HELIOS GENERAL HANDBOOK Siemens Traffic Controls Sopers Lane Poole Dorset BH17 7ER HELIOS GENERAL HANDBOOK THIS DOCUMENT IS ELECTRONICALLY HELD AND APPROVED PREPARED: Roy Bowen / Dave Martin FUNCTION: Senior Group Leader ssue 1 3 5 7 9 11 13 15 17 19 21 23 Change Ref ------------TS001228 TS001552 TS002133 TS002541 TS003362 TS004269 TS004957 TS005846 TS006160 TS006640 TS006850 Date Aug 2001 29/11/2002 26/06/2003 19/07/2004 5/06/2005 09/08/2006 23/01/2008 03/07/2009 07/12/2010 18/07/2011 26/07/2012 30
HELIOS GENERAL HANDBOOK SAFETY WARNING HEALTH AND SAFETY AT WORK Safety of Installation and Maintenance Personnel In the interests of health and safety, when installing, using or servicing this equipment the following instructions must be noted and adhered to: (i) Only skilled or instructed personnel with relevant technical knowledge and experience, who are also familiar with the safety procedures required when dealing with modern electrical/electronic equipment, are to be allowed to use and/or work on th
HELIOS GENERAL HANDBOOK (k) Any power tools must be regularly inspected and tested. (l) Any ladders used must be inspected before use to ensure they are sound and not damaged. (m)When using a ladder, before climbing it, ensure that it is erected properly and is not liable to collapse or move. If using a ladder near a carriageway ensure that the area is properly coned and signed. (n) Any personnel working on site must wear the appropriate protective clothing, e.g. reflective vests, etc.
HELIOS GENERAL HANDBOOK MAINTENANCE PROVISION (MP) 1. Product Reference Helios Traffic Signals 2. Specifications The Modular traffic signals are designed to meet the following specifications: EN12368 H.A. TR2206 Draft 1 BS 7987:2000 (HD 638) 3. Installation and Commissioning Methods of Installation and Commissioning are detailed in the Siemens Traffic Controls document: 667/HB/30000/000 Helios General Handbook 4.
HELIOS GENERAL HANDBOOK TABLE OF CONTENTS SAFETY WARNING .................................................................................. 2 MAINTENANCE PROVISION (MP) ........................................................... 4 1. INTRODUCTION.................................................................................................... 11 1.1 Purpose .............................................................................................................. 11 1.2 Scope ........................
HELIOS GENERAL HANDBOOK 2.6.5 Green Arrow (LED and LED (NLM)) ............................................................ 42 2.6.6 Equestrian (Halogen, CLS with LMF, CLS (NLM), CLS ELV, LED and LED (NLM)) .................................................................................................................... 43 2.6.7 Four in Line ................................................................................................. 43 2.7 Side Boxes ...................................................
HELIOS GENERAL HANDBOOK 2.34 Above Ground Detector (AGD) ........................................................................... 88 2.35 Bleep and Sweep Unit ........................................................................................ 89 2.36 Fitting Signal Head to Pole ................................................................................. 91 2.36.1 Adjusting Tilt and Rotation........................................................................... 92 2.36.
HELIOS GENERAL HANDBOOK INDEX .................................................................................................... 142 FIGURES Figure 1 – Helios front view ........................................................................................... 16 Figure 2 – Helios TRAM indicator front view ................................................................. 17 Figure 3 CLS ELV Type A .............................................................................................
HELIOS GENERAL HANDBOOK Figure 45 – Toucan Nearside Signal and Demand Unit ................................................ 62 Figure 46 – Nearside Signal - Shows the Two PCBs (Mk 1) ......................................... 63 Figure 47 – Red Man PCB from Puffin Nearside Unit (Mk 1) ........................................ 63 Figure 48 – Nearside Signal Shown with Red Man/Cycle/Equestrian PCB Removed (Mk 1) ....................................................................................................
HELIOS GENERAL HANDBOOK Figure 95 – Separated Modules .................................................................................. 119 Figure 96 – Front View ................................................................................................ 120 Figure 97 – Rear View................................................................................................. 121 Figure 98 – Top View ..................................................................................................
HELIOS GENERAL HANDBOOK 1. INTRODUCTION 1.1 Purpose This handbook gives a general description and specification along with the procedures for installation, commissioning and maintenance for the following versions of Helios Signal Head: CLS with LMF Signal Aspect. CLS (NLM) Signal Aspect. CLS ELV Signal Aspect. LED. LED (NLM). LED TRAM Indicator (ELV). Tungsten Halogen.
HELIOS GENERAL HANDBOOK 1.3 Related Documents 667/HE/20661/000 - General Principles 667/HE/20662/000 - Signals and Poles (for reference only) 667/HE/20663/000 - Detectors and Cable Terminations 667/HE/20664/000 - Installation and Testing 667/HE/20665/000 - Above Ground Detectors 1.
HELIOS GENERAL HANDBOOK 667/1/30198/004 Up Arrow Green LED - 0.06 A per optical unit 667/1/30198/005 L/R Arrow Green LED - 0.08 A per optical unit 667/1/30200/907 Red (NLM) LED - 0.102A per optical unit 667/1/30200/908 Amber (NLM) LED - 0.117A per optical unit 667/1/30200/906 Green (NLM) LED - 0.
HELIOS GENERAL HANDBOOK All other states 11 watts 3 watts Reference EN12368 Performance level class A3.
HELIOS GENERAL HANDBOOK 3 Aspect 200mm lantern (doors removed) 2 Aspect 200mm lantern 1 Aspect regulatory sign 1 Aspect regulatory sign (door removed) 1 Aspect TRAM indicator (fully equipped) Pedestrian push button 4.0m Pole Pair of mounting brackets 9 Kg 11 Kg 3 Kg 2.25 Kg 9.5 Kg 3.6 Kg 68 Kg 3.
HELIOS GENERAL HANDBOOK 2. SIGNALS AND POLES 2.1 General The Helios range of traffic signals has been developed to give optimum clarity, reliability and longevity with a pleasing appearance. It incorporates newly developed lens form and masking patterns, which ensure that the signal is extremely clear and easy to see in all conditions. There are tungsten halogen and LED aspects, which may be mixed in one signal head.
HELIOS GENERAL HANDBOOK Figure 2 – Helios TRAM indicator front view The basic three-aspect lantern assembly is constructed on a modular principle. Each aspect is self-contained and consists of one of the following: Halogen Option A high intensity tungsten halogen lamp and lamp-holder fitted into a reflector assembly, a red, amber or green coloured lens and a lamp transformer fitted with sufficient cable on its input to reach the pole cap wherever the lantern is mounted on the pole.
HELIOS GENERAL HANDBOOK CLS ELV OPTION The Central Light Source (CLS) is fitted behind a clear lens and is connected directly to the ST900 (ELV) or ST750 (ELV) controller phase output. The output from the controller is 48V (bright) with the controller capable of performing Lamp Monitoring of each aspect. The CLS ELV unit contains a number of high intensity LEDs. There are two different types of CLS ELV units, each type has a Red, Amber and a Green variant.
HELIOS GENERAL HANDBOOK WARNING – The CLS ELV OPTION CAN ONLY BE USED WITH SIEMENS ST900 (ELV) and ST750 (ELV) CONTROLLERS. ELV TRAM indicator OPTION This ELV Helios unit is designed specifically for use with light rail and TRAMS. The Light colour is white and the aspects take the form of a bar of discrete lights. The central dot is normally constantly illuminated to indicate the optic as on. The same LED driver is used so the profile for monitoring purposes is the same as other ELV HELIOS optical units.
HELIOS GENERAL HANDBOOK The halogen, CLS with LMF, CLS (NLM) and CLS ELV green arrow may have a green arrow mask placed in a number of positions in 22.5 increments. The LED and LED (NLM) options can have up (ahead) or left and right green arrows PCB’s fitted as standard (these utilise sub equipment green LED PCBs) along with a green arrow mask, but to have a green arrow in any other position, a fully equipped green LED PCB assembly is required along with a green arrow mask.
HELIOS GENERAL HANDBOOK 2.2 Helios Signals 2.2.1 Order of Installation The recommended order in which installation should take place is as follows: 1. Read the Safety Warning on page 2 of this Handbook. 2. Unpack items from packaging (section 2.2.3) 3. Install pole (section 2.3) 4. Add mounting kit to pole (section 2.3) 5. Wire pole (section 2.3.5 or 2.3.6) 6. Fit extension arm(s) (section 2.5.1) 7. Remove doors (section 2.6.3) 8. Adjust green arrow mask (section 2.6.4) 9.
HELIOS GENERAL HANDBOOK M10 screws and bolts – 20 Nm As signal heads rely on the security of their mounting fixings these fixings must be torqued up and the recommended procedure for this is found in appendix D. 2.2.3 Signal Head packaging Helios modular signals are supplied boxed in two forms: The three aspect box can contain a one-, two- or three-aspect head with attached brackets with the backing boards loose in the box. Hoods and other fixings are supplied in a separate box.
HELIOS GENERAL HANDBOOK Figure 7 – Three Aspect LED Internal Fitting Figure 8 – Three Aspect LED (NLM) Internal Fitting 667/HB/30000/000 Issue 24 Page 23 of 143
HELIOS GENERAL HANDBOOK Figure 9 – Three Aspect CLS with LMF Internal Fitting The single aspect box will contain a single module with its side box mounting kit or the four-in-line fixing kit, and all the hoods and fixings for the assembly. All these elements should be assembled on the ground prior to fixing to the pole. Lanterns are assembled in accordance with the requirements of the STS for primary and secondary signals. Assembly and attachment of side boxes are described in section 2.7. 2.2.
HELIOS GENERAL HANDBOOK lamp changing without exposing the reflector to the elements and possible surface damage. The lens is screened with a specially designed mask, to reduce the phantom effect. The lamp voltage is derived from a small step-down transformer, one per signal aspect mounted in the lamp body. 2.2.4.
HELIOS GENERAL HANDBOOK The 48V supply voltage for the CLS ELV is derived from the ST900 (ELV) or ST750 (ELV) controller phase outputs. The Controller phase driver PCBs monitor the load current of the CLS ELV unit. 2.2.4.5 LV Regulatory Signs Two 230 mm (9”) 6 W fluorescent tubes are mounted in front of a metal reflector. The tubes are connected in such a way as to provide protection against total signal failure.
HELIOS GENERAL HANDBOOK 2.3 Assembling and Terminating a Signal Pole 2.3.1 Pole Types General - PVC-covered Poles 667/2/01459/ETC Galvanised Poles 667/2/03686/ETC Cranked Pole 667/2/30230/000-001 667/2/30231/000-001 Formed Pole 667/2/28107/001-003 NOTE – If the Pole is a Formed or Cranked Type or the Pole has an Extension Arm fitted, an Anti-Rotate Rod must be fitted to the Pole (See Figure 10).
HELIOS GENERAL HANDBOOK 2.3.2 Pole Selection Centre Line of Amber Lower edge of container 2.4m min to 4.0m max (see note 1) Pedestrian Pushbutton Box 2.1m min (see note 3) 400 - 550mm (see note 5) 2.1m min to 2.6m max (see note 2) 1.0m min to 1.1m max (see note 4) Ground level Cables entering via slot in pole Concrete Anti-rotate rod Figure 10 – Typical Signal Pole Assembly showing heights for compliance with Traffic Signs Regulations Notes: 1.
HELIOS GENERAL HANDBOOK LTN 1-98]. This dimension applies if the push button is a single housing or a separate housing Demand/Display unit. 5. The height dimension of the pushbutton unit applies to a single housing or separate housing Demand/Display unit [see TR2181C]. ---------------------- The following information is provided to enable pole length requirements and planting depths to be determined. This assumes a 667/2/01459/ETC pole and a 3-aspect signal.
HELIOS GENERAL HANDBOOK 505mm 835mm Amber C/L 1065mm Green C/L Min clearance line Ground level Planting Depth Concrete Cables entering via slot in pole Anti-rotate rod Figure 11 – Signal Pole Assembly showing useful dimensions for Pole Selection and planting depth Note - The planting depth must be a minimum of 610 mm to cover the cable entry slot. Install under direction from the Civil Engineer, dependent on the ground conditions. 2.3.
HELIOS GENERAL HANDBOOK 2.3.4 Erecting the Pole The pole assembly may be completed to the point of having drawn up the cables and fitted at least the pole cap prior to erection, in which case see Section 2.3.5. Alternatively, assembly may follow erection in which case go to Section 2.3.6. Transport lantern bracket assemblies, pole cap assembly, pole draw rope, ladders and all necessary tools to the first pole location.
HELIOS GENERAL HANDBOOK Measure off wires to length, cut, strip, terminate necessary cores to terminal block and terminate two cables cores in earthing block for test purposes as described in Section 2.3.8. Once this operation is completed, the excavation at the base of the pole may be back-filled. Note that lanterns are not terminated until after the cables have been tested. On completion of all pole top terminations, the tests described in the Installation and Testing Handbook (see section 1.
HELIOS GENERAL HANDBOOK However for new LED sites where it is desired to reduce the likelihood of incorrect displays, particularly involving green signals, it is recommended that individual neutral returns are used for each green signal. For existing incandescent sites where LED signals are being now fitted and spare cables cores are available these may be used to provide additional neutral connections. 2.3.
HELIOS GENERAL HANDBOOK Number of Lamps Lit 17 18 19 20 Current 4.58 4.86 5.13 5.40 Total Length of Cable 22 21 19 18 Typical Cable Run on STS 16 15 13 12 If there is a danger of neutral connectors being disconnected it is recommended that separate neutrals be used for: 1. Signals and green arrows 2. Wait indicators 3. Box Signs, Solar Cell and MVDs 4. Sonalert on Pelican Controllers.
HELIOS GENERAL HANDBOOK Phase drive R A G Controller neutral Figure 12 – Wiring of the Neutral Terminal Block 2.5 Helios Bracket Assemblies There are four types of bracket for Helios: 1. The standard bracket that is used top and bottom on a three aspect case (667/2/30070/003) and the bottom bracket on the four in-line, two in-line and single aspect assemblies. 2. A four in line assembly has a long top bracket (667/2/30070/004) and a standard bottom bracket. 3.
HELIOS GENERAL HANDBOOK Add bolts and spacers to the extension bracket on which to hang the signal head. All bolts should be securely tightened. Figure 13 – Extension Bracket Connections from the signal head to the pole are enabled by the use of a terminal block in the top aspect case. 2.5.2 Side Mounting Bracket Where signal heads are to be fitted at an angle of rotation greater than 45 , and also need to be tilted, side mounting brackets (part no.
HELIOS GENERAL HANDBOOK 2.6 Signal Head Arrangement KEY-May be green aspect, green arrow, pedestrian green man/red man or regulatory sign, e.g. No Left Turn, No U Turn, etc. Figure 15 – Example Mounting Arrangements Figure shows a selection of arrangements, but it is not an exhaustive depiction of what is possible. A maximum of eight modules may be incorporated on one assembly, arranged as a four-aspect lantern assembly with two side boxes on each side. 2.6.
HELIOS GENERAL HANDBOOK Plain cap ( no teeth ), goes at the top of the signal head. Toothed cap, goes at the bottom of the signal head. Figure 16 – Sacrificial Cap parts The sacrificial caps must be fitted correctly. The smooth cap is fitted to the top of the signal head and the toothed cap is fitted to the bottom. Assemble the parts as follows: 1. Attach one end cap at each end of the signal head using five screws.
HELIOS GENERAL HANDBOOK Figure 17 – Sacrificial Cap assembly 2.6.2 Brackets Most signal head assemblies are delivered to site with the sacrificial caps and brackets ready attached to the signal head. In those cases where the assembly has to be made on site, follow the instructions given below. The brackets should be attached to the signal head-to-bracket fixings at both ends of the signal head, using the M10 screws and bolts supplied. Do not fully tighten the screws, as adjustment is required later.
HELIOS GENERAL HANDBOOK Figure shows a door clip in the half-open position with the door sitting above and unconnected. The door ‘peg’ is held in place by the door clip. Figure 19 – Door clip detail 2.6.4 Green Arrow (Halogen), CLS with LMF, CLS (NLM) and CLS ELV The green arrow optic includes a metal mask (667/2/30074/101) as shown in Figure . This module is delivered with the mask positioned either vertically (straight ahead) or horizontally for left- or right-turn.
HELIOS GENERAL HANDBOOK Helios (Halogen) To alter the position of the mask, unscrew the reflector from the rear of the door and remove it. Tip the mask out from behind the lens (replacing the lens in its original position if necessary) and replace in the position required. Make sure that the two seals (lens/door and lens/reflector) are in place and screw the reflector back into position. See section 4.2.15 and Figure for details.
HELIOS GENERAL HANDBOOK Figure 21 CLS ELV Type B Anti-rotation Clip b) Rotate the enclosure body anticlockwise and withdraw the enclosure from the door ring. c) Insert or adjust the mask as required. Figure 22 CLS ELV Arrow Mask d) Re-fit the enclosure to the door by inserting and rotating clockwise. Ensure that the anti-rotation clip has engaged and that the enclosure cannot be rotated anti-clockwise. 2.6.
HELIOS GENERAL HANDBOOK 2.6.6 Equestrian (Halogen, CLS with LMF, CLS (NLM), CLS ELV, LED and LED (NLM)) Lens are available for displaying equestrian figures. These lens have the equestrian figure ‘silk-screened’ on to them. a) Red and Green Equestrian Lens for the Halogen Helios options 667/1/30200/399 – Red Equestrian (Lamp) Lens 667/1/30200/398 – Green Equestrian (Lamp) Lens b) Clear Equestrian Lens for the LED and LED (NLM) Helios options 667/1/30200/397 – Clear Equestrian Lens (LED) Lens.
HELIOS GENERAL HANDBOOK Figure 23 – Side box showing fixing plates and conduit Figure 24 – Side box fitted on right of main signal head Both ends of any side fittings should have end caps fitted as shown in Figure . There is an O ring supplied to seal the fittings to the body that should be placed in the groove inside the end cap.
HELIOS GENERAL HANDBOOK 2.7.1 Wiring Side Boxes Check that the internal illumination assembly is correctly fitted into each side box. Green arrow and cycle side boxes have internal fittings similar to the main signal head; regulatory signs are fitted as shown in Figure . Feed the cable through the conduit, up through the main signal head via the cable gland and wire to the top cap. Figure 26 – Regulatory Sign internal fitting 2.7.
HELIOS GENERAL HANDBOOK Clean the door aperture and outside of the lens carefully and ensure that both are completely dry before fitting the lens. Place the strip of sealant around the inside of the door aperture, carefully align the lens and press both parts together. Remove any surplus seal from the face of the lens. 2.8 Transformers (Halogen) The transformers will normally be factory fitted before delivery.
HELIOS GENERAL HANDBOOK Figure 29 – PSU assembly fitted into case 2.10 Transformers LED (NLM) The transformers will normally be factory fitted before delivery. The usual position is in the bottom right corner of the module, although they may be placed in any of the four corners. If the transformer is to be fitted in one of the upper positions, four screws are required, one in each corner.
HELIOS GENERAL HANDBOOK 2.11 CLS Unit The CLS units will normally be factory fitted into the appropriate door before delivery. There are three variants of the CLS unit a) Red CLS unit - 667/7/28584/100 b) Amber CLS unit - 667/7/28584/101 c) Green CLS unit - 667/7/28584/102 The CLS unit is obtained from 2 manufacturers, Futurit and Dialight. The Futurit CLS unit is positioned into the lens retaining ring and held in place with two CLS retaining clips (667/2/31501/000).
HELIOS GENERAL HANDBOOK Figure 32 – Dialight CLS Unit 2.12 CLS ELV Units The CLS units will normally be factory fitted into the appropriate door before delivery. There are two different types of CLS ELV units, each type has a Red, Amber and a Green variant.
HELIOS GENERAL HANDBOOK 2.13 CLS ELV Type B Transformer Placement If CLS ELV Type B units are to be retro-fitted to an existing installation it may be necessary to relocate transformers fitted within the signal head enclosure to avoid a clash with the aspect enclosure body. Lamp transformers tend to offer sufficient clearance, however 24V transformers with top mounted fused terminal blocks (as used for AGD units) must be mounted on the rear of the signal head enclosure NOT on the bottom (see Figure 33).
HELIOS GENERAL HANDBOOK Note that the Mains wiring to other LMF Units is tied to the LMF chassis with two Pushbutton Ties which prevents any heat from the LMF unit from damaging any of the cable forms. CLS Unit Pushbutton Cable Ties LMF Mains Input Wiring LMF Unit Figure 34 – CLS with LMF 2.15 ELV TRAM Indicator The TRAM indicator should only be replaced as a complete module. The maintenance spares should always be fully equipped modules but the originally supplied equipment may be sub equipped.
HELIOS GENERAL HANDBOOK Keyhole slot Molex connector Figure 36 – TRAM Indicator rear view showing Keyhole slots To remove the Tram indicator from its housing: The Tram indicator is a complete module and must be replaced as a complete assembly. The LED and power supply assembly is fitted into a standard Helios aspect box. This assembly remains in the rear part of the box when the door/lens assembly is opened.
HELIOS GENERAL HANDBOOK Do not undo this nut Keyhole slot Individual LED dot LENS Figure 37 – TRAM Indicator showing keyhole slot from the front 2.16 Terminal Blocks Fixing positions have been provided for terminal blocks, which are generally only fitted in aspects where an extension bracket has been used. Figure shows a terminal block fitted in one of the positions provided and Figure gives all the possible fixing positions. 2.17 Bridge Rectifier See Figure and Figure for the fixing position.
HELIOS GENERAL HANDBOOK 2. Side mounted signals may have the cable gland fitted in one of the three recesses in the side of the module. 3. Pedestrian signals may have the cable gland fitted in any position to reduce the length of the conduit. Wherever the gland is fitted, consideration should be given to the length of the transformer/PSU wires and the amount of conduit tubing between the signal head and the pole. A long length of tubing is unsightly and should be avoided wherever possible.
HELIOS GENERAL HANDBOOK Figure 40 – Angled Hood fitting An optional Pedestrian Aspect Hood is available. This hood is supplied with predrilled fixing holes but is of a non formed construction. The hood is fitted to the aspect using fir-tree clips. 2.19.1 Drilling Hoods To fit hoods that do not have fixing holes that align with those on the Helios door, including louvred and tunnel hoods, the fitting positions have to be drilled using a 6 mm drill bit.
HELIOS GENERAL HANDBOOK Figure 41 – Solar Cell The solar cell used is a Royce Thompson Electric Ltd type RTE/P5 (55 Lux) (STCL part number 506/4/97891/000) or equivalent, which plugs into a Rotaloc Socket. The cell is mounted on the top of the 3-aspect case, through a 20 mm diameter hole, drilled using one of the two central guide indents on top of the case.
HELIOS GENERAL HANDBOOK 2.21 Pedestrian Push Button (Mk 1) There are two variants of push button units currently in use in the United Kingdom: Standard push button with no Sonalert (667/1/01478/000) (2 man) Pelican push button fitted with Sonalert (667/1/01478/001) (3 man) Figure 42 – Pedestrian push button unit 2.21.1 Optional Wiring Kits for Pedestrian Pushbutton (Mk 1) The pedestrian push button unit comes complete with its fixing kit.
HELIOS GENERAL HANDBOOK Red Red Aud. Signal + Black Black Aud. Signal - Blue Blue Wait Ind N Brown Brown Wait Ind. L Violet *¹ Green*² Tactile motor + Yellow *¹ Yellow*² Tactile motor - The wires within the Pedestrian push button should be arranged and cable tied so that the wiring cannot touch the push button micro-switch housing. Each wire is 4 metres long and connects to the terminal block in the pole cap assembly.
HELIOS GENERAL HANDBOOK Figure 43 – LED Wait Box The L.E.D. Wait Box comes complete with its fixing kit. The unit fastens to the pole using the ‘U’ bolt provided. When installing a pushbutton box, the centre of the pushbutton should be between 1.0m – 1.1m above the footway level. 2.22.1 Optional Wiring Kits for L.E.D.
HELIOS GENERAL HANDBOOK (*¹ NOTE – If the Optional Audible Supply Kit (667/1/27006/000) is fitted, wire Violet to Audio 2 and Yellow to Audio 0v Common) (*² NOTE – If the Optional Audible Supply Kit (998/4/88324/000) is fitted, wire Green to Audio 2 and Yellow to Audio 0v Common) (Ensure that the wiring at the controller is to 667/GA/27006/000 Sht 2 Issue 3)) Optional Radix Tactile Equipment (667/7/17390/000) is available for all variants of L.E.D. Wait Box. 2.22.2 L.E.D.
HELIOS GENERAL HANDBOOK Pushbutton Assembly ‘WAIT’ PCB Assembly Figure 44 – LED Wait Box Door Assembly (Mk 1) 2.23 Nearside Signal and Demand Unit (Mk 1) There are three variants of the Nearside Signal and Demand Unit, which are dual housed, for use in UK Puffin, Toucan and Equestrian Crossing applications. The Nearside Signal is illuminated using either Red or Green LEDs, whilst the Demand unit uses a Touch Sensitive switch around which is illuminated by Red LEDs when a Demand is registered.
HELIOS GENERAL HANDBOOK Figure 45 – Toucan Nearside Signal and Demand Unit 2.23.1 Nearside Signal Unit (Mk 1) The three variants of Nearside Signal come with a door assembly which contain the following items – a) a PCB which contains all the Display Red LEDs arranged to illuminate either the Red Man (Puffin), Red Man and Red Cycle(Toucan) or a Red Horse (Equestrian).
HELIOS GENERAL HANDBOOK Figure 46 – Nearside Signal - Shows the Two PCBs (Mk 1) Figure 47 – Red Man PCB from Puffin Nearside Unit (Mk 1) 667/HB/30000/000 Issue 24 Page 63 of 143
HELIOS GENERAL HANDBOOK Red Man/Cycle/Equestrian PCB Position of Red Man/Cycle/Equestrian PCB Position of Green Man/Cycle/Equestrian PCB Figure 48 – Nearside Signal Shown with Red Man/Cycle/Equestrian PCB Removed (Mk 1) The Following PCB variants are available for the Nearside Signal – 1) Green Puffin - 667/1/30695/001 2) Red Puffin - 667/1/30695/002 3) Green Toucan - 667/1/30695/003 4) Red Toucan - 667/1/30695/004 5) Green Equestrian - 667/1/30695/005 6) Red Equestrian - 667/1/30695/006 2.
HELIOS GENERAL HANDBOOK Vandal Resistant Pushbutton LED PCB Figure 49 – Demand Unit 2.23.3 Optional Wiring Kits for Nearside Signal Unit and Demand Unit (Mk 1) Two wiring kits (667/1/26942/000) and (998/4/88324/000) are available for connection to the terminal block/s inside the Nearside Signal Unit and Demand Unit to the terminal blocks in the pole cap assembly. (Note that each wire is 4 metres long).
HELIOS GENERAL HANDBOOK Orange Orange - TB1.5 - Push Button + Orange White - TB1.6 - Push Button - Red Red TB1.1 - RED 48VAC1 TB1.3 - Audio 1 *¹ Black Black TB1.2 - RED 40VAC2 TB1.4 - Audio 2 *¹ Blue Blue TB1.4 - GREEN 48VAC2 TB1.2 - 48v RET Brown Brown TB1.3 - GREEN 48VAC1 TB1.
HELIOS GENERAL HANDBOOK 2.
HELIOS GENERAL HANDBOOK 2.26 Installation of Nearside and WAIT Mk2 fixing kits to pole DEMAND, SIGNAL AND WAIT U-BOLTS CAN BE INSTALLED THROUGH FIXING HOLES BUT COMBINED UBOLTS MUST BE FITTED THROUGH GLAND HOLE.
HELIOS GENERAL HANDBOOK 2.27 Installation of WAIT, Demand, Signal and Combined Mk2 units to pole Figure 52: Mounting of Nearside/Pedestrian WAIT units to Pole. Typical to all assemblies, Combined unit shown.
HELIOS GENERAL HANDBOOK 2.
HELIOS GENERAL HANDBOOK 2.28.1 Terminal Block Layout for STD Wait Mk2 Indicator units Shown below are the diagrams of the terminal block assembly used within both of the Nearside Mk2 STD Wait Indicator units 2.29 LED Wait Mk2 Indicator Units There are four variants of the 48 Volt L.E.D. Wait Box (with Mechanical switch) available for use in the United Kingdom.
HELIOS GENERAL HANDBOOK Figure 54 - LED Mk2 Wait Box The L.E.D. Wait Box comes complete with its fixing kit. The unit fastens to the pole using the ‘U’ bolt provided. When installing a pushbutton box, the centre of the pushbutton should be between 1.0m – 1.1m above the footway level. 2.29.
HELIOS GENERAL HANDBOOK 2.30 CLS Wait Two versions of CLS Wait are available; a retrofit solution and a production replacement for the existing LED Wait. Both versions offer the benefit of CLS technology and the possibility of lamp monitoring depending on the controller type. Table 1 shows the lamp monitoring options.
HELIOS GENERAL HANDBOOK 667 /1/47701/000 Siemens MK2 Spacer Kit 667 /1/12800/000 PB800 issue 31 or greater (ST800 ) 667 /1/21029/001 Wait Drive Transformer 48V AC 160 VA Figure 55 CLS Wait Retrofit and MK2 Spacer Figure 56 CLS Wait Retrofit reverse side showing the Driver PCB 667/HB/30000/000 Issue 24 Page 74 of 143
HELIOS GENERAL HANDBOOK 2.30.2 CLS Wait (Production) The CLS Wait has been designed as a production replacement for the LED Wait unit and as such shares the same part numbers. This unit offers the benefit of CLS technology and provides a clear uniform display banner. CLS Wait units are also lamp monitorable. Figure 57 CLS Wait Unit There are four variants of the CLS Wait Box (with Mechanical switch) available for use in the United Kingdom.
HELIOS GENERAL HANDBOOK The mechanical installation of the equipment is as defined for the LED Wait Mk2 Indicator Units, see sections 2.25, 2.26, 2.27, 2.29. Module Replacement Should it become necessary to replace the CLS Wait Module the part number is 667/1/47710/00. 1. Disconnect the earth connection from the module. 2. Gently prise the four plastic retaining clips and withdraw the module. 3. Disconnect the red and black wires from the driver board terminal block noting their position. 4.
HELIOS GENERAL HANDBOOK This will enable Wait indicator monitoring on the internal sensor. Different faults may be displayed depending on the combination of lamps illuminated. Refer to the handset handbook 667-HH-27000-000. Ensure that all lamp loads are learned using the KLR and KML commands. Follow usual commissioning procedures for completion of site installation. 2.
HELIOS GENERAL HANDBOOK Figure 58 – Nearside Mk2 Signal Unit Each Nearside Signal Unit and Demand Unit comes complete with its fixing kit. Each unit fastens to the Signal Pole using the ‘U’ bolt provided. When installing the Nearside Signal and Demand Unit the following must be observed – a) Centre of the Demand Unit Push button must be 1.0m – 1.1m above the footway level.
HELIOS GENERAL HANDBOOK 667/2/30690/001 – Toucan 667/2/30690/002 – Equestrian The following are the Mk2 Door Assemblies that are available – Puffin Door Assembly - 667/1/33661/000 Toucan Door Assembly - 667/1/33661/001 Equestrian Door Assembly - 667/1/33661/002 Puffin Door NFOV Assembly - 667/1/33661/500 Toucan Door NFOV Assembly - 667/1/33661/501 Equestrian Door NFOV Assembly - 667/1/33661/502 For Nearside Mk2. LP replace ‘33661’ with ‘33668’.e.g. 667/1/33668/010 2.31.
HELIOS GENERAL HANDBOOK The UK Variants, with piezo switch are – Nearside Demand Unit – 667/1/33606/000 The Demand Unit comes with a door assembly that contains the following – a) A PCB which contains all the red LEDs arranged in a circle around the push button which illuminate when a Pedestrian Demand is Registered b) A vandal resistant Stainless Steel mechanical switch or piezo touchswitch c) A polycarbonate front panel (667/6/33652/000).
HELIOS GENERAL HANDBOOK 667/HB/30000/000 Issue 24 Page 81 of 143
HELIOS GENERAL HANDBOOK 2.31.5 Nearside Mk2 and Mk2 LP Combined Unit There are three variants of the Nearside Combined Unit, which are single housed, for use in UK Puffin, Toucan and Equestrian Crossing applications. A Narrow Field of View (NFOV) option is also available on these assemblies.
HELIOS GENERAL HANDBOOK Figure 60 – Nearside Mk2 Combined Unit 667/HB/30000/000 Issue 24 Page 83 of 143
HELIOS GENERAL HANDBOOK Each Nearside Combined Unit comes complete with a fixing kit. Each unit fastens to the Signal Pole using the ‘U’ bolt provided. When installing the Nearside Combined Unit the following must be observed – a) Centre of the Demand Push button must be 1.0m – 1.1m above the footway level.
HELIOS GENERAL HANDBOOK e) A vandal resistant Stainless Steel switch or piezo switch The following are the standard Mk2 Door Assemblies that are available – Puffin Door (Mechanical Switch) - 667/1/33662/010 Toucan Door (Mechanical Switch) - 667/1/33662/011 Equestrian Door (Mechanical Switch) - 667/1/33662/012 Puffin Door NFOV (Mechanical Switch) - 667/1/33662/510 Toucan Door NFOV (Mechanical Switch) - 667/1/33662/511 Equestrian Door NFOV (Mechanical Switch) - 667/1/33662/512 For Nearside Mk2.
HELIOS GENERAL HANDBOOK 2.32 Radix/Sedgwell Power Supply for Tactile It is recommended that, where used, this unit be fitted in the amber aspect case, in the upper position as shown in Figure , otherwise the halogen reflector will stop the door closing. Move the cables connecting the transformers and fit the power supply to the case as shown using the mounting positions shown in Figure . NOTE – There are two variants of the Radix Tactile Unit.
HELIOS GENERAL HANDBOOK Figure 62 – Radix power supply This equipment comes with its own fitting instructions. Note that Sedgwell may include rivnuts; remove them for best fixing to Helios. 2.33 Backing Boards Where specified, these are delivered with the main packaging for the signal head. Where side boxes form part of the installation, these should be assembled before fitting backing boards. See section 2.7 for details.
HELIOS GENERAL HANDBOOK Figure 63 – Backing board fixings 2.33.1 Reflective Tape Some installations require the use of reflective tape over the backing boards. Backing boards with the tape already fitted are available. If retro fitted reflective tape is required then this glues into position before fitting the boards as described in section 2.33. Ensure the surfaces are clean and dry.
HELIOS GENERAL HANDBOOK Nut caps fitted over top and bottom bracket nuts and bolts. Figure 64 – AGD fitted to signal head bracket The AGD connector cable is generally fitted to the topmost indent on the red Aspect (either side). The hole should be drilled using the rear drill start point. Connect the cable in accordance with the Supplier’s instructions. See the Above Ground Detector handbook (see section 1.3) for further details. 2.
HELIOS GENERAL HANDBOOK Red Man Aspect Green Man Aspect Bleep & Sweep Aspect Figure 65 – Bleep and Sweep Signal Head Arrangement Bleep and Sweep Control Unit Standoffs provided in Bleep & brush off Kit Figure 66 – Bleep & Sweep Unit Mounted in Signal Aspect 667/HB/30000/000 Issue 24 Page 90 of 143
HELIOS GENERAL HANDBOOK Bleep and Sweep Microphone and speaker Figure 67 - Bleep and Sweep Microphone and Speaker Mounting 2.36 Fitting Signal Head to Pole This section describes the recommended method of installing the assembled signal head onto the pole. To carry the signal head with any attached side boxes safely, remove all doors and place a hand inside the top module. Do not carry the signal head by the top bracket. Hang the signal head on the pole mountings.
HELIOS GENERAL HANDBOOK Figure 68 – Bottom bracket fitted 2.36.1 Adjusting Tilt and Rotation Once the signal head has been fitted to the pole, the angles of tilt and rotation (see Figure and Figure ) need to be adjusted before finally tightening the Allen bolts and hex screws. Helios may be tilted up to 6 from the upright and rotated up to 90 . Note that it is not possible to tilt a signal head that is rotated over 45 without the use of side mounting brackets (section 2.5.2).
HELIOS GENERAL HANDBOOK Figure 70 – Angle of Rotation Make sure that the Allen bolts are loose enough so that the toothed sacrificial cap on the bottom bracket is not engaged before rotating the signal head.
HELIOS GENERAL HANDBOOK Figure 71 – Pole Cap fitted 2.36.3 Fit Bulbs (Halogen) Note that bulbs are not delivered with the signal head assembly; they are kept by STCL Services department. Fit a tungsten halogen bulb into each of the bulb holders using the sleeve in which the bulb is supplied to push the bulb into place. It should not be touched with the fingers.
HELIOS GENERAL HANDBOOK Figure 72 – Door Clip closed 667/HB/30000/000 Issue 24 Page 95 of 143
HELIOS GENERAL HANDBOOK 3. COMMISSIONING Adjust the angles of tilt, rotation and arrow directions to customer satisfaction. In the absence of alternative instructions from the customer, the primary signals should be focussed to 40 m from the stop line and secondary signals should be focussed to the centre of the stop line.
HELIOS GENERAL HANDBOOK Nearside Signal ELV Compatible PCB Assemblies 667/1/30695/001 667/1/30695/002 667/1/30695/003 667/1/30695/004 667/1/30695/005 667/1/30695/006 Issue 9 and above. Issue 9 and above. Issue 9 and above. Issue 10 and above. Issue 9 and above. Issue 10 and above. Nearside Mk1/Mk2 Nearside Mk1/Mk2 Nearside Mk1/Mk2 Nearside Mk1/Mk2 Nearside Mk1/Mk2 Nearside Mk1/Mk2 Nearside Wait ELV Compatible PCB Assemblies 667/1/30211/001 Issue 4 and above.
HELIOS GENERAL HANDBOOK 4. MAINTENANCE Before starting any maintenance work, read the Safety Warning on page 2 of this Handbook. 4.1 Routine Maintenance Visits Warning: Mains voltages are present in LED and LED (NLM) aspects. The mains supply to the signal head must be disconnected/switched off before working on an LED or LED (NLM) aspect. The interval between visits depends on local conditions but typically would be every six months.
HELIOS GENERAL HANDBOOK so that the head is level with the outer edge of the clip. This should enable the clip to slide without the door hitting the screw. 4.2.1 Bulb Replacement (Halogen) Where a bulb is to be replaced, the door may be opened from either side and the bulb holder removed by gently squeezing the bulb holder clips. Pull the bulb free of the bulb holder and push the new bulb into place.
HELIOS GENERAL HANDBOOK Cut the mains leads to the transformer as close as possible to the transformer. Remove and retain the two screws that are holding the transformer to the bottom of the Aspect and extract the transformer from the aspect. Fit the new transformer into the same position as the one removed using the retained screws. Cut the new transformer mains input leads about 25 – 30 cm from the transformer. Using 2 off Red Butt Crimps (703/4/97182/000 - TAG INLINE SPLICE 0.5-1.
HELIOS GENERAL HANDBOOK Connector Fuse Figure 73 – LED PCB front Figure 74 – LED PCB rear Connector Figure 75 – LED (NLM) PCB front 667/HB/30000/000 Issue 24 Page 101 of 143
HELIOS GENERAL HANDBOOK 4.2.5 PCB Fuse Replacement (LED) Warning: Mains voltages are present. The mains supply to the signal head must be disconnected/switched off before working on an LED aspect. Warning: Anti-static precautions must be taken when handling LED PCB Assemblies. See the note in section 4.2 regarding anti-vandal screws. Undo the door clips on one side and open the door.
HELIOS GENERAL HANDBOOK Figure 76 – PSU White Molex Connectors 4.2.7 Transformer Replacement – LED (NLM) Warning: Mains voltages are present. The mains supply to the signal head must be disconnected/switched off before working on an LED (NLM) aspect. Either of the following procedures may now be used. Disconnect the transformer mains input from the top of the Signal Pole and feed the cables back to the transformer that is to be replaced. Disconnect the transformer connection from the LED (NLM) PCB.
HELIOS GENERAL HANDBOOK Figure 77 – LED (NLM) Transformer 4.2.8 CLS Unit (Futurit Type) Replacement Disconnect the power lead of the CLS unit for the LMF unit by removing PL1 from the LMF unit or disconnecting PL1 of the CLS unit from SKT1 of the Mains power cable of a CLS (NLM) aspect. Remove the two screws holding the CLS Retaining Clip in position and remove the CLS retaining clips. Remove the CLS unit from the retaining ring by unclipping it from the four retaining clip of the retaining ring.
HELIOS GENERAL HANDBOOK CLS Retaining Clips Figure 79 – Futurit CLS Unit, Retaining Ring and retaining Clips Locating ‘pip’ at the top of CLS unit Figure 80 – ‘Pip’ at the top of the Futurit CLS Unit CLS engaging slot Figure 81 – Futurit CLS engaging slot 4.2.9 CLS NLM Unit (Dialight Type) Replacement See the note in section 4.2 regarding anti-vandal screws.
HELIOS GENERAL HANDBOOK Figure 82 – Dialight CLS Unit CLS ELV units are identified by the label displayed in Figure below. SIEMENS PART NO. : 667/7/28586/100 COLOUR : RED VOLTAGE (BRIGHT/DIM) : 48V/27.5V POWER (BRIGHT/DIM) : 12W/4W ce MODEL TYPE : ELV Figure 83 – ELV CLS LABEL 4.2.10 CLS ELV Type A Replacement See the note in section 4.2 regarding anti-vandal screws. Undo the door clips on one side, open the door and disconnect the plug to the input lead.
HELIOS GENERAL HANDBOOK Refit the door to the signal head and re-connect the input lead. 4.2.11 CLS ELV Type B Replacement See the note in section 4.2 regarding anti-vandal screws. Undo the door clips on one side, open the door and disconnect the plug to the input lead. Remove the door assembly from the module and work on the ground. Gently press the anti-rotation clip at the bottom of the CLS enclosure using a small screwdriver or other suitable tool (see Figure 84 ).
HELIOS GENERAL HANDBOOK 4.2.12 LMF Fuse Replacement Remove power to the LMF unit by removing the connector in PL1 of the LMF unit. Remove the fuse by unscrewing the fuse cap from the fuse holder. Replace the fuse (518/4/97068/000 – Ceramic 20 x 5 1A 240v) in the fuse cap and screw the cap back into the fuse holder.
HELIOS GENERAL HANDBOOK M3 x 10mm screws. Place the Jumper (508/4/21405/001) between pins 6 and 8 of PL2 as identified in Figure . Replace the LMF Unit’s cover and screws and add the Amber/Green 230v Identification Label (667/2/31190/001). The Unit is now ready for fitting. Place Identification Label Here Pin 8 Pin 6 PL2 PL2 Figure 86 – LMF with Cover Removed Note the forming of the power cable into PL1 of the LMF unit. This prevents any water ingress down this cable from dropping into the LMF unit.
HELIOS GENERAL HANDBOOK 4.2.15 Aspect Door Replacement (Halogen) Normally a door/lens assembly is replaced complete. When the appropriate variant is not available, any undamaged lens, reflector and hood may be re-used. See the note in section 4.2 regarding anti-vandal screws. Undo the door clips on one side, open the door and remove the halogen lamp holder from the reflector. Undo the remaining door clips and remove the door from the module and work on the ground.
HELIOS GENERAL HANDBOOK Figure 90 – Reflector with seal in place Secure the door, tightening the anti-vandal screws if supplied. 4.2.16 Aspect Door Assembly Replacement (LED and LED (NLM)) Warning: Mains voltages are present. The mains supply to the signal head must be disconnected/switched off before working on an LED or LED (NLM) aspect. Warning: Anti-static precautions must be taken when handling LED and LED (NLM) PCB Assemblies. Normally a door/lens assembly is replaced complete.
HELIOS GENERAL HANDBOOK Figure 91 – LED Aspect Door Figure 92 – LED (NLM) Aspect Door Secure the door, tightening the anti-vandal screws if supplied. If necessary, reattach the hood. 4.2.17 CLS with LMF, CLS (NLM) Door Replacement Normally a door/lens assembly is replaced complete. When the appropriate variant is not available, any undamaged lens, CLS unit and hood of the correct variant may be re-used. See the note in section 4.2 regarding anti-vandal screws.
HELIOS GENERAL HANDBOOK If the existing hood is to be re-used, remove it as described in section 4.2.21 and retain it for re-use. Otherwise, fit a new hood as described in section 2.19. Fit the replacement door back on to the aspect body, connecting the lead from the CLS unit to either SKT1 on the LMF unit and then the phase power connector to PL1 (CLS with LMF) or the mains input plug if CLS (NLM) or CLS (ELV). Secure the door, tightening the anti-vandal screws if supplied.
HELIOS GENERAL HANDBOOK 4.2.19 Regulatory Sign Door Replacement Replacing any regulatory sign door except mandatory arrow simply involves removing the old door and replacing it with a new one. To replace a mandatory arrow door, follow the additional fitting instructions in section 2.7.2. Alternatively, it may be possible to remove a broken mandatory arrow lens and replace the sealant and lens without having to replace the door. Secure the door, tightening the anti-vandal screws if supplied. 4.2.
HELIOS GENERAL HANDBOOK A damaged lens should only be replaced with one displaying the correct aspect. Part numbers are given in APPENDIX B. Undo the door (loosening the anti-vandal screws as described in section 4.2 if fitted) and unclip the bulb holder from the rear of the reflector. Tuck the bulb holder securely in the module and remove the door from the front of the module. Unscrew the reflector from the door and remove the lens. Replace the lens or reflector as required.
HELIOS GENERAL HANDBOOK (see Figure and Figure ). Make sure that the clear plastic shield covers the cable connector to give protection from the mains voltage present. Do up the other door clips (and any anti-vandal screws). 4.2.24 Lens Replacement CLS with LMF or CLS (NLM) Note: As the lens to door seal is difficult to align once removed, this procedure should not be carried out on site. A complete replacement door assembly should be fitted as described in section 4.2.
HELIOS GENERAL HANDBOOK 4.2.25 Lens Replacement CLS ELV Note: As the lens to door seal is difficult to align once removed, this procedure should not be carried out on site. A complete replacement door assembly should be fitted as described in section 4.2.17 and the lens replacement done at the depot. A damaged lens should only be replaced with one displaying the correct aspect. Part numbers are given in APPENDIX B. Undo the door (loosening the anti-vandal screws as described in section 4.
HELIOS GENERAL HANDBOOK Remove and replace the toothed sacrificial cap and refit the Allen bolt loosely. Re-align the signal head (section 2.36.1) and re-tighten all bolts and screws. 4.2.27 Sacrifical Caps – Screw Tightening Procedure It is possible for the Allen screws to become loosened after a collision with the signal head.
HELIOS GENERAL HANDBOOK Figure 95 – Separated Modules 4.3 Second Line Maintenance It is recommended that undamaged parts be reused where possible.
HELIOS GENERAL HANDBOOK APPENDIX A – DRAWINGS The drawings given in this appendix are reproduced from 667/2/28968/000 sheets 1 to 3 issue 1 and are intended to assist with installation and maintenance. They show fitting positions for the various components and the fixings to be used.
HELIOS GENERAL HANDBOOK Figure 97 – Rear View 667/HB/30000/000 Issue 24 Page 121 of 143
HELIOS GENERAL HANDBOOK Figure 98 – Top View Figure 99 – Underside View 667/HB/30000/000 Issue 24 Page 122 of 143
HELIOS GENERAL HANDBOOK APPENDIX B – SPARES LIST Listed below are the part numbers for approved Spares for the Helios signal head and associated equipment. CLS only CLS (ELV) Description LED only Part Number Hal. only See the warning on page 4 regarding the use of parts other than those listed.
CLS only CLS (ELV) Description LED only Part Number Hal.
667/1/30200/807 Single Body Side Mounted Reg Sign (no doors) 667/1/30200/058 Side mounting and AGD bracket 667/4/00977/000 Transformer 667/1/30194/001 Linear PSU Assembly 667/7/30632/000 Transformer for LED (NLM) 667/1/02293/001 Regulatory Sign – Internal illumination assembly 667/1/30200/411 NRT Reg Sign & Door 667/1/30200/412 NLT Reg Sign & Door 667/1/30200/413 Except Buses Reg Sign & Door 667/1/30200/414 Mandatory Arrow Reg Sign & Door 667/1/30200/415 NUT Reg Sign & Door 667/1
999/4/44188/000 M4 x 10 mm S/S screws Pan head Pozidriv PLAS-TECH 25 Screws to fix transformer/PSU assembly. 999/4/44189/000 S/S hex head Pozidriv M5 x 12 mm screws for fixing 1. Backing board 2. End cap 3. Reflector/lens holder to door.
667/1/31505/000 667/HB/30000/000 CLS only CLS (ELV) Description LED only Part Number Hal.
HELIOS GENERAL HANDBOOK APPENDIX C - Visual Identification of ELV Compatible PCB’s LED WAIT Identification: Components to left hand side of “W” as shown in this photograph indicate that the unit is ELV compliant PCB Assembly Issue 667/1/30211 Issue 4onwards. The issue number is the last two digits on the serial number label.
HELIOS GENERAL HANDBOOK CALL DEMAND Identification: Additional capacitor on the rear of the p.c.b. Indicates that this board is ELV compliant. PCB Assembly Number 667/1/30680 Issue 3 onwards. The issue number is the last two digits on the serial number label.
HELIOS GENERAL HANDBOOK NEARSIDE ASPECT Identification: Capacitor on the rear of the board indicates that this board is ELV compliant. This feature is also present for 667/1/33655 boards which are all ELV compliant from Issue 1. PCB Assembly Number 667/1/30695 Issue 9 onwards. The issue number is the last two digits on the serial number label.
HELIOS GENERAL HANDBOOK APPENDIX D - Helios Signal Head Screw Fixing Procedure D.1 Introduction The tightening of the single fixing between the bracket and the signal end caps is of crucial importance to the security of the signal and in the following appendix we cover four specific topics associated with this. 1) The correct method of tightening the bolts / end-cap fixings: These parts can be damaged by over tightening or vehicle impact.
HELIOS GENERAL HANDBOOK D.3 Inspection Procedure With reference to the figure immediately below, inspect the end cap fasteners on both ends of the Helios head. Determine if the securing screws are tight. The screw should be seated firmly in position, securing the bracket/head correctly. There should be no evidence that the screws have been over tightened, for example the threads should not have been stripped out of the screw hole.
HELIOS GENERAL HANDBOOK Important Note, Where / If necessary the main fasteners should be removed or replaced using the recommended process / method noted below. 1. Replacement of Main bolts and or washers. a. Secure the signal head bracket which requires the fasteners replaced, using a 6 metre Thule securing strap, as shown in the figures immediately below for the appropriate brackets (top and bottom).
HELIOS GENERAL HANDBOOK b. Replace the bolt, and washer with items appropriate to the type of end cap in use (see section D.4 for details). Ensure that the mating parts of the sacrificial bracket are joined and the whole bracket has engaged in its position correctly. Tighten the securing bolt using a torque wrench set to 20 Newton Metres. Sacrificial Bracket Torque to 20Nm c. Remove the 6 metre Thule securing straps. Make a general inspection of the signal head to ensure that it is secure. D.
HELIOS GENERAL HANDBOOK For the shorter bossed end cap use a 32mm bolt (part number 999/4/44333/532 or kit 667/1/31505/000, which includes nordlock washers). To aid identification of the correct 32mm length bolt (as supplied by Siemens) is coloured black. For the longer bossed end cap use a 40mm bolt (part number 999/4/44333/040).
HELIOS GENERAL HANDBOOK D.5 Upgrades Recommended If the fixing present is not a Nordlock then upgrading to Nordlock should be considered, and the upgrade to Nordlock is recommended where either the washer combination includes a spring washer or where after having been tightened and torqued to the recommended 20 Nm a second inspection within 6 months has shown the fixing to have loosened again. To determine if the present fixing has a spring washer, check as follows.
HELIOS GENERAL HANDBOOK If a plain rounder washer can be seen then a spring washer may also be included (generally with the external or internal serrated washers, the serrations will be visible). Below you will see a plain and spring washer combination, and it is this combination that we at present recommend upgrading to Nordlock washers (using the method as described in section D.
HELIOS GENERAL HANDBOOK 667/HB/30000/000 Issue 24 Page 138 of 143
HELIOS GENERAL HANDBOOK Appendix E- TRAM Indicator Cable connections and Aspects The Tram indicator unit is similar to the Regulatory Signs as the main optical assembly remains in the Lantern when the door assembly is opened. The appearance of the Tram indicator is shown below. Optional demand indicator Tram indicator door assembly showing dots Warning! When the Door assembly is open and the unit powered, the dots will be very bright, do NOT look directly into them.
HELIOS GENERAL HANDBOOK The optical assembly must NOT be further dismantled and care should be taken not to damage the unit or to get any contaminants on the lenses. The optic has a multi-way cable that needs to be terminated (usually to the pole cap assembly) in the normal way. The Cable Colour code is shown in Table 1 below. It should be noted that not all aspects (dots) are used in every installation and the controller specification should be studied to enable the correct aspects to be connected.
HELIOS GENERAL HANDBOOK Below is a representation of the Aspects. It should be noted that Aspect F is normally always lit whilst the optic is in use. Thus it is shown lit in all the diagrams. Aspect A Aspect B Aspect C Aspect D Aspect E Aspect F Where more than 3 aspects are driven special conditioning and drives for the Tram Aspects will be required. In these circumstances the controller Specification and Special instructions must be consulted.
HELIOS GENERAL HANDBOOK INDEX Tools .................................................................. 11 Upgrade ............................................................. 18 A Adjusting angle....................................................... 75 AGD ....................................................................... 71 AGD fitting .............................................................. 31 B Backing board .................................................70, 105 Bleep and Sweep ........
HELIOS GENERAL HANDBOOK Sacrificial cap replacement .................................... 97 Safety Warning......................................................... 2 Screws ..................................................................106 Seal .......................................................................106 Side boxes .................................... 11, 17, 37, 70, 105 Side mounting ........................................................ 31 Signal head arrangement .......................
