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American Dynamics SensorRail IIIE, Service Manual

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American Dynamics SensorRail IIIE Service Manual Download Page 23

 

SENSORRAIL IIIE 

8200-0593-03, REV. A 

SERVICE GUIDE 

23 of 34

 

Copper Install Tool ADRLCIT 

This tool is used to install new copper strips and also reverse old copper strips due to green patina from 
previous collectors that ran over it. The latest tool is turned using a wheel instead of handles. 

 

 

To wind the existing copper back 
on to the wheel, rotate the wheel 
in the direction of the arrow shown 
above. 

To unwind the copper back into 
the rail, flip the support bars 180° 
and rest the wheel in the slot as 
shown.  Use the service trolley to 
pull the strips. 

Summary of Contents for SensorRail IIIE

Page 1: ...mponents on the CPU board How to program or operate the system Refer to SensorRail IIIE User Guide 8200 0593 04 Product specifications Refer to SensorRail IIIE Installation Guide 8200 0593 02 If you need assistance contact American Dynamics Technical Services United States Toll Free 800 507 6268 Option 2 International 561 912 6259 Option 2 Fax 845 624 7658 In Europe Technical Services at EMEA AD T...

Page 2: ...es 27Vdc and RS 232 data provided by the four sliding collectors Five LEDs Enable quick diagnostics in case of technical problems RF 2 4GHz transmitter board Replaceable by removing four soldered attachment points RF 2 4GHz emitter connector Provides power and composite video signal to RF link emitter BNC connector Receives composite video signal from the dome ATMEGA 128 microcontroller Receives a...

Page 3: ...e efficient while achieving throughputs up to ten times faster than conventional CISC microcontrollers The ATMEGA 128 µP has the following features 128K bytes of in system programmable flash with read while write capabilities 4Kb EEPROM 4Kb SRAM 53 general purpose I O lines 32 general purpose working registers Real time counter RTC 4 flexible timer counters with compare mode and PWM 2 UARTs Byte o...

Page 4: ...programming mode Holding this pin low during a power on reset causes the device to enter the SPI serial programming mode PEN has no function during normal operation Motor Command When the ATMEGA microcontroller receives an IRIS or FOCUS command it sends one of four output signals to the PWM driver sampling frequency is 25kHz PWM Digital value directly related to the movement speed of the trolley 1...

Page 5: ...ords trolley movement in kilometers This measurement is performed by incrementing a counter at the TOP_SYNC pulse independent of direction When the value reaches 640000 the odometer increments by 1 I Max Circuit To avoid burning up the motor due to electrical over current an I Max circuit is installed on the CPU This circuitry provides feedback of 0 6V per ampere with an extreme limitation of 5 2A...

Page 6: ...deo link receiver and planar receiving antenna Direct connection through the DB29 plug enables product configuration and troubleshooting using a laptop and AD SensorRail Control software Main power connection is through an IEC connector that includes an AC filter Data connects through a standard 4 position terminal RS 422 and a 3 position terminal RS 232 Vision Area Dead Zone and Maintenance Area ...

Page 7: ...IE 8200 0593 03 REV A SERVICE GUIDE 7 of 34 CPU Board Layout RF 2 4GHz Emitter ATMEGA 128 µP X Tal Electronic Brake Devices BNC RF 2 4GHz connector JTAG Connector B Sensor Main Connector Power Connector DIP Switches ...

Page 8: ...0593 03 REV A SERVICE GUIDE 8 of 34 Trolley Circuit Block Diagram VA channel Synchro top Motor ATMEGA 128 232 to 422 Max 202 To Matrix Sensor B Sensor A JTAG Interface Watchdog PWM Drivers Brake I max Disable Cmd PWM Motor ...

Page 9: ...SENSORRAIL IIIE 8200 0593 03 REV A SERVICE GUIDE 9 of 34 ATMEGA Pin configurations ...

Page 10: ...ion area for surveillance dead zones for stopping and maintenance areas for servicing Vision Area Vision Area Two 1 5m 4 9ft Dead Zones Vision Area Two 1 5m 5ft Dead Zones Two 30cm 1ft Light Reduction Sections Total Length of Rail Total Length of Rail Two 0 6m 2ft Maintenance Areas Rail ...

Page 11: ...s Unlimited 3 AD2150 Yes 16 3 AD168 Yes 4 3 AD1024 Yes 16 3 MP48 Yes 4 3 Requires AD2083 02AX code translator Requires RCSN422 code translator Including remote control via Intellex and Network Client VM96 V5 0 RCTTRKE 220Vac From 10 to 100 meters 32 8ft to 328 08ft Composite Video PowerRail Or RS 422 Half Duplex ADTT16E RCSN422 AD Matrix AD Keyboard ...

Page 12: ...etection see CAUTION below The dome can be oriented to see the function LEDs on the CPU board CAUTION Do not run the trolley at full speed in case of detection failure 6 Check the DATA link in and out Communication LEDs can be seen from the Dome 7 Write down all failures Structure Check and Maintenance 1 Using a soft cloth soaked with isopropyl alcohol clean the following rail parts Copper tracks ...

Page 13: ...ntographs Guiding and Stabilizing Wheels Tracking and stabilizing wheels absorb vibrations and force coming from the trolley movement and rail junctions Estimated lifetime for these wheels is 10000km therefore no replacement should be expected However for safety reasons check for lateral excess movement of the bearings Sliding Collectors When copper collectors are worn the plastic support can slid...

Page 14: ...ustment available for belt tension When the belt is too loose replace it as follows Removing the motor assembly 1 Mark the position of the old motor to ensure the new motor is installed in the same location 2 Remove the two M6 screws at each end of the motor support 3 Pull out the motor assembly from the trolley 4 Remove the belt from the motor gear Re installing the motor assembly 1 Install a new...

Page 15: ... resets the trolley to off Aux 2 displays the software version and trolley travel in kilometers on the video screen for about 5 seconds For example Note Turn Aux Output 2 off after viewing to return to control of trolley movement Aux 3 or 4 enables access to the dome camera menu Note Turn Aux 3 or 4 off after viewing to return to control of trolley movement Supports new RS 422 command for expanded...

Page 16: ... an RS 232 to RS 422 converter from the control room where the RS 422 terminates However only the rail being upgraded can be connected to the converter DO NOT connect other domes or trolleys 2 For RS 232 mode only move jumpers ST4 and ST5 to the PC position 3 Launch the ProgChariotV3 exe application The following window appears 4 Select the COM port to which the communications cable is connected O...

Page 17: ... with the encoder installed To replace the motor 1 Mark the position of the old motor to ensure the new motor is installed in the same location 2 Unscrew the two M6 screws at each end of the motor support 3 Unplug the encoder cable 4 Disconnect the motor wires from the main connector on CPU board pins 12 and 16 5 Pull out the motor assembly from the trolley 6 Remove the belt from the motor gear 7 ...

Page 18: ...Retrofitting Collectors Wires Brackets 1 Remove the trolley from the rail and carefully place it on its side Locate the 4 pin connector and mark the collector numbers on the trolley brackets so the wires can be replaced in the correct order Wire labels should match the numbers marked on the brackets Note The picture shows bare aluminum brackets the shipped product will be black 2 Open the black co...

Page 19: ...03 REV A SERVICE GUIDE 19 of 34 7 Route wires into place and attach them to the 4 pin connector shown below and to the collectors Cut wires to length on the open end 8 Secure the black cover and check the connections and numbers ...

Page 20: ...e assembly by snapping push pins into the corresponding holes Exploded view shows all assembly components Plastic cases strip brushes KST25 collector and push pins 1 Insert strip brushes into corresponding dovetail pockets Follow the arrows 2 Insert the KST25 collector as shown Then mate the other half of the plastic case to the assembly Carefully align the dovetail pockets with the strip brushes ...

Page 21: ...5mm Approximately 2 5 3 0mm Copper strip and collector contact line red line Brush stock material when assembled with a new collector sits below the contact line KST25 Collector Note If collectors are worn out before installing new brushes trim brush hair approximately 0 5mm ...

Page 22: ... and turn on the PowerRail module The trolley should perform its power up routine 4 Using a voltmeter set to dc Track 1 voltage Track 2 Gnd connect its probes to the contacts shown below Then using a small screwdriver adjust the potentiometer to 27Vdc maximum 5 Test the trolley s motion to the furthest point and back Note Because the PowerRail module RS 422 output is not tri state additional devic...

Page 23: ...to green patina from previous collectors that ran over it The latest tool is turned using a wheel instead of handles To wind the existing copper back on to the wheel rotate the wheel in the direction of the arrow shown above To unwind the copper back into the rail flip the support bars 180 and rest the wheel in the slot as shown Use the service trolley to pull the strips ...

Page 24: ...SENSORRAIL IIIE 8200 0593 03 REV A SERVICE GUIDE 24 of 34 ...

Page 25: ...t Reduction Kit SR3 END COVER and ADRL3BUL3 5U This kit prevents light reflections from entering the cowling from each end of the rail 1 Mount the ection onto the existing rail using the hardware provided 2 Attach the top hat to the top of the section to cover the large cutout 3 Add extra cowling to the rail structure 4 Attach the new end cover Note be sure to follow the installation guide for min...

Page 26: ...go The strap should also slide 8 At the start end of the rail insert the slit of the second service block into the stop groove to hold the tape above it 9 Let the roll of strap uncoil to the floor and very carefully power up the rail As the trolley homes it will pull some of the strap into the rail 10 After the trolley homes use AD SensorRail Control software to set the maximum speed to 1m s 3 3ft...

Page 27: ... block Note Do not punch hole into strapping tape Material will break Instead use a soldering iron to burn the hole into the tape Tape feeding procedure Service block slot feature to be used to secure second block on the aluminum structure while feeding the tape attached to the other one ...

Page 28: ...tenna to be easily moved to where the least number of RF holes exist 2 If RF holes cannot be eliminated move the antenna to the outside of the rail 3 Ensure that the RF antenna does not receive transmissions from another system If it does select a different transmission frequency RF Link DIP Switch Settings If 2 4GHz devices interfere with the SensorRail select one of the following alternate frequ...

Page 29: ... into the rail as shown below Ensure the screw does not touch the copper or connector at the start and end of the rail End Cover Replacement If RF video dropouts occur use the black plastic end cover ADRL3ECB Affix the plastic cover using the same screws that held the metal version CAUTION The black cover is only used with the new rail extension containing the top hat DO NOT use this cover without...

Page 30: ...r universal ADRL3DRVACCP SensorRail III driving system accessories with gear belt universal ADRL3CMF25U OBS SensorRail III sliding contact universal ADRL3CPUU SensorRail III CPU board PAL ADRL3RFT24P SensorRail III RF link transmitter 2 4GHz PAL ADRL3ATEN24U SensorRail III RF transmitter antennas 2 4GHz PAL ADRL3RFT58P SensorRail III RF transmitter 5 8GHz PAL ADRL3ATEN58U SensorRail III PowerRail ...

Page 31: ...acks 20m 65 62ft 4 rolls of 20m universal ADRL3CUI25U SensorRail III copper tracks 25m 82 02ft 4 rolls of 25m universal ADRL3CUI30U SensorRail III copper tracks 30m 98 43ft 4 rolls of 30m universal ADRL3CUI35U SensorRail III copper tracks 35m 114 83ft 4 rolls of 35m universal ADRL3CUI40U SensorRail III copper tracks 40m 131 23ft 4 rolls of 40m universal ADRL3CUI45U SensorRail III copper tracks 45m...

Page 32: ...t universal ADRL3BUL50U SensorRail III mirrored cowling 50m 164 04ft universal ADRL3BUL55U SensorRail III mirrored cowling 55m 180 45ft universal ADRL3BUL60U SensorRail III mirrored cowling 60m 196 85ft universal ADRL3BUL65U SensorRail III mirrored cowling 65m 213 25ft universal ADRL3BUL70U SensorRail III mirrored cowling 70m 229 66ft universal ADRL3BUL75U SensorRail III mirrored cowling 75m 246 0...

Page 33: ...A RF link receiver RF frequency range 2 4 2 483GHz PAL over 5 channels Video output Composite PAL 1V p p Sensitivity 86dBm 21dBµV Power supply 8 10Vdc Nominal current 250mA Trolley motor Nominal voltage 24Vdc Nominal speed 6700rpm clockwise Nominal torque 1250m Nm Nominal current w o load 0 120A Speed constant 287rpm V Cabling Power IEC connector Video Coaxial RG59 U RS 422 data Cat 5 1 x twisted ...

Page 34: ...as current when published The manufacturer reserves the right to revise and improve its products All specifications are therefore subject to change without notice LIMITED RIGHTS NOTICE For units of the Department of Defense all documentation and manuals were developed at private expense and no part of it was developed using Government Funds The restrictions governing the use and disclosure of tech...

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