= Introduction =
Welcome to the installation guide for your new SensorLink system. This article provides instructions to ensure a safe and efficient installation. Safety is paramount throughout this process. Railroad environments present unique hazards, and strict adherence to all safety protocols is mandatory. Precise workmanship is equally critical for the reliable operation of this SensorLink system. Carefully follow each step, double-check connections, and ensure all components are securely mounted. Your diligence in both safety and workmanship will guarantee a successful and long-lasting installation. 
 [[Appendix G - Glossary|Common Vocabulary]]
{| class="wikitable" style="border-collapse: collapse; width: 100%;"
|- style="background-color: rgb(194, 224, 244);"
! style="width: 100%;" |Read Instructions Thoroughly Before Beginning; Understanding all of the Steps will Help Avoid Difficult Situations

|}
== Scope of Supply ==

This installation package includes all necessary components for the complete installation of youe SensorLink system.

'''Provided Components:'''
*SensorLink Assembly in NEMA Enclosure
*4x4 Galvanized Metal Post
*Conduit and Fittings for system connections
*RFID Antennas
*Frauscher Wheel detector and accessories
*Radar Presence Circuit kit
*Cellular Antenna

== Tools and Materials Needed ==

Installer will be required to provide the following.
*100lbs sack concrete (recommended)
*Basic hand tools (imperial and metric)
*Two-person auger w/ 14-16" bit
*Basic RF cabling tools

== Process Overview ==
Here's a general installation process overview for a SensorLink system, broken down into key stages:
#Site Preparation and Planning:
##Site Survey: Conduct a thorough site survey to determine optimal reader and antenna placement, identify potential obstructions, and assess power and cabling pathways.
##Permitting and Approvals: Obtain all necessary permits and approvals from relevant authorities.
##Safety Planning: Develop a detailed safety plan, including emergency response procedures as sites are often remote.
##Material Acquisition: Gather all required materials, including those provided in the scope of supply and those the installer is responsible for (concrete, electrical supplies, tools, etc.).
#Post and Conduit Installation
#SensorLink Subsystem Assembly
##Antenna Mounting and Hookup
##Frauscher Wheel Transducer mount and Hookup
##Radar Presence installation
##Cellular Antenna Installation
#Electrical Installation: 
##Install and connect system backup batteries.
##Power Supply Connection: Connect the power supply unit to the electrical circuit and the reader unit.
##Grounding: Ensure proper grounding of all electrical components. Bond '''[grounding point TBD]''' to grounding rods.
#System Configuration and Commissioning (Optimization)
##Power-Up and Initial Checks: Power on the system and perform initial checks to verify proper operation.
##System Configuration: Configure the AEI system according to the site-specific requirements.
##Tag Testing: Perform tag testing to verify accurate tag reads and system performance.
##Data Verification: Verify that the system is transmitting data correctly to the designated data collection system.
#Final Inspection and Documentation:
##Final Inspection: Conduct a thorough final inspection to ensure all components are properly installed and functioning.
##Documentation: Complete all necessary documentation and optimization checklist. 

= Site Considerations =

*Site should be readily accessible to nearby roads to facilitate maintenance.
*Site should be located near commercial power source.
*Site should be located with consideration to the availability of appropriate communication facilities for system reporting and maintenance (cell coverage).
*Site should be located to avoid discontinuities in the track structure (joints, switches, grade or rail crossings) in the immediate vicinity of the AEI system.

*Site should provide sufficient space to install wayside equipment with respect to railroad clearance restriction requirements.
*The site should be located in order to satisfy railroad application requirements and with a consideration of the communication and processing lead-time required by the user of the AEI data.
*When feasible, multiple track locations should be located where track centers are greatest in order to locate antennas such that AEI tag read time is maximized. Where feasible, the number of tracks should be minimized.
*High vandalism areas should be avoided.
*Avoid low areas where flooding may occur.
*Consideration should be given to consolidation with other types of railroad installations such as defect detectors.
*Site selections should be made with an understanding of the railroad traffic patterns. Where feasible, site selection should avoid locations where stopping, reverse moves, doubling, or light engine movements occur frequently.
*If feasible, sites should be located to avoid potential sources of interference including large metallic objects and obstructions in close proximity to the reading area, reflective surfaces, and high voltage power lines, and other fixed and portable AEI reader systems.
*In order to reduce the potential for interference and subsequent performance degradation, site selection should be made to avoid having two AEI systems powered on at the same frequency at the same time. Two like frequencies should be kept a minimum of 1,500 Ft. apart. AEI transmitter frequencies are: 902.25 MHz, 903.75 MHz, 910.00 MHz, '''911.50 MHz''', 913.00 MHz, 915.00 MHz, 917.00 MHz, 918.50 MHz, 920.00 MHz, and 921.25 MHz 

= Pre-construction =

#Determine the transducer location first. This is the center of the site. The center of the transducer must be located between two ties.  This allows for the transducer claw to clamp under the rail.
#Mark the 4x4 post locations. Posts should be directly out from the transducer 12 feet 6 inches from center of track.

Before digging, contact a qualified utility locator service. Utilities need to be marked before digging to safely avoid them. 
See below a non-comprehensive list of utility locator services. Local authorities need to be notified before work begins.
{| class="wikitable" style="border-collapse: collapse; width: 60%; margin-left: auto; margin-right: auto; height: 121px;" border="1px" cellpadding="2px"
|- style="height: 23px;"
| style="width: 31.6921%; height: 23px; background-color: #ced4d9;" | Service Provider
| style="width: 36.7892%; height: 23px; background-color: #ced4d9;" | Locality
| style="width: 31.5187%; height: 23px; background-color: #ced4d9;" | Contact
|- style="height: 49px;"
| style="width: 31.6921%; height: 49px;" | Call 811
| style="width: 36.7892%; height: 49px;" | United States
| style="width: 31.5187%; height: 49px;" | Call 811 or visit [https://call811.com/ https://call811.com/]
|- style="height: 49px;"
| style="width: 31.6921%; height: 49px;" | Click Before You Dig
| style="width: 36.7892%; height: 49px;" | Canada
| style="width: 31.5187%; height: 49px;" | Visit [https://www.clickbeforeyoudig.com/ https://www.clickbeforeyoudig.com/]
|}

Comet Industries is not affiliated with or endorsed by any of the service providers listed.

= Earthwork =
Two 4x4 galvanized posts and a 1" conduit need to be installed below grade.

'''Post holes'''
*Hole centered 12 feet 6 inches from center of rail.
*Hole must be 8" diameter and 3' deep.
'''Scratching'''
*All conduit must be laid 3" below top of soil.
*One 3" deep conduit channel is needed between the two post holes. 
SITE LAYOUT DIAGRAM

SITE ELEVATION DIAGRAM

== Posts ==
Install 4x4 galvanized posts [[400072]] and post caps [[400079]].

Posts should be setback per layout, 12 foot 6 inches from center of track. They should be angled parallel with track and level.
*Install a post cap on one end of the post prior to erecting the post. Leave the capped end unburied. Repeat for other post.
*Set the post in ballast.
**Far-side post can be set in native backfill.
**Near-side should be set in 100lbs sack concrete and covered in native backfill. In most cases, adding dry concrete is sufficient. No need to cure before completing installation.
**Posts should be set and backfilled after the conduit is in the trench.
**Posts are to be hand backfilled and tamped, checking and adjusting for square and level.
*Mark on the post 42.5" from top of rail. This marks where the RF antenna will be placed later.

== Conduit ==
Install one run of conduit [[400514|400514]] between the two foundations.
*Conduit is provided in the kit.
*Self-Priming PVC cement is provided in the kit.
*Cut and glue pieces to put one conduit run between the Tower Foundations.
*Conduit run to be laid in 3" deep channel.
*Conduit to be vertical on each end. '''(as shown)'''
*Use supplied 90° sweeps.
*Leave several feet of conduit above top of Foundation (to be trimmed later). 
*Maintain the plumb nature of each end as backfill continues.

= Ground Rods =
[[file:RNNGroundingDetail.png|thumb|100px|right|Ground Rod Placement]]

Driving the ground rods [[400421]] directly after back-fill before further assembly can help keep a clear workspace.
*Drive one ground rod 6-12 inches from each foundation tower.
*Ground Rods should be driven to 4-8" above grade
*If you mushroom the head of the rod in the process, it will need to be ground back to profile in order to CADweld the bonding wire to it. (process later in the procedure)

= Far Side Junction Box =

Once the towers are erected, the Far-side Junction box [[400944|400944]] is installed:
*This is the non-enclosure side of the system
*Bolt Unistrut to the back of the junction box using provided hardware
*Cut the 3-inch conduit off 10 inches above the foundation plate.
*Glue a 3-inch PVC slip by thread adapter onto the end of the PVC Conduit.
*The Junction Box should be mounted using the cone nuts (4) '''as shown in the photo.'''

= Mounting of SensorLink Enclosure =
The System is ready for the mounting of the SensorLink Enclosure''' [INSERT PART NUMBER]'''.
{| class="wikitable" style="border-collapse: collapse; width: 100%;"
|- style="background-color: rgb(149, 165, 166);"
! style="width: 100%; text-align: center;" | The SensorLink enclosure is heavy and awkward to handle. Plan your movements, this is a multiple person job.
|}

*The enclosure is to be mounted to the 4x4 post on the side that is opposite to the track. '''[INSERT ORIENTATION DIAGRAM]'''
*Hold the enclosure in place while the cone nuts (4) are tightened to secure the enclosure to the post.
 

= Antenna Mounting =

[[file:AntennaMount.jpg|thumb|200px|right|Antenna Clamp Configuration]]
*Mounting hardware for the two ParaPanel Antennas [[400942]] is included in the Antenna boxes.
*The vertical center of the Antenna should be 42 inches above top of rail, facing the track.
*Note: Mounting hardware for the parapanel antenna is stainless steel.  Caution should be taken to avoid thread galling.  This includes thread lubrication (best case "anti-seize"), and careful handling.
*Use the provided screws to attach "L" brackets to the back of the antenna (2).
*Provided "V" block sits against the long "L" and the "U" bolt goes around the tower post. As shown.
*Mount the Near-side antenna first.  It should hang off the tower facing the track on the opposite pole as the RailNET enclosure. 
*Place the second antenna directly across from the first.
[[file:NearsideAntPlacement.jpg|thumb|200px|center|Near-Side Antenna Tower Placement]]

[[file:FarsideAntPlacement.jpg|thumb|300px|center|Far Side Antenna Alignment]]

= Antenna Connections =
The antennas are hooked up using coaxial cable and type "N" connections.  Care and craftmanship are required to ensure good RF performance.  Ensure that all connections are tightened firmly against their washers.  Moisture ingress significantly degrades performance.  Do not kink or smash coaxial cable. Heliax, [[400263]] is a stiff, high efficiency, conduit rated coaxial cable that will be used for the far-side antenna connection.  It requires careful handling to avoid kinking or smashing.

Several flexible coaxial whips with pre crimped ends are used in this step.  Pay attention to the length in each step to make sure you have proper lengths for the other connections.
== Far-Side Antenna Connection ==
The far-side connection requires 3 steps
*Installation of Heliax in the 3" conduit
*Connection of the Antenna
*Connection in the RailNET NEMA enclosure 

=== I. Heliax Installation ===
'''Materials Needed:'''
*Supplied 40-foot length of Heliax [[400263]]
*(2) Heliax field installable terminator Type N Female  [[400261]]
***One terminator is packed with the Junction Box materials, and one is in the box containing the antennas.
*3" PVC Slip joint to 3" female thread adapter.
*PVC cement (provided)3" to 1" Reducer
*4-6 feet of carflex 1" metallic flexible conduit
*(2) 1" carflex fittings
*Electrical tape
'''Tools Needed (not provided)'''
*Hacksaw or angle grinder with cutoff wheel
*Coaxial Cable stripping tool
*Coaxial cutting tool
*Pipe wrench
'''Procedure'''
#Cut the near-side conduit 4-6 inches above the tower foundation top plate.
#Cement the 3" slip joint by 3" female thread adapter onto the end of the conduit. 
#Seat one carflex fitting into the 3" x 1" reducer.  The reducer is tapered.  the fitting needs to be in the "big" end.  It can be difficult to see the taper.  Use the PVC conduit end to find the taper direction if needed.  The reducer will only screw in when engaging the smaller end.
#Thread the reducer into the conduit end a turn or two without tightening.
#Attach one end of the provided carflex to the fitting now attached to the conduit and route the conduit to one of the carflex fittings in the bottom of the NEMA enclosure.
#Mark and cut the carflex.  Complete the connections as a test fit, (do not tighten)
#Completely remove the carflex and reducer from the conduit and enclosure.  Remove the carflex from the reducer leaving the fitting in the reducer.
#Untape the heliax coil and straighten the first 3-4 feet of cable.  Bend 4-6 inches of cable back upon itself and tape it tight.  This creates a blunt end that will not catch on PVC joints.  Push the heliax cable through the conduit from near-side to far-side.  The heliax should thread through easily.  When you can see the cable in the far-side junction box, go to the far-side, and gently pull the cable out the front of the box and up another 8 to ten inches.
#Return to the nearside.  Thread the reducer over the remaining heliax cable down to the conduit.  Tighten (apply a bit of PVC cement to the threads to seal)
#Thread the prepared carflex length onto the heliax cable.  Tighten the fitting to the reducer.
#Thread the heliax cable into the NEMA enclosure until the carflex fits as planned and tighten to the box.  Be carful to not damage the heliax in this process.
#In the NEMA enclosure, cut the Heliax 12-14 inches into the box.  Follow end prep guidlines and install the female N heliax end. [[media:400261InstallInstructions.pdf|Install Instructions]]
#On the far side cut the heliax to end 4-6 inches above the bottom of the junction box.  Follow end prep guidelines and install the female N heliax end [[media:400261InstallInstructions.pdf|Install Instructions]]

=== II. Far-Side Antenna/ Antenna Connection ===
[[file:FarSideConnection.jpg|thumb|200px|right|Far Side Connection]]

'''Materials Needed'''
*Hood and Conduit Assembly [[400950]]
*Coaxial Whip 3-foot Male N x Male N
'''Tools Needed'''
*Wrench 
'''Procedure'''
#Check that the carflex fitting is tight to the hood on the conduit assembly.
#Thread the coaxial whip through the conduit assembly.
#Connect the conduit to the junction box through the hole in the top with the fitting attached to the conduit assembly.
#Tighten the N connector on the hood end of the conduit to the back of the antenna.
#Latch the hood to the Antenna
#Without kinking the heliax, tighten the N connector from the whip onto the N heliax end.

=== III. Far-Side Antenna/ NEMA Enclosure Connection ===
'''Materials Needed'''
*Coaxial whip 3-foot Male N x male N
'''Tools Needed'''
*None
'''Procedure'''
#Tighten one end of the whip to the heliax end in the NEMA Enclosure
#Tighten the other end to the surge arrestor marked for the far-side connection.

{| class="wikitable" style="border-collapse: collapse; width: 100%;"
|- style="background-color: rgb(149, 165, 166);"
! style="width: 100%;" | Care should be taken to avoid the space reserved for the batteries inside the NEMA enclosure. 
|}

== Near-side Antenna Connection ==
'''Materials Needed'''
*Hood [[400375]]
*Carflex 1" metallic flexible conduit
*(2) carflex fittings
*Coaxial whip 10-foot, Male N x Male N
'''Tools Needed'''
*Hacksaw or angle grinder with a cutoff wheel
*Wrench
'''Procedure'''
#Assemble a carflex fitting to hood.  Use far-side conduit assembly as a model.
#Latch the hood to the nearside antenna
#Route the conduit to the bottom of the NEMA enclosure and mark.
#Remove the partial assembly from the antenna.
#Cut the carflex to length and install the fitting insert.
#Push the Coaxial whip through the conduit and hood.
#Screw the coaxial whip end to the back of the antenna and latch the hood.
#Thread the whip through the fitting in the bottom of the enclosure and tighten up the fitting.
#Tighten the whip end to the marked surge suppressor for the near-side antenna connection.

= Wheel Sensor =
Refer to [[Frauscher Wheel Detector Installation and Optimization]] for instruction on installing the wheel sensor.
*The mounting point on the track should be as close to in a line with the antennas as possible.
*The Frauscher's protective hose should be cut to the appropriate length and then installed in the conduit fitting on the bottom of the NEMA enclosure.  (As shown)
*The sensor wire should be cut to length, (with a service loop) and landed in the enclosure as shown.

= Presence Subsystem =
'''Materials Needed'''
*150-foot Bondstrand reinforced cable
*Loop nail-down kit
*3/4-inch non-metallic flexible conduit.
'''Tools Needed'''
*Hammer
*Knife
*Measuring tape
*Marking paint
*Cable Cutter
*Wire Stripper
*Pick and shovel
*Terminal screwdriver

'''Procedure for Loop Kit [[400053|400053]]'''
#Measure 20 feet up track and 20 feet down track.  Mark the nearest tie in each location.  This will be the extent of the presence detection loop.
#Create a small trench by clearing ballast from the outside surface of the ties.
#Uncoil the provided bondstrand and find the center.
#Start on the far side of the track at least 4" from the tie plates.  Put the center in line with the wheel transducer.  
#Lay the bondstrand down and secure to each tie using the nail down tie clips.
#After clipping down 3-4 ties in both directions, lay out the rest of the loop.  Pull through the trench you made in step 2.
#Route back to the center.
#Finish clipping down the cable on the far-side.
#When you get to the point where the cable crosses the track, Route the cable down the side of the tie at least 4 inches then across the tie.
#Clip across the vertical tie face 4 times.
#Route back to tie top and clip the cable to the ties until they come together.
#Double clip the cable as they come together.
#Twist the cable together 5 twists for each foot between the track and the NEMA enclosure.
#Cut the non-metallic conduit long enough to go from the NEMA enclosure to 1 foot from the rail.
#Slip the conduit over the twisted cable.
#Thread the cable through the fitting in the bottom of the NEMA enclosure, then secure the conduit in the fitting.
#Cut, strip and land the loop cable in the terminals marked for the loop.
#Fill in the trenches dug.
#Cover the non-metallic conduit with ballast.

= Cell Antenna =
Install the cell antenna [[400214|400214]] high on the tower, above the AEI box[[File:Cell Antenna parts pic copy.jpg|300px|right|thumb]]
*4G LTE 50-ohm Omni Plus Antenna
*Bracket that can connect antenna to tower is included
*Rated wind velocity up to 130 mph
*Rated Temperature limit -40 to 149 degrees 

=Electrical Connections=

== Grounding Connections ==
'''Materials Needed'''
*No 6 bare copper wire
*(2) cadweld mold ground rod to wire
*(2) cadweld mold wire to tower.
'''Tools Needed'''
*Wire cutter
*cadweld sparker
'''Procedure'''
#Weld wire to nearside tower.  Use procedure  As shown.
#Weld wire to grounding rod.  Use procedure.  As shown.
#Cut the copper wire on the excess side of the grounding rod.
#Repeat for far-side tower

== Wiring Power to the NEMA Enclosure ==

*A certified electrician should wire the power to the NEMA Enclosure.
*Power to the NEMA Enclosure should be run through the opening in the bottom of the enclosure. It is the single opening on the left side when looking at the box.
*Power is wired into the 110v receptacle located on the left side.
NOTE: There is also an AC Transformer [[400355]] wired into the receptacle. Do not remove or alter this wiring.

[[File:RINE battery2.png|300px|right|thumb]]
== Batteries ==
*An area inside the NEMA enclosure has been marked for battery [[400917|400917]] placement.
*Install the batteries in the marked area.
*Install the bonding bar between the two batteries.
*Connect the batteries using the color codes (Black -)(Red +)
[[File:Heater2.png|300px|right|thumb|Heater]]

= Final Connections =

*Plug the panel heater [[400077|400077]] into the duplex outlet.  
*Turn the thermostat until the heater turns on. Once verified, return the thermostat to 40 degrees farenheit.
*Plug the battery maintainer in to the duplex outlet.
*Check for healthy light pattern (as shown)

= Next Steps =
The next steps are commsioning and documenting the operation of the system.
 
[[AEI Site Optimization Procedure]]