the
shared use of a cable is not permissible.
Note
External supply via a shared cable is also possible with a DC voltage of up to
100 V (ripple 3%). However, there must be no more than 72 V DC (ripple
3%) at the trackside connection box. The difference equates to the drop in
voltage on the supply line.
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7
Risk of accident
Wheels are not detected.
If the wheel detection equipment is used at a location with ambient conditions
that deviate greatly from the permissible operating environment, it must not be
used without the approval of the specialist department.
The wheel detection equipment consists of the double wheel detector with connecting
cables and the trackside connection box.
Note
The wheel detection equipment is also available factory-preassembled
(completely fitted with components and with connected double wheel
detector). The code numbers can be found in Table 17 in Section 10.3.1.
7.1
These distances apply regardless of the axle counting system. The double
wheel detector must not be installed on the movable parts of a switch.
The double wheel detector must not be installed in the area of check rails. A
minimum distance of 0.3 m to check rails must be observed.
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7.1.1
DEK 43
double wheel
detector
DEK 43 double
wheel detector
Figure 4
Double wheel detectors in the track area, different types can be mounted directly
adjacent to each other
>5m
DEK 43 double
wheel detector
DEK 43 double
wheel detector
>1m
DEK 43 double
wheel detector
Figure 5
DEK 43 double
wheel detector
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7.1.2
The following minimum distances must be observed when installing double wheel
detectors on the same track:
1.2 m
DEK 43 double
wheel detector
DEK 43 double
wheel detector
0.6 m
DEK 43 double
wheel detector
Figure 6
DEK 43 double
wheel detector
Note
The following minimum distances between two double wheel detectors (center
to center) must be observed:
1.2 m when installing them on the same rail
0.6 m when installing them on different rails
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7.1.3
In contrast to the minimum distance of four tie cribs between double wheel detector and
rail joint as indicated in Section 7.4.1, shorter distances are permitted if the following
speed restrictions are observed:
Figure 7
Maximum
speed
No restriction
60 km/h
120 km/h
Table 4
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Note
The restrictions specified in Table 4 do not apply for the installation of a
double wheel detector on a continuously welded rail opposite a welded rail
joint.
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7.1.4
Figure 8
The distance between a double wheel detector and an electrodynamic rail brake must not
be less than 10 m. The bonds are necessary in order to keep rail currents generated when
switching the rail brake on and off away from the double wheel detector.
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7.1.5
Figure 9
Case 1: One of the two double wheel detectors may be installed in this area if the stated
minimum dimension of 1 m is adhered to.
Case 2: With distance (a) between the rail heads and a simultaneous offset of at least
1 m in the longitudinal direction, one double wheel detector may be installed on
one, freely selectable side only of each track.
Case 3: With distance (b) between the rail heads, one double wheel detector may be
installed on one, freely selectable side only of each track.
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7.1.6
0.3 m
0.3 m
0.3 m
Figure 10
0.3 m
Note
The distance between the rail head carrying the double wheel detector and the
adjacent rail may not be less than 0.3 m, measured from the center of the
double wheel detector.
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7.1.7
A maximum speed of 120 km/h must be observed for the reduced distances between
double wheel detectors specified in this section and deviating from the standard design
documents. The following minimum distances must be observed for installation in switch
and crossing areas:
1.2 m
0.6 m
Figure 11
Note
The distance (center to center) between two double wheel detectors mounted
on adjacent rails must be min. 1.2 m in the longitudinal rail direction if the
transverse distance between the rails is less than the standard gage.
If the transverse distance is more than the standard gage, the longitudinal
distance between the double wheel detectors may be reduced to 0.6 m.
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7.1.8
Figure 12
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7.1.9
When installing double wheel detectors and track magnets for intermittent automatic train
control (intermittent ATC) on the same rail, the intermediate distance must be at least one
empty tie crib. Both components can be situated in the same tie crib when installing them
on opposing rails.
Note
Track magnets for intermittent ATC may not be installed in the interference
suppression area of the double wheel detector.
7.1.10
The following minimum distances between double wheel detectors and the track magnets
of the magnetic train stop must be observed:
Figure 13
Note
The minimum distance of 0.7 m applies to the following track magnets:
SCN S25000-Q5697-A5; SCN S25000-Q5697-A6
SCN S25000-Q5697-B5; SCN S25000-Q5697-B6
SCN S25000-Q5697-C5
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7.1.11
The following minimum distances must be observed between double wheel detectors and
balises:
Figure 14
Note
The minimum distance of >1.0 m applies for the Eurobalise S21 in the following
specification:
Fixed balise:
SCN S25421-A1-B100 and variants -B110 to -B190
Transparent balise:
SCN S25421-A1-B200 and variants -B205 and -B210 to -B290
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7.1.12
The following minimum distances must be observed between double wheel detectors and
the leaky feeders of a Euroloop S21:
Figure 15
Double wheel detector in the area of the leaky feeder of a Euroloop S21
Note
The minimum distance of >1.0 m applies for the leaky cables of a Euroloop S21.
The rail opposite the leaky feeder of a Euroloop S21 is not subject to any restrictions for the installation of double wheel detectors.
7.1.13
The following minimum distances must be observed between double wheel detectors and
loops:
Figure 16
Double wheel detector in the area of the FSS vehicle sensor system
Note
The minimum distance of >1.0 m applies for Siemens FSS loops and Scheidt &
Bachmanns FSSB loops.
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7.1.14
Between double wheel detectors and the wheel detectors listed below, a minimum
distance (center to center) of 0.5 m (or one tie crib) must be observed:
RSE 45, WSR, WSS , WSD and WSD-E electronic wheel detector
All other detectors have to be located at a distance of min. five tie cribs.
7.1.15
This section does not apply if the ATC track coupling coil is fitted in the area
outside the track.
7.1.15.1
The distance between the double wheel detector and ATC track coupling coils must be
two tie cribs, but min. 1 m.
7.1.15.2
If problems with track clear indications occur frequently, the following measures must be
taken:
Consistent connection of cable shields and the trackside connection box to the
railway earth conductor.
This measure is also stipulated in Section 5.1 or 7.5.5.
Fit the double wheel detector to the insulated rail if possible unless there are
compelling reasons to the contrary.
Minimum distance of 5 m between the double wheel detector and the rail joint.
Additional rail earthing of the two non-insulated rails on the open line at a distance of
approx. 2 m from the rail joint, in whose vicinity a double wheel detector is fitted.
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Open line
Station area
2m
5m
DEK
ZP D 43
Cable distributor
TCB
To the
interlocking
Key:
DEK
TCB
ZP D 43
Figure 17
Distances and earthing measures for ATC track coupling coils in the area within
the track as for example on Swiss Federal Railways (SBB)
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7.2
7.2.1
Standard application
The double wheel detector is bolted to the rail web and linked with the trackside
connection box via connecting cables approx. 5 m long (alternatively 10 m or 15 m). The
maximum possible distance with the standard connecting cables is around 4.2 m,
depending on local conditions. If the 10 m or 15 m long connecting cables are used in
exceptional cases, the maximum distance can be around 9.2 m or 14.2 m respectively.
Reducing plates
Receiver
Transmitter and
receiver cables
with flexible tube
Pipe support
with plastic
insulating
sleeve
Flexible tube
for signaling
cable
Figure 18
Note
Unpack the double wheel detector only after reaching the installation site to
prevent any damage beforehand.
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7.2.2
The trackside connection box can also be arranged vertically in tunnels or on bridges
where there is little space. Since only a PG16 gland is available for inserting the trackside
cable in this setup, an appropriate flexible tube must be ordered. A cable distribution box
must be provided for the external supply, double usage and double usage with external
supply application variants.
Clamping claw
Figure 19
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7.3
Tools required
Drilling machine or drilling jig, e.g. SCN C25326-A28-A1 (other drilling jigs are also
possible)
Twist drill, 13 mm
Countersink, 90, 25 mm
Wire brush
Angle grinder with rough-cutting disc (if required; for grinding off inscriptions on the
rail web)
7.4
7.4.1
The installation site selected for operational and safety-related reasons is indicated in the
track layout diagram.
Installation in the center of a tie crib (see Section 7.4.3.2 for exception).
The connection between the rail and the tie must be secure.
There must be at least four empty tie cribs between the double wheel detector
installation site and a rail joint or a weld (see Section 7.1.3 for exceptions).
Install the double wheel detector on straight lines on the right-hand rail in the main
direction of travel, in curves with a radius of 180 m on the outer rail and with a
radius of < 180 m on the inner rail, unless there are reasons to the contrary (see
Section 7.1).
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With a permanent way with Y steel ties, install the double wheel detector between two
separate ties only (not between the two legs of a Y steel tie).
The length of a section must be longer than the largest axle spacing occurring in a
train, so that there is no track clear indication under the train.
There must be no cables carrying traction return currents, cables carrying heavy
current (e.g. switch heaters) and cables emitting 43 kHz or conductor rails within the
interference suppression areas in accordance with Figure 20.
The vertical extension of the interference suppression area extends 600 mm upwards
and downwards from the center of the drill hole.
Note
The above-mentioned points must also be observed if the double wheel
detector is subsequently moved to another installation site.
The vertical extension of the interference suppression areas is not shown in Figure 20.
450 mm
450 mm
Interference
suppression
area 1
600 mm
Transmitter
Rail
Receiver
600 mm
Interference
suppression
area 2
Figure 20
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Note
On high-speed lines and rapid transit railways with 15 kV, cross bonds must
be installed within 200 m of the installation site at a distance of no more than
75 m. This is also to be observed if the double wheel detector is later
relocated to a different installation site.
On lines where track-to-track bonds and rail-to-rail cross bonds are installed,
the interference suppression areas of the double wheel detectors (see
Figure 20) must be observed.
Risk of accident
Wheels are not detected.
This interference suppression area also applies for the installation of
continuous ATC loop cables.
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7.4.2
Clean the rail web at the installation site thoroughly using a wire brush. Grind off any web
inscriptions.
7.4.3
7.4.3.1
To drill the holes using a simple drill, punch-mark the web holes before drilling in
accordance with the dimensions below.
270 135
Figure 21
The drilling dimensions of the rail profiles with the associated distance dimensions X are
listed in Table 22 in Section 10.3.6. Please refer to Product List SCN C25326-A21-A3-*-47
for the distance dimensions X for unlisted rail profiles or request them.
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Centre of hole
X 1.5 mm
Figure 22
Distance dimension X from the lower edge of the rail base to the center of the
hole
You may use the drilling jig (SCN C25326-A28-A1) for the web drill holes ( 13 mm).
Please indicate the rail profile when ordering the drilling jig. Profiled fishplates are used for
adaptation to the various rail profiles. They fit into the web area of the respective rail
profile and determine the correct distance from the web holes to the rail base, and thus
the mounting position of the equipment. Profiled fishplates are available for all rail profiles.
Step 1
Insert the drilling template with the two profiled fishplates matching the rail
profile into the web area and fasten the drilling template of the drilling jig on
the rail web with two clamps.
Step 2
Cracking
Cracking in the rail originating from the drill hole is possible at a later stage if
you do not take the following action.
Countersink the rail web holes on both sides using a countersink (90,
25 mm) and an extended drill socket MK2-2 1.5 45. This corresponds to
a countersink depth of 1.5 mm. It is absolutely essential to chamfer the drill
hole to prevent cracking in the rail originating from the drill hole.
Step 3
Remove the ballast far enough to preclude damage to the connecting cables
when the rail is traversed. With a ballastless track, leave sufficient clearance to
allow for routing of the connecting cables including the flexible tube (avoid
crimping).
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7.4.3.2
The double wheel detector may be installed above ties in the following cases:
Table 1: Overview of tie mounting
Rail profile
S49
S54
UIC60
Others
Permanent way W
Not permitted
Not permitted
See Section
7.4.3.3
Not permitted
Permanent ways K
and KS on wooden
ties
See Section
7.4.3.4
See Section
7.4.3.4
See Section
7.4.3.6
Not permitted
Permanent ways K
and KS on
concrete ties
See Section
7.4.3.5
See Section
7.4.3.5
See Section
7.4.3.6
Not permitted
Other types of
permanent way
Not permitted
Not permitted
Not permitted
Not permitted
Note
A special reducing plate is required when installing the DEK 43 double wheel
detector above ties (see Table 22).
Notice
Functional impairment of double wheel detector
The installation of double wheel detectors above steel ties could affect faultfree operation of the wheel detection equipment.
The installation of double wheel detectors above steel ties is not permitted.
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Caution
Damage to double wheel detector
Excessive traversal speeds may damage double wheel detectors installed
above ties (in accordance with Sections 7.4.3.5 and 7.4.3.6).
Adhere to the maximum permissible traversal speed of 160 km/h.
Drill the web holes in accordance with the instructions in Section 7.4.3.1.
Figure 23
Drilling dimensions for fastening the double wheel detector above the tie
After drilling, install the fastening components for the corresponding permanent
way approved by the railway operator.
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7.4.3.3
Parts required for installation of the DEK 43 double wheel detector on UIC60 rail profile
with permanent way W on concrete ties:
Use tie bolt Ss 350 with a shortened bolt head (17 mm instead of 35 mm) on the gage
side of the rail (under the double wheel detector receiver, see Figure 25).
Figure 24
Figure 25
Tie bolt Ss 350 with a shortened bolt head (17 mm instead of 35 mm)
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7.4.3.4
Parts required for installation of the DEK 43 double wheel detector on S49 or S54 rail
profile with permanent ways K and KS on wooden ties:
shortened fishtail bolt with a flat nut (EMA no. / material no. 117 846)
set of fastening material including clamp, hexagon nut, fishtail bolt and locking washer
(SCN C25326-A21-D1)
The tie bolt on the gage side of the rail (Figure 25) under the cable entry of the double
wheel detector receiver is not required any longer.
Step 1
Step 2
Check the other three tie bolts as to whether they are force-locked.
The clamp and fishtail bolt including nut and locking washer (spring washer)
are not required any longer on the gage side of the rail (under the double
wheel detector receiver).
Step 3
On the outer side of the rail, install the shortened fishtail bolt with a flat nut
instead of fishtail bolt Hs 26-65.
Step 4
On the outer side of the rail, install the flat clamp (SCN C25326-A21-C71)
instead of clamp Kpo 6 or Kpo 9.
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Figure 26
7.4.3.5
Parts required for installation of the DEK 43 double wheel detector on S49 or S54 rail
profile with permanent ways K and KS on concrete ties:
shortened fishtail bolt with a flat nut (EMA no. / material no. 117 846)
set of fastening material including clamp, hexagon nut, fishtail bolt and locking washer
(SCN C25326-A21-D1)
The clamp and fishtail bolt including nut and locking washer (spring washer) are not
required any longer on the gage side of the rail (under the double wheel detector
receiver).
Step 1
On the outer side of the rail, install the shortened fishtail bolt with a flat nut
instead of fishtail bolt Hs 26-65.
Step 2
On the outer side of the rail, install the flat clamp (SCN C25326-A21-C71)
instead of clamp Kpo 6 or Kpo 9.
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Figure 27
7.4.3.6
Reducing plates with a notch (SCN C25326-A21-B86) must be used when installing the
DEK 43 double wheel detector on UIC60 rail profile with permanent ways K and KS on
wooden and concrete ties.
Other measures are not required.
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7.4.4
The transmitter and receiver of the double wheel detector are bolted to the rail web after
drilling. The procedure for this is as follows:
Figure 28
Step 1
G-n plus"
or "Molykote G-Rapid plus" to ensure that the nuts (4) can easily be undone
at a later date.
Step 2
Fit the appropriate reducing plate (8), together with the receiver (7) and the
mushroom-head bolts (6) with the square washer (9), to the gage side of the
rail (1).
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Step 3
Then place the second reducing plate (8) and the transmitter (3) on the outer
side of the rail (2) onto the bolts. The shape of the reducing plates depends on
the rail profile. Reshaping of or longitudinal changes to the reducing plates in
order to adapt them to another rail profile or particular permanent-way types
are not permissible.
Step 4
Next, slip-fit the plain washers (5) and the M12 self-locking hexagon nuts (4)
onto the bolts.
Note
Make sure that the reducing plates are flush with the edges of the double
wheel detector before tightening the hexagon nuts.
Step 5
Tighten the self-locking hexagon nuts (4) using a torque wrench (tightening
torque of 40 Nm to 50 Nm).
Risk of accident
Wheels are not detected.
The fastenings will settle after approx. 20 train runs. Retighten the nuts. This is
necessary after each mounting process, i.e. also after exchanging the double
wheel detector. Recalibrate the wheel detection equipment (see Section 9.3).
Self-locking nuts with an external locking element (Vargal nuts) can be reused
after each dismantling operation.
Whenever installing or re-installing a double wheel detector, grease the
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7.5
Damage possible
Moisture may damage the electronics in the trackside connection box.
Work in a manner ensuring that no moisture can penetrate the interior of the
trackside connection box.
7.5.1
1,350 mm
Station
2,100 mm
Open line
Table 5
Lay the cables to the trackside connection box outside the clearance gage and
without loops (risk of tripping).
The upper side of the trackside connection box should be roughly equal to the height
of the top of the rail.
The flexible tube for the incoming signaling cable must extend into the ground or into
the ballast.
Available pipe support heights are 400 mm, 500 mm (standard height), 1,000 mm and
90 mm (on bridges, in tunnels, etc.).
Note
Fasten the box on the pipe support with the enclosed insulating sleeve.
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Note
The trackside connection box can be moved within the specified distances in
parallel to the track axis and can be rotated 90 so that the connecting cables
do not form rings or loops.
Note
The screws of the trackside connection boxs cover may be tightened with a
maximum torque of 10 Nm.
7.5.2
The wall must have an even surface. Depending on the type of fastening, the following
procedures must be observed (Figure 19).
7.5.2.1
Plug fitting
The following walls are suitable for the SCN C25165-A63-D4 plug fitting:
solid stone
Step 1
Step 2
Step 3
Slide the clamping claws into the side recesses of the lower part of the
trackside connection box and screw the hexagon screws (width across flats
13) and washers into the plugs.
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7.5.2.2
Anchor fitting
Note
The temperature of the anchoring base must not fall below -5C to allow the
adhesive to harden.
The hardening time depends on temperature:
300 minutes at -5C
60 minutes at 0C
30 minutes at 10C
20 minutes at more than 20C
Walls of natural stone and concrete with a strength of > 25 N/mm2 (strength class B 25)
are suited to anchor fitting SCN C25165-A63-B30.
Step 1
Step 2
Step 3
Step 4
Once the exposed adhesive has hardened, slide the clamping claws into the
side recesses of the lower part of the trackside connection box and screw the
hexagon nuts and washers to the anchor rods.
7.5.3
The procedure for mounting a trackside connection box onto a slim or lattice post is explained by Installation Instructions A25165-A42-B111-*-31 (available as from October
2009) (see also Section Error! Reference source not found.).
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7.5.4
Connect the double wheel detector to the trackside connection box by means of the
shielded connecting cables. On delivery, these connecting cables are already connected
to the transmitter and receiver of the double wheel detector and provided with a flexible
tube.
Note
The connecting cables at the double wheel detector must not be shortened.
The wheel detection equipment's connecting cables must not be laid together
with cables carrying traction current, traction return current or heavy current
(230/400 V AC) in a cable route or cable trough. Routing in the rail base is not
permitted, either.
The connecting cables must be laid in parallel, closely held together by cable
straps, on the edge of the sleeper bay. The connecting cables must not be
fixed.
Trackside connection
box
Cable straps
Connecting cables
Figure 29
Step 1
Shorten the flexible tubes at the installation site to the required length
(Figure 30). The flexible tubes are somewhat longer than the connecting
cables. The position of the cable recess can be felt through the flexible tube.
Shorten the flexible tube by around 60 mm away from this recess. Take care
not to damage the connecting cables.
Step 2
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Step 3
Next, insert the two connecting cables into the connection box. Use the tube
clips to secure the flexible tubes.
Step 4
Connect the individual cores in accordance with Figure 33 and Figure 37 (with
overvoltage protection module).
60 mm
Figure 30
7.5.5
the railway earth conductor and / or the return system on railways with DC traction
and mixed traction (AC / DC) in accordance with Figure 31
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Signal
Prohibited area
Trackside equipment
Cable trough
for main and
tail cables
Cable trough
for tail cable
Insulated installation
Area of return system
Area of railway earth
Figure 31
The following minimum cross-sections are permissible for the earth conductor:
NYY-O Cu wire
NYY-O Cu wire
NYY-O Cu wire
The hole for connecting the earth conductor to the rail must comply with the conditions
listed below:
drilled in the neutral zone of the rail (corresponds to dimension X in Table 22 for
mounting the double wheel detector)
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Cracking
Cracking in the rail originating from the drill hole is possible at a later stage if
you do not take the following action.
Countersink the rail web holes on both sides using a countersink (90,
25 mm) and an extended drill socket MK2-2 1.5 45. This corresponds to
a countersink depth of 1.5 mm. It is absolutely essential to chamfer the drill
hole.
Note
If present, the overvoltage protection board must always be connected to the
earthing terminal.
Notice
Disruption of operations possible
If the trackside connection box is to be earthed, calibration may only be
undertaken afterwards.
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7.5.6
Step 1
Step 2
Fasten the flexible tube using a tube clip after introducing the signaling cable.
Step 3
Step 4
Connect the individual cores in line with Figure 33 and Figure 37 (with the
overvoltage protection board).
Step 5
Step 6
Close the trackside connection box and tighten the hexagon screws on the
cover with a maximum torque of 10 Nm.
1350 mm or 2100 mm
Trackside
connection box
Receiver
Transmitter
Figure 32
Earth conductor
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7.5.7
The ZP 43 E can be converted to a ZP D 43. This involves replacing the mounting frame
contained in the ZP 43 E by the ZP D 43 board contained in the conversion kit.
Any additional core-earth overvoltage protection present in the ZP 43 E must again be
mounted in the ZP D 43 after conversion. Even if the existing ZP 43 E does not have any
additional core-earth overvoltage protection, there is the possibility of converting it by ordering a conversion kit with core-earth overvoltage protection.
Table 6 shows the correlations between the existing ZP 43 E variants and the ZP 43 D
conversion kits.
ZP 43 E set up as:
Conversion kit:
Standard
S25552-T4100-U3
S25552-T4110-U3
External supply
S25552-T4100-U1*)
S25552-T4110-U1*)
Double usage
S25552-T4100-U2
S25552-T4110-U2
S25552-T4100-U1
S25552-T4110-U1
*) The connection for double usage remains open.
Table 6
7.5.7.1
ZP 43 E / ZP D 43 application variants
Conversion
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7.5.8
The ZP 43 V can be replaced by a ZP D 43 wheel detection equipment unit. For this purpose, the ZP 43 V trackside connection box (including wiring backplane and boards) is
replaced by a ZP D 43 trackside connection box (including board) with a plastic cover.
Any additional core-earth overvoltage protection present in the ZP 43 V must again be
mounted in the ZP D 43 after conversion. Even if the existing ZP 43 V does not have any
additional core-earth overvoltage protection, there is the possibility of converting it by ordering a wheel detection equipment unit with core-earth overvoltage protection.
Table 7 shows the correlations between the existing ZP 43 V variants and the ZP D 43
conversion kits.
ZP 43 V set up as:
ZP D 43 trackside connection
box:
Standard
S25552-T4150-A3
S25552-T4160-A3
External supply
S25552-T4150-A1*)
S25552-T4160-A1*)
Double usage
S25552-T4150-A2
S25552-T4160-A2
S25552-T4150-A1
S25552-T4160-A1
*) The connection for double usage remains open.
Table 7
ZP 43 V / ZP D 43 application variants
Note
Conversion kit C25165-A63-D1 (A2V00000217572) is always to be ordered for
the wheel detection equipment. It includes insulating bushing C25165-A63-C39
(A2V00000315784) and tube clip D3017-S9050-Z3 (A2V00000216357).
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7.5.8.1
Replacement steps
Step 1
Step 2
Step 3
Step 4
First re-establish all connections to the double wheel detector and then the
connections to the interlocking (see Figure 33 and Figure 37, if core-earth
overvoltage protection is fitted).
If the cores of the double wheel detector are not long enough, the flexible tube
has to be shortened.
It is to be noted that the terminal designations of both wheel detection
equipment variants are different (see Table 8).
Step 5
Step 6
Close the trackside connection box and tighten the hexagon screws on the
cover with a maximum torque of 10 Nm.
Connection to interlocking
ZP 43 V terminal designation
ZP D 43 terminal designation
12 (+)
NS +
Normal supply +
13 (-)
NS -
Normal supply -
10
FS
External supply
11
FS
External supply
18
DN
Double usage
19
DN
Double usage
ZP 43 V / ZP D 43 terminal designations
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7.6
green
yellow
red
4
-
blue
green
yellow
red
4
-
red
yellow
red
7
8
blue
red
yellow
red
green
blue
Figure 33
green
DN
FS
NS
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8
For some axle counting system operators, the effect of electromagnetic interference
(atmospheric effects such as thunderstorms and technical interference such as catenary
contact with track and its equipment) is particularly great. In such cases, additional
overvoltage protection measures (core to earth) beyond the existing overvoltage
protection (core to core) are necessary.
8.1
8.1.1
The board with the additional overvoltage protection components (core to earth) is
suitable for all three application variants of the wheel detection equipment. It is secured to
the protuding part of the base plate using four screws.
Order variants
SCN S25552-B734-B1: overvoltage protection board only (Figure 34)
S25552-B734B1-*
Figure 34
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8.1.2
Installation
Use the four cheese-head screws to screw the overvoltage protection board to the
protruding part of the base plate (terminals facing outwards). The screws are
supplied.
Figure 35
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8.2
Electrical connection
Step 1
Insert the enclosed black wires into the corresponding WAGO terminals in line
with Figure 35 and Figure 37.
Step 2
Insert the end of the green / yellow wire featuring the wire end ferrule into the
Erde (EARTH) WAGO terminal and use the enclosed screw to secure the
cable lug in the bottom part of the connection box.
8.3
If wheel detection equipment with overvoltage protection is used which is directly powered by a non-earthed interlocking battery, their signaling cable is to
be monitored by automatic earth-leakage detectors for the purpose of checking
the overvoltage protection elements. If monitoring with automatic earth-leakage
detectors is not possible, insulation measurement to earth must be carried out
every 24 months.
To facilitate measurement, core-to-earth insulation measurement is performed
on the cable termination rack of the indoor equipment.
If the wheel detection equipment is not supplied directly from a non-earthed
interlocking battery but using a DC-DC converter (e.g. SVK5715 for Az S M
/ Az S 350 or SVK2150 for Az S 350 U), insulation measurement to earth is
not required but is recommended according to VDE 0831 to ensure
availability.
The test voltage is 250 V DC. The insulation resistance must be greater than
1M .
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Note
Insulation measurement is used to check the overvoltage protection
components in the wheel detection equipment and does not substitute
insulation testing of the signaling cable.
If the overvoltage protection module in the cable termination rack is to be tested
separately, it must be unplugged from the socket. As a result, the connection to
the outdoor equipment is interrupted and disruptions occur due to the occupied
indication for the track vacancy detection section limited by the relevant wheel
detection equipment unit.
For testing the overvoltage protection module, it must be plugged into the
WAGO test device (order no. 511 97 389, see Figure 36), which is connected
directly to the insulation test device. The same test parameters apply here as
for insulation measurement of the wheel detection equipment (250 V DC, Ri
1 M ).
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Insulation test
250 V DC
R 1 M
-
Figure 36
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8.4
Figure 37
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9
Destruction of components
The MOS components mounted on the circuit board of the wheel detection
equipment can be damaged by electrostatic discharge from charged persons
or equipment.
Observe the notes given in Section 3.4 for handling the circuit board.
Keep the board in its original protective packaging until it is installed in the wheel
detection equipment.
9.1
Required tools
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9.2
Preliminary testing
Step 1
Check the installation site of the double wheel detector according to the track
layout diagram and the conditions described in Sections 7.1, 7.4.1 and 7.5.1.
Step 2
Check the serial number and / or SCN, including the equipment revision level
of the wheel detection equipment and SCN of the coding plug. The data can
be found on the connection box and / or inside the box.
Risk of accident
If this data cannot be read unambiguously and has not been noted elsewhere
(e.g. delivery note, inventory list), the wheel detection equipment must not be
installed in safety-related systems.
Step 3
Check whether there is any visible damage on the double wheel detector and
the connecting cables.
Step 4
Check whether the reducing plates are mounted on the double wheel detector
under the transmitter and receiver.
Step 5
Check whether the fastening bolts of the double wheel detector are tight
(tightening torque of 40 Nm to 50 Nm).
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Step 6
Check whether there is a desiccant bag in the trackside connection box. The
desiccant bag must be replaced if the indicator is colored pink and moisture
can also be seen in the trackside connection box.
Step 7
Check whether the cables are connected to the right terminals (see Sections
7.6 and 8.4).
Notice
Damage to wheel detection equipment
Wheel detection equipment is not working.
The signaling cable must be connected with the right polarity
(see Figure 33 and Figure 37).
Step 8
Notice
When switching on the supply voltage or after it has been interrupted, the
ZP D 43 takes max. 30 seconds to start up. Passing trains are not reported
during this period, any indications issued by the wheel detection equipment
cannot be defined and the LEDs may display any status.
The wheel detection equipment only shows the actual status once started.
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9.3
Calibration of ZP D 43
Notice
Ensure that the double wheel detector is idle (no wheels or other metallic
objects in its proximity).
Step 2
Step 3
Press the T3 and T4 calibration buttons at the same time until the L4 LEDs on
both channels light up permanently (see Figure 38).Then release the buttons.
The L3 and L4 LEDs then briefly light up.
After a few seconds, the L4 LEDs go out and the L3 LEDs flash. This indicates that
calibration has been correctly completed.
Should calibration fail (L4 flashes), the process can only be repeated after a waiting time
of 10 s.
Note
Passage of a train interrupts the calibration process. The wheel detection
equipment uses its last calibration data for further operations.
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9.4
Figure 38
The L1 to L4 LEDs are present for each channel. The L5 LED applies to both channels.
The L1 and L5 LEDs are red and the L2 to L4 LEDs are green.
Wheel detection equipment in calibration status
LED
Meaning
Measures
L4 lights up
L4 flashes
Calibration failed
Meaning
Measures
L2 lights up
L3 flashes
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Wheel detection equipment in error status
LED
Meaning
Measures
L1 lights up
L1 and L2
light up
L2 and L4
light up
L5 lights up
Briefly unplug coding plug and then recalibrate the wheel detection equipment.
The LED still lights up: replace the board.
9.5
Electrical testing
Note
Scope of testing
Commercially available multimeter: the requirements laid down in Section 11.2 must
be observed.
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9.5.1
Use the 4 mm measuring sockets with the supplied laboratory leads. The wheel
detection equipment adapter board is not needed.
When taking DC measurements, ensure that the measuring leads are correctly
assigned to the sockets: the positive input is indicated by the red socket.
Observe the Operating Instructions for FTGS/GLS/AZS Test Set (PEGA 1211), SCN
A25921-Z1-A19-*-7619.
Note
For later fault location or diagnostics, it is beneficial to note down the indicated
measured values on an adhesive label beside the table of measured values in
the trackside connection box or on a test record.
Notice
Risk of destruction
The maximum permissible input voltage of the PEGA 1211 is 280 Vrms.
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Display
kHz
V
mV
Measuring socket,
positive input
Next function/
next-higher frequency
Measuring socket,
negative input
Sach-Nr. V25921-Z1-A19
Previous function/
next-lower frequency
mode
on/off
Display illumination
on/off
Figure 39
Confirmation
(back with
OK
Mode/function
display
(value displayed again
with OK )
Mode
selection
9.5.2
If the "Lo bAt" display appears after switching on, the batteries must be replaced.
Preparatory work
Remove all stray metal parts (e.g. tools) within a radius of 50 cm of the double
wheel detector.
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9.5.3
Step 1
Step 2
Step 3
Step 4
Take a measurement on the NS terminal block (see Figure 37) or, in the case
of an external supply, on the FS terminal block.
The voltage displayed must be between 30 V DC and 72 V DC.
With external supply, the voltage displayed must be between the following
values:
30 V DC and 72 V DC or
26 V AC and 50 V AC
If "-POL" is displayed, check whether the measuring leads are correctly
connected. If that is the case, the two cores of the signaling cable are
reversed. Connect the cable cores correctly.
The next parameters to be measured can be called up using the "Next function" or
"Previous function" keys. They appear flashing in the display.
9.5.4
Step 1
Step 2
Step 3
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9.5.5
The level of the receiver voltages depends on the rail profile used.
Step 1
Step 2
Step 3
Step 4
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9.6
Display
Measured quantity
Terminal*
Permitted ranges
U60=
NS**
30 V DC to 72 V DC
U60
FS
30 V DC to 72 V DC
26 V AC to 50 V AC
FS
Transmitter frequency
of the double wheel
detector
6 and 7 or
8 and 9
uE1
Receiver voltage 1
3 and 4
uE2
Receiver voltage 2
1 and 2
The details contained in the Display column refer to the PEGA 1211 test set.
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10
Maintenance
CAUTION
detachment detection (dismantle the double wheel detector or shield the double
wheel detector with a plate)
of the wheel detection equipment must be checked. During these checks, the wheel
detection equipment must be de-energized.
10.1
Inspection
The wheel detection equipment inspections must be carried out in accordance with this
Operating and Service Manual.
Note
Additional stipulations of the railway operator and requirements relating to the
configuration of the overall system (see the documentation of the
corresponding evaluation computer) must also be observed.
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Scope of inspection:
Place the sheet-steel plate horizontally on the rail and move it in a longitudinal
direction over the double wheel detector.
Note
As a result of this, occupied indications are issued for adjacent sections.
This sheet-steel plate does not simulate a wheel with the minimum dimensions
permitted in line with the German Railway Building and Operation Regulations
(EBO).
Detachment detection
The sheet-steel plate used for simulating the passage of a train can also be used for
detachment detection.
Note
As a result of this, occupied indications are issued for adjacent sections.
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10.2
Note
The PEGA 1211 test set must be used following the details provided in the
Operating and Service Manual.
10.2.1
Fault location
The cause of faults (counting errors or untimely occupied indication of sections) is located
using the following measurements.
You will find the measuring sockets on the front panel of the corresponding WDE interface
board (Vesti, Zan or Vesba, depending on the type of evaluation computer).
Measure signal frequencies f1 (3.60 kHz 0.05 kHz) and f2 (6.52 kHz 0.10 kHz)
on the evaluation computer at measuring sockets F.
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Case 3: Signal frequencies f1 and / or f2 are outside the tolerance range:
Check the wheel detection equipment. Replace a defective board and have it
repaired in a Siemens workshop.
Note
Recalibrate the wheel detection equipment after replacing the board
(see Section 9.3).
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10.2.2
Single faults
10.2.2.1
Measure
Table 10
Measure
Table 11
10.2.2.2
Transmitter frequency fs
Measure
Generator defective
Table 12
fs fault
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10.2.2.3
Fault: Receiver voltages UE1 and / or UE2 are lower than 54 mV.
Cause of fault
Measure
Table 13
Fault: Receiver voltages UE1 and / or UE2 are higher than 180 mV.
Cause of fault
Measure
Table 14
Fault: The difference between UE1 and UE2 is higher than 10 mV.
Cause of fault
Measure
Table 15
Measure
Table 16
Calibration failed
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10.3
Note:
10.3.1
The reducing plates have to be ordered in pairs commensurate with the rail profile (see
Table 22).
Designation
Comments
S25554-A6100-A300
S25554-A7100-A300
S25554-A6150-A300
S25554-A6110-A300
S25554-A7110-A300
S25554-A8110-A300
S25554-A6160-A300
S25554-A6100-A200
S25554-A6150-A200
S25554-A6110-A200
S25554-A6160-A200
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Designation
Comments
S25554-A6100-A100
S25554-A6150-A100
S25554-A6110-A100
S25554-A8110-A100
S25554-A6160-A100
Table 17
10.3.2
Conversion kits
Designation
S25552-T4100-U3
S25552-T4110-U3
S25552-T4100-U2
S25552-T4110-U2
S25552-T4100-U1
If only an external supply is required, the double usage connection remains open.
S25552-T4110-U1
If only an external supply is required, the double usage connection remains open.
Table 18
Comments
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10.3.3
Parts
Designation
Siemens code
number
Comments
S25552-M43-A1
V25552-M43-A2
V25552-M43-A3
S25552-M43-A6
V25552-M43-A4
V25552-M43-A5
S25552-M43-A8
V25552-M43-A6
V25552-M43-A7
C25123-Z11-C488
Reducing plate
C25326-A21-...
See Table 22
S25552-T4100-A3
(S25552-T4110-A3)
S25552-T4150-A3
(S25552-T4160-A3)
Circuit board
S25552-B159-A3
Standard
S25552-T4100-A2
(S25552-T4110-A2)
S25552-T4150-A2
(S25552-T4160-A2)
Circuit board
S25552-B159-A2
Double usage
S25552-T4100-A1
(S25552-T4110-A1)
External supply with double usage, metal cover (with overvoltage protection)
S25552-T4150-A1
(S25552-T4160-A1)
External supply with double usage, plastic cover (with overvoltage protection)
Circuit board
S25552-B159-A1
C25165-A63-B21
Height 95 mm
C25165-A63-B121
Height 95 mm
S25552-B734-B1
Optional: core-to-earth
overvoltage protection
C25165-A63-B101
Optional: core-to-earth
overvoltage protection
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Designation
Siemens code
number
Comments
V25131-U-A45
D3017-S9020-Z3
V25131-U-A77
D3017-S9025-Z3
C25165-A42-B47
C25165-A42-B51
C25165-A42-B9
C25165-A42-B68
C25165-A63-D1
C25165-A42-B111
C25165-A63-D4
C25165-A63-B30
C25326-A8-B101
Table 19
10.3.4
Designation
Siemens code
number
S25552-T701-C1
S25552-T701C11
S25552-T701C12
S25552-T701C15
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Designation
Siemens code
number
Comments
V25131-U-A45
D3017-S9020-Z3
V25131-U-A77
D3017-S9025-Z3
C25165-A42-B47
C25165-A42-B51
C25165-A42-B9
C25165-A42-B68
D3017-S9050-Z3
Fastening
C25320-A37-A1
V25319-Z1-A9
V25319-Z1-A14
Table 20
10.3.5
Service accessories
Designation
Siemens code
number
V25921-Z1-A19
V25921-Z1-A39
Comments
WAGO,
order no. 511 97 389
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10.3.6
Rail profile
Dimension X
45 kg R.R.
67 mm
C25326-A21-C139
63.7 mm
On request
50 kg
66.5 mm
C25326-A21-C139
50 T
67.5 mm
C25326-A21-B79
66 mm
On request
53 kg A.S.
70.6 mm
C25326-A21-B77
60 kg A.S.
83.5 mm
C25326-A21-C141
63 T
67.5 mm
C25326-A21-B80
91 LB N.Z.R.
66.5 mm
C25326-A21-C139
94 A.S.-47
62 mm
C25326-A21-C132
95 RBH Bull-Head
58.5 mm
C25326-A21-C179
100 LB ARA-A
69.85 mm
C25326-A21-C143
100 LB AREA
68.7 mm
C25326-A21-C143
63.7 mm
C25326-A21-C163
100 RE
64 mm
On request
125/36.8 d.HHA
53 mm
On request
67.5 mm
C25326-A21-B80
AREA 115 RE
82.55 mm
C25326-A21-C148
Bavaria IX
58 mm
On request
BS 113 A
72.5 mm
C25326-A21-C177
C.F.L.S 33 / U33
65 mm
C25326-A21-C146
Shape 6 (S 33)
58 mm
C25326-A21-B76
Shape 8
62.5 mm
C25326-A21-B75
Shape 17
62.5 mm
On request
K 43 S
62.5 mm
C25326-A21-B75
NP 46, Rotterdam
62.5 mm
C25326-A21-C142
BB shape A
59.5 mm
C25326-A21-C116
BB shape B
62.5 mm
C25326-A21-B71
BB shape C
71.5 mm
C25326-A21-B74
P 50
68.5 mm
C25326-A21-C129
R 65 / R 75
93.5 mm / 105
mm
C25326-A21-B81
RI 59*)
82.0 mm
C25326-A21-B82
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Rail profile
Dimension X
RI 60*)
82.0 mm
C25326-A21-B82
Rail Xa/Xa 10
53 mm
C25326-A21-C162
S 41
62.5 mm
C25326-A21-B75
S 45
62.5 mm
C25326-A21-B75
S 49
62.5 mm
C25326-A21-B71
62.5 mm
C25326-A21-B85
S 54
67 mm
C25326-A21-B71
67 mm
C25326-A21-B85
S 64
85 mm
C25326-A21-C118
S-60 SAR
85 mm
C25326-A21-C106
SAR 48 kg/m
63.5 mm
C25326-A21-B73
SAR 57 kg/m
77.5 mm
C25326-A21-C113
SBB I
62.5 mm
C25326-A21-B78
Tipo 4
63.5 mm
C25326-A21-B71
U 50
66 mm
C25326-A21-C130
UIC 50
66 mm
On request
UIC 54
72 mm
C25326-A21-B74
UIC 60
85 mm
C25326-A21-B72
85 mm
C25326-A21-B86
Underground S 27
49.5 mm
On request
Underground S 34
52 mm
On request
VA 71 B (Austria)
82 mm
C25326-A21-B82
54 mm
C25326-A21-C144
*) Installation of the double wheel detector on special rails for example grooved rails (RI59, RI60,
VST36) is described in Installation Instructions A25552-M43-A1-*-31.
Table 22
Note
Please refer to Product List SCN C25326-A21-A3-*-47 for details of rail
profiles not listed. These are also available on request.
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11
Technical data
11.1
ZP D 43
Dimensions:
Receiver: approx. 316 mm x 119 mm x 55 mm
Transmitter: approx. 316 mm x 119 mm x 90 mm
Weight: (total) approx. 10 kg
-40C to +80C
EN 61000-6-2 (08/2005)
EN 50121-4 (07/2006)
EN 61000-6-4 (01/2007)
EN 50121-4 (07/2006)
Rail types
Tie material
Ballast resistance
Any
Wheel width
115 mm
Wheel diameter
300 mm
Train speed
Test voltage
10 kV to rail
Cable type
Operating frequency
43 kHz
1.75 Vrms
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Transmission level at the wheel
detection equipment with external
supply
2.60 Vrms
Signal frequency f1
(double wheel detector not
traversed)
3.60 kHz
Signal frequency f2
(double wheel detector not
traversed)
6.52 kHz
30 V DC to 72 V DC
26 V AC to 50 V AC
Altitude
For the maximum speed, refer to the user documentation of the relevant axle
counting systems.
11.2
Multimeter requirements
Input resistance
200 k
-20C to +55C
Protection class
II
2.5 kV
DC measuring range
280 mV to 280 V,
measuring error 0.5% (for Vmeas 100 mV)
AC measuring range
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11.3
PEGA 1211
11.3.1
General
Input resistance
200 k
-20C to +55C
-25C to +60C
Protection class
II
2.5 kV
IP rating
IP54
Max. 1.5 kg
Table 24
11.3.2
ZP 43 operating mode
Range selection
DC measuring range
280 mV to 280 V,
measuring error 0.5%
(for Vmeas 100 mV)
AC measuring range
Table 25
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Declaration of conformity
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List of abbreviations
AC
alternating current
ADC
ATC
Az S M
Az S 350
BBT
broadband transformer
CH
counting head
DC
direct current
DEK 43
DIN
DN
DSP
EBA
EBO
EC
EMC
electromagnetic compatibility
FS
FTG S
GLS
track circuit
GUE
IT
isolating transformer
MOS
Np
Neper; 1 Np = 8.68 dB
NS
PWM
pulse-width modulation
SCN
TCB
Tr
transformer
Vesba
amplifier, trigger and bandpass filter board (in the Az S 350 U evaluation
computer)
Vesti
amplifier and trigger board (in the Az S (M) 350 evaluation computer, Versions B,
M and T as well as Az S 350 B1 and B5)
WDE
Zan
ZP D 43
digital wheel detection equipment with 43 kHz operating frequency, model with
aluminum housing
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List of figures
Figure 1
Overview of ZP D 43 components
21
Figure 2
22
Figure 3
ZP D 43 board layout
38
Figure 4
Double wheel detectors in the track area, different types can be mounted
directly adjacent to each other
44
Figure 5
44
Figure 6
45
Figure 7
46
Figure 8
48
Figure 9
49
Figure 10 Double wheel detectors in the area of switches and crossings, minimum
distances to adjacent rails at speeds of up to 120 km/h
50
Figure 11 Double wheel detectors in the area of switches and crossings at speeds
of up to 120 km/h
51
52
53
54
Figure 15 Double wheel detector in the area of the leaky feeder of a Euroloop S21
55
Figure 16 Double wheel detector in the area of the FSS vehicle sensor system
55
Figure 17 Distances and earthing measures for ATC track coupling coils in the
area within the track as for example on Swiss Federal Railways (SBB)
57
58
59
61
63
Figure 22 Distance dimension X from the lower edge of the rail base to the center
of the hole
64
Figure 23 Drilling dimensions for fastening the double wheel detector above the tie
66
Figure 24 Installation on UIC60 rail profile with permanent way W on concrete ties
67
Figure 25 Tie bolt Ss 350 with a shortened bolt head (17 mm instead of 35 mm)
67
69
Figure 27 Installation with permanent way K on concrete ties (in accordance with
approved BZA document S 8690.20.1 *)
70
71
76
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Figure 30 Shortening of the flexible tube
77
78
80
84
85
86
89
90
95
98
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List of tables
Table 1
Application variants
24
Table 2
36
Table 3
46
Table 4
73
Table 5
ZP 43 E / ZP D 43 application variants
81
Table 6
ZP 43 V / ZP D 43 application variants
82
Table 7
ZP 43 V / ZP D 43 terminal designations
83
Table 8
101
Table 9
106
Table 10
106
Table 11
fs fault
106
Table 12
107
Table 13
107
Table 14
107
Table 15
Calibration failed
107
Table 16
109
Table 17
109
Table 18
111
Table 19
112
Table 20
112
Table 21
114
Table 22
ZP D 43 technical data
116
Table 23
117
Table 24
117
A6Z00001887496, ,A,
SBPACD&EDC015
Siemens AG 2010
31.05.2010
A25552-T4100-A1-2-76N9
All rights reserved. Confidentiality: None