Introduction

Welcome to the installation guide for your new RailNET Automatic Equipment Identification (AEI) system. This document 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 AEI 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.

Common Vocabulary

Scope of Supply

This installation package includes all necessary components for the complete installation of your RailNET Automatic Equipment Identification (AEI) system.

Provided Components:

RailNET assembly in NEMA Enclosure
Rohn towers for near and far side antennas with Ballast foundations
Conduit and Fittings for system connections
RFID Antennas
Frauscher Wheel detector and accessories
Traffic Loop prescence circuit kit
Cellular Antennas

Tools and Materials Needed

Installer will be required to provide the following.

200lbs sack concrete (recommended)
Basic hand tools (imperial and metric)
Basic RF cabling tools

110V/1P/60Hz/15A Electrical Circuit and Associated Materials: The installation crew is responsible for providing and installing a dedicated 110V/1P/60Hz/15A electrical circuit, including all necessary wiring, conduit, breakers, and any other materials required to supply power to the AEI system.

Process Overview

Here's a general installation process overview for a RailNET AEI system, broken down into key stages:

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.).
Foundation and Conduit Installation: Prepare the foundation according to the installation specifications.
AEI Subsystem Assembly
1. Antenna Mounting and Hookup
2. Loop installation
3. Frauscher Wheel Trasnducer mount and Hookup
4. Cellular Antenna Installation
Electrical Installation:
1. Circuit Installation: Install the dedicated 110V/1P/60Hz/15A electrical circuit, adhering to all applicable electrical codes.
2. Install and connect system backup batteries.
3. Power Supply Connection: Connect the power supply unit to the electrical circuit and the reader unit.
4. Grounding: Ensure proper grounding of all electrical components. Bond towers to grounding rods.
System Configuration and Commissioning:
1. Power-Up and Initial Checks: Power on the system and perform initial checks to verify proper operation.
2. System Configuration: Configure the AEI system according to the site-specific requirements.
3. Tag Testing: Perform tag testing to verify accurate tag reads and system performance.
  1. Data Verification: Verify that the system is transmitting data correctly to the designated data collection system.
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, including as-built drawings, test reports, and commissioning checklists.
3. System Handover: Hand over the completed system to the customer, providing training on operation and maintenance.

Site Considerations

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

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 tower locations. Tower Foundations 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.
Site Layout Diagram

Earthwork

Two Tower Foundations and a 3" conduits need to be installed below grade. All trenching must be at least 36" below top of rail.

Tower foundation holes

Minimum size 24" x 24" centered 12 feet 6 inches from center of rail.
Hole must be deep enough to set the foundations at top of rail.

Trenching

All trenching must be at least 36" below top of rail.
One conduit trench is needed between the two foundation holes running through their center.

Tower Foundations

Install house foundation legs at top of tie level. All trenching is to be 36" below top of tie. Set tower foundations.

Recommended: 200lbs of Sakrete for the nearside.

Conduit

Install all conduits in the same trench. Lay conduit out, make the necessary cuts, glue cut pieces together as necessary, and bury the conduit.

Conduit runs on drawings are guidelines. They may be changed to fit site specific requirements. Use sweeps, not elbows!

Towers

Install tower sections and tower caps. There are holes present at the bottom of the tower. Use these holes to guide drilling through the foundation, and secure tower to foundation using provided bolts. Secure towers with six bolts each, for twelve total bolts.

Ground Rods

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.

Junction Box and AEI Box

On the side of the nearside tower that the AEI box will be installed on, place the AEI box on top of the 4x4 spacers. While the box is supported, slide the tower clamps into the unistrut located on the back of the box. The clamps should be bolted to the tower securely once they have been slid into place.

The Junction box can be installed in the same fashion on the farside.

Antenna Connections

HELIAX: A 40-foot length of Heliax (black cable, 400263)) has been provided with installation materials.

(NOTE: You will eventually need to cut the Heliax, but make sure you have plenty of length to complete the tasks below.)

Fish the Heliax through the conduit under the track from far side to near side.
Ensure that the cable is long enough to complete the next two steps.
- - Pull the Heliax from the top of the conduit at least 4.5 inches up through the bottom of the Junction Box and also through the bottom of the NEMA Enclosure.
  - After pulling the Heliax into the JBox and NEMA Enclosure, attach the female terminators (400261) to both ends.
    - - One terminator is packed with the Junction Box materials, and one is in the box containing the antennas.

COAX: Three pieces of COAX (400691) are included with installation materials. Two are used now (the third is for installation of the Cell Modem; see below).

The materials also include 50' of the protective cable sheath called Carflex.

The far-side COAX should be run through Carflex (400254) and connected to the Heliax terminator inside the Junction Box.
- - Then pull the COAX through the opening in the top of the box to connect to the back of the antenna.

The nearside COAX should be run through Carflex and connected to the Heliax terminator inside the NEMA Enclosure.
- - Then pull the COAX through the bottom of the enclosure, loosely loop it once to prevent crimping and run it up to connect to antenna.

Antenna Mounting

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 the rail, facing the track.
Clamp the mounting hardware to the tower.
Bolt the clamp to the Antenna through the two holes on the bracket on the back of the Antenna.
Place the second antenna directly across from the first.

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 (400XXX) located on the left side.

NOTE: There is also an AC Transformer (400355) wired into the receptacle. Do not remove or alter this wiring.

Wheel Sensor

Refer to Frauscher Wheel Detector Installation and Optimization for instruction on installing the wheel sensor.

Presense Subsystem

Refer to Presense Detector Installation and Loop Detector Pin Connections for instruction on installing the presense subsystem.

Batteries

An area inside each NEMA enclosure has been marked for battery placement. Install the batteries in the marked area.

Cell Antenna

Install the cell antenna above the AEI box.