ST750 GENERAL HANDBOOK Traffic Solutions Sopers Lane, Poole, Dorset, BH17 7ER United Kingdom +44 (0)1202 782000 www.siemens.co.uk/traffic ST750 General Handbook PREPARED: Andy White FUNCTION: Engineering Manager THIS DOCUMENT IS ELECTRONICALLY HELD AND APPROVED © Siemens plc. 2011 All rights reserved. The information contained herein is the property of Siemens plc and is supplied without liability for errors or omissions.
ST750 GENERAL HANDBOOK Change History Issue 1 2 3 4 5 Change Ref First Issue TS004961 TS005209 TS005637 TS005954 667/HB/33750/000 Date 11 February 2009 27 February 2009 28 August 2009 31 August 2010 10 February 2011 Page 2 Issue 5
ST750 GENERAL HANDBOOK SAFETY INFORMATION HEALTH AND SAFETY AT WORK DISCONNECT ALL POWER TO THE CABINET BEFORE REMOVING OR INSTALLING ANY EQUIPMENT INTO THE CABINET.
ST750 GENERAL HANDBOOK When working on the controller in countries where both sides of the incoming supply are above earth potential, the Master Switch or Circuit Warning Breaker on the rear of the Cabinet should be opened, since the Controller Switch on the front of the ST750 does not isolate both sides of the supply. When re-commissioning signals, the following sequence is recommended: 1. 2. 3.
ST750 GENERAL HANDBOOK WARNING To isolate the equipment the master switch must be in the “Off” position. Switching either the Controller or the Manual Panel Signals On/Off switch to “Off” does not guarantee isolation of the equipment. WARNING These (this) controller(s) require specific configuration to enable them (it) to function correctly when installed.
ST750 GENERAL HANDBOOK Safety of Road Users It is important that all personnel are aware of the dangers to road users that could arise during repair and maintenance of traffic control equipment. Ensure that the crossing area is coned and signed as necessary to warn motorists and pedestrians of any dangers and to help protect the personnel working on the site.
ST750 GENERAL HANDBOOK TABLE OF CONTENTS 1. INTRODUCTION................................................................................................................................ 11 1.1 PURPOSE OF THIS HANDBOOK...................................................................................................11 1.2 CONTACT US.................................................................................................................................. 11 1.3 REFERENCE DOCUMENTS......................
ST750 GENERAL HANDBOOK 3.3 PEDESTRIAN DEMAND CONTROL...............................................................................................36 3.3.1 INTRODUCTION ...................................................................................................................... 36 3.3.2 PEDESTRIAN DEMAND ACCEPTANCE ................................................................................38 3.3.3 PEDESTRIAN DEMAND DELAY (PDD) ...................................................................
ST750 GENERAL HANDBOOK 7. ROUTINE MAINTENANCE PROCEDURES.....................................................................................95 7.1 ROUTINE INSPECTION OF SIGNAL EQUIPMENT .......................................................................95 7.2 ROUTINE INSPECTION AND ELECTRICAL TESTING OF ST750 ...............................................95 7.3 ROUTINE SETUP CHECK .............................................................................................................. 97 7.
ST750 GENERAL HANDBOOK Figure 28 - Allocation of Red Lamp Monitor Channels for ST750LED Controllers with LV CLS (NLM) monitoring ...................................................................................................................................... 74 Figure 29 - Dimming Transformer Tap Selection.................................................................................. 77 Figure 30 - Connector PL5.........................................................................................
ST750 GENERAL HANDBOOK 1. INTRODUCTION 1.1 Purpose of this handbook The purpose of this handbook is to give a general description and specification of the ST750 Rack Assembly and the procedures for its Installation, Commissioning and Maintenance in the ST750 Cabinet Assembly and other Cabinets. Also provided is guidance on testing and maintenance procedures. Note Ongoing development means that some of the delivered items may differ in detail from the information included in this handbook. 1.
ST750 GENERAL HANDBOOK 1.3.3 Essential Documents – Cabling 13. Publisher Siemens Reference Number 667/HE/20664/000 14. Siemens 667/HE/20663/000 Document Title Installation and Commissioning Handbook Installation Testing (General) Loop Detector and Cable Terminations – Installation and Commissioning 1.3.4 Essential Documents – Ancillary Equipment 15. Publisher Siemens Reference Number 667/HE/20662/000 16. Siemens 667/HE/20665/000 17. 18. 19. 20. 21. 22.
ST750 GENERAL HANDBOOK Training requirements for non UK users may be different 1.4.2 REQUIRED TOOLS In addition to a standard Engineer’s tool kit, the following tools are required when carrying out any work on the ST750 Controller: T-bar key S-18 key – Main Cabinet Serial handset Techterm, or Old Oyster handset, or Larger Screened Oyster handset Manual Panel key Type 900 Part Number 667/2/20234/000 4/MC 289 667/4/13296/001 667/4/13296/000 667/4/13296/002 667/4/13651/000 1.
ST750 GENERAL HANDBOOK 1.6 Abbreviations AC AGD BIT CET CLF CLS CPU DC DFM ELV EPROM FT IC IC4 I/O I/P LED LV ms NLM OMU OTU PCB PLD PROM PSU RAM RCD RFL RMS ROW RTC SA SDE ST UTC UTMC VA Alternating Current Above Ground Detector Binary digit (i.e.
ST750 GENERAL HANDBOOK 2. SPECIFICATION The Specification that follows is for the ST750 Cabinet Assembly. Where appropriate it also applies to the ST750 Rack Assembly as supplied for installation in another Cabinet. Non-UK specifications specifications. are detailed where they differ from standard UK 2.1 Equipment Introduction The ST750 is a Pedestrian Controller and Small Non-UK Traffic Controller and can be supplied in either small or large single-door outer cases.
ST750 GENERAL HANDBOOK monitors the actions of the other, and independently turns off the lights to the motorists and pedestrians if either processor causes an error. The software is written in a powerful high level language that allows the implementation of the ST750’s extensive facilities. The ST750 offers both Single and Dual Pedestrian operation and up to a 6 Phase Traffic Controller operation, each with solid state switching.
ST750 GENERAL HANDBOOK This board can expand the inputs/outputs as follows: 16 Inputs 16 Outputs • Detectors These can be Siemens, Microsense or Sarasota self tuning units. Up to 4 units can be accommodated in the ST750 cabinet, each unit having four detector channels. • Ancillary Equipment OTU – Outstation Transmission Unit for Tele Command 12. OMU – Outstation Monitoring Unit for Remote Monitoring System. 2.1.
ST750 GENERAL HANDBOOK Note The ST750 requires a CPU board with a /003 part number suffix for UK applications or /007 for Non-UK applications. Earlier i.e. ST700 CPU boards can NOT be used in an ST750 • PHP – PB801 and the ST750 require PB817 issue 5 or later; PB800 and the ST700 can use PB817 issue 3 or later (which includes PB817 issue 5). • IO – PB801 firmware on the ST750 controller continues to use the I/O built in to the CPU Card, with the option of adding one ST800 style Expansion I/O Board.
ST750 GENERAL HANDBOOK 2.1.7 Spares Compatibility between the ST750 and ST700 With the exception of the CPU board all components of the ST700 system are compatible with the ST750. The ST750 requires a CPU board with a /003 part number suffix for UK applications or /007 for Non-UK applications. Earlier i.e. ST700 CPU boards can NOT be used in an ST750 due to the difference in RAM requirement.
ST750 GENERAL HANDBOOK 2.3 MAINS SUPPLY The following supply voltages may be used: Nominal Voltage 100-240 Minimum Voltage 85 Maximum Voltage 264 It is recommended that the signals are supplied at the nominal mains voltage during Bright. I.e. For a 200V nominal supply, use 200V transformer/bulbs. THE PROSPECTIVE SHORT CIRCUIT CURRENT OF THE Note SUPPLY MUST NOT EXCEED 16,000 AMPS Frequency: 50Hz ±2Hz or 60Hz ±2Hz Mains Brownout: Continues operating with up to 50ms loss of mains.
ST750 GENERAL HANDBOOK 2.3.1.1 Supply Transients The ST750 has been designed to withstand all the transients as defined in EN50293 on its supply. 2.3.1.2 Electrical Interference The ST750 has been designed to create very little electrical interference, by the use of mains filters and solid state lamp switching control. The mains filters protect the incoming mains supply from any ST750 generated signals. The lamp switches are switched at zero crossover of the mains supply to reduce any switching transients.
ST750 GENERAL HANDBOOK The typical supply requirements for an ST750 are: Power (Watts) Single (2 Phase) or Dual (4 Phase) Pedestrian Controller 40 W Non-UK Controller (6 Phase) 50 W Table 1 – ST750 Supply Requirements These requirements exclude lamp loads, detectors and OTU but include dimming transformer. 2.4.2 Lamp Drive Capability Max Current (Amps) Maximum lamp current that the ST750 can supply including short-term illumination, i.e. red/amber.
ST750 GENERAL HANDBOOK Power (Watts) Siemens ST4R/ST4S detectors 2.4 watts per detector Sarasota MTS36Z (2 channel) or MTS38Z (4 channel) detectors. (NB The power consumption is the same for both 2 and 4 channel units.) 3 watts per detector Microsense detectors 6 watts per detector Table 4 – Detector Power Consumption Key: Traffic Red / Amber / Green Signal (Primary) Traffic Red / Amber / Green Signal (Secondary) Pedestrian Red / Green Signal. Pedestrian Wait Indicator Box (on pole).
ST750 GENERAL HANDBOOK Assuming that HI lamps take 63W each, the theoretical crossing (Figure 1) calculation would be: One lamp per signal head @ 63W x 12 signal heads Wait indicators at 40W x 4 Total average signal lamp power = = = 756W 160W 916W 2.4.4 Intersection’s Power Requirements for Running Costs Estimate The following worked example is based upon a 230V/240V mains supply. 1. Calculate the total average controller power 2. Calculate the total average lamp power for the junction as shown in 2.4.
ST750 GENERAL HANDBOOK If an estimate of running costs is required that includes the period of time that the signals are dimmed, this can be approximated as follows: Total average Junction Power (Dimmed) is: Total average Signal Power x (Dimmed Voltage / Nominal Mains voltage) plus Total average Controller Power. Therefore for the theoretical crossing in Figure 1: Total average Junction Power (Dimmed) = (916W x (160V/240V)) + 46W = 657 W 2.4.
ST750 GENERAL HANDBOOK • On the left-hand side flange of the metal outer case frame just above the Master Switch Panel, using the four appropriate fixing holes. 2.4.7 Audible and Tactile Supplies The Audible and Tactile power supplies on the ST750 are designed to provide a DC voltage between 10V and 24V, and typically provide a maximum of 100mA at 18V DC. The ST750 provides three audible outputs on each of the 2 pedestrian phases. These are located on the CPU card PL2 (Phase D) and PL3 (Phase B).
ST750 GENERAL HANDBOOK to be time switched, then the ‘Tactile’ output is used to control the tactile PSU interlock signal input. 2.5 PHASES The ST750 Pedestrian Controller supports either 2 ‘Real’ Phases for a single pedestrian crossing or 4 ‘Real’ Phases for a dual pedestrian crossing. The ST750 Small Non-UK Controller can support up to 6 ‘Real’ Phases. The ST750 software can support up 32 phases, which can be any combination of real and software phases. 2.
ST750 GENERAL HANDBOOK random signals not being synchronised to the clock pulse, may add up to 200ms to the time. If the result of the above timings is required to change the signal lamps, a further error may occur up to a maximum of 21ms. The set-up accuracy of the real time clock and the accuracy of any offsets calculated from it will be 1 second. 2.
ST750 GENERAL HANDBOOK The following intersection modes are available on the ST750 Non-UK controller: • Start Up • Part-time (Off period) • Urban Traffic Control. • Emergency Vehicle • Priority (Non-emergency vehicle) • Hurry Call • Manual Operation • Manual Step-On, if fitted. • VA, CLF or FT Operation (selected via mode switch) • Cableless Linking • Vehicle Actuated (VA) • Fixed Time (FT) For more information refer to the ST900 Family General Handbook 2.
ST750 GENERAL HANDBOOK For more details on the Small and Large cabinets refer to section 4.1 The case is manufactured in grey or black powder coated aluminium. In addition to the screw-locks, the main controller door is fitted with a S18 lock. There is a facility to change the S18 lock to a Yale with an RKA27C pattern barrel. The key lock should not be operated unless the screw locks are tight, i.e. Note Unlock the case before undoing the screw lock and only lock the case after tightening the screw locks.
ST750 GENERAL HANDBOOK 3. PEDESTRIAN FACILITIES 3.1 Types of Pedestrian Crossings 3.1.1 Pelican Crossing The vehicle to pedestrian intergreen is controlled by the PAR Pedestrian All-Red period. The PAR handset command allows different all-red periods to be executed depending on why the vehicle phase left green. Different times can be specified for each of the following: fixed vehicle period mode (see section 3.2.1), VA mode ‘gap’ change and VA mode ‘max’ change (see section 3.2.
ST750 GENERAL HANDBOOK Veh: Green Amber Ped: Red Red 3 Red Green PAR Green R/A MIN PBT CDY0 2 IPX Gap Change On-Crossing Detector: Max Change R/A Green Red Red CMX CDY1 2 On intersections, the appearance of the vehicle phase will be delayed further if the IGN intergreen time is larger than PBT plus the red/amber period. 3.1.3 Far Sided Pedestrian Crossing The vehicle to pedestrian intergreen on a stand-alone crossing is controlled by PAR.
ST750 GENERAL HANDBOOK Veh: Green Amber Ped: Red Red 3 Green PAR MIN Green R/A Red Blackout PBT CRD 2 IPX Gap Change On-Crossing Detector: Max Change R/A Green Red Red Blackout CMX CDY1 CRD 2 If a fixed black-out period is required, i.e.
ST750 GENERAL HANDBOOK Also note that if the Continuous Ped Demand (CPD) button on the manual is pressed, then the red clearance of near-sided signals will be extended to its maximum as required by TR2500A. If an on-crossing detector has not been activated from the end of the preceding pedestrian clearance period to the end of the current pedestrian steady green period, then the clearance period is forced to run to its maximum.
ST750 GENERAL HANDBOOK If the pedestrian phase is demanded after this ‘minimum’ period has expired and no vehicles are present, then the vehicle phase loses right of way immediately. If the vehicle detectors indicate that vehicles are present, then the vehicle phase will remain at green until the vehicles are no longer present. This is referred to as a ‘gap change’ since the vehicle phase loses right of way to service the pedestrian demand when a gap in the traffic appears.
ST750 GENERAL HANDBOOK during certain stages of the intersection controller to help the traffic entering and/or leaving the nearby intersection. Cableless Link – Using the controller’s Master Time Clock and CLF facilities, the controller can be given one or more ‘windows’ during the CLF cycle when it is allowed to service the pedestrian demands. For the rest of cycle, the vehicle phase remains at green. UTC – The ‘PV’ control bit from the instation holds the vehicle phase at green.
ST750 GENERAL HANDBOOK Figure 2 – Ped Demand Processing SPECIAL CONDITIONING READ/WRITE ACCESS PUSHBUTTON ACTIVE (ENG 254) OR NOT SET ROW CLR KBSACT KERBSIDE ACTIVE OR x4 LATCHED PUSHBUTTON PBNLAT (ENG 284) (ENG 255) ALL KERBSIDES INACTIVE PUSHBUTTON & KERBSIDE LATCH SET PBKLAT (ENG 256) LATCHD 1WTCTRL (ENG 197) CLR PEDBUT OR OR (ENG 29) ROW VARIOUS FACILITIES UNLPUF PDX OR DEMAND BUT NOT KERBSIDE NOT IPX AND PED DEMAND PROCESSING LATCHED PHASE DEMANDS OR PHASE DEMAND PROCE
ST750 GENERAL HANDBOOK 3.3.2 Pedestrian Demand Acceptance For the purposes of this section, push button inputs include any demand inputs assigned to a pedestrian phase, including for example inductive loops for cycles. If no kerbside detectors are configured on the phase, pressing the push buttons generates a latched demand for the pedestrian phase, which is only cleared when the pedestrian phase gains right of way.
ST750 GENERAL HANDBOOK • • In VA mode, if no real phases in the same stream are at right of way, the delay is introduced, so delaying the appearance of the pedestrian green after a quiescent all-red period, for example. In all other modes, the delay will always be introduced. This is to cater for cases such as ‘fixed vehicle period’ mode, UTC inserting a demand dependant force for the pedestrian phase, or CLF introducing a demand dependant move just after the push-button is pressed.
ST750 GENERAL HANDBOOK * Note that for the input to be seen inactive at the 200ms processing rate, all ten 20ms samples must have been inactive. Thereafter, the force is only removed after 5 consecutive tests of the detector have passed, but the fault log entry remains set and the DFM indicator remains illuminated, until RFL=1 is entered. If the maintenance engineer enters RFL=1, the controller will automatically perform a test.
ST750 GENERAL HANDBOOK 4. HARDWARE OVERVIEW 4.
ST750 GENERAL HANDBOOK ST750 Rack Assembly Detector PSU Kit Gemini Loop Detectors 11” Detector Rack Kit Rack 11” Swing Frame Mains (Dimming) Transformer Figure 4 – ST750 in Small Outer Case configured with optional 11” Swing Frame 667/HB/33750/000 Page 42 Issue 5
ST750 GENERAL HANDBOOK 19” Swing Frame ST700 Rack Assembly 19” Rack Assembly Figure 5 – ST750 in Large Outer Case configured with optional 19” Swing Frame 667/HB/33750/000 Page 43 Issue 5
ST750 GENERAL HANDBOOK 4.
ST750 GENERAL HANDBOOK Figure 7 – CPU and Phase Driver Cards I/O Expansion Card Figure 8 – I.
ST750 GENERAL HANDBOOK 4.3 ST750 CPU LEDS There are 21 LED indicators on the component side of the ST750 CPU PCB in two groups, Status (see section 4.3.1) and Signal (see section 4.3.2), as shown in Figure 9. LED SIGNAL VISUAL DISPLAYS VIEW OF PHASE 'F' A B C D E F PP RED AMB SE F GRN WD STATUS VISUAL DISPLAYS Figure 9 - CPU LEDs 4.3.1 Status LED Group The top Status LED is green and is labelled ‘PP’ for power present.
ST750 GENERAL HANDBOOK 4.3.2 Signal LED Group These LEDs are in groups of three, one for each traffic phase A to F. Each group has a red at the top, amber in the middle and green at the bottom (see View of Phase ‘F’ in Figure 9) to represent a set of traffic lights. They provide visual representation of the state of the red, amber and green drives for their respective phase. 4.
ST750 GENERAL HANDBOOK 4.5 FUSES Figure 42 on page 111 lists the types and placing of fuses in the ST750. Fuses should only be replaced by ones of a similar rating and type. 4.6 Mains Dimming Transformer Mains Dimming Voltages are derived from the Mains Dimming Transformer, mounted in the bottom left hand corner of the controller, and delivered to SK1 on the Phase Driver PCB. Please refer to Figure 11. Figure 11 – Mains Dimming Transformer 4.
ST750 GENERAL HANDBOOK 4.8 Detector Mounting The ST750 supports Single Detector Back Planes only - the Intelligent Detector Backplane as fitted to ST750 ELV / ST900 / ST900 ELV controllers is NOT supported. For full details on the connection of detectors and power requirements please refer to ST4R/ST4S Detector Manual 667/HB/27663/000. Single Detector Backplane Kits (rear view) Figure 13 – Single Detector Backplanes 4.8.
ST750 GENERAL HANDBOOK Gemini Unit Detectors Figure 14 – Detector Swing Frame Note The Detector swing frame supported in the ST750 is a different part (667/1/33770/000) to that supported in the ST700. The detector mounting frame 667/1/27854, as used in the ST700 is NOT supported in the ST750 If more than four Detector PCBs are required, an 11” Swing Frame will be required in the cabinet.
ST750 GENERAL HANDBOOK 4.8.2 Detector Back Planes in Large Outer Case With reference to Figure 16, when a Large Outer Case is used a 19” Swing Frame is required. One or more 19” Detector Rack Kits should be specified and mounted to the 19” Swing Frame, which in turn provides the platform to mount the Detector Back Planes. The maximum number of Detector PCBs, which can be specified, is eight. Figure 16 shows the mounting position for the 19” Detector Rack Kit.
ST750 GENERAL HANDBOOK 4.10 Gemini2 4.10.1 Gemini2 in Small Outer Case When a Gemini2 unit is required, it can be positioned in one of two locations, depending on the quantity of Detector PCBs fitted. If four or less Detector PCBs are required then the Gemini2 unit can be accommodated in a Detector Swing Frame, refer to Figure 18.
ST750 GENERAL HANDBOOK If more than four Detector PCBs are required then an 11” Swing Frames will have to be fitted to accommodate the Detector PCBs along with the Gemini2. Refer to Figure 19. Figure 19 - Gemini in an 11" Swing Frame Warning! When fitting a Gemini2 unit in a swing frame care must be taken to ensure that the internal lead acid battery terminals point UPWARDS to prevent leakage. With a Gemini2 orientated as In Figure 19 it will be necessary to invert the battery BEFORE installation.
ST750 GENERAL HANDBOOK Warning! When fitting a Gemini2 unit in a swing frame care must be taken to ensure that the internal lead acid battery terminals point UPWARDS to prevent leakage. With a Gemini2 orientated as In Figure 20 it will be necessary to invert the battery BEFORE installation. Refer to 667/HB/32600/000 for full details.
ST750 GENERAL HANDBOOK 4.11 TC12 OTU The Outstation Transmission Unit (OTU) based around the Tele 12 (TC12) Command System, is available in two configurations – • • Integral OTU Freestanding OTU 4.11.1 Integral TC12 OTU in Small or Large Outer Cases The Integral Tele 12 OTU PCB occupies the same position as the I/O Expansion PCB in the Rack Assembly (refer to Figure 8). Therefore, both Integral OTU and I/O Expansion units cannot be fitted in the same controller.
ST750 GENERAL HANDBOOK Freestanding OTU in 11” Swing Frame Figure 21 - Freestanding TC12 OTU in Small Outer Case 667/HB/33750/000 Page 56 Issue 5
ST750 GENERAL HANDBOOK 4.11.3 Freestanding TC12 OTU in a Large Outer Case A freestanding OTU must be specified in a 5U 19” rack unit.. With reference to Figure 22, the 5U Rack is mounted at the bottom of the 19” Swing Frame. Mains Power to the Freestanding OTU is obtained from the Master Switch Unit. For connections and configuration details for the TC12 OTU connection scheme refer to the TC12 General Handbook 667/HB/43100/000.
ST750 GENERAL HANDBOOK 4.12 SDE/SA The ST750 does not support the SDE/SA PCB. Instead, the functionality associated with Speed Discrimination and Speed Assessment is contained within the standard ST750 controller firmware. Please refer to the doc 667/HH/32900/00 for the appropriate handset commands.
ST750 GENERAL HANDBOOK 5. INSTALLATION AND COMMISSIONING This section details the procedure for installing and commissioning of the ST750 pedestrian controller in both the small and large controller cabinet arrangements. Refer to section 6 for instructions on installing and commissioning of the ST750 Rack Assembly into other traffic controller cabinets. 5.
ST750 GENERAL HANDBOOK Dimming tap positions Figure 23 - Dimming Transformer Tap Selection Once the hardware has been checked as above, it is recommended that a self-test is run (see section 5.16) before leaving the service centre. 5.2 ST750 Cabinet preparation The controller cabinets are normally delivered from the manufacturing department in a fully assembled and tested state. However to aid installation, the internal equipment has been designed to be readily removable.
ST750 GENERAL HANDBOOK carriageway. Where no pedestrian guard rails are fitted, a clearance of at least 600mm should be left between the cabinet and the kerb edge so that guard rails may be installed at a later date without the need to disturb the cabinet installation. (iii) Any person having control over the junction, whether manual control or test box simulation, MUST have a good view of the intersection. (iv) When the ST750 controller cabinet is to be located on unmade ground (e.g.
ST750 GENERAL HANDBOOK 5.4.1 Install Controller Cabinet and Stool A hole should be excavated and a flagstone at least 600mm x 450mm embedded securely at the bottom of the hole. Refer to Figure 24 for the general method of installation and dimensions. Care should be taken to ensure the correct orientation of the controller cabinet. Care must be taken that the controller and stool are not buried to deep as the controller isolation transformer in this cabinet is very low.
ST750 GENERAL HANDBOOK Figure 24 - Stool Installation, Small Cabinet 5.5 Installation of the ST750 Large Cabinet The following list details the order in which it is recommended that the ST750 installation take place. - the controller cabinet cannot be made waterproof Remove the Rack assembly if necessary – section 5.2 Install the stool and controller cabinet into the ground – section 5.4.1 Pull the cables into position – section 5.6 Terminate the armour to the CET connectors – section 5.
ST750 GENERAL HANDBOOK 5.5.1 Remove the controller cabinet from the stool Remove the stool by removing its four fixing nuts and bolts and lift the controller cabinet off the stool. 5.5.2 Install the stool A hole should be excavated and a flagstone at least 900mm x 600mm embedded securely at the bottom of the hole. Refer to Figure 25 for the general method of installation and dimensions.
ST750 GENERAL HANDBOOK Figure 25 - Stool Installation, Large Cabinet 5.6 Cabling to the ST750 small and large cabinets All cables into the ST750 controller cabinets should be fed through the ducts and into the stool/base as close to the controller termination positions as possible. This is to prevent unnecessary damage being caused should any cables need to be moved once they are in place. Care must be taken not to obstruct the Electricity Supply Company cut-out with any cabling.
ST750 GENERAL HANDBOOK The inner sheathing is removed to expose the individual cores that are connected to associated terminals, leaving sufficient spare length for re-making off the ends should this become necessary. Unused cores should be left with sufficient length to enable them to be connected to any terminal should this subsequently become necessary. The ST750S, controller cabinet (Small outer-case) has 2 CET bars and the CET bars are mounted directly to the controller cabinet.
ST750 GENERAL HANDBOOK SIDE VIEW Mounted at CET Lower Fixing Position Cores Inner Insulation Ident 55mm to 65mm Higher CET Fixing Position (Armouring not shown at front of ring for clarity) Lower CET Fixing Position Stud Hose Clip Nut Ident (Alternative position) CET Bar Incoming Cable CET Ring (Earthing Band) PLAN VIEW Wormdrive Hose Clip 991/4/01375/028 Earthing Band 667/2/02348/000 Figure 26 - Termination of Armoured CAble to CET bar 5.
ST750 GENERAL HANDBOOK 5.8 Fit the cabinet to the Stool If the controller cabinet was not installed with the mounting stool then it should be done as follows: Clean the top surface of the stool and the lower surface of the cabinet that will be in contact when the cabinet is fitted. The cabinet is installed by lowering it onto the stool and fitting the four retaining bolts. When fitting the cabinet onto the stool, make sure that all the cables are in their correct position with regard to the CET bar.
ST750 GENERAL HANDBOOK A concrete fillet around the outside of the stool may be completed before or after the epoxy sealing to suit site conditions. Refer to Figure 24 and Figure 25 for general method of in-fill, kiln dried sand, sealing and concrete fillet. Warning! Should the controller cabinet base/stool NOT be in-filled with kiln dried sand and sealed with an approved epoxy resin the controller electronics/electrical circuits may be damaged. 5.
ST750 GENERAL HANDBOOK and back of the cabinet’s inner metal frame. The position of these terminal blocks means that a short screwdriver (No1 Pozidriv) is required to terminate the wires due to the proximity of the dimming transformer (if fitted). If there are many cables, access to the terminal blocks becomes restricted. 5.11.
ST750 GENERAL HANDBOOK Softwire kit Cableform 667/1/27877/000 15 16 Not used (for isolation purposes) Green Phase B Green GB Coding Details: The plug mount connector on the Phase Drive board PL6 has coding pins 2 and 15 fitted, with the cable fitted socket connector that mates with PL6 having coding pins 1 and 16 fitted. This coding prevent the incorrect connection between PL6 and PL7.
ST750 GENERAL HANDBOOK Coding Details: The plug mount connector on the Phase Drive board PL7 has coding pins 1 and 16 fitted, with the cable fitted socket connector that mates with PL7 having coding pins 2 and 15 fitted. This coding prevent the incorrect connection between PL7 and PL6.
ST750 GENERAL HANDBOOK PL6 Vehicle Supply 240v Phase A R A G Triacs and Monitors RAU RA1 Vehicle RLM YA1 Channel 1 GA1 5 33 RLM LMU+RLM 37 RA2 Vehicle RLM YA2 Channel 2 GA2 6 Vehicle RLM Channel 3 Vehicle RLM Channel 4 RLM LMU+RLM Pedestrian Supply 240/48V Wait Supply 240/48V Current sensor number, in this case sensor 6.
ST750 GENERAL HANDBOOK PL6 Phase A Vehicle Supply 230V R A G Triacs and Monitors RAU RA1 5 YA1 Vehicle RLM Channel 1 GA1 LMU + RLM RA2 6 YA2 Vehicle RLM Channel 2 GA2 Pedestrian Supply 230/48V Wait Supply 48V Phase B R G W LMU + RLM RB (Red Man) 34 GB (Green Man) LMU only 38 YB Triacs and Monitors Wait LMU only PL7 Phase C Vehicle Supply 230V R A G Triacs and Monitors RAU No external RLM on Phase C RA1 7 YA1 Vehicle RLM Channel 1 GA1 LMU + RLM RA2 8 YA2 Vehicle RLM Channel
ST750 GENERAL HANDBOOK Table 9 – Phase Drive SK1 Connector SK1 Pin No Signal Phase Drive Returns, Solar Cell, Detector and AUX mains supplies 1 2 3 4 5 6 7 8 9 10 11 12 13 Signal Lamp Supply Return Signal Lamp Supply Return Signal Lamp Supply Return Signal Lamp Supply Return Signal Lamp Supply Return Signal Lamp Supply Return Signal Lamp Supply Return Aux Mains Supply Aux Mains Supply 2 ( not used) 230V Detector Supply Solar Cell Live Solar Cell Input Not used (for isolation purposes) 14 15 16 17 Soft
ST750 GENERAL HANDBOOK Coding Details: Connector PL1 has no coding elements, as it is the only 3-way connector and can only be inserted one way. Table 11 – Phase Drive SK2 Connector No Dimming If the installation has no Dimming Transformer, then insert the Cableform 667/1/27868/002. This cable is provided as standard with rack assemblies. Cabinet assemblies have a dimming transformer fitted as standard, which includes the cable 667/1/27868/000. See Table 12 below for details.
ST750 GENERAL HANDBOOK Figure 29 - Dimming Transformer Tap Selection Dimming tap positions Required Dimming voltage 160V 140V 120V Input Tap IP2 IP3 IP4 If the ST750 is installed in another cabinet, the 667/1/27868/001 cable should be used with connections as shown above. This cable is provided with the cabinet modification kit. Note 1: Note 2: The links between pins 3 to 6 need to be rearranged.
ST750 GENERAL HANDBOOK 9 10 11 12 13 14 15 16 External Sensor 37 – Red External Sensor 37 – White External Sensor 38 – Red External Sensor 38 – White External Sensor 39 – Red External Sensor 39 – White External Sensor 40 – Red External Sensor 40 – White Note that the ST750LED Phase Driver PCB with LV CLS (NLM) monitoring only has connections on PL5 for External Sensors 38 and 40 (Phase B and Phase D Waits).
ST750 GENERAL HANDBOOK ELV:0 – All signals at 230v 34/36 – Monitor Red+Green 38/40 – Not Required Wait (all cables thro’ toroid twice) Note ELV:1 – Waits at 48v 34/36 – Monitor Red+Green (Red & Green thro’ toroid twice) (Wait cables thro’ toroid once) 38/40 –Monitor Wait (Wait cables thro’ toroid once) ELV:2 – All ped signals at 48V 34/36 – Monitor Red+Green (all cables thro’ toroid once) 38/40 –Monitor Wait (all cables thro’ toroid once) At the time of writing, the controller is unable to monitor th
ST750 GENERAL HANDBOOK When installing in any other cabinet, a Softwire kit is required. Wire the loose wire ends of the Softwire kit cableform to the terminal blocks in the cabinet, using the relevant signals as defined by the works specification and shown in the tables that follow: Table 14 – Processor Card PL3 Connector Note: These terminals must be tightened correctly, using Phoenix Screwdriver Part Number SZS 0.4 x 2,5 or equivalent.
ST750 GENERAL HANDBOOK Coding for PL3 Mating Half PL3 2 Coding Ridge Removes in 3 positions 8 Coding Pin Inserted in 3 Positions 13 PL3 on PCB Figure 31 - Connector PL3 Table 15 – Processor Card PL7 Connector Note: These terminals must be tightened correctly using Phoenix Screwdriver Part Number SZS 0.4 x 2,5 or equivalent.
ST750 GENERAL HANDBOOK prevents the incorrect connection between PL7 and PL6. For more details see the following diagram: Coding for PL7 Mating Half PL7 2 Coding Ridge Removes in 3 positions 8 Coding Pin Inserted in 3 Positions 16 PL7 on PCB Figure 32 - Connector PL7 Table 16 – Processor Card PL2 Connector Note: These terminals must be tightened correctly using Phoenix Screwdriver Part Number SZS 0.4 x 2,5 or equivalent.
ST750 GENERAL HANDBOOK Coding for PL2 Mating Half PL2 1 Coding Ridge Removes in 3 positions 6 Coding Pin Inserted in 3 Positions 12 PL2 on PCB Figure 33 - Connector PL2 Table 17 – Processor Card PL6 Connector Note: These terminals must be tightened correctly using Phoenix Screwdriver Part Number SZS 0.4 x 2,5 or equivalent.
ST750 GENERAL HANDBOOK prevent the incorrect connection between PL6 and PL7. For more details see the following diagram: Coding for PL6 Mating Half PL6 1 Coding Ridge Removes in 3 positions 7 Coding Pin Inserted in 3 Positions 15 PL6 on PCB Figure 34 - Connector PL6 5.12 REGULATORY SIGNS MONITORING The ST750 Rack Assembly does not cover regulatory signs and their associated monitoring. There is a fuse position labelled ‘F3 Detector’ which could be used to supply regulatory signs if required.
ST750 GENERAL HANDBOOK 5.13.1 CPU PCB Switch and Link Setup See the following pages for switch and link settings.
ST750 GENERAL HANDBOOK 5.13.1.1 DIL Switch S4 Settings For use in the UK, the hardware fail flash facility should be disabled. The settings are shown in Figure 36. For use in Non-UK versions, the flash rate can be set to different speeds for 40ms to 600ms (on 50Hz operation) by setting the right combination of S4 switches to the off position.
ST750 GENERAL HANDBOOK S2 Phase:- S3 Phase:- 1 1 RED AMBER 6 6 7&8 not used OFF 7&8 not used ON OFF ON Figure 37 – Phase Output Flash Selection 5.13.1.
ST750 GENERAL HANDBOOK 5.13.
ST750 GENERAL HANDBOOK 5.13.2.1 Fuse/Dummy Fuse Settings The output voltage for the Pedestrian Red and Pedestrian Green can be set to either 230V or 48V operation. Fitting the fuse and dummy fuse as follows sets the voltage: • For 230V operation fit the 10A fuse in F10 and the dummy fuse in F11. • For 48V operation fit the 10A fuse in F11 and the dummy fuse in F10. The output voltage for the Pedestrian Waits can be set to either 230V or 48V operation.
ST750 GENERAL HANDBOOK Note that the ST750LED Phase Driver PCB with LV CLS (NLM) monitoring always provides Waits at 48V, so LK16, LK19 and LK21 do not exist. Note: Links LK16 and LK19 are accessed through the two rectangular cut outs in the heatsink cover. See Figure 39 for details. A pair of long nose pliers is required to insert and extract the handbag links. Both the Red and Blue links are wire shorting links in the form of a handbag, with a handle to aid insertion and extraction.
ST750 GENERAL HANDBOOK Select and run the self-test – see section 8. If the self test passes, replace the 10A fuses in the Phase Drive PCB. The ST750P stand-alone pedestrian controllers normally run one of the standard configurations generated by Siemens Poole that are listed below: EM30700 Single/dual stand-alone Pelican crossing EM30701 Single/dual stand-alone crossing with a red clearance period, i.e. nearsided Puffin or Toucan crossing.
ST750 GENERAL HANDBOOK must be carried out, to ensure that the individual approaches are wired correctly as shown in Figure 27. The ST750 signals can now be switched on (using the switch on the manual panel) and the ST750 powered up normally. If the solar cell and signal dimming are not required then the following test can be ignored. 1. Cover the photoelectric cell for at least one minute to exclude any light and check that the signals are dimmed. 2.
ST750 GENERAL HANDBOOK 5.17 COMMON RETURNS FOR PUSH BUTTON For the connections for the common returns see the following drawings :ST750 in small outer case - 667/CC/29000/002 ST750 in large outer case - 667/CC/29000/003 5.
ST750 GENERAL HANDBOOK 6. FITTING THE ST750 RACK ASSEMBLY INTO ALTERNATIVE CABINETS Warning! DISCONNECT ALL POWER TO THE CABINET BEFORE REMOVING OR INSTALLING ANY EQUIPMENT INTO THE CABINET. The ST750 Rack Assembly may be fitted into enclosures other than the ST750 Cabinet Assembly. In the UK, the Cabinet must be one that has previously been approved with a different controller.
ST750 GENERAL HANDBOOK 7. ROUTINE MAINTENANCE PROCEDURES This section contains a list of checks to be performed at an ST750 on a regular basis (normally annually). If for any reason, the power is switched off to the ST750, then a total installation Megger test should be carried out, as defined in the General Testing Handbook. 7.1 ROUTINE INSPECTION OF SIGNAL EQUIPMENT Check all signal heads/aspects for damage and take any necessary corrective action.
ST750 GENERAL HANDBOOK Warning! The following tests will result in the signals extinguishing. • Test the 300mA RCD (if fitted) by pressing the test button. The breaker should operate immediately. If the contract specifies the testing of RCD speed, then this test should be performed using the appropriate equipment. If the RCD is faulty then the results should be recorded the unit replaced. Any replacement unit is to be similarly tested to ensure correct operation before leaving site.
ST750 GENERAL HANDBOOK If the fault still persists then: (2) Increase the number of conductors/cable cores used for the neutral. Or (3) Replace the cable that has failed the test. Re-test the cable to ensure that corrective action taken has removed the problem. • With the handset, check that all inputs used are operating correctly. • Test the maintenance socket RCD by pressing the test button. The breaker should operate immediately (See notes on RCD testing earlier in this section).
ST750 GENERAL HANDBOOK 7.4.1 Safety Requirements Warning! Before replacing any fuses, PCBs etc., IT IS ESSENTIAL THAT THE POWER TO THE ST750 IS ISOLATED. See the Safety Warning on page 2 for details. Failure to isolate the supply before changing parts may result in Warning! damage to the ST750 7.4.2 General Requirements When replacing PCBs the original PCB should be inspected and the following points checked: (a) Check the connectors on the PCB.
ST750 GENERAL HANDBOOK To open the hinged plate, the 64-way Phase Control Ribbon cables at the front of the ST750 Rack Assembly must be disconnected. Disconnection of the cable disconnects all logic power from the CPU Warning and therefore prevents the ST750 operating the lights, but it does not switch the incoming mains off. The mains must be isolated at the master switch before any disconnection of cables or fuse replacement takes place. 7.4.
ST750 GENERAL HANDBOOK • • • • • Unclip the earth lead from the hinged front plate Remove the front plate 1 holding the CPU (and I/O or OTU) and store carefully Disconnect the earth wires from the fixing point in the assembly Disconnect PL6, PL7, PL8 and SK2 Disconnect PL1 and SK1. Warning Care must be exercised when removing or inserting the green connectors and their cables from the PCB, as strong extraction and insertion forces are required.
ST750 GENERAL HANDBOOK Where an Internal Manual panel is fitted, it may be removed directly by removal of the screws holding it to the 19 inch panel; it may be easier to remove the 19 inch panel from the rack first. No sealing is required on refitting. 7.4.
ST750 GENERAL HANDBOOK 8. SELF-TEST FACILITY The self-test facility can be used to check the hardware fitted to the controller, even before a configuration is loaded. It is designed to be used both in the factory by production and on the street by installation/ maintenance engineers. Self-test is initiated by holding down the level 3 access button while switching on the power to the controller. The button should be released once the green heartbeat LED starts to flash.
ST750 GENERAL HANDBOOK Figure 41 – Handset 0 = - 1 = - E 0000 00 2 = F – 3 = F E 0 1 2 3 4 5 6 7 = = = = = = = = - C C C C B B – B B A – A A – A 8 9 A B C D E F = = = = = = = = D D D D D D D D – – C C C C B B – B B A – A A – A 0000 00 0 2 So in the above example, there are no voltages on Phase B amber (or Wait).
ST750 GENERAL HANDBOOK ZXO Sync’d... If the phase bus processor cannot synchronise to the mains zero cross-over signal, then self-test will wait indefinitely at this point with the red system error LED flashing. Mains Freq Error If the mains frequency is more than 5% out from either 50Hz or 60Hz. • Checks all the ADC test voltages on all of the lamp switch cards: ADC Tests....Failed ADC Test Readings 0.0V 2.5V 5.0V B0+ nnnn nnnn nnnn B0- nnnn nnnn nnnn ... .... .... ....
ST750 GENERAL HANDBOOK Bad L/S Cards Once initialised, the phase bus processor performs more thorough checks on the lamp switch card and may detect faults. • Checks the monitor validation signal: M/V Test ....Failed Mon Val Failed The monitor validation signal is generated by the main processor to check the phase bus processor, so a failure is probably due to a faulty processor card. • Step 1 Complete, Start Step 2: At this point, the self-test has successfully checked-out the logic side of the cards.
ST750 GENERAL HANDBOOK If any of the voltage monitors appear to be detecting mains, then it would imply that those triacs are not holding off the mains and the lamp switch card should be replaced. • L/S Supply Failure: L/S Monitor Fault The lamp supply can be detected on the voltage monitors, but no signal is present from the lamp supply monitoring transformer. Replace the lamp switch card.
ST750 GENERAL HANDBOOK • Checks all of the triacs in turn by applying a very short pulse to each phase’s colour: A/Red:Extra Sigs On R-00000001+00000001 A-00000001+00000001 G-00000001+00000001 A fault will be logged if extra signals are detected as on when one particular aspect is pulsed. This would normally imply a short-circuit in the street cabling or a open neutral connection. No Voltages On...
ST750 GENERAL HANDBOOK Appendix A - PART NUMBERS AND SPARES LIST Use of components other than those listed, or modifications or enhancements that have not been authorised by Siemens Traffic may invalidate the warranty or safety of this product. A.
ST750 GENERAL HANDBOOK Description Manual Panel RS232 Kit 300mA RCD Kit Lightning Suppression Kit 24V AC Detector PSU Kit Dimming/48V Transformer Kit Controller Handset Current Monitoring Transformer Siemens Part Number 667/1/27110/000 667/1/27117/000 667/1/27118/000 667/1/27853/000 667/1/27867/000 667/4/13296/000 667/7/25171/000 GEC125/104 Conversion Kit CST – McQue Conversion Kit T110 Pole Mount Conversion Kit T500P Conversion Kit GEC125 in 25 Case Conversion Kit T400S/T500S Conversion Kit Microsense M
ST750 GENERAL HANDBOOK A.2.2 – FUSES See Appendix A.3 for details of where these fuses are used 0.5A cartridge fuse 16A HRC cartridge fuse (Pre Nov 2003) 20A MCB SP C Type (Post Nov 2003) 5A HRC cartridge fuse 3.15A fuse 5A HRC cartridge fuse 10A cartridge fuse 5A cartridge fuse 16A HRC cartridge fuse 518/4/90285/004 518/4/90352/005 516/4/97076/010 518/4/90638/000 518/4/97020/115 518/4/97052/017 518/4/90301/013 518/4/90301/010 518/4/97056/012 A.2.
ST750 GENERAL HANDBOOK Controller Switch Fuse 518/4/97056/012 16A HRC cartridge fuse size 0 (32mm x 6.4mm) marked ‘F1’ on Phase Drive PCB AC Detector Fuse 518/4/90301/010 5A cartridge fuse (20mm x 5mm) marked ‘F3’ on Phase Drive PCB. Solar Cell Fuses 518/4/90301/010 5A cartridge fuse (20mm x 5mm) marked ‘F2’ on Phase Drive PCB. 230V R/A Supply Fuse 518/4/90301/013 10A cartridge fuse (20mm x 5mm) marked ‘F9’ on Phase Drive PCB.
ST750 GENERAL HANDBOOK LAST PAGE OF THE ST750 GENERAL HANDBOOK 667/HB/33750/000 Page 112 Issue 5
