Page 2 - SAFETY WARNING; HEALTH AND SAFETY AT WORK; Before any; the earth connections within the CLS with LMF signal head are; WARNING; be connected to ELV
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 2 of 143 SAFETY WARNING HEALTH AND SAFETY AT WORK Safety of Installation and Maintenance Personnel In the interests of health and safety, when installing, using or servicing this equipment the following instructions must be noted and adhered ...
Page 3 - Any power tools must be regularly inspected and tested.; Safety of Road Users
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 3 of 143 (k) Any power tools must be regularly inspected and tested. (l) Any ladders used must be inspected before use to ensure they are sound and not damaged. (m)When using a ladder, before climbing it, ensure that it is erected properly an...
Page 5 - TABLE OF CONTENTS
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 5 of 143 TABLE OF CONTENTS SAFETY WARNING .................................................................................. 2 MAINTENANCE PROVISION (MP) ........................................................... 4 1. INTRODUCTION .............
Page 7 - Transformer Replacement; APPENDIX A
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 7 of 143 2.34 Above Ground Detector (AGD) ........................................................................... 88 2.35 Bleep and Sweep Unit ........................................................................................ 89 2.3...
Page 8 - FIGURES
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 8 of 143 INDEX .................................................................................................... 142 FIGURES Figure 1 – Helios front view ........................................................................................
Page 11 - INTRODUCTION
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 11 of 143 1. INTRODUCTION 1.1 Purpose This handbook gives a general description and specification along with the procedures for installation, commissioning and maintenance for the following versions of Helios Signal Head: CLS with LMF Signal ...
Page 12 - Related Documents
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 12 of 143 1.3 Related Documents 667/HE/20661/000 - General Principles 667/HE/20662/000 - Signals and Poles (for reference only) 667/HE/20663/000 - Detectors and Cable Terminations 667/HE/20664/000 - Installation and Testing 667/HE/20665/000 -...
Page 13 - Power Consumption (CLS; NOTE; Power Consumption
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 13 of 143 667/1/30198/004 Up Arrow Green LED - 0.06 A per optical unit 667/1/30198/005 L/R Arrow Green LED - 0.08 A per optical unit 667/1/30200/907 Red (NLM) LED - 0.102A per optical unit 667/1/30200/908 Amber (NLM) LED - 0.117A per optical ...
Page 16 - SIGNALS AND POLES; CLS ELV aspects should; ONLY; be connected to Siemens ST900 (ELV) and; not; utilise a LMF Unit.; Figure 1
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 16 of 143 2. SIGNALS AND POLES 2.1 General The Helios range of traffic signals has been developed to give optimum clarity, reliability and longevity with a pleasing appearance. It incorporates newly developed lens form and masking patterns, w...
Page 17 - Figure 2
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 17 of 143 Figure 2 – Helios TRAM indicator front view The basic three-aspect lantern assembly is constructed on a modular principle. Each aspect is self-contained and consists of one of the following: Halogen Option A high intensity tungsten ...
Page 18 - CLS ELV OPTION; CLS ELV Type A; Figure 3 CLS ELV Type A; CLS ELV Type B; Figure 4 CLS ELV Type B
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 18 of 143 CLS ELV OPTION The Central Light Source (CLS) is fitted behind a clear lens and is connected directly to the ST900 (ELV) or ST750 (ELV) controller phase output. The output from the controller is 48V (bright) with the controller capa...
Page 20 - Installation at a new site
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 20 of 143 The halogen, CLS with LMF, CLS (NLM) and CLS ELV green arrow may have a green arrow mask placed in a number of positions in 22.5 increments. The LED and LED (NLM) options can have up (ahead) or left and right green arrows PCB’s fitt...
Page 21 - Order of Installation
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 21 of 143 2.2 Helios Signals 2.2.1 Order of Installation The recommended order in which installation should take place is as follows: 1. Read the Safety Warning on page 2 of this Handbook. 2. Unpack items from packaging (section 2.2.3) 3. Ins...
Page 22 - M10 screws and bolts; Signal Head packaging; Helios modular signals are supplied boxed in two forms:; Figure 6
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 22 of 143 M10 screws and bolts – 20 Nm As signal heads rely on the security of their mounting fixings these fixings must be torqued up and the recommended procedure for this is found in appendix D. 2.2.3 Signal Head packaging Helios modular s...
Page 23 - Figure 7
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 23 of 143 Figure 7 – Three Aspect LED Internal Fitting Figure 8 – Three Aspect LED (NLM) Internal Fitting
Page 24 - Figure 9; Assembly and attachment of side boxes are described in section 2.7.; Optical Units; interchangeable with the Helios lens.; 00 mm Aspects for Vehicle, Pedestrian and Green Arrow Signals
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 24 of 143 Figure 9 – Three Aspect CLS with LMF Internal Fitting The single aspect box will contain a single module with its side box mounting kit or the four-in-line fixing kit, and all the hoods and fixings for the assembly. All these elemen...
Page 25 - CLS ELV
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 25 of 143 lamp changing without exposing the reflector to the elements and possible surface damage. The lens is screened with a specially designed mask, to reduce the phantom effect. The lamp voltage is derived from a small step-down transfor...
Page 26 - LV Regulatory Signs
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 26 of 143 The 48V supply voltage for the CLS ELV is derived from the ST900 (ELV) or ST750 (ELV) controller phase outputs. The Controller phase driver PCBs monitor the load current of the CLS ELV unit. 2.2.4.5 LV Regulatory Signs Two 230 mm (9...
Page 27 - Assembling and Terminating a Signal Pole; Galvanised Poles
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 27 of 143 2.3 Assembling and Terminating a Signal Pole 2.3.1 Pole Types General - PVC-covered Poles 667/2/01459/ETC Galvanised Poles 667/2/03686/ETC Cranked Pole 667/2/30230/000-001 667/2/30231/000-001 Formed Pole 667/2/28107/001-003 NOTE – I...
Page 28 - Pole Selection; – Typical Signal Pole Assembly showing heights for compliance; The dimensions on this drawing show the
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 28 of 143 2.3.2 Pole Selection Ground level Cables entering via slot in pole Concrete Centre Line of Amber 2.4m min to 4.0m max (see note 1) 2.1m min (see note 3) 2.1m min to 2.6m max (see note 2) Anti-rotate rod Pedestrian Pushbutton Box 1.0...
Page 29 - Example 1
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 29 of 143 LTN 1-98]. This dimension applies if the push button is a single housing or a separate housing Demand/Display unit. 5. The height dimension of the pushbutton unit applies to a single housing or separate housing Demand/Display unit [...
Page 30 - – Signal Pole Assembly showing useful dimensions for Pole
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 30 of 143 Planting Depth Ground level Cables entering via slot in pole Concrete 1065mm Amber C/L Green C/L Min clearance line 505mm 835mm Anti-rotate rod Figure 11 – Signal Pole Assembly showing useful dimensions for Pole Selection and planti...
Page 31 - Erecting the Pole; This operation is then repeated for each pole at the intersection.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 31 of 143 2.3.4 Erecting the Pole The pole assembly may be completed to the point of having drawn up the cables and fitted at least the pole cap prior to erection, in which case see Section 2.3.5. Alternatively, assembly may follow erection i...
Page 32 - Neutral Connections General
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 32 of 143 Measure off wires to length, cut, strip, terminate necessary cores to terminal block and terminate two cables cores in earthing block for test purposes as described in Section 2.3.8. Once this operation is completed, the excavation ...
Page 34 - – Traffic Signal Junction Cabling Design Certification for; Controller Neutral Connection; Cut lengths of wire 60 mm long and bare each end for 10 mm.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 34 of 143 Number of Lamps Lit Current Total Length of Cable Typical Cable Run on STS 17 4.58 22 16 18 4.86 21 15 19 5.13 19 13 20 5.40 18 12 If there is a danger of neutral connectors being disconnected it is recommended that separate neutral...
Page 35 - – Wiring of the Neutral Terminal Block; There are four types of bracket for Helios:; Extension Bracket Assembly
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 35 of 143 Controllerneutral Phase driveR A G Figure 12 – Wiring of the Neutral Terminal Block 2.5 Helios Bracket Assemblies There are four types of bracket for Helios: 1. The standard bracket that is used top and bottom on a three aspect case...
Page 36 - – Extension Bracket
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 36 of 143 Add bolts and spacers to the extension bracket on which to hang the signal head. All bolts should be securely tightened. Figure 13 – Extension Bracket Connections from the signal head to the pole are enabled by the use of a terminal...
Page 37 - Signal Head Arrangement
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 37 of 143 2.6 Signal Head Arrangement KEY-May be green aspect,green arrow, pedestriangreen man/red man orregulatory sign, e.g. No LeftTurn, No U Turn, etc. Figure 15 – Example Mounting Arrangements Figure shows a selection of arrangements, bu...
Page 38 - – Sacrificial Cap parts; . The smooth cap is fitted to the; Note
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 38 of 143 Figure 16 – Sacrificial Cap parts The sacrificial caps must be fitted correctly . The smooth cap is fitted to the top of the signal head and the toothed cap is fitted to the bottom. Assemble the parts as follows: 1. Attach one end c...
Page 39 - – Sacrificial Cap assembly
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 39 of 143 Figure 17 – Sacrificial Cap assembly 2.6.2 Brackets Most signal head assemblies are delivered to site with the sacrificial caps and brackets ready attached to the signal head. In those cases where the assembly has to be made on site...
Page 40 - – Door clip detail
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 40 of 143 Figure shows a door clip in the half-open position with the door sitting above and unconnected. The door ‘peg’ is held in place by the door clip. Figure 19 – Door clip detail 2.6.4 Green Arrow (Halogen), CLS with LMF, CLS (NLM) and ...
Page 42 - Figure 21 CLS ELV Type B Anti-rotation Clip; Insert or adjust the mask as required.; Figure 22 CLS ELV Arrow Mask; Secure the door, tightening the anti-vandal screws if supplied.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 42 of 143 Figure 21 CLS ELV Type B Anti-rotation Clip b) Rotate the enclosure body anticlockwise and withdraw the enclosure from the door ring. c) Insert or adjust the mask as required. Figure 22 CLS ELV Arrow Mask d) Re-fit the enclosure to ...
Page 43 - Four in Line
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 43 of 143 2.6.6 Equestrian (Halogen, CLS with LMF, CLS (NLM), CLS ELV, LED and LED (NLM)) Lens are available for displaying equestrian figures. These lens have the equestrian figure ‘silk-screened’ on to them. a) Red and Green Equestrian Lens...
Page 44 - – Side box showing fixing plates and conduit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 44 of 143 Figure 23 – Side box showing fixing plates and conduit Figure 24 – Side box fitted on right of main signal head Both ends of any side fittings should have end caps fitted as shown in Figure . There is an O ring supplied to seal the ...
Page 45 - Wiring Side Boxes
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 45 of 143 2.7.1 Wiring Side Boxes Check that the internal illumination assembly is correctly fitted into each side box. Green arrow and cycle side boxes have internal fittings similar to the main signal head; regulatory signs are fitted as sh...
Page 46 - Remove any surplus seal from the face of the lens.; – Transformer fitted to floor of case
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 46 of 143 Clean the door aperture and outside of the lens carefully and ensure that both are completely dry before fitting the lens. Place the strip of sealant around the inside of the door aperture, carefully align the lens and press both pa...
Page 47 - – PSU assembly fitted into case
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 47 of 143 Figure 29 – PSU assembly fitted into case 2.10 Transformers LED (NLM) The transformers will normally be factory fitted before delivery. The usual position is in the bottom right corner of the module, although they may be placed in a...
Page 48 - Red CLS unit; – Futurit CLS Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 48 of 143 2.11 CLS Unit The CLS units will normally be factory fitted into the appropriate door before delivery. There are three variants of the CLS unit a) Red CLS unit - 667/7/28584/100 b) Amber CLS unit - 667/7/28584/101 c) Green CLS unit ...
Page 49 - – Dialight CLS Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 49 of 143 Figure 32 – Dialight CLS Unit 2.12 CLS ELV Units The CLS units will normally be factory fitted into the appropriate door before delivery. There are two different types of CLS ELV units, each type has a Red, Amber and a Green variant...
Page 50 - CLS ELV Type B Transformer Placement; Figure 33 Transformer mounting points; LMF for Red Aspect
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 50 of 143 2.13 CLS ELV Type B Transformer Placement If CLS ELV Type B units are to be retro-fitted to an existing installation it may be necessary to relocate transformers fitted within the signal head enclosure to avoid a clash with the aspe...
Page 51 - – CLS with LMF; CLS Unit; Do not undo this nut; Internal Chassis Plate
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 51 of 143 Note that the Mains wiring to other LMF Units is tied to the LMF chassis with two Pushbutton Ties which prevents any heat from the LMF unit from damaging any of the cable forms. Figure 34 – CLS with LMF 2.15 ELV TRAM Indicator The T...
Page 52 - – TRAM Indicator rear view showing Keyhole slots; To remove the Tram indicator from its housing:
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 52 of 143 Figure 36 – TRAM Indicator rear view showing Keyhole slots To remove the Tram indicator from its housing: The Tram indicator is a complete module and must be replaced as a complete assembly. The LED and power supply assembly is fitt...
Page 53 - – TRAM Indicator showing keyhole slot from the front; See Figure and Figure for the fixing position.; – Bridge Rectifier; Keyhole slot
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 53 of 143 Figure 37 – TRAM Indicator showing keyhole slot from the front 2.16 Terminal Blocks Fixing positions have been provided for terminal blocks, which are generally only fitted in aspects where an extension bracket has been used. Figure...
Page 54 - – Standard Hood fitting
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 54 of 143 2. Side mounted signals may have the cable gland fitted in one of the three recesses in the side of the module. 3. Pedestrian signals may have the cable gland fitted in any position to reduce the length of the conduit. Wherever the ...
Page 55 - – Angled Hood fitting
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 55 of 143 Figure 40 – Angled Hood fitting An optional Pedestrian Aspect Hood is available. This hood is supplied with predrilled fixing holes but is of a non formed construction. The hood is fitted to the aspect using fir-tree clips. 2.19.1 D...
Page 56 - – Solar Cell
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 56 of 143 Figure 41 – Solar Cell The solar cell used is a Royce Thompson Electric Ltd type RTE/P5 (55 Lux) (STCL part number 506/4/97891/000) or equivalent, which plugs into a Rotaloc Socket. The cell is mounted on the top of the 3-aspect cas...
Page 57 - – Pedestrian push button unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 57 of 143 2.21 Pedestrian Push Button (Mk 1) There are two variants of push button units currently in use in the United Kingdom: Standard push button with no Sonalert (667/1/01478/000) (2 man) Pelican push button fitted with Sonalert (667/1/0...
Page 58 - Violet
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 58 of 143 Red Red Aud. Signal + Black Black Aud. Signal - Blue Blue Wait Ind N Brown Brown Wait Ind. L Violet *¹ Green*² Tactile motor + Yellow *¹ Yellow*² Tactile motor - The wires within the Pedestrian push button should be arranged and cab...
Page 59 - – LED Wait Box
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 59 of 143 Figure 43 – LED Wait Box The L.E.D. Wait Box comes complete with its fixing kit. The unit fastens to the pole using the ‘U’ bolt provided. When installing a pushbutton box, the centre of the pushbutton should be between 1.0m – 1.1m ...
Page 61 - Pushbutton Assembly
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 61 of 143 Pushbutton Assembly ‘WAIT’ PCB Assembly Figure 44 – LED Wait Box Door Assembly (Mk 1) 2.23 Nearside Signal and Demand Unit (Mk 1) There are three variants of the Nearside Signal and Demand Unit, which are dual housed, for use in UK ...
Page 62 - – Toucan Nearside Signal and Demand Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 62 of 143 Figure 45 – Toucan Nearside Signal and Demand Unit 2.23.1 Nearside Signal Unit (Mk 1) The three variants of Nearside Signal come with a door assembly which contain the following items – a) a PCB which contains all the Display Red LE...
Page 63 - – Red Man PCB from Puffin Nearside Unit (Mk 1)
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 63 of 143 Figure 46 – Nearside Signal - Shows the Two PCBs (Mk 1) Figure 47 – Red Man PCB from Puffin Nearside Unit (Mk 1)
Page 64 - – Nearside Signal Shown with Red Man/Cycle/Equestrian PCB
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 64 of 143 Figure 48 – Nearside Signal Shown with Red Man/Cycle/Equestrian PCB Removed (Mk 1) The Following PCB variants are available for the Nearside Signal – 1) Green Puffin - 667/1/30695/001 2) Red Puffin - 667/1/30695/002 3) Green Toucan ...
Page 65 - – Demand Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 65 of 143 Figure 49 – Demand Unit 2.23.3 Optional Wiring Kits for Nearside Signal Unit and Demand Unit (Mk 1) Two wiring kits (667/1/26942/000) and (998/4/88324/000) are available for connection to the terminal block/s inside the Nearside Sig...
Page 66 - Nearside Mk2 Range of units
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 66 of 143 Orange Orange - TB1.5 - Push Button + Orange White - TB1.6 - Push Button - Red Red TB1.1 - RED 48VAC1 TB1.3 - Audio 1 *¹ Black Black TB1.2 - RED 40VAC2 TB1.4 - Audio 2 *¹ Blue Blue TB1.4 - GREEN 48VAC2 TB1.2 - 48v RET Brown Brown TB...
Page 67 - Nearside Mk2/Pedestrian Wait Mk2 Pole drilling positions
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 67 of 143 2.25 Nearside Mk2/Pedestrian Wait Mk2 Pole drilling positions Figure 50: Drilling guide for Nearside and Pedestrian WAIT range
Page 68 - Installation of Nearside and WAIT Mk2 fixing kits to pole
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 68 of 143 2.26 Installation of Nearside and WAIT Mk2 fixing kits to pole Figure 51: U-bolt and cable gland installation (Mk2) DEMAND, SIGNAL AND WAIT U-BOLTS CAN BE INSTALLED THROUGH FIXING HOLES BUT COMBINED U- BOLTS MUST BE FITTED THROUGH G...
Page 69 - Figure 52: Mounting of Nearside/Pedestrian WAIT units to Pole.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 69 of 143 2.27 Installation of WAIT, Demand, Signal and Combined Mk2 units to pole Figure 52: Mounting of Nearside/Pedestrian WAIT units to Pole. Typical to all assemblies, Combined unit shown.
Page 70 - Standard Wait Mk2 Indicator Units
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 70 of 143 2.28 Standard Wait Mk2 Indicator Units Figure 53 - Standard Wait Mk2 Indicator unit There are four main variants of Standard Wait Indicator units (with Mechanical Switch) available for use in the United Kingdom: Pedestrian WAIT push...
Page 71 - Terminal Block Layout for STD Wait Mk2 Indicator units
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 71 of 143 2.28.1 Terminal Block Layout for STD Wait Mk2 Indicator units Shown below are the diagrams of the terminal block assembly used within both of the Nearside Mk2 STD Wait Indicator units 2.29 LED Wait Mk2 Indicator Units There are four...
Page 72 - Figure 54 - LED Mk2 Wait Box
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 72 of 143 Figure 54 - LED Mk2 Wait Box The L.E.D. Wait Box comes complete with its fixing kit. The unit fastens to the pole using the ‘U’ bolt provided. When installing a pushbutton box, the centre of the pushbutton should be between 1.0m – 1...
Page 73 - Table 1 CLS Wait Lamp Monitoring Options
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 73 of 143 2.30 CLS Wait Two versions of CLS Wait are available; a retrofit solution and a production replacement for the existing LED Wait. Both versions offer the benefit of CLS technology and the possibility of lamp monitoring depending on ...
Page 74 - Figure 55 CLS Wait Retrofit and MK2 Spacer
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 74 of 143 667 /1/47701/000 Siemens MK2 Spacer Kit 667 /1/12800/000 PB800 issue 31 or greater (ST800 ) 667 /1/21029/001 Wait Drive Transformer 48V AC 160 VA Figure 55 CLS Wait Retrofit and MK2 Spacer Figure 56 CLS Wait Retrofit reverse side sh...
Page 75 - Figure 57 CLS Wait Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 75 of 143 2.30.2 CLS Wait (Production) The CLS Wait has been designed as a production replacement for the LED Wait unit and as such shares the same part numbers. This unit offers the benefit of CLS technology and provides a clear uniform disp...
Page 76 - Module Replacement; Disconnect the earth connection from the module.; Lamp Monitoring ELV
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 76 of 143 The mechanical installation of the equipment is as defined for the LED Wait Mk2 Indicator Units, see sections 2.25, 2.26, 2.27, 2.29. Module Replacement Should it become necessary to replace the CLS Wait Module the part number is 66...
Page 77 - Nearside Mk2 Signal and Demand Units
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 77 of 143 This will enable Wait indicator monitoring on the internal sensor. Different faults may be displayed depending on the combination of lamps illuminated. Refer to the handset handbook 667-HH-27000-000. Ensure that all lamp loads are l...
Page 78 - – Nearside Mk2 Signal Unit; Centre of the Demand Unit Push button must be 1.0m
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 78 of 143 Figure 58 – Nearside Mk2 Signal Unit Each Nearside Signal Unit and Demand Unit comes complete with its fixing kit. Each unit fastens to the Signal Pole using the ‘U’ bolt provided. When installing the Nearside Signal and Demand Unit...
Page 79 - Terminal Block Layout for Nearside Signal units
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 79 of 143 667/2/30690/001 – Toucan 667/2/30690/002 – Equestrian The following are the Mk2 Door Assemblies that are available – Puffin Door Assembly - 667/1/33661/000 Toucan Door Assembly - 667/1/33661/001 Equestrian Door Assembly - 667/1/3366...
Page 80 - The UK Variants, with piezo switch are; – Nearside Mk2 Demand Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 80 of 143 The UK Variants, with piezo switch are – Nearside Demand Unit – 667/1/33606/000 The Demand Unit comes with a door assembly that contains the following – a) A PCB which contains all the red LEDs arranged in a circle around the push b...
Page 82 - Nearside Mk2 and Mk2 LP Combined Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 82 of 143 2.31.5 Nearside Mk2 and Mk2 LP Combined Unit There are three variants of the Nearside Combined Unit, which are single housed, for use in UK Puffin, Toucan and Equestrian Crossing applications. A Narrow Field of View (NFOV) option is...
Page 83 - – Nearside Mk2 Combined Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 83 of 143 Figure 60 – Nearside Mk2 Combined Unit
Page 84 - Centre of the Demand Push button must be 1.0m; – Nearside Mk2 Combined Unit - Shows the Three PCBs; d) a front panel, the type which is dependant on the Nearside Signal
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 84 of 143 Each Nearside Combined Unit comes complete with a fixing kit. Each unit fastens to the Signal Pole using the ‘U’ bolt provided. When installing the Nearside Combined Unit the following must be observed – a) Centre of the Demand Push...
Page 85 - e) A vandal resistant Stainless Steel switch or piezo switch; Terminal Block Layout for Nearside Combined units
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 85 of 143 e) A vandal resistant Stainless Steel switch or piezo switch The following are the standard Mk2 Door Assemblies that are available – Puffin Door (Mechanical Switch) - 667/1/33662/010 Toucan Door (Mechanical Switch) - 667/1/33662/011...
Page 86 - Radix/Sedgwell Power Supply for Tactile
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 86 of 143 2.32 Radix/Sedgwell Power Supply for Tactile It is recommended that, where used, this unit be fitted in the amber aspect case, in the upper position as shown in Figure , otherwise the halogen reflector will stop the door closing. Mo...
Page 87 - – Radix power supply; This equipment comes with its own fitting instructions.; Backing Boards
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 87 of 143 Figure 62 – Radix power supply This equipment comes with its own fitting instructions. Note that Sedgwell may include rivnuts; remove them for best fixing to Helios. 2.33 Backing Boards Where specified, these are delivered with the ...
Page 88 - – Backing board fixings
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 88 of 143 Figure 63 – Backing board fixings 2.33.1 Reflective Tape Some installations require the use of reflective tape over the backing boards. Backing boards with the tape already fitted are available. If retro fitted reflective tape is re...
Page 89 - – AGD fitted to signal head bracket; The following are the Signal Head options for Bleep and Sweep
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 89 of 143 Figure 64 – AGD fitted to signal head bracket The AGD connector cable is generally fitted to the topmost indent on the red Aspect (either side). The hole should be drilled using the rear drill start point. Connect the cable in accor...
Page 90 - – Bleep and Sweep Signal Head Arrangement; Bleep and Sweep Control Unit
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 90 of 143 Figure 65 – Bleep and Sweep Signal Head Arrangement Figure 66 – Bleep & Sweep Unit Mounted in Signal Aspect Red Man Aspect Green Man Aspect Bleep & Sweep Aspect Bleep and Sweep Control Unit Standoffs provided in Bleep & ...
Page 91 - Figure 67 - Bleep and Sweep Microphone and Speaker Mounting
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 91 of 143 Figure 67 - Bleep and Sweep Microphone and Speaker Mounting 2.36 Fitting Signal Head to Pole This section describes the recommended method of installing the assembled signal head onto the pole. To carry the signal head with any atta...
Page 92 - – Bottom bracket fitted
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 92 of 143 Figure 68 – Bottom bracket fitted 2.36.1 Adjusting Tilt and Rotation Once the signal head has been fitted to the pole, the angles of tilt and rotation (see Figure and Figure ) need to be adjusted before finally tightening the Allen ...
Page 93 - – Angle of Rotation; engaged before rotating the signal head. Adjust; Signal Head to Pole Connection
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 93 of 143 Figure 70 – Angle of Rotation Make sure that the Allen bolts are loose enough so that the toothed sacrificial cap on the bottom bracket is not engaged before rotating the signal head. Adjust as required, tighten the Allen bolts top,...
Page 94 - – Pole Cap fitted; Making sure they are the; right way up; fit each door over its correct module and
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 94 of 143 Figure 71 – Pole Cap fitted 2.36.3 Fit Bulbs (Halogen) Note that bulbs are not delivered with the signal head assembly; they are kept by STCL Services department. Fit a tungsten halogen bulb into each of the bulb holders using the s...
Page 95 - – Door Clip closed
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 95 of 143 Figure 72 – Door Clip closed
Page 96 - COMMISSIONING
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 96 of 143 3. COMMISSIONING Adjust the angles of tilt, rotation and arrow directions to customer satisfaction. In the absence of alternative instructions from the customer, the primary signals should be focussed to 40 m from the stop line and ...
Page 97 - ELV Controllers
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 97 of 143 Nearside Signal ELV Compatible PCB Assemblies 667/1/30695/001 Issue 9 and above. Nearside Mk1/Mk2 667/1/30695/002 Issue 9 and above. Nearside Mk1/Mk2 667/1/30695/003 Issue 9 and above. Nearside Mk1/Mk2 667/1/30695/004 Issue 10 and a...
Page 98 - MAINTENANCE; Check that; First Line Maintenance
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 98 of 143 4. MAINTENANCE Before starting any maintenance work, read the Safety Warning on page 2 of this Handbook. 4.1 Routine Maintenance Visits Warning: Mains voltages are present in LED and LED (NLM) aspects. The mains supply to the signal...
Page 99 - Either of the following procedures may now be used.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 99 of 143 so that the head is level with the outer edge of the clip. This should enable the clip to slide without the door hitting the screw. 4.2.1 Bulb Replacement (Halogen) Where a bulb is to be replaced, the door may be opened from either ...
Page 100 - leads about 25
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 100 of 143 Cut the mains leads to the transformer as close as possible to the transformer. Remove and retain the two screws that are holding the transformer to the bottom of the Aspect and extract the transformer from the aspect. Fit the new ...
Page 101 - – LED PCB front
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 101 of 143 Connector Fuse Figure 73 – LED PCB front Figure 74 – LED PCB rear Connector Figure 75 – LED (NLM) PCB front
Page 102 - Clip the PCB back into place on the door assembly.; he Earth connections are daisy-chained from the red, to the
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 102 of 143 4.2.5 PCB Fuse Replacement (LED) Warning: Mains voltages are present. The mains supply to the signal head must be disconnected/switched off before working on an LED aspect. Warning: Anti-static precautions must be taken when handli...
Page 103 - – PSU White Molex Connectors
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 103 of 143 Figure 76 – PSU White Molex Connectors 4.2.7 Transformer Replacement – LED (NLM) Warning: Mains voltages are present. The mains supply to the signal head must be disconnected/switched off before working on an LED (NLM) aspect. Eith...
Page 104 - – CLS Unit fitted into door
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 104 of 143 Figure 77 – LED (NLM) Transformer 4.2.8 CLS Unit (Futurit Type) Replacement Disconnect the power lead of the CLS unit for the LMF unit by removing PL1 from the LMF unit or disconnecting PL1 of the CLS unit from SKT1 of the Mains po...
Page 105 - – Futurit CLS Unit, Retaining Ring and retaining Clips; Remove the 4 screws that holds the CLS Unit to the door.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 105 of 143 Figure 79 – Futurit CLS Unit, Retaining Ring and retaining Clips Figure 80 – ‘Pip’ at the top of the Futurit CLS Unit Figure 81 – Futurit CLS engaging slot 4.2.9 CLS NLM Unit (Dialight Type) Replacement See the note in section 4.2 ...
Page 106 - SIEMENS; ce; ELV; – ELV CLS LABEL
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 106 of 143 Figure 82 – Dialight CLS Unit CLS ELV units are identified by the label displayed in Figure below. SIEMENS PART NO. : 667/7/28586/100 COLOUR : RED VOLTAGE (BRIGHT/DIM) : 48V/27.5V POWER (BRIGHT/DIM) : 12W/4W ce MODEL TYPE : ELV Fig...
Page 107 - CLS ELV Type B Replacement; Refit the door to the signal head and re-connect the input lead.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 107 of 143 Refit the door to the signal head and re-connect the input lead. 4.2.11 CLS ELV Type B Replacement See the note in section 4.2 regarding anti-vandal screws. Undo the door clips on one side, open the door and disconnect the plug to ...
Page 108 - LMF Fuse Replacement; – Ceramic 20 x 5 1A 240v) in the fuse cap and screw; Fuse Holder
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 108 of 143 4.2.12 LMF Fuse Replacement Remove power to the LMF unit by removing the connector in PL1 of the LMF unit. Remove the fuse by unscrewing the fuse cap from the fuse holder. Replace the fuse (518/4/97068/000 – Ceramic 20 x 5 1A 240v)...
Page 109 - . Replace the LMF Unit’s cover and screws and add; – LMF with Cover Removed; water ingress down this cable from dropping into the LMF unit.; – LMF unit within a signal aspect; Earth Terminal
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 109 of 143 M3 x 10mm screws. Place the Jumper (508/4/21405/001) between pins 6 and 8 of PL2 as identified in Figure . Replace the LMF Unit’s cover and screws and add the Amber/Green 230v Identification Label (667/2/31190/001). The Unit is now...
Page 110 - – Lens with seal in place
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 110 of 143 4.2.15 Aspect Door Replacement (Halogen) Normally a door/lens assembly is replaced complete. When the appropriate variant is not available, any undamaged lens, reflector and hood may be re-used. See the note in section 4.2 regardin...
Page 111 - – Reflector with seal in place; Therefore, this procedure should be avoided wherever possible.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 111 of 143 Figure 90 – Reflector with seal in place Secure the door, tightening the anti-vandal screws if supplied. 4.2.16 Aspect Door Assembly Replacement (LED and LED (NLM)) Warning: Mains voltages are present. The mains supply to the signa...
Page 112 - – LED Aspect Door
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 112 of 143 Figure 91 – LED Aspect Door Figure 92 – LED (NLM) Aspect Door Secure the door, tightening the anti-vandal screws if supplied. If necessary, re-attach the hood. 4.2.17 CLS with LMF, CLS (NLM) Door Replacement Normally a door/lens as...
Page 113 - – CLS Aspect Door; Normally a door/lens assembly is replaced complete.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 113 of 143 If the existing hood is to be re-used, remove it as described in section 4.2.21 and retain it for re-use. Otherwise, fit a new hood as described in section 2.19. Fit the replacement door back on to the aspect body, connecting the l...
Page 114 - Regulatory Sign Door Replacement; Door Clip Replacement
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 114 of 143 4.2.19 Regulatory Sign Door Replacement Replacing any regulatory sign door except mandatory arrow simply involves removing the old door and replacing it with a new one. To replace a mandatory arrow door, follow the additional fitti...
Page 115 - Remove the door and work on the ground.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 115 of 143 A damaged lens should only be replaced with one displaying the correct aspect. Part numbers are given in APPENDIX B. Undo the door (loosening the anti-vandal screws as described in section 4.2 if fitted) and unclip the bulb holder ...
Page 116 - Lens Replacement CLS with LMF or CLS (NLM); – CLS with LMF) or the Mains Input cable on
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 116 of 143 (see Figure and Figure ). Make sure that the clear plastic shield covers the cable connector to give protection from the mains voltage present. Do up the other door clips (and any anti-vandal screws). 4.2.24 Lens Replacement CLS wi...
Page 117 - Lens Replacement CLS ELV; Working on the ground CLS ELV Type A; Sacrificial Cap Replacement; the entire signal head carefully for associated damage.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 117 of 143 4.2.25 Lens Replacement CLS ELV Note: As the lens to door seal is difficult to align once removed, this procedure should not be carried out on site. A complete replacement door assembly should be fitted as described in section 4.2....
Page 118 - Sacrifical Caps
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 118 of 143 Remove and replace the toothed sacrificial cap and refit the Allen bolt loosely. Re-align the signal head (section 2.36.1) and re-tighten all bolts and screws. 4.2.27 Sacrifical Caps – Screw Tightening Procedure It is possible for ...
Page 119 - – Separated Modules; It is recommended that undamaged parts be reused where possible.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 119 of 143 Figure 95 – Separated Modules 4.3 Second Line Maintenance It is recommended that undamaged parts be reused where possible. The following parts should be returned to Poole when replaced on site: Regulatory sign lamp mounting plate L...
Page 120 - – Front View
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 120 of 143 APPENDIX A – DRAWINGS The drawings given in this appendix are reproduced from 667/2/28968/000 sheets 1 to 3 issue 1 and are intended to assist with installation and maintenance. They show fitting positions for the various component...
Page 121 - – Rear View
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 121 of 143 Figure 97 – Rear View
Page 122 - – Top View
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 122 of 143 Figure 98 – Top View Figure 99 – Underside View
Page 123 - APPENDIX B; Part Number; Ha
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 123 of 143 APPENDIX B – SPARES LIST Listed below are the part numbers for approved Spares for the Helios signal head and associated equipment. See the warning on page 4 regarding the use of parts other than those listed. Part Number Descripti...
Page 128 - APPENDIX C; LED WAIT; The issue number is the last two digits on the serial number label.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 128 of 143 APPENDIX C - Visual Identification of ELV Compatible PCB’s LED WAIT Identification: Components to left hand side of “W” as shown in this photograph indicate that the unit is ELV compliant PCB Assembly Issue 667/1/30211 Issue 4onwar...
Page 129 - CALL DEMAND
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 129 of 143 CALL DEMAND Identification: Additional capacitor on the rear of the p.c.b. Indicates that this board is ELV compliant. PCB Assembly Number 667/1/30680 Issue 3 onwards. The issue number is the last two digits on the serial number la...
Page 131 - APPENDIX D; Introduction; Tools and Consumables Required; Tightening Procedure
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 131 of 143 APPENDIX D - Helios Signal Head Screw Fixing Procedure D.1 Introduction The tightening of the single fixing between the bracket and the signal end caps is of crucial importance to the security of the signal and in the following app...
Page 132 - Inspection Procedure; each
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 132 of 143 D.3 Inspection Procedure With reference to the figure immediately below, inspect the end cap fasteners on both ends of the Helios head. Determine if the securing screws are tight. The screw should be seated firmly in position, secu...
Page 133 - Replacement of Main bolts and or washers.
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 133 of 143 Important Note, Where / If necessary the main fasteners should be removed or replaced using the recommended process / method noted below. 1. Replacement of Main bolts and or washers. a. Secure the signal head bracket which requires...
Page 134 - Different Fixings In the field; Torque to 20Nm
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 134 of 143 b. Replace the bolt, and washer with items appropriate to the type of end cap in use (see section D.4 for details). Ensure that the mating parts of the sacrificial bracket are joined and the whole bracket has engaged in its positio...
Page 136 - Upgrades Recommended
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 136 of 143 D.5 Upgrades Recommended If the fixing present is not a Nordlock then upgrading to Nordlock should be considered, and the upgrade to Nordlock is recommended where either the washer combination includes a spring washer or where afte...
Page 139 - Appendix E- TRAM Indicator Cable connections and Aspects; When the Door assembly is
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 139 of 143 Appendix E- TRAM Indicator Cable connections and Aspects The Tram indicator unit is similar to the Regulatory Signs as the main optical assembly remains in the Lantern when the door assembly is opened. The appearance of the Tram in...
Page 141 - digital; correct polarity; ELV TRAM indicator 6 aspect internal assembly
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 141 of 143 Below is a representation of the Aspects. It should be noted that Aspect F is normally always lit whilst the optic is in use. Thus it is shown lit in all the diagrams. Aspect A Aspect B Aspect C Aspect D Aspect E Aspect F Where mor...
Page 142 - INDEX
H ELIOS G ENERAL H ANDBOOK 667/HB/30000/000 Issue 24 Page 142 of 143 INDEX A Adjusting angle ....................................................... 75 AGD ....................................................................... 71 AGD fitting ............................................................