BOMBARDIER SPA-5/LVA Technical Documentation Manual

TECHNICAL DOCUMENTATION

No:

DTRen-2008/

SPA-5/LVA

Total Page:

B

AUTOMATIC LEVEL CROSSING

SYSTEM SPA-5/LVA

pages: 44 1

AUTOMATIC LEVEL CROSSING SYSTEM

SPA-5/LVA

December 16

th

, 2008

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TABLE OF CONTENTS:

1

DOCUMENT REVISION 3

2 ABBREVIATIONS AND DEFINITIONS 3

3 APPLICATION 4

3.1 PRODUCT DESTINATION...................................................................................................................... 4

3.2 PRODUCT DESCRIPTION ..................................................................................................................... 4

3.3 APPLICATION SCOPE.......................................................................................................................... 4

4 TECHNICAL DESCRIPTION 5

4.1 TECHNICAL DATA............................................................................................................................... 5

4.2 CONSTRUCTION AND CONFIGURATION................................................................................................. 8

4.2.1 System configuration....................................................................................................................... 8

4.2.2 ERR-20 – LX shelter construction................................................................................................... 9

4.2.3 Power supply rack......................................................................................................................... 10

4.2.4 Control rack ................................................................................................................................... 11

4.2.5 LX start procedure......................................................................................................................... 12

4.3 LX SYSTEM STRUCTURE................................................................................................................... 13

4.3.1 System structure............................................................................................................................ 13

4.3.2 Power supply system..................................................................................................................... 15

4.3.3 Interface between SPA-5/LVA and interlocking system................................................................ 16

4.3.4 EHZ-8 – LED Road Signal............................................................................................................. 22

4.3.5 Electrical Gate Machines............................................................................................................... 24

4.3.6 EAR-1 – Control Panel (CP).......................................................................................................... 26

4.4 SYSTEM ELEMENTS.......................................................................................................................... 27

4.4.1 Programmable Logic Controllers (PLC) ........................................................................................ 27

4.4.2 EMF-6 stabilized DC/DC power converter module....................................................................... 28

4.4.3 EDL-5 DC/AC converter............................................................................................................... 29

4.4.4 EMK-2 Battery voltage control module.......................................................................................... 30

4.4.5 EMB-10 Safety Breaker Module................................................................................................... 31

4.4.6 EMH-2 Manual Control Unit.......................................................................................................... 33

4.4.7 EDG-4 Audible alarm generator.................................................................................................... 35

4.4.8 EZE-2 Event Logger...................................................................................................................... 36

4.4.9 EDZ-30 module ............................................................................................................................. 37

4.4.10 Auxiliary elements ......................................................................................................................... 38

4.5 ENVIRONMENTAL CONDITIONS .......................................................................................................... 39

4.6 PRODUCT SYMBOL........................................................................................................................... 40

5 SAFETY OPERATION RULES 42

6 PACKAGING, STORAGE AND TRANSPORT 42

6.1 ERR-2 SHELTER.............................................................................................................................. 42

6.2 OTHER ELEMENTS............................................................................................................................ 42

7 REMOVAL AND RECYCLING 43

8 RELATED DOCUMENTS 44

9 MANUFACTURER 44

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1 DOCUMENT REVISION

Revision Date Author Remarks

Change

No.

2008.12.16 Bartłomiej Pawełek Document created

0 2009.06.17 Tomasz Pisarek Document verification E150/2009

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

2 ABBREVIATIONS AND DEFINITIONS

LX Automatic Level Crossing System. Set of devices that

automatically warn road users about approaching

trains.

LX

disengagement

(released state)

LX status when warning devices are active and don’t

forbid road users to enter the crossing.

LX engagement LX status when warning devices are active and forbid

road users to enter the crossing.

LX safe state

LX state when normal operation of the system is

stopped, road signals forbid road users to enter the

crossing (as long as batteries are full).The only way-

out of the safe state is manual system restart.

Critical failure Failure that causes loss of the system operation

credibility and causes that system falls to the safe

state, i.e. loss of communication between control

channels, no PLC power supply, software operation

failure detection.

PLC

Programmable Logic Controller

CP

Control Panel

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3 APPLICATION

3.1 Product destination

Automatic Level Crossing System is destined to assure safety on crossings of

railway tracks and public roads. It automatically warns road users about trains

approaching to the crossings. It can be installed on level crossings with barriers or

half barriers situated on one- or more-track railway lines equipped with electrical

traction or having no traction at all. Railway line can be equipped with line block of

any technology or it can have no such system.

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

following crossing types:

a) Unguarded level crossings equipped with automatic light signalling (train-

operated or operated from the station interlocking system)

b) Guarded level crossings equipped with automatic warning light signalling and

with automatic or semiautomatic barrier booms of electrical gate machines (barrier

booms close automatically but open by means of button pressing by gate keeper)

c) Unguarded level crossing equipped with automatic light signalling with

automatic barrier booms of electrical gate machines, which may have a

supervisory monitoring at the nearest station and C.T.C control office.

3.2 Product description

Automatic Level Crossing System SPA-5/LVA is designed in accordance with

requirement specification defined by Latvian Railways.

Technical data of the system is presented in paragraph 4.1.

SPA-5/LVA is connected with Ebilock interlocking system. Ebilock is responsible to

send engagement and disengagement commands to LX. Depending on the

system state (engagement or disengagement) warning devices perform their tasks

according to the requirements. In case of guarded crossings a control panel is

used to enable operations of the gate keeper.

Information about LX status is sent to the remote control device that is placed in

the dispatcher’s room. Remote control device enables supervision of the LX

system operation and logging of events and faults.

3.3 Application scope

The number and type of equipment applied in the LX system can be defined for

each specific application. The version of a control unit as well as all the facilities of

the LX system can be adapted according to the specific requirements and

configuration of any crossing. Product symbol (4.6) defines the most important

configuration parameters of the system.

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4 TECHNICAL DESCRIPTION

4.1 Technical data

Parameter Data

Remarks

Power supply

Primary power supply

voltage

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

Power consumption:

Maximum

Average

1500W

300W

Stabilised power supply

DC/DC converters to

charge batteries

EMF-65 26-31 V DC Manufacturer

BT ZWUS

Buffered power supply of

LX devices

Types of batteries

24 V DC, 2-4 batteries

24V/85Ah,

24V/115Ah,

24V/150Ah

e.g.

A512/85A

Time of normal system

operation in case of no

supply 230V/50Hz

min. 8h / 100 pairs of trains

Warning devices

LED Road signal:

- Flashing frequency

- LED unit

- Power consumption

EHZ-8

0,67Hz

EHE-2

4W per one LED unit

Manufacturer

BT ZWUS

Audible alarm:

- Supply voltage

- Pulse frequency

- Sound intensity

Sound generator EDG-40 and

loudspeaker EDE-1000

12V or 24V DC

1Hz ±20%

60÷80dB in the distance of 7m

Manufacturer

BT ZWUS

Electrical gate machine:

- Barrier boom length

- Supply voltage

- Type

EEG-1

<= 12m

24VDC

no self-falling

Manufacturer

BT ZWUS

Barrier boom:

- Length

ESD-8

3,5 – 6,5m

Manufacturer

BT ZWUS

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- Braking boom detector

circuits

- Brake-away protection

Yes

multiple use (with ball safety device)

Interlocking interface

Interlocking (Ebilock)

interface

EDJ-5 (electronic interface)

Manufacturer

BT ZWUS

Control System

Control and power supply

unit

ERR-20 – LX shelter

ERR-24 – LX rack

Manufacturer

BT ZWUS

Control system:

- CPU

- RAM

- Program Memory

- Program cycle

2 x PLC series 2003

7CP476

750Kbyte SRAM,

1,5Mbyte Flash PROM

50ms

Manufacturer

B&R (Austria)

Automatic/manual operation

Automatic operation System engagement /

disengagement from the interlocking

system

Manual operation Manual system engagement /

disengagement from the shelter/rack

and from the Control Panel

Monitoring and diagnostics

Remote Control Device:

- Visualization of 1-8 LXs

- Registration time

ERP-7

Panel PC with 12”LCD touch-screen

2 x 8 LED

2 x Audible alarm

at least 1 month

Manufacturer

BT ZWUS

Local Diagnostic Panel:

- Visualization

- Operation

EZG-17

LCD display 2x40 digits

5-key keyboard

Manufacturer

BT ZWUS

Event Logging Unit

- Data access

- Registration

EZE-2

PC application

65000 records

Manufacturer

BT ZWUS

Safety

Hardware - 2 independent PLC controlled

channels A and B

- 2 independent power supply

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channels

- Both channel realising the same

functional requirements

Software - A and B channel,

- 2 different compilers,

- 2 programming languages,

- error detecting codes, CRCs

- program sequence check

LX engagement

LX disengagement

1 out of 2

2 out of 2

Cyclic on-line testing - Testing of detectors and warning

devices

- Testing of intermediate modules

Environmental parameters

Temperature range for

track-side equipment

placed directly on field or

in cabinets

-40°C ÷ +70°C

Relative humidity 0 ÷ 95% without water vapour

condensation

Protection degree at least IP44 for shelters

Protection against electric

shocks

P 302 25-30-AC

Residual-Current Circuit Breaker

30mA Power supply –24V DC

Fire protection Constructional elements of the racks

non-flammable; electronic modules

designed with excess assuring that

their surface temperature does not

exceed the ambient temperature more

than 15%

Burglary protection LX system control unit receives signal

indicating that the ERR-20 shelter

door is open and sends information

about this to the Remote Control

Device.

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4.2 Construction and configuration

4.2.1 System configuration

SPA-5/LVA consists of the control and supply devices ERR-2 (in shelter or as a

rack to be placed in the interlocking shelter) and external devices. Application

configuration is defined by a product symbol (see 4.6).

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

Device Quantity

EHZ-8 LED Road Signal with two or three

aspects

max 6

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

EDG-4 Audible Alarm max 4

EDJ-50 Interlocking Interface 1

Control Panel 1

EZE-2 Event Logger 1 (option)

EZG-17 Local Diagnostic Panel 1

ERP-7 Remote Control Device 1

EAR-1 Control Panel 1 (option)

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4.2.2 ERR-20 – LX shelter construction

SPA-5/LVA in ERR-20 variant is based on a standard shelter type EST-6022/LVA.

Control and power supply modules of LX SPA5/LVA are mounted inside this

shelter. Control racks (A and B) are mounted on the left side of the shelter, power

supply rack is installed on the right side.

All the cables from external devices go inside the shelter through respective cable

inlets located in the shelter’s floor and then they are connected to the terminal

strips. Further the cables are distributed, via terminal strips, to particular modules

of the control unit.

1604

1764

2452

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

Figure 1

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4.2.3 Power supply rack

Power supply rack

Figure 2

List of elements placed on power supply rack.

1. Rack frame.

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

control circuits of channel A.

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

control circuits of channel B.

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

5. Power distribution terminal with fuses.

6. Mains control circuits.

7. Terminal strips of first mains.

8. Terminal strips of second mains (optional).

9. N/A.

10. Separation transformer.

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11. Electrolytic capacitor.

12. Rectifier.

13. Grounding terminal strip.

14. Battery.

4.2.4 Control rack

Control racks are configured according to the specific requirements of the

application. The example of the rack is presented below.

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

Figure 3

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The most important elements placed on Control Rack.

5. EMB-10 Safety breaker module

6. EDJ-50 Ebilock interface

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

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

11. PLC A and PLC input, output modules

12. PLC B and PLC input, output modules

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

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

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

(channel A)

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

(channel B)

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

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

49 RAD ASM-20 modem for interface Ebilock

4.2.5 LX start procedure

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

the crossing.

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

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

LBB on Control Rack B.

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

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

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

e) After at least 2 seconds push START switch.

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4.3 LX system structure

4.3.1 System structure

A Typical layout of the SPA-5/LVA LX is presented at the Figure 4. Types and

number of devices at LX, as well as the presence and types of the interfaces are

individually defined for the specific system localization.

ERR-2 (SPA-5/LVA control and power supply unit) is connected via serial

transmission link with the Ebilock interlocking system. Separate transmission link

connects ERR-2 with Remote Control Device (ERP-7).

Ebilock sends orders (e.g. engagement and disengagement commands) to LX and

receives statuses and simplified diagnostic messages from LX.

Control Room

ERR

-2

TRACK2

TRACK1

N2

N4

N1

N3

S1

S2

S3

S4

Dz1

Dz2

EZG

-

17

RS485

MODEM

PC

EBILOCK

ERP-7

Control

Panel

(optionally)

Typical layout of LX

Figure 4

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Local Diagnostic Panel EZG-17 and Event Logger EZE-2 are foreseen to be used

directly at the crossing – in the LX shelter.

ERP-7 remote control device should be installed in the dispatcher’s room. In case

of the standard transmission cable the distance form ERP-7 to LX should not

exceed 5km. For longer distances amplifying units or modems must be used.

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

and Figure 6.

SPA-5/LVA structure - example.

Figure 5

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4.3.2 Power supply system

SPA-5/LVA power supply system is located on a dedicated rack. Power supply is

divided into two parts – 230V AC and 24V DC part.

ERR-2 - power supply structure.

Figure 6

230V AC voltage part

230V AC voltage part is responsible for the supply of the system batteries, fun,

heater, lighting and also electric socket inside shelter. TRA and TRB transformers

assure a galvanic insulation of the system supply from the 230V AC input power

supply.

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24V DC voltage part

Low voltage part is responsible for the constant batteries’ charging and for the

power supply distribution for all the devices of ERR-2. Batteries (24V DC) are main

power supply of the whole LX equipment (modules on the racks and external

devices).

Voltage from transformers (about 29V AC) is to be rectified and stabilized. EMF-65

suppliers ZsA and ZsB are destined to charge the batteries. Information about

performance of ZsA is passed to the PLC A and information about performance of

ZsB is passed to the PLC B. EMK-2 module checks the value of the battery

voltage from which is powered. Output 5 of EMK-2 is used to pass the information

about the voltage level of the battery to PLC. Threshold value is about 21V. Output

7 of EMK-2 controls the coil of StA (StB) contactor (depending on the control

channel). StA (StB) switches-off the load when the battery voltage is too low.

4.3.3 Interface between SPA-5/LVA and interlocking system

Interlocking system is responsible for sending to SPA-5/LVA engagement and

disengagement commands during normal automatic operation. SPA-5/LVA

operation is based on the electronic interface with the interlocking system Ebilock.

Ebilock sends commands to LX and receives back confirmations and simplified

diagnostic messages.

Different variants of the connection between LX and Ebilock can be prepared

depending on the design requirements (distance between LX rack and interlocking

rack, number of LXs connected to the same station, etc.). Generally 3 types of

devices are necessary to realize interface between SPA-5/LVA and Ebilock:

electronic interface EDJ-5, Protocol Converter Unit PCU and modem (e.g. RAD

ASM-20).

PCU (Protocol Converter Unit)

PCU performs a bidirectional conversion of HDLC data streams into Ethernet data

streams used at the main level of the Ebilock communication. HDLC (High Level

Data Link Control) is a bit-oriented synchronous data link layer protocol developed

by the International Organization for Standardization used in transmission between

Ebilock and its object controllers.

EDJ-5 (transmission converter).

EDJ-5 is a bidirectional converter of HDLC data streams (maximally two streams)

required by Ebilock into one RS-232 data stream used by the object controller.

SPA-5/LVA works as an object controller.

Modem (e.g. RAD ASM-20)

Modems are required in case of long distances between elements of the

SPA-5/LVA – Ebilock interface. Modems are connected with four wire cable and

work in full duplex mode. Modem from one side has a digital interface (HDLC or

V.24/RS232) and on the other side diphase modulated signal (EUROCOM Std.

D1) to provide immunity from background noise, eliminate a normal line distortion

and enable efficient transmission and reception of serial data over a twisted pair

cable for assurance long distance transmission. Modems can be placed between

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SPA-5/LVA PLCs and EDJ-5 modules or between EDJ-5 modules and PCU

modules depending on the application design requirements.

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

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

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

b) LX configuration – without barrier machines

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

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

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

ERR-2

MODEM

Type: ASM-20

EDJ-5

PCU

SWITCH

MODEM

Type: ASM-20

NETWORK

STATION INTERLOCKING

located at station, or another container

PLC B

CAN

RS232

PLC A

CAN

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

Figure 7

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4.3.3.2 SPA-5/LVA – Ebilock interface - variant 2

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

b) LX configuration – with barrier machines

c) Modem connection – two channel connection (transmission channel

redundancy)

d) Digital interfaces of modems - HDLC

e) Example – N/A

SPA-5/LVA – Ebilock interface - variant 2.

Figure 8

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4.3.3.3 SPA-5/LVA – Ebilock interface - variant 3

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

b) LX configuration – with or without barrier machines

c) Modem connection – N/A

d) Digital interfaces of modems – N/A

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

135.966

SPA-5/LVA – Ebilock interface - variant 3.

Figure 9

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BOMBARDIER SPA-5/LVA Technical Documentation Manual

BOMBARDIER SPA-5/LVA Technical Documentation Manual

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