Frauscher Wheel Detector Installation and Optimization

The following details installation and optimization of the Frauscher RSR110, dual segment wheel detector (aka. wheel sensor), utilizing the SK150-002 rail clamp.

Site Considerations:

• The RSR110 wheel sensor must be mounted on the inside face of rail (wheel flange side). Drilling the rail is not required. Wheel sensor mounting utilizes the SK150-002 rail clamp. It is adjustable for 100 lb rail up to 141 lb rail. 
• If mounting on a curve, the wheel sensor should be mounted on the rail which shows less lateral wear of head of rail. This is usually the inside rail.
• Insure when mounted that the housing edge of the wheel sensor does not touch the head of rail. (see clamp adjustments)
• 2’ (600mm) minimum distance from rail joints (including welded joints).
• 10” (250mm) minimum distance from guard rails or other route’s rail/frog, etc., if mounted in a switch.
• 2’ (600mm) minimum distance from another Frauscher on the same rail.
• 3’ (1 meter) minimum distance from other manufacturer’s wheel detectors.
• 20” (500mm) minimum from ANY movable metal objects

Requirements:

• The APU-102 must have a TDA204, Track Directional Analyzer card, strapped for Frauscher Wheel detector.
• Minimum AEI software version 5.2.0.6+

Tools Required:

• 17mm 6-point socket
• 19mm 6-point socket
• Ratchet handle (drive to fit sockets above)
• Torque wrench (drive to fit sockets above), minimum torque range from 15 to 40 Nm (about 10-30 ft/lb)
• 6 mm hex key (Allen wrench)
• 36mm wrench, 36mm deep socket with ratchet, or adjustable wrench
• Wire brush
• Combination square or string and tape measure
• Shovel
• Pick
• Rake
• Hammer
• Misc. small hand tools.
• Laptop PC with terminal emulation program (or someone with remote access to the APU)
• Null modem Cable to Local Port (or connect via network if available)
• Digital Voltmeter

Mounting the Frauscher with Rail Clamp to the Rail

Pre-configuration of the Rail Clamp

This procedure is for the SK150-002 rail clamp with BBK11 bolt kit. The clamp should be preconfigured before mounting to the rail. Determine the size of the rail the Frauscher will be mounted to and refer to the charts below for proper assembly recommendations and alignment dimensions for most common rail sizes. Attach the bolt kit to the wheel sensor. Torque to 11 ft/lbs. (15Nm) Preset the clamp for horizontal dimension “C”. Adjust BOTH sides of the horizontal adjusters equally. (Use the combination square to assist) Torque to 29.5 ft/lbs. (40Nm).

Preset the clamp for vertical dimension “D”. (Use the combination square to assist) The vertical measurement is for new rail and may need adjustment for worn rail. Verify proper/even seating of the interlocking grooves on the vertical adjuster. Tighten nuts snugly. Torque after final vertical adjustments to compensate for rail wear are done. This adjustment will be made on the rail. If necessary, mount the sensor to the clamp (17mm). Ensure the flat washer is in the correct position per the chart below and the spring washer is installed correctly (center bulge toward the nut). Torque to 29.5 ft/lbs. (40Nm).

Important information: The wheel sensor RSR110 may only be used for non-safety-relevant applications! The instructions in D4231 “Mounting, commissioning and maintenance Wheel sensor RSR110 (Mounting with rail claw)” must be observed and complied with! ▪  This brief instruction is only valid for main lines and for wheel flanges according to EBO and/or UIC 510‑2 or equivalent standards (see also respective valid documentation of the higher-ranking system). ▪  The RSR110 must be mounted on the inside face of the rail (wheel flange side). Choose the rail with less lateral wear of rail head. In track curves, this is usually on the inside of the curve. ▪  The RSR110 must be mounted in the middle between 2 rail ties. ▪  The RSR110 must not touch the rail head. ▪  The distance of the RSR110 to a rail joint of poor quality must be as big as possible. ▪  After disconnecting the pluggable wheel sensor cable from the RSR110, the plug contacts on the RSR110 and on the wheel sensor cable must be protected with the enclosed protection caps.	Measurements C and D: Guide values for pre-adjusting the rail claw before mounting. Tooth pitch: 2.5 mm. Rail profile C D 100 RE 5.0 mm 3/16” 36.5 mm 1 7/16” 112 RE 7.5 mm 9/32” 41.5 mm 1 5/8” 115 RE 7.5 mm 9/32” 21.5 mm 27/32” 119 RE * 7.5 mm 9/32” 16.5 mm 21/32” 132 RE * 7.5 mm 9/32” 7.5 mm 9/32” 133 RE * 7.5 mm 9/32” 10.0 mm 3/8” 136 RE * 7.5 mm 9/32” 2.5 mm 3/32” 140 RE * 7.5 mm 9/32” 2.5 mm 3/32” 141 RE * 7.5 mm 9/32” 0 mm 0 * Reposition flat washer to inside of mounting plate. Measurement C: Measurement D:
Measurement A: From highest point of RSR110 to top of rail. Measurement B: From outer edge of rail head to inner side of RSR110. Measurement C: Measured on toothed area of lateral clamping parts. Measurement D: Measured on toothed area of mounting plate. See Figure 1 for SAE torque values.
Flat washer position: For rail profiles marked with * in the table above, reposition the flat washer from the standard position on the outside of the mounting plate to the inside (sensor side) in order to achieve Measurement B. The conical spring washer must remain on the outside of the mounting plate!   Standard position Repositioned	Conical spring washer:     Ensure that the conical spring washers are in the correct position (top surfaces must face outwards towards the locknuts).

Excerpt from Frauscher document, D6284-1: Brief instruction – Mounting RSR110 with SK150-002 and BBK11

Figure 1

Mounting the Sensor and Clamp to the Rail

1. Determine mounting location as outlined above. The crib chosen should be in line with the RFID antennas.
2. Clear the ballast from the crib, 4-6 inches below the foot of the rail.
3. Remove creeper clip(s) if necessary.
4. Trench from the crib back to the track-side junction box or wiring pedestal. Usually “scratched” in, but follow your railroad’s standard practices.
5. Clean the foot of the rail with the wire brush.
6. Slide the mounting claw under the rail from inside the gauge. Hook the sensor end of the mount on the foot of the rail. Lift the bolt end and slide the clamping cube into position on the foot of the rail. Hand tighten the mounting nut.

 

NOTE	When mounted, the sensor must not touch the rail head.

1. The sensor should tuck under the rail head up to ¼” (0-6mm) for all rail sizes. Dimension “B” from the chart. Verify horizontal adjustment by sighting vertically down the edge of the rail head. The vertical edge of the rail head should align somewhere on the angled edge of the sensor. See Figure 1 for detail. (Compensate for mushrooming if necessary) If horizontal adjustment is necessary, remove the clamp from the rail and adjust BOTH horizontal adjusters equally. Once horizontal adjustment is complete, torque the horizontal adjuster nuts to 29.5 ft/lbs. (40Nm)
2. Rotate the spring washer of the foot clamp so the ends are visible. Observe the ends of the washer while tightening the nut (36mm). Tighten until the washer ends touch the center ring of the washer. Tighten the nut one more full revolution.

Vertical Adjustment

1. The top of the sensor should be between 1 ^9/16” to 1 ^3/4” (40-45mm) below the top of rail for all rail sizes, preference to the high end. Dimension “A” from chart.
2. Place the combination square level on the rail and slide the rule until it contacts the sensor. Lock in place and read the rule. If distance is out of the valid range, loosen the vertical adjuster nuts enough to move the sensor. Adjust as necessary. Ensure proper/even seating of the interlocking grooves on the vertical adjuster. Tighten nuts snugly. Recheck vertical alignment and repeat if necessary.
3. Torque vertical adjuster nuts to 29.5 ft/lbs. (40Nm)

Alternate measurement method: Use a 5’ piece of string weighted on both ends. String it across the gauge and measure from the string to the top of the sensor.

Connect the Cable

Remove the connector flange from the sensor (6mm internal hex screws). Remove the protection caps from the clamp and cable. Insert the cable connector into the sensor. Reinstall the connector flange and torque the screws to 11 ft/lbs. (15Nm). Retain the protection caps at the site for future use. Feed the cable with cable/conduit assembly under the sensor and rail and run back to the junction box/pedestal. If upgrading from a Tiefenbach with TDA105, remove the 2-pin power connector to the TDA105. Connect the cable at the junction box per the site wiring diagram, 70-0180-02. If replacing a Tiefenbach, the Frauscher sensor lead cable uses the same colors.

At the APU-102

Disable Maintenance Reporting

During the upgrade process, maintenance messages will be generated and may interfere with setting of some parameters. If your site has maintenance reporting, disable it for all applicable sessions.

Wiring to the APU-102

Connections will be from the surge protection devices directly to the APU-102. If upgrading from a Tiefenbach, the TDA105 will be removed from the system. Power off the APU-102 and unplug the power lead from the TDA105. Rewire as necessary. Refer to drawing 70-0180-02 for details.

Strap the TDA204

Remove the TDA204 from the APU-102 if installed. If upgrading to TDA204, remove the TDA104 from the APU-102. Set or verify jumpers on the TDA204 are set for “DIRECT” and “FRAUSCHER”. Refer to drawing 70-0180-02 for details or legend on solder side of the TDA204. Install the TDA204 into the APU-102. (Cable connections are the same as TDA104) Power on the APU-102.

Configure the Parameters for the Frauscher Wheel Detector

Set/verify parameters for the Frauscher as follows. Remaining parameters in this section will be set to default values. They should only be changed on advice from Comet Electronics Engineering staff.

Acquisition.Operating.WheelDetectorSeparation=50

Acquisition.Operating.WheelDetectorGain=50

Acquisition.Operating.WheelDetectorThreshold=50

Acquisition.Operating.WheelDetCsegMode=2

Acquisition.ACQProcess.Enabled=1

Acquisition.ACQProcess.MaxACQs=200

Acquisition.TDA204.Digitizer.DigitizerEnable=1

Acquisition.TDA204.Digitizer.DigitizerMaxFileSizeBytes=5000000

            OR (depending on software version)

Acquisition.TDA204.Digitizer.DigitizerMaxFileSizeKBytes=10000

NOTE	Parameters may be changed, added or removed as the software evolves. Refer to the on-line parameter help, <CTRL>-U, as necessary.

 

Exit the parameter editor. Re-enter the parameter editor and verify the Acquisition.Operating parameters were set. Activities such as maintenance reporting, login and log off activity share the same file as these parameters. If not set correctly, set again, exit and re-verify. Perform a fast reboot (R,F) so changes take effect.

Calibrating the Frauscher Wheel Sensor

Log into the APU-102 to the Supervisory level on Session One (Change1> prompt).

Ensure site is clear (no train).

Enter command “TDA204” to enter the TDA204 setup utility.

NOTE	While running the TDA204 utility, the APU-102 will NOT record axles/trains. Commands within the TDA204 utility are hotkeys (do not follow command with <ENTER>). When done executing commands, the display will refresh.

Sample TDA204 utility display (voltage levels may vary)

Verify the Configuration line display is correct (TDA204 with Direct Connected Frauscher Transducer). Press “T” to change if necessary.

Press “Z” to set the null adjustment.

Press “C” to calibrate the Frauscher Wheel Detector.

Press “R” to use the Voltage Reversal method.

When done, the display will refresh.

Press “Z” to set the null adjustment.

NOTE: If the wheel detector does not null the 2^nd time, try to calibrate with the [P]ulse Stream method and re-null.

Press <ESC> when done to exit the TDA204 Utility.

Perform a Fast Reboot on the APU102 (R,F and confirm)

Finalize Installation

Testing the Frauscher Wheel Sensor

Testing the Frauscher wheel sensor is the same as testing the Tiefenbach wheel sensor.

Put metal on each segment and observe on the APU-102 Front Panel Buttons and the I/O screen. Train patterned strokes across the sensor to simulate a train.

Sensor Voltages (Sensor Input)

Voltage across either sensor segment should be approximately 8.75VDC ± 0.25 V with no wheel or metal over the sensor. “A” segment voltage may be measured at APU-102 MAIN BLX, pin 3 (+) and pin 4 (-). “B” segment voltage is measured at APU-102 MAIN BLX, pin 5 (+) and pin 6 (-). The segments are 2 separate circuits within the sensor and the voltages will not match between “A” and “B” but should be close. Placing a piece of metal over a sensor segment causes the corresponding segment input voltage to rise to approximately 10 VDC ± 0.5 VDC. (This voltage varies depending on the size and placement of metal over sensor segment.)

Housekeeping

If maintenance reporting was disabled earlier, re-enable for all applicable sessions.

Optional-Use the NOTE command to add a login notice regarding the Frauscher installation

e.g.,     NOTE A Frauscher installed, 10/18/2019 09:30

NOTE L

If parameters were changed, perform the parameter backup (BP)

If parameters were changed, update the mirror image (IBACKUP)

Correct any site deficiencies.

TDA-204 Card with Frauscher Wheel Detector

Card Layout	Jumper Settings
	J1 OPEN (50-pin connector) J2 OPEN (10-pin connector) J3 2-3  (12V) J5 ALL OPEN J6 ALL OPEN J7 ALL JUMPERED J8/J9 ALL OPEN J11 ALL OPEN J12 ALL OPEN P1 ALL OPEN P4 1-2, 3-4, 5-6   SENSOR CONFIGURATION Direct with Frauscher A B SS1 SS11 2-3 SS2 SS12 2-3 SS3 S13 2-3 SS4 SS14 2-3 SS5 SS15 2-3 SS6 SS16 2-3 SS7 SS17 2-3 SS8 SS18 1-2 SS9 SS19 1-2 SS10 SS20 1-2