Railert ATR Installation Guide
1 Overview
This chapter explains how to prepare and install a Railert Reader site. If your site installation involves a procedure not included here, refer to section 1.3, Additional Information.
2 Site Preparation
2.1 Site Considerations
Pre-construction
1) Find the transducer location first. This is the center of the site. The center of the transducer must be located between two ties (aka “crib”). This allows the cable at the bottom of the transducer to enter the Carflex conduit without binding.
2) Find the tower location(s). The center of the tower(s) will be in-line with the transducer location.
3) Locate underground utilities before digging.
Areas to Avoid
Comet Electronics recommends that the following site areas are avoided. Use this list as a guide only. Since all installations are unique in some manner, avoiding these areas is not always possible. A survey of each site should be done to determine preferred equipment locations, conduit runs, and antenna configuration based upon the particular application. The user and the system integrator must ensure correct and accurate system operation in the event the areas described below cannot be avoided.
● Large metallic objects and obstructions in close proximity to the reading area
● Areas where reverse train movements occur
● Areas where train switching moves occur
● Areas where “building” moves occur (dropping and adding cars)
● Areas where train stoppage in front of reader systems is likely to occur
● Areas with severe or multiple curves in the track
● Switches
● Track joints
2.2 Construction
Drill 36” diameter hole approximately 48” deep for each antenna location.
Add 3” of rock to bottom of hole(s) to level foundation.
Set tower foundation(s).
If site is configured for 2 antennas, trench between the holes. Recommended 36” deep.
If site is configured for single antenna, trench from transducer location on the near rail to Railert enclosure location. Usually “scratched” in, but follow your railroad’s standard practices.
Trench and place 1" conduit between Railert enclosure location and AC power source.
Install all conduits in the same trench. Conduit runs on drawings are guidelines. They may be changed to fit site specific requirements. Use sweeps-not elbows!
Install tower sections and tower caps.
Install ¾” Carflex conduit from Railert enclosure to transducer location.
Optional Presence circuit installation:
Trench from crib adjacent to transducer location to Railert enclosure location. Usually “scratched” in, but follow your railroad’s standard practices.
Install loop cable on track.
Loop cable must be twisted 5 times per foot from track to enclosure.
Install ground rods and cabling. (Pigtail at corner ground rods into hut).
Use the CADWELD exothermic welding system for ground cable to grounding rod connections.
Tamp all excavations and trenches.
Restore ballast to pre-dig condition. Supply fresh ballast where required.
Tape all ends of exposed conduits or Carflex conduit to prevent water, rocks, or other debris from entering.
Clean up site area.
1. Clear the ballast from the crib, 4-6 inches below the foot of the rail.
2. Remove creeper clip(s) if necessary.
3. Trench from the crib back to the track-side junction box or wiring pedestal. Usually “scratched” in, but follow your railroad’s standard practices.
2.3 Single and Double Track Sites
Single Track Site Installation
1) Set instrument house, securing all four corners.
2) Connect ground wire pigtails to ground panel.
3) Seal cable entry holes with Ductseal.
4) Mount parapanel antennas with check tags.
5) Install Sealtite assembly and 4' coax jumpers to parapanel antennas.
6) Insert check tag cable into Sealtite assembly to tower junction box.
7) Pull in 1/2" Heliax and 4c 22 gauge check tag cable from near side tower junction box to bungalow. (3” conduit)
8) Pull in 1pr 16 gauge loop lead-in and 2pr 18 gauge transducer cables from junction box or splice pedestal (if used-otherwise install in 3" with heliax) to building. (2” conduit)
9) Mount antennas without check tags to remaining locations.
10) Pull in 1/2" Heliax cable from far side antenna box.
11) Splice, waterproof, and terminate all cables.
12) Install the Tiefenbach transducer. Refer to Section 2.3.1 Tiefenbach Installation for installation instructions.
Double Track Site Installation (Restricted)
1) Set instrument house, securing all four corners.
2) Connect ground wire pigtails to ground panel.
3) Seal cable entry holes with Ductseal.
4) Mount parapanel antennas with check tags to towers on all sites. The near track gets the antenna with a check tag. The check tag is mounted on the antenna that is on the bungalow side of the tracks. On double tracks, the far track also gets an antenna with a check tag. It is mounted on the antenna farthest from the bungalow.
5) Install Sealtite assembly and 4' coax jumpers to parapanel antennas.
6) Insert check tag cable into Sealtite assembly to antenna junction box.
7) Pull in 1/2" Heliax cable and 4c 22 gauge check tag cable from each tower junction box. (3" conduit)
8) Pull in 1pr 16 gauge loop lead-in and 2pr 18 gauge transducer cables from far side junction box or splice pedestal (if used-otherwise install in 3" with heliax) to building.
9) Mount log periodic antenna. (if required by site configuration)
10) Pull in 1/2" Heliax cable from each log periodic antenna. (3” conduit). (if required by site configuration) Optionally, wheel detector and loop termination may be in log periodic enclosure for antenna 0 of far track. Install accordingly.
11) Splice, waterproof, and terminate all cables.
12) Install the Tiefenbach transducer. Refer to Section 3.1 Tiefenbach Installation for installation instructions.
3 AEI Component Installation
3.1 Wiring Diagram
Use the following wiring diagram to make connections when installing the AEI components. Color codes listed are typical and may vary.
Figure 1: Wiring Diagram
3.2 Tiefenbach Transducer Installation
Mount the Wheel Detector
For full size drawing, refer to drawing number 101-08 when performing this procedure.
Caution Verify that the APU-102 is turned off before beginning this procedure.
NOTE Proper mounting of the wheel detector is crucial to accurately acquire axle data. Use a rail mounted drill for precision.
1) Locate the rail mounting position between the ties and on the centerline of the antenna(s).
Figure 2: Transducer installation location
Figure 3: Tiefenbach transducer installation
2) Secure and level the rail mounting template and tighten setscrew.
3) Insert the center punch into each hole and mark the rail by striking the center punch.
4) Remove template and drill two pilot holes (approximately 1/8” diameter and 1/8” deep) where marked to serve as a guide.
5) Using the pilot holes, drill two 17/32” mounting holes.
6) Pull the 4-conductor sensor cable through the 3/4” Carflex conduit to the splice box.
7) Connect the end of the 3/4 inch Carflex conduit around the transducer flange with the 1 inch adjustable clamp.
8) Choose the appropriate distance shims on both mounting studs depending on rail weight.
Rail Weight Distance Shims
Less than 90 lb Do not use any distance shims
90lb to 136lb Use the green distance shims
Over 136lb Stack one each of the red and brick colored distance shims together.
9) Use the transducer’s lower mounting holes to mount the transducer onto rail. Insure some slack in the Carflex to allow movement with the rail.
10) Tighten the transducer rail mounting bolts until spring washers are flattened out. Do not over tighten to avoid deforming the distance shims. Torque specification is 40 lb-ft.
Verify Transducer Is Parallel With Top of Rail
1) Measure the distance between the top left side of the transducer (at ridge) and the bottom of the ball of the rail.
2) Perform the same measurement for the top right side of the transducer.
NOTE If the distance for one side measures within 3 mm of the other side, the transducer is installed correctly with respect to the top of the rail.
3.3 TDA-105 Installation
Refer to Figure 3.8: TDA-105 layout and Figure 3.11: Wiring Flow Chart when following the steps below.
1) Mount the TDA-105 on the wall near the lower left corner of APU-102.
2) When wiring the TDA-105 to the sensor, keep the following points in mind:
Required! Reliable connections at splice box and protection panel are IMPERATIVE for correct operation of wheel detectors.
a) Refer to your particular site drawing when checking hut wiring as there may be a change in color designation.
b) If the wheel detector splice is in an underground splice box, the splice must be soldered and waterproofed. If ring terminals are used in a weatherproof junction box, verify crimps are secure and proper ring terminals are being used with transducer lead and shielded pair cable to protection panel.
3) Using the supplied DC input cable, install DC power from the hut DC distribution point to TDA-105 interface board J3. Input voltage and range from +9 to +36 VDC.
4) Connect earth ground to chassis ground point on the TDA-105 with the # 6 ground wire.
5) Connect the transducer wiring from the surge protection panel to the TDA-105 J1 inputs 1, 2, 5, and 6 (left to right) as shown in the following image and in drawing 601-419H, Appendix C.
Figure 2.4: TDA-105 case
3.4 Antenna Installation
1) Place the center of the antenna 3 feet 6 inches above the top of the rail and 11 feet 6 inches away from the center of the rail. (The tower face should be 12 feet from the center of the rail.)
2) Place the second antenna directly across from the first.
3) Refer to Appendix C: Site Drawings for detailed installation drawings.
3.5 Presence Detector Installation
Loop Installation
When laying out the loops, keep the following guidelines in mind:
1) Place the loop wire at least four inches away from the rail at all points (to the side of rail and where it passes under the rail).
2) Fasten the loop to each tie to prevent movement.
Loop Design
The loop may be constructed of #10 or larger insulated wire in neoprene or similar non-metallic jacket. When installing cable, keep the following guidelines in mind:
1) Be careful not to cut the wire insulation.
2) Keep loop wire away from contact with gauge plates, switch rods, switch movements, and other metallic parts.
3) Fasten the loop securely to prevent loop movement on the rail and ensure a stable frequency.
Refer to Appendix C: Site Drawings for loop installation drawings.
Note: if using alternate presence detection, refer to appropriate documentation.
3.6 Heliax Coaxial Cable Installation
Refer to manufacturer's documentation for connector and wiring installation procedures.
4 Preparation for Optimization
Unless the site optimization process is to begin immediately, disconnect the negative battery cable connection. Make sure that the APU-102 and battery charger are turned off.