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BOMBARDIER SPA-5/LVA, Technical Documentation Manual

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BOMBARDIER SPA-5/LVA Technical Documentation Manual Download Page 6

B 

DTRen-2008/SPA-5/LVA 

Rev.: 

a 

Page  6 

 

Bombardier Transportation (ZWUS) Polska Sp. z o.o. 

 

 

- Braking boom detector 
circuits 
- Brake-away protection 

Yes 
 
multiple use (with ball safety device) 

Interlocking interface 

Interlocking (Ebilock) 
interface 

EDJ-5 (electronic interface)  
 

Manufacturer
BT ZWUS 

Control System 

Control and power supply 
unit 

ERR-20 – LX shelter 
ERR-24 – LX rack 

Manufacturer
BT ZWUS 

Control system: 
 
- CPU 
- RAM 
- Program Memory 
- Program cycle 

2 x PLC series 2003 
 
7CP476 
750Kbyte SRAM, 
1,5Mbyte Flash PROM 
50ms 

Manufacturer
B&R (Austria) 

Automatic/manual operation 

Automatic operation 

System engagement / 
disengagement from the interlocking 
system 

 

Manual operation 

Manual system engagement / 
disengagement from the shelter/rack 
and from the Control Panel 

 

Monitoring and diagnostics 

Remote Control Device: 
 
- Visualization of 1-8 LXs 
 
 
- Registration time 

ERP-7 
 
Panel PC with 12”LCD touch-screen 
2 x 8 LED 
2 x Audible alarm 
at least 1 month 

Manufacturer
BT ZWUS 

Local Diagnostic Panel: 
 
- Visualization 
- Operation 

EZG-17 
 
LCD display  2x40 digits 
5-key keyboard  

Manufacturer 
BT ZWUS 

Event Logging Unit 
 
- Data access 
- Registration  

EZE-2 
 
PC application 
65000 records 

Manufacturer
BT ZWUS 

Safety 

Hardware 

- 2 independent PLC controlled 
channels A and B 
- 2 independent power supply 

 

This 

training 

material 

has 

been 

prepared 

only 

for 

educational 

purposes 

and 

it 

isn't 

technical 

documentation.

Summary of Contents for SPA-5/LVA

Page 1: ... pages 44 1 All rights reserved Copying and publishing without prior permission of Bombardier Transportation ZWUS Polska is prohibited AUTOMATIC LEVEL CROSSING SYSTEM SPA 5 LVA December 16th 2008 This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 2: ... 3 4 EHZ 8 LED Road Signal 22 4 3 5 Electrical Gate Machines 24 4 3 6 EAR 1 Control Panel CP 26 4 4 SYSTEM ELEMENTS 27 4 4 1 Programmable Logic Controllers PLC 27 4 4 2 EMF 6 stabilized DC DC power converter module 28 4 4 3 EDL 5 DC AC converter 29 4 4 4 EMK 2 Battery voltage control module 30 4 4 5 EMB 10 Safety Breaker Module 31 4 4 6 EMH 2 Manual Control Unit 33 4 4 7 EDG 4 Audible alarm genera...

Page 3: ...n t forbid road users to enter the crossing LX engagement LX status when warning devices are active and forbid road users to enter the crossing LX safe state LX state when normal operation of the system is stopped road signals forbid road users to enter the crossing as long as batteries are full The only way out of the safe state is manual system restart Critical failure Failure that causes loss o...

Page 4: ...ctrical gate machines which may have a supervisory monitoring at the nearest station and C T C control office 3 2 Product description Automatic Level Crossing System SPA 5 LVA is designed in accordance with requirement specification defined by Latvian Railways Technical data of the system is presented in paragraph 4 1 SPA 5 LVA is connected with Ebilock interlocking system Ebilock is responsible t...

Page 5: ...normal system operation in case of no supply 230V 50Hz min 8h 100 pairs of trains Warning devices LED Road signal Flashing frequency LED unit Power consumption EHZ 8 0 67Hz EHE 2 4W per one LED unit Manufacturer BT ZWUS Audible alarm Supply voltage Pulse frequency Sound intensity Sound generator EDG 40 and loudspeaker EDE 1000 12V or 24V DC 1Hz 20 60 80dB in the distance of 7m Manufacturer BT ZWUS...

Page 6: ...stem engagement disengagement from the interlocking system Manual operation Manual system engagement disengagement from the shelter rack and from the Control Panel Monitoring and diagnostics Remote Control Device Visualization of 1 8 LXs Registration time ERP 7 Panel PC with 12 LCD touch screen 2 x 8 LED 2 x Audible alarm at least 1 month Manufacturer BT ZWUS Local Diagnostic Panel Visualization O...

Page 7: ... or in cabinets 40 C 70 C Relative humidity 0 95 without water vapour condensation Protection degree at least IP44 for shelters Protection against electric shocks P 302 25 30 AC Residual Current Circuit Breaker 30mA Power supply 24V DC Fire protection Constructional elements of the racks non flammable electronic modules designed with excess assuring that their surface temperature does not exceed t...

Page 8: ...on is defined by a product symbol see 4 6 Following external devices can be connected to the SPA 5 LVA Device Quantity EHZ 8 LED Road Signal with two or three aspects max 6 EEG 1 Gate Machine with ESD 8 boom max 8 EDG 4 Audible Alarm max 4 EDJ 50 Interlocking Interface 1 Control Panel 1 EZE 2 Event Logger 1 option EZG 17 Local Diagnostic Panel 1 ERP 7 Remote Control Device 1 EAR 1 Control Panel 1 ...

Page 9: ...de of the shelter power supply rack is installed on the right side All the cables from external devices go inside the shelter through respective cable inlets located in the shelter s floor and then they are connected to the terminal strips Further the cables are distributed via terminal strips to particular modules of the control unit 1604 1764 2452 Dimensions of the shelter ERR 20 housing type ES...

Page 10: ... circuits of channel A 3 Terminal strip with outputs of channel B power source circuits and voltage control circuits of channel B 4 DC DC converters EMF 65 for battery charging for A and B channel 5 Power distribution terminal with fuses 6 Mains control circuits 7 Terminal strips of first mains 8 Terminal strips of second mains optional 9 N A 10 Separation transformer This training material has be...

Page 11: ...strip 14 Battery 4 2 4 Control rack Control racks are configured according to the specific requirements of the application The example of the rack is presented below Example of Control Rack channel A KANAŁ A and channel B KANAŁ B Figure 3 This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 12: ...hannel A 26 RS 485 repeaters galvanic isolation for road signals and EDG 40 module channel B 27 Lighting protection and EDZ 3 modules set channel A 28 Lighting protection and EDZ 3 modules set channel B 49 RAD ASM 20 modem for interface Ebilock 4 2 5 LX start procedure Because of safety reasons SPA 5 LVA can be started restarted only manually at the crossing Procedure of SPA 5 LVA system start res...

Page 13: ...power supply unit is connected via serial transmission link with the Ebilock interlocking system Separate transmission link connects ERR 2 with Remote Control Device ERP 7 Ebilock sends orders e g engagement and disengagement commands to LX and receives statuses and simplified diagnostic messages from LX Control Room ERR 2 TRACK2 TRACK1 N2 N4 N1 N3 S1 S2 S3 S4 Dz1 Dz2 EZG 17 RS485 MODEM MODEM PC E...

Page 14: ...vice should be installed in the dispatcher s room In case of the standard transmission cable the distance form ERP 7 to LX should not exceed 5km For longer distances amplifying units or modems must be used Connections of elements of SPA 5 LVA ERR 2 are shown at Figure 5 and Figure 6 SPA 5 LVA structure example Figure 5 This training material has been prepared only for educational purposes and it i...

Page 15: ...24V DC part ERR 2 power supply structure Figure 6 230V AC voltage part 230V AC voltage part is responsible for the supply of the system batteries fun heater lighting and also electric socket inside shelter TRA and TRB transformers assure a galvanic insulation of the system supply from the 230V AC input power supply This training material has been prepared only for educational purposes and it isn t...

Page 16: ...Ebilock can be prepared depending on the design requirements distance between LX rack and interlocking rack number of LXs connected to the same station etc Generally 3 types of devices are necessary to realize interface between SPA 5 LVA and Ebilock electronic interface EDJ 5 Protocol Converter Unit PCU and modem e g RAD ASM 20 PCU Protocol Converter Unit PCU performs a bidirectional conversion of...

Page 17: ...PLCs and EDJ 5 modules or between EDJ 5 modules and PCU modules depending on the application design requirements Variants of the interface between SPA 5 LVA and Ebilock are specified below This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 18: ... connection no redundancy d Digital interfaces of modems V 24 RS 232 e Example interface between station Mezare km154 4 and LX km 153 991 ERR 2 MODEM Type ASM 20 EDJ 5 PCU PCU SWITCH SWITCH MODEM Type ASM 20 NETWORK STATION INTERLOCKING located at station or another container PLC B CAN RS232 PLC A CAN SPA 5 LVA Ebilock interface variant 1 Figure 7 This training material has been prepared only for ...

Page 19: ...ated far from station container b LX configuration with barrier machines c Modem connection two channel connection transmission channel redundancy d Digital interfaces of modems HDLC e Example N A SPA 5 LVA Ebilock interface variant 2 Figure 8 This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 20: ...the station container b LX configuration with or without barrier machines c Modem connection N A d Digital interfaces of modems N A e Example interface between interlocking SER km 136 27 and LX km 135 966 SPA 5 LVA Ebilock interface variant 3 Figure 9 This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 21: ... distant LX no modems necessary for the second LX d digital interfaces of modems V 24 RS 232 for the first LX no modems for the second LX e example interface between interlocking SER km 136 27 and LX km 135 966 and LX km 132 72 NOTE The same PCUs are used for both LXs ERR 2 MODEM Type ASM 20 PLC B CAN RS232 PLC A CAN ERR 2 RACK SWITCH SWITCH EDJ 5 PCU PCU PLC B CAN RS232 PLC A CAN MODEM Type ASM 2...

Page 22: ...emitting light and audible signals for the purpose of controlling the road traffic and ensuring safety at the level crossing SPA 5 LVA is capable of controlling of maximally 6 EHZ 8 road signals with two or three aspects SPA 5 LVA is able to control up to 4 audible alarms bells EHZ 8 road signal can be equipped with a Two red light chambers always b One white light chamber option c One audible ala...

Page 23: ...Bombardier Transportation ZWUS Polska Sp z o o Example of LX system with 4 EHZ 8 road signals with 2 bells audible alarms Figure 11 This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 24: ...n after configured time delay PLCs will switch on respective contactors of the individual movement That causes the breaker to be released and voltage is connected to the motor Barriers go down When barrier machine reaches down position then PLC switches off individual contactor that controls barrier s movement Information about down position is received from the limiter switch Change of the LX sta...

Page 25: ... is prepared to close barriers Continuity of the barrier is checked If lack of the barrier continuity is detected then respective barrier machine will not move any more Related documents DTRen 2009 EEG 1 3 DTRen 2009 EEG 3 4 DTRen 2003 ESD 8 5 This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 26: ...with Mono stable and bi stable switches LEDs indicating state of the controlled signalling equipment Bell optional Example of orders that can be executed from the Control Panel Turn bell off Engage LX Emergency gate machines open Emergence gate machine blocking in upper position Engage LX and switch on barrage signals Permission for automatic open LX Test CP LEDs NOTE CP functionality depends on t...

Page 27: ...ected with each other via CAN standard transmission link This link enables synchronisation of the operation of some LX devices and allows detecting any possible A B synchronisation faults which is identified as one of the LX system critical failures Both programs have been designed in different programming languages by two separate groups of programmers CPU 7CP476 60 1 1 interface RS232 1 interfac...

Page 28: ...eparated from the EMF 6 output current Each of the control circuits is supplied from the independent DC voltage and generates two logic output signals Ip1_A B and Ip2_A B which are interpreted by the PLC program Logical value of Ip1_A B and Ip2_A B depends on the value of the output current of EMF 6 in comparison to two threshold values Ip1 and Ip2 Ip2 Ip1 Ip1_A B and Ip2_A B are in low state L if...

Page 29: ...C AC converter EDL 5 converter supplied from the battery is used to control contactors responsible for the direction of the movement of barrier machines up or down 24V 50Hz rectangular wave is obtained on EDL 5 output Output signal of EDL 5 converter can be achieved only if control signals from PLC outputs are correct EDL 5 block diagram Figure 17 This training material has been prepared only for ...

Page 30: ...utput voltage of a battery will lower below threshold voltage typically 21 6V 0 5V then after defined time delay typically 30 60 seconds main contactor will be switched off and by this way batteries will be disconnected from the rest of the system If the battery voltage will lower below low threshold value typically about 17 V 0 5V then disconnection of batteries will be done without any delay Bat...

Page 31: ...rectly and rectangular waves are transmitted to the EMB 10 the output signals from EMB 10 galvanically separated UA and UB voltage supply input output modules of PLCs responsible for the operation of the safety critical functions In case of any EMB 10 hardware failure or in case of any PLC software critical failure rectangular waves will be distorted and it will result in cutting off of the EMB 10...

Page 32: ...on from the moment of the critical failure appearance Normal operation of SPA 5 LVA is possible after removal of the failure and after system restart System restart procedure requires to restart both PLCs and to depress and afterwards to press the START key of EMH 2 module see chapter 4 2 5 This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 33: ...ngage O the system manually O Z switches are doubled they are placed not only in EMH 2 module but also in a small case for manual LX operation outside LX shelter O Zz switch That enables to control LX system without opening of the shelter NOTE There is a logical OR between order LX engage sent from Ebilock and manual engage order Z position of O Z or O Zz switch That means that as long as O Z or O...

Page 34: ...rol device is a transmission master and EZG 17 listens to the telegrams and informs about LX status Choosing L position of the switch causes that transmission to remote control device ERP 7 is broken local diagnostic panel EZG 17 is a transmission master in such situation event logging is still possible if EZE 2 module is used Z L switch can be equipped with blocking key This training material has...

Page 35: ...m the generator can be used to check if audible alarm works properly EDG 4 module circuit Figure 21 Activation and deactivation of the audible alarm is realised by digital PLC output OutA If OutA is in high state then audible alarm is active If OutA is in low state then audible alarm is not active EDE 1 GENERATOR EDG 4 VA PLC A Ip1 A Ip2 A Out A Out L Ip1 B Ip2 B PLC B This training material has b...

Page 36: ...or at least 65000 events or failures to be logged in the buffer 8 LED indicators inform about EZE 2 performance Meaning of LEDs is as follows D1 green power supply D2 yellow not used D3 yellow not used D4 yellow CAN transmission from PLC to EZE 2 Z2 connection D5 yellow CAN transmission from EZE 2 to PLC Z2 connection D6 yellow RS232 transmission from PC to EZE 2 Z3 connection D7 yellow RS232 tran...

Page 37: ...for the activation of the lamp green LED on means lamp activated from PLC and checking of the lamp circuit s current red LED on not used in SPA 5 LVA The front panel of EDZ 30 module is shown below AM PLIFIER1 Output 1 8 4 U1 U1 5 7 EDZ 30 Input1 D 1V D 1C AM PLIFIER2 Output 2 2 10 U2 U2 11 9 Input2 D 2V D 2C 1 3 EDZ 30 internal scheme Figure 23 This training material has been prepared only for ed...

Page 38: ...ally coupled with locks Position of upper and lower lock is monitored by controller PLC A and position of middle lock by PLC B 13 14 13 14 UA UB InDrzwi B 13 14 InDrzwi A Control box door switch Upper door switch Lower door switch PLC A PLC B Connection of hut door switches Figure 24 This training material has been prepared only for educational purposes and it isn t technical documentation ...

Page 39: ...ange from 0 C to 70 C for in door equipment placed inside buildings and shelters As a protection against electrical shocks all devices of ERR 2 are connected to the equipotential surface residual current breaker is used and shields for circuits with high voltage are used Smoke detector with fun circuit breaker and fire extinguisher are placed inside ERR 2 shelter for fire protection purposes This ...

Page 40: ... system without detectors ERR 2x1xxxxxx reserved ERR 2x2xxxxxx reserved ERR 2x3xxxxxx Non standard number of detectors of EOC 1 or EOC 3 type ERR 2x4xxxxxx reserved ERR 2x5xxxxxx reserved ERR 2x6xxxxxx Non standard number of detectors of ELS 95 type ERR 2x9xxxxxx Non standard crossing with different types of detectors digit 4 road signals ERR 2xx0xxxxx system without road signals ERR 2xx1xxxxx 1 r...

Page 41: ...tronic interface to EBILOCK station type ERR 2xxxxx9xx Non standard interlocking connection digit 8 white lamp for road signals ERR 2xxxxxx0x System without white lamps ERR 2xxxxxx1x White lamp for 1 road signal S1 ERR 2xxxxxx2x White lamp for 2 road signals S1 S2 ERR 2xxxxxx3x White lamp for 3 road signals S1 S2 S3 ERR 2xxxxxx4x White lamp for 4 road signals S1 S2 S3 S4 ERR 2xxxxxx5x White lamp f...

Page 42: ...ACKAGING STORAGE AND TRANSPORT 6 1 ERR 2 shelter There are no special requirements for the container packing During transportation the container is pre packed with a plastic bubble wrap and placed at an open pallet Inside buildings the container should be stored indoor where relative humidity level can be in the range of 25 to 75 and temperature can be in the range of 10 C to 50 C 263 323K It is a...

Page 43: ...ste dumps for non toxic materials because they are not dangerous to the environment In case of the removal of batteries it is necessary to proceed according to the rules defined by the producer of batteries In case of dismantling of ERR 2 container it is necessary to proceed according to the procedure bellow a Turn off power supply b Disconnect power supply cables and transmission cables c Cables ...

Page 44: ...hine DTRen 2009 EEG 1 4 EEG 3 Electrical gate machine DTRen 2009 EEG 3 5 ESD 8 Barrier boom DTRen 2003 ESD 8 6 Operating Manual X 4 02658en 7 Maintenance Instruction X 4 02657en 9 MANUFACTURER Bombardier Transportation ZWUS Polska Sp z o o ul Modelarska 12 40 142 Katowice tel 48 32 730 50 00 fax 48 32 204 22 44 THE END Prepared Bartłomiej Pawełek Verified Tomasz Pisarek Approved Alfred Kurkowski T...

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