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Introduction

WelcomeX 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.

Safety Statement

Site Work Requirements

Common Vocabulary

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
• 4x4 Galvanized Metal Post
• Conduit and Fittings for system connections
• RFID Antennas
• Frauscher Wheel detector and accessories
• Radar Presence kit
  

Tools and Materials Needed

Installer will be required to provide the following.

• 200lbs sack concrete (recommended)
• Basic hand tools (imperial and metric)
• Two-person auger w/ 8" diameter bit
  

Process Overview

The following is a general installation process overview for a SensorLink system, broken down into key stages:

1. Site Preparation and Planning:
   1. Site Survey: Conduct a thorough site survey to determine optimal reader and antenna placement, identify potential obstructions, and assess power and cabling pathways.
   2. Permitting and Approvals: Obtain all necessary permits and approvals from relevant authorities.
   3. Safety Planning: Develop a detailed safety plan, including emergency response procedures as sites are often remote.
   4. 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.).
2. Post and Ground Rod Installation
3. SensorLink Subsystem Assembly
4. Electrical Installation
5. System Configuration and Commissioning (Optimization)
   1. Power-Up and Initial Checks: Power on the system and perform initial checks to verify proper operation.
      
   2. Tag Testing: Perform tag testing to verify accurate tag reads and system performance.
   3. Data Verification: Verify that the system is transmitting data correctly to the designated data collection system.
6. Final Inspection and Documentation:
   1. Final Inspection: Conduct a thorough final inspection to ensure all components are properly installed and functioning.
   2. 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

1. 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.
2. 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.

Service Provider	Locality	Contact
Call 811	United States	Call 811 or visit https://call811.com/
Click Before You Dig	Canada	Visit 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 1" Sealtight 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

4x4 galvanized posts 400072 with post caps 400079 will be installed on each side of the track.

Posts should be setback per layout, 12 foot 6 inches from center of track. They should be angled parallel with track. Both posts should be set in 100lbs of sack concrete and covered in native backfill. In most cases, adding dry concrete is sufficient. No need to cure before completing installation. Posts are to be hand backfilled and tamped, checking and adjusting for plumb, square, and level.

• Install post cap on one end of the post prior to erecting the post. A cap should be installed on both posts.
• Set the post in ballast, capped end upright.
• Mark on the posts 42.5" from top of rail. This marks where the RF antennas will be placed later.

Ground Rods

Drive the ground rods 400421 directly after back-fill before further assembly to help keep a clear workspace. If you mushroom the head of the rod during installation, it will need to be ground back to profile in order to CADweld the bonding wire to it. NEED PLACEMENT DIAGRAM

• Drive one ground rod 2-6" from each post.
• Ground Rods should be driven to 4-8" above grade.

Subsystem Install

Solar Panel

When attaching the solar panel, be aware of its position relative to the sun. In the northern hemisphere, south facing solar panels allow for optimal exposure to the sun. Depending on positioning of the rail, optimal placement may not be possible.

• Assemble brackets onto solar panel.
• Attach to nearside post using provided U-bolts according to optimal placement.

Radar Presence Detector

The radar must be attached to the nearside post, facing the rail. PHOTO NEEDED, MORE PRODUCT INFO NEEDED

• Attach radar facing the track, using provided U-bolts, to nearside post.

SensorLink Enclosure

The system is ready for the mounting of the SensorLink Enclosure [INSERT PART NUMBER].

The SensorLink enclosure is heavy and awkward to handle. Plan your movements, this is a multiple person job.

Before attaching the enclosure, mark on the nearside post where the enclosure will be attached. Ideal placement of the SensorLink enclosure will ensure accessibility when working inside the enclosure later. The SensorLink enclosure should be attached on the side of the post that is opposite to the track.

[INSERT ORIENTATION DIAGRAM]

• Attach to nearside post using provided U-Bolts on the side of the post opposite to the track.

Antenna Mounting

NEED DIAGRAMS
Two ParaPanel Antennas 400942 need to be installed, one on each post. The vertical center of the antenna should be 42 inches above top of rail, facing the track. If the posts were marked during Posts, the mark can be used to aid in mounting the antennas at the proper height.

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.

• Attach L-brackets to the back of the antennas using provided screws.
• Mount the nearside antenna first. The antenna should be attached facing the track, opposite the SensorLink enclosure.
  
  • The provided plate sits against the long side of the L-bracket.
  • The U-bolts attach around the tower post.
• Attach the second antenna directly across from the first in the same manner.

Antenna Connections

Sealtight conduit 400514 is used to connect the RF antennas to the SensorLink enclosure. Sealtight conduit is provided in the kit for this purpose.

The conduit should be laid in the 3" deep channel made in Earthwork.

Wheel Sensor

Refer to Frauscher Wheel Detector Installation and Optimization for instruction on installing the wheel sensor to the rail. The mounting point on the track should be in line with the antennas as much as possible.

• Cut the Frauscher's protective hose to the appropriate length and install using the grey cable fitting on the bottom of the enclosure.
• Cut the sensor wire to length, (with a service loop) and landed in the enclosure as shown. NEED PHOTO/DIAGRAM

Presence Detector Connections

Materials Needed

Tools Needed

Electrical Connections

Grounding Connections

Materials Needed

• No. 6 Bare Copper Wire

Tools Needed

• Wire cutter
  

Procedure

1. On the nearside post, partially unscrew the grounding lug's inner bolt and insert copper wire. Secure wire by tightening the inner bolt.
2. Secure wire to grounding rod with grounding rod clamp.
3. Cut the copper wire on the excess side of the grounding rod.
   
4. On the farside, screw ground lug to antenna.
5. Repeat steps 1-3 on the farside post.

Solar Panel Connections

Connections from the solar panel should be run to the enclosure. The cables should run through the second and third black cable fittings. The cable fittings are found on the bottom of the enclosure.

Batteries

An area inside the SensorLink enclosure has been marked for battery 400266 placement.

• Install the battery in the marked area.
• Connect the battery using the color codes (Black -)(Red +)

Final Inspection

Calibrating the wheel sensor, checking the reader and reporting to RSM. NEEDS MORE INFORMATION