nr/l3/sig/11231 signal maintenance testing handbook nr ... · nr/l3/sig/11231 signal maintenance...

NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07 Index Issue No. 04 Issue Date: 03/03/18 Compliance Date: 31/05/18

The issue status of each SMT is detailed in the NR/L3/SIG/11231 section and in the header of the individual document.

This section contains details of maintenance testing of signalling assets that are a like for like replacement but are part of pre-planned activities. Test plans relevant to this activity included in this section. Details of the processes to undertake the work are in NR/SMTH/Part 02.

Subject Number Issue Renew Cables by Top Nutting Part 07/ Appendix A 01 Status of Existing Cable Checksheet Part 07/Appendix A01 01 Cables Terminated on RHS Checksheet Part 07/Appendix A02 01 Cables Terminated on LHS Checksheet Part 07/Appendix A03 01 Top Nutted Cable on LHS Checksheet Part 07/Appendix A04 01 Top Nutted Cable on RHS Checksheet Part 07/Appendix A05 01 Cables on LHS Changeover Checksheet Part 07/Appendix A06 01 Cables on RHS Changeover Checksheet Part 07/Appendix A07 01 Isolation of TPWS Equipment at Simple Permanent Speed Restrictions (PSR) Part 07/AP51 02

Relocate a TPWS Buffer Stop Arming Loop Part 07/AP53 01 Replace an Axle Counter Sub-rack Part 07/AX69 01 Top Nut an Existing Cable Test Plan Part 07/CA51 01 Change Over a Top Nutted Cable Test Plan Part 07/CA52 01 Replace an Electro-mechanical banner repeating signal with an LED type, using a Howells Interface Unit. Part 07/EL23 01

Upgrade a TRTS push button Part 07/EL50 01 Installation of Intelligent infrastructure data logger Part 07/ER01 01 HABD Equipment: Phoenix MB Remove and Refit for Tamping Work Part 07/HD01 01

Replace a BR843 Level Crossing Barrier Pedestal Part 07/LD52 01 Replace a Level Crossing Filament Light Unit Part 07/LD58 01 Replace a Complete Point Machine Part 07/PC51 01 Replace a Filament Light Type Signal Head Part 07/SG51 02 Replace an Electro-Mechanical Signal Part 07/SG52 01 Replace an Electro-Mechanical Indicator Part 07/SG53 01 Replace a Fibre Optic Signal Part 07/SG54 02 Replace a Light Emitting Diode (LED) Signal Part 07/SG55 03 Signal House Fibre Optic Banner to LED conversion - Style Off 1 On 2 Part 07/SG56 01

Signal House Fibre Optic Banner to LED conversion - Style Off 2 On 2 Part 07/SG57 01

Replace a Missing Filament Lamp Signal Head Part M07/SG51X 02

End

Copyright Network Rail Provided by IHS Markit under license with Network Rail Licensee=Resourcing Solutions Limited /1121226001, User=Christopherson, Joseph

Not for Resale, 03/09/2018 04:00:33 MSTNo reproduction or networking permitted without license from IHS

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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A Renewing Cables by Top-Nutting Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2

1. Authority, Planning and Timescale Considerations

This work shall be classed as Pre-Planned work and shall follow the process described in Part 02 Section 8.

Authority to renew a cable using this process shall be given by the Section Manager (Signals).

Where cable sizes/ specification/ type will change, a set of temporary, updated site records shall be issued pending the final issue of updated site records.

The renewal process includes two specific activities:

(i) Top-nutting the existing cable.

(ii) Installation and changeover the new cable.

The maximum time limit between (i) and (ii) is 30 days.

2. Top-Nut the Existing Cable

Maintenance Test Plan Part 07/CA51 shall be used to top-nut the existing cable.

During the top-nutting process, check sheets Part 07/Appendix A01, Part 07/Appendix A02, Part 07/Appendix A03, Part 07/Appendix A04 and Part 07/Appendix A05 shall be endorsed as each core is changed over.

One copy of the completed check sheets Part 07/Appendix A01, Part 07/Appendix A02, Part 07/Appendix A03, Part 07/Appendix A04 and Part 07/Appendix A05 shall be attached to the circuit diagrams and the original set returned to the Section Manager (Signals) for record purposes.

3. Installing and Commissioning the New Cable

After the existing cable has been top-nutted, the replacement cable may be terminated and commissioned using Maintenance Test Plan Part 07/CA52.

As each activity is completed, check sheets Part 07/Appendix A06 and Part 07/Appendix A07 shall be endorsed.

After the new cable has been installed and tested, the old cable has been disconnected and the links restored, a CABLE FUNCTION TEST shall be carried out on all affected circuits.

4. Check Sheets

The following check sheets shall be used to record each stage of the cable renewal process:

Top-Nutting the Existing Cable

(included in Maintenance Test Plan Part 07/CA51)

Part 07/Appendix A01 - Status of existing cable

Part 07/Appendix A02 - Top-nut a cable from RHS to LHS (B-A)



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A Renewing Cables by Top-Nutting Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

Part 07/Appendix A03 - Top-nut a cable from LHS to RHS (A-B)

Before Changeover is Started:


Part 07/Appendix A04 - Original / existing cable top-nutted on LHS (A)

Part 07/Appendix A05 - Original / existing cable top-nutted on RHS (B)

Commissioning a Replacement Cable:


Part 07/Appendix A06 - Original / existing cable top-nutted on LHS (A)

Part 07/Appendix A07 - Original / existing cable top-nutted on RHS (B)

5. Records

If the cable renewal has involved a change in cable size or type, or removal of jumpers, the site maintenance records shall be endorsed accordingly. Final updated records shall be arranged in accordance with NR/L3/SIG/10064/D031.

The cable database shall be updated to reflect the renewal.

Cable check sheets shall be returned to the Section Manager (Signals) with the Maintenance Test Log / Test Plan.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/ Appendix A01 Status of Existing Cable Checksheet Issue No.01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2

Signal Box: Cable Identification: Location/Equipment Room From:

Location/Equipment Room To:

Name: Date: Signature: Company:

Comments:

Status of Existing Cable

Cable C

ore No.

Wire Count Red Dome Nuts

No Link Fitted Either Or Or

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/ Appendix A01 Status of Existing Cable Checksheet Issue No.01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

Status of Existing Cable

Cable C

ore N

o.

Wire Count Red Dome Nuts

No Link Fitted either or or

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A02 Cable Terminated on Right Hand Side Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2




Comments:

Top Nut a Cable From Right Hand Side to Left Hand Side (B-A)

Cable C

ore No.

Top Nutting Process Final Wire Count Normal

Situation Faulty Core

Diverted Core

Either Or Or

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A02 Cable Terminated on Right Hand Side Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

Top Nut a Cable From Right Hand Side to Left Hand Side (B-A)

Cable C

ore N

o.



Diverted Core

Either Or Or

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A03 Cable Terminated on Left Hand Side Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2




Comments:

Top Nut a Cable From Left Hand Side to Right Hand Side (A-B)

Cable C

ore No.



Diverted Core

Either Or Or

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A03 Cable Terminated on Left Hand Side Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

Top Nut a Cable From Left Hand Side to Right Hand Side (A-B)

Cable C

ore N

o.



Diverted Core

Either Or Or

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A04 Top-Nutted Cable on Left Hand Side Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2




Comments:

Original / Existing Cable Top-Nutted on Left Hand Side (A)

Cable C

ore N

o.

Check and Wire Count Cable Run and Insulation Tested Either Or Or

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A04 Top-Nutted Cable on Left Hand Side Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

Original / Existing Cable Top-Nutted on Left Hand Side (A)

Cable C

ore N

o.


23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A05 Top-Nutted Cable on Right Hand Side Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2




Comments:

Original / Existing Cable Top-Nutted on Right Hand side (B)

Cable C

ore No.


01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A05 Top-Nutted Cable on Right Hand Side Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

23

24

25

Original / Existing Cable Top-Nutted on Right Hand side (B)

Cable C

ore N

o.


26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A06 Cable on Left Hand Side Changeover Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2




Comments:

Original / Existing Cable Top Nutted on Left Hand Side (A)

Cable C

ore N

o.

Cable Terminated &

Insulation Tested

Cable Core Changeover Cable Complete

Either Or Or

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A06 Cable on Left Hand Side Changeover Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

Original / Existing Cable Top nutted on Left Hand Side (A)

Cable C

ore No.

Cable Terminated &

Insulation Tested

Cable Core Changeover Cable Complete

Either Or Or

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A/07 Cable on Right Hand Side Changeover Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2




Comments:

Original / Existing Cable Top Nutted on Right Hand Side (B)

Cable C

ore N

o.

Cable Terminated &

Insulation Tested

Cable Core Changeover Cable Complete Either Or Or

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/Appendix A/07 Cable on Right Hand Side Changeover Checksheet Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

Original / Existing Cable Top Nutted on Right Hand Side (B)

Cable C

ore N

o.

Cable Terminated &

Insulation Tested

Cable Core Changeover Cable Complete Either Or Or

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 7/AP51 Isolation of TPWS Equipment at Simple Permanent Speed Restrictions (PSR) Issue No. 02 Issue Date: 04/03/17 Compliance Date: 31/05/17

Page 1 of 3

This test plan shall only be used where authorised by the Route Asset Manager (Signals) for specific installations only. The installation work shall be carried out by a competent person independent of the person undertaking the maintenance testing The PSR installation at a simple PSR consists of an arming loop (which the train runs over first in the direction of travel) and a trigger loop as the second loop.

BEFORE INSTALLATION WORK 1. Check diagrams on site to confirm this is a “simple” installation.

‘Simple’ means there are no control contacts between the feed fuse or MCB and the TPWS loops, and that the proving circuit is either not used or is only a single contact cut into the local first filament [EKR] circuit. (See typical circuit in appendix A). If the installation is not simple, do not proceed with the work.

2. Check existing wiring has safe insulation. 3. Wire Count the TPWS circuit wiring to its diagrams. 4. Measure the voltage of the arming loop and trigger loop. The voltage will be between

29mV and 53mV with the meter set on the 50mV range. If this test fails, STOP AND INVESTIGATE. Check whether the installation has failed, or whether there is some other reason (circuitry not simple).

5. Check the VCR relay is energised (where fitted). Where there is no proving of the PSR, go to step 19.

6. Hand trace the wiring from the links on the EKR circuit to the VCR contact, to prove there are no additional controls in the circuit.

7. Check first filament failure circuit is showing ‘clear’ (where the PSR installation is cut into the first filament failure circuit) at the controlling signal box.

8. Check that slipping the top link of the outgoing first filament failure (EKR) circuit causes a first filament failure indication at the controlling signal box.

9. Restore the top link and reset the first filament circuit.

Includes: Simple PSRs where an overspeed installation has previously been retro-fitted to the signalling system AND the installation is either not proven or is connected to the signalling system through the first filament failure alarm circuit using a ‘VCR’ relay.

Excludes: Any PSRs where the TPWS is cut into the signalling system other than through the first filament failure circuit. All SSI fed installations



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Page 2 of 3

10. Check that slipping the bottom link of the outgoing first filament failure (EKR) circuit causes a first filament failure indication at the controlling signal box. Restore the bottom link and reset the first filament circuit.

DURING INSTALLATION WORK 11. The installer shall remove the fuse or operate the MCB feeding the VCR circuit. The

SMTH Tester shall check that the VCR relay has de-energised and that a first filament indication has occurred at the controlling signal box.

12. Check that the installer has secured the fuse or locked off the MCB so it may not be replaced (wooden dowel or equivalent device inserted into protective device).

13. The installer shall install a new wire across the VCR contact cut into the first filament failure circuit (by removing each contact wire in turn and crimping one end of a short wire strap into the crimp with the contact wire). A label shall be attached to the TPWS equipment indicating it is disconnected, and the diagrams amended and signed to indicate the alteration made.

14. The SMTH tester shall check that the installer has installed a wire across the VCR contact in the EKR circuit

15. Wire Count the VCR contacts to prove that the previous wires are installed together with the strap.

16. Reset the first filament indication at the controlling signal box. Check that slipping the top link of the outgoing first filament failure (EKR) circuit causes a first filament failure indication at the controlling signal box.

17. Reset the first filament circuit. Check that slipping the bottom link of the outgoing first filament failure (EKR) circuit causes a first filament failure indication at the controlling signal box. Reset the first filament circuit.

18. Measure the voltage of the arming loop and trigger loop. The voltage will be between 29mV and 53mV with the meter set on the 50mV range. (This check’s the loops are still energised following the first phase of the work).

19. The installer shall remove the fuse or operate the MCB feeding the TPWS loops, securing the fuse so it may not be replaced or locking off the MCB.

20. The SMTH tester shall check that the installer has secured the fuse or locked off the MCB so it may not be replaced (wooden dowel or equivalent lock-off device inserted).

21. Measure the voltage of the arming loop and trigger loop. The voltage will now have been removed.

22. The SMTH tester shall check that the installer has amended the location diagrams to show the fuses removed and the relay contact strapped out by a wire loop.

AFTER INSTALLATION WORK 23. Advise the Route Asset Manager (Signals) that the work has been completed.



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Page 3 of 3

APPENDIX A: Typical TPWS at PSR Installation with First Filament Proving

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/AP53 Relocate a TPWS Buffer Stop Arming Loop Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2

This test plan shall only be used where authorised by the Route Asset Manager (Signals) for specific installations only.

The installation work shall be carried out by a competent person independent of the person undertaking the maintenance testing

The arming loop is the first loop which the train runs over in the direction of travel for which the loops are provided, and the trigger loop is the second loop. Great care shall be exercised to ensure that each loop is connected to its correct module, as shown on the location wiring diagrams.

BEFORE WORK BEGINS

1. Check that the position of the TPWS Buffer Stop Loops are correct as identified onthe Survey form and the fitment has not been altered since the survey wasundertaken. If the installed position has changed since the survey, update the surveyform and return the package to your Section Manager (Signals).

2. Measure out and mark the new position of arming loop as detailed in the WorkInstruction Form and Check there are no obstructions that will prevent installation.

Loops shall be installed in the correct positions as detailed in the Work Instruction Form. This shall necessitate marking appropriate bearers/sleepers after carefully measuring the new distances between loops, and buffer stops, before removal of the existing loop.

BEFORE RE-INSTALLATION WORK

3. Check repositioned loop is Not Damaged and is Correct Type (shall be correct for thetype of sleepers).

Buffer stop mini-loops shall not be replaced with standard TPWS transmitter loops

4. If the cable is to be replaced, this shall be carried out in accordance withmaintenance test plan NR/SMTH/Part 04/CA03.

5. Check repositioned loop connection and plug coupler has Safe Insulation.

6. Check repositioned loop is Correctly Labelled.

Includes: TPWS Buffer Stop arming loops (including loops on concrete slab track) to be relocated as part of TPWS Buffer Stop Optimisation Project.

Excludes: Any other works associated with TPWS transmitter loops



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/AP53 Relocate a TPWS Buffer Stop Arming Loop Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

7. Test that repositioned loop resistance is less than 10 ohms and that each core is isolated from the screen. This shall only be done using a digital multi-meter (DMM) and not a high voltage insulation tester (Megger).

8. Check existing loop is Isolated from the supply.

AFTER RE-INSTALLATION WORK

9. Check repositioned loop is Correctly Installed (no metallic debris, correct position as detailed in method statement or work plan, correct track).

It is very important that the transmitter loops are installed at the correct height below rail level (see NR/SMS/Part/Z03).

10. Check security of the repositioned loop (mountings).

11. Check the plug coupler to ensure that no metallic dust, moisture or other contaminants exist between the two halves before reconnecting.

It is vital that each loop is connected back to its correct terminations in the TPWS enclosure or apparatus case and in particular that arming loop and trigger loop tail / feeder cables are not crossed over, particularly if the disconnection box has been disturbed.

12 TPWS BUFFER STOP OPTIMISATION PROJECT EQUIPMENT TEST.

13 Check or arrange for Correct Labelling of unit.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/AX69 Replace a Thales Axle Counter Sub-rack Issue No. 1 Issue Date: 03/03/18 Compliance Date: 31/05/18

This Test Plan shall not be attempted without the express consent of the RAM(S) and needs to be done in conjunction with Thales. A “Release of Controls” is required and this is not easily achieved safely.

Before any work is undertaken the following shall be undertaken:

Possession of the axle counter section(s) shall be taken.

Disconnection of the output of the evaluator to the signalling system.

During the replacement process “No Additional work”, disturbance to EAK’s or any other equipment connected to the ACE shall be allowed.

Appropriate electrostatic precautions shall be taken when working

inside the unit.

Alternative protection shall be in place before the reconnection of the disconnection links to allow the testing of the reset circuits.

The ACE shall be powered down for the replacement of this unit.

For Further Information see SMS Appendix 15 – General Information on the Thales Axle Counter Systems

BEFORE INSTALLATION WORK 1. Check that the affected section(s) are correctly isolated from the Interlocking.

2. Check that the ACE is Correctly Isolated from the power supply.

3. Check that the replacement ACE Sub-rack is of the Correct Type and is Not

Damaged.

4. WIRE COUNT the ACE Sub rack to the wiring diagrams.

5. Check the existing wiring has Safe Insulation.

6. Check the existing wiring and connectors are Correctly Labelled.

AFTER INSTALLATION WORK

7. Check the replacement Sub rack is correctly installed and secure

Includes: Replace a Thales Axle Counter Sub-rack Excludes: All other types of Axle Counter and Non-Axle Counter Sub-rack



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/AX69 Replace a Thales Axle Counter Sub-rack Issue No. 1 Issue Date: 03/03/18 Compliance Date: 31/05/18

8. Check that all cards in the Sub-rack are fitted and secure

9. Check that the wiring and connectors are replaced as labelled and secure. 10. WIRE COUNT the replacement unit to the wiring diagram.

11. If fitted, check the replacement power supply card is correctly installed and secure.

12. Restore the power to the ACE.

13. Check that the correct I/O card LEDs are illuminated correctly and use diagnostic

system (where available) [LED indications (NR/SMS/Appendix 15)].

14. Check the LED indications on the cards and the diagnostic system (where available) to shows the affected section(s) are disturbed.

15. If fitted, check the LED’s on the front of power supply cards. If extinguished the

voltages are out of tolerance and should be investigated.

16. If fitted, check the LED’s on the CPUs are showing the correct indication.

17. With the signaller’s permission, reconnect the equipment to the Interlocking.

18. Where the ACE has multiple sections and outputs to the interlocking this must be tested and corresponded to the correct section, reset type and the correct indication to the signaller. This shall be completed for each section and each output and shall be observed using the AzLM Diagnostic software as well as the LED indications. (Not applicable for 70/30)

19. Check with the signaller all the affected section(s) are showing occupied.

20. Request the section(s) is reset, observe that the section(s) are successfully restored to normal operation.

21. If Possible, observe the passage of a train over the affected section(s).

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/CA51 Top Nut an Existing Cable Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2

Includes: Top-nutting an existing cable terminated on 2BA links (one core at a time) to enable a replacement cable to be terminated ready for changeover.

Excludes: Cables with any cores terminated on binding posts, Clamp type terminations, Tail cables

BEFORE INSTALLATION WORK

Checksheet Part 07/Appendix A01 shall be completed for each core during this test

1. WIRE COUNT existing cable terminations.

Where an undocumented wire exists on the internal side of the termination, STOP and consult your Section Manager (Signals). All such anomalies must be resolved before proceeding beyond step 07.

2. Check that no terminals are used as binding posts (or fitted with red dome nuts, unless associated with temporary strapping).

3. Note any terminals with no link fitted.

4. Note any cable cores that are through crimped.

5. Check the identity of the existing cable by tracing or electrically proving.

6. Check no intermediate terminations, links or contacts exist between the cable ends to be disconnected.

7. Check equipment terminals associated with the existing cable are Correctly Labelled

8. Check that each cable core is Isolated from the supply.

TOP-NUT THE EXISTING CABLE

Each core shall be top-nutted ONE CORE AT A TIME at both ends of the cable

Checksheet Part 07/Appendix A02 or Part 07/Appendix A03 shall be completed for each core during this test.



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/CA51 Top Nut an Existing Cable Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

9. Establish communication between each end of the cable and ensure that each end understands that work is to be completed on one core at a time.

10. Remove the link (where appropriate) and transfer the cable core from the external to the internal side of the termination point.

11. Fit red dome nuts to terminals (A & B/ L & R).

12. Endorse the appropriate column of checksheet Part 07/Appendix A02 or Part 07/Appendix A03 as a record of each core top-nutted.

13 Where temporary strapping exists (link previously removed), remove and insulate the faulty core.

14 A core that has been used for a diversion shall be moved to the internal side together with the temporary strap.

AFTER TOP-NUTTING COMPLETED

15 Check top-nutted cable is Correctly Installed.

16 Check top-nutted cable is not susceptible to mechanical damage.

17 WIRE COUNT the top-nutted cable and Record the results on checksheet Part 07/Appendix A02 or Part 07/Appendix A03.

18 Check red dome nuts are secure and correctly fitted.

19 Test all affected circuits for correct operation.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/CA52 Change Over a Top Nut Cable Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2

Includes: Changing over a previously top-nutted cable terminated on 2BA links. Excludes: Tail cables, clamp type terminations


Checksheet Part 07/Appendix A02 or Part 07/Appendix A03 shall be completed for each core during this test

Steps 1 to 3 may be waived if cable changeover immediately follows top-nutting of the existing cable

1. Check identity of the existing cable by physically tracing or electrically proving.

2. Check no intermediate terminations, links or contacts exist between the cable ends to be disconnected.

3. Check and WIRE COUNT the top-nutted cable and record the results using checksheet Part 07/Appendix A04 or Part 07/Appendix A05. This shall correlate to the FINAL WIRE COUNT previously recorded on checksheet Part 07/Appendix A02 or Part 07/Appendix A03 (see Part 07/CA51).

4. Check the replacement cable is the Correct Type and is Not Damaged.

5. Check the terminals associated with the existing cable are Correctly Labelled.

6. Check replacement cable is Correctly Installed and Correctly Labelled. Record the results using checksheet Part 07/Appendix A04 or Part 07/Appendix A05.

PREPARE THE REPLACEMENT CABLE

Checksheet Part 07/Appendix A06 or Part 07/Appendix A07 shall be completed for each core during this test.

7. Establish communication between each end of the cable.

8. Check the replacement cable is Correctly Installed and Correctly Labelled.

9. CONTINUITY TEST all cores in the replacement cable.

10. INSULATION TEST all cores in the replacement cable.

11. Check replacement cable has Safe Insulation.

12. Check replacement cable is not susceptible to mechanical damage.

CHANGEOVER THE REPLACEMENT CABLE

The changeover shall be completed simultaneously at both ends of the cable, one core at a time.

Record completion of each core using checksheet Part 07/Appendix A06 or Part 07/Appendix A07



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13. Remove and insulate existing cable cores/ straps and replace the required links using the information previously recorded on checksheet Part 07/Appendix A/01 (see Part 07/CA51).

COMMISSION THE REPLACEMENT CABLE

14. WIRE COUNT the replacement cable to the wiring diagram.

15. Check any links and red dome nuts are correctly replaced and secure.

16. CABLE FUNCTION TEST the affected circuits.

17. Check that updated (temporary) record copy diagrams are left on site.

18. Completed check sheets shall be returned to your Section Manager (Signals).

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/EL23 Replace an Electro-mechanical banner repeating signal with an LED type, using a Howells Interface Unit. Issue No. 01 Issue Date: 03/03/18 Compliance Date: 31/05/18

Includes: Howells Interface unit Excludes: All other interface units

BEFORE RE-INSTALLATION WORK

1 Check replacement signal is Not Damaged and is Correct Type.

2 WIRE COUNT existing signal to wiring diagram.

3 INSULATION TEST replacement signal and interface unit (minimum 2M ohms terminals to case.)

4 Check existing signal is Isolated from the supply.

AFTER RE-INSTALLATION WORK

5 Check replacement signal is Correctly Installed and within structure gauge.

6 WIRE COUNT replacement signal and interface unit to the revised installation drawing.

7 Check any links and red dome nuts or equivalent, are correctly replaced and

secure.

8 Check terminations are secure and suitably protected.

9 Check cable entries and plug couplers are secure.

10 Check interface unit wiring is not susceptible to mechanical damage.

11 EARTH TEST circuits if designad to be earth free.

12 Test the supply to each SLM and Record the test measurements along with the other details required on the appropriate NR/SMS record card, together with the reason for the test.

13 Check for correct signal sighting and beam alignment (NR/SMS/SG00).

14 ASPECT TEST signal.

15 Check or arrange for Correct Labelling of the units.

16 Check interface unit lid fits correctly (Door seal intact, no case damage).

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part07/EL50 Upgrade a TRTS Push Button Issue No. 01 Issue Date: 03/03/18 Compliance Date: 31/05/18

Includes: Train ready to start switch (TRTS),

Excludes: All other types of Push Buttons (Domino panel switch, Point micro switch, Block switch, Time switch, Sealed releases etc)

BEFORE INSTALLATION WORK 1. Check replacement unit is Not Damaged and is Correct Type.

Each replacement kit contains:

A. Complete Push Button B. Front Gasket C. Light Shield D. Bag of Fixings

2. Remove the two 3mm A/F Allen key

“faceplate” retaining screws. 3. WIRE COUNT existing unit to the wiring diagram. 4. Check existing wiring has Safe Insulation. 5. Check existing wiring is Correctly Labelled as applicable 6. Check existing unit is Isolated from supply as required. METHOD OF REPLACEMENT 7. Identify the Switch / Button to be replaced.

A B C D



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8. Remove 2 off M4 nuts and washers

using a 7mm A/F nut spinner to remove M4 nuts.

9. Once the nuts, Grover washers are

removed, lift of the contact block leaving the wires connected.

10. Remove the pressel carrier, surround and gasket from the faceplate.

Check that the spacers are not sitting on the head of the weld studs.

11. Place the gasket over the weld studs

ensuring that the gasket fits evenly around the pressel hole.

12. Remove the elastic bands from each

side of the assembly. Important (the button must be held together at this point).



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13. Holding the button assembly together,

slide the assembly on to the weld studs. 14. Place the light shield on to the weld

studs as shown and replace the flat washer, grover (spring washer) and nut on to the weld studs.

Tighten nuts using 7mm A/F nut spinner.

15. Remove wires from old contact block,

and place them in the same position on the new contact block.

16. Check wiring is replaced as labelled 17. WIRE COUNT replacement unit to the wiring

diagram 18. Once all wires have been transferred to the new contact block, replace the

faceplate ensuring no wires are trapped. 19. Replace the two 3mm A/F Allen key “faceplate” retaining screws. AFTER INSTALLATION WORK 20. Check replacement unit is Correctly

Installed 21. Check circuit operates correctly for all

positions of the replacement unit. (despatching trains as appropriate)



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End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/ER01 Installation of Intelligent infrastructure data logger Issue No. 01 Issue Date: 03/03/18 Compliance Date: 31/05/18

Page 1 of 2

Includes: Data loggers approved for connection to the Intelligent Infrastructure system. Excludes: All other types of data logger.

This test plan is for the initial installation of loggers and not for the ‘like for like’ replacement.

BEFORE INSTALLATION WORK 1. Check equipment is not damaged and is of the correct type. 2. Check location wiring and layout complies with the site installation overlay diagram. 3. Check relay contacts to be used are spare. 4. Check fuse / terminal positions to be used are spare. 5. Check identified positions for installing equipment are spare and there is sufficient

room. 6. EARTH TEST affected signalling supplies. 7. Check existing wiring has safe insulation. 8. Where existing wiring is to be rerouted or renewed via current transducers each wire

shall be hand traced to confirm that it correlates with the diagram. 9. Check existing wiring is correctly labelled. 10. Check the logger is isolated from the power supply. Install the following in accordance with the site installation overlay diagram:

a) The logger and current transducers.

b) Monitoring cables and wiring.

c) Disconnect / reconnect / replace existing wiring to reroute through current transducers in accordance with the appropriate SMTH test plans.

d) Install logger antenna or FTN connection

AFTER INSTALLATION WORK 11. Check new equipment and wiring is correctly installed. 12. Check new equipment & wiring is correctly labelled.



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/ER01 Installation of Intelligent infrastructure data logger Issue No. 01 Issue Date: 03/03/18 Compliance Date: 31/05/18

Page 2 of 2

13. WIRE COUNT and correlate monitoring wiring and all other affected circuits to the

site installation overlay diagram and site wiring diagrams. 14. CONTINUITY TEST new cables and wiring with reference to site overlay diagram

with affected links and fuses disconnected. 15. Check terminations are secure and suitably protected. 16. Check cables are sleeved and tidy & where required, glands are fitted and effective. 17. Install logger fuse and check unit powers up correctly. 18. EARTH TEST affected signalling supplies. 19. Check logger configuration is loaded and correct. (Further guidance can be found

within this TI). 20. Check each logger input state corresponds to the correct output. 21. For each monitored asset, arrange for a function test of the logger to the remote

monitoring point.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part-07/HD01 HABD Equipment: Phoenix MB Remove and Refit for Tamping Work Issue No. 01 Issue Date: 02/03/13 Compliance Date: 07/09/13

Page 1 of 3

Includes: Phoenix HABD Excludes: All other HABD Systems

These tests shall be followed in the correct order to ensure that no damage occurs to the HABD equipment when tamping works are scheduled within the limits of the HABD site. To reduce the down-time of the HABD system the disconnection and reconnection shall be planned as close to the tamping works as reasonable practicable. Care shall be taken when removing washers, spacers etc to ensure that no items are lost as they are essential items to ensure that the sensors are correctly affixed to their mountings.

PRIOR TO WORK 1. Inform the Signaller which HABD site is to be disconnected and for what duration. 2. Use shut down to close the SCT program correctly to save data to disk. 3. Turn off the power to the cabinet via the incoming supply circuit breaker. 4. Switch off the UPS. SENSOR MODULE REMOVAL 5. Note the serial numbers or label the sleeper-mounted sensor modules with regards to

their respective positions within the sleepers. 6. Remove the 4 X safety screws and washers from the protective cover of the sensor. 7. Release the cover heater 4-pin plug . Cover the plug coupler at the cable end with a

protecting end cap. Push the protected cable end back into the sleeper. 8. Release the 4 X M10 nuts holding the sensor module onto the frame fastening. 9. Remove the respective spring washers, large washers and top part of the rubber

damper. 10. Lift out the sensor module from the frame taking care not damage the connector

cable. Release the connector cable and cover the plug coupler on the cable with a protecting end cap. Replace the cable in the sleeper.

11. Store the sensor module and sensor cover in the HABD equipment room. 12. Remove the remaining lower part of the sensor fastenings (i.e. 2 X large washers,

spacer and the lower part of the rubber damper) from the plate stud.



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Page 2 of 3

13. Screw the protecting cover plate onto the sensor mounting frame to cover the hole.

Store the sensor module and cover in the HABD equipment room. 14. Store the sensor module and cover in the HABD equipment room 15. Repeat the above steps for all sensors 16. Release the cable clamps at the end of the sleeper and withdraw all cables from the

sleeper. Protect the removed cables as appropriate RAIL CONTACT REMOVAL 17. Note the serial numbers or label the rail contacts with regards to their respective

positions.. 18. Mark the exact position of the rail contacts on the rail. 19. Push back the short piece of neoprene and release the contacts at the end of the rail

contact cable. 20. Cover the cable end with a protecting end cap. 21. Remove the M24 nut at the double coil washer. 22. Remove the rail contact, including the clamp and cable from the vicinity of the rails.

Store within the equipment rooms. 23. Repeat the above for all rail contacts. RE-CONNECTION 24. Re-connect all removed components in reverse order as appropriate. Check that

cables are not swapped, all contacts and plugs are connected correctly, and all components are restored to their original positions.

25. Check that all spacers, washers and spring washers are installed in the correct order

(APPENDIX A). FINAL CHECKS 26. Check that the interior of the sleeper is free from gravel. 27. Check that the sensor fastening components are not damaged paying particular

attention to the rubber dampers. 28. Check that the connectors of all the sensors face into the centre of the 4 foot.



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Page 3 of 3

29. Check the clearances of the sensors. There shall be a small gap of between 1mm to 3mm between the front edge of the scanner cover and the front edge of the chair steel piece.

30. Check the position of the rail contacts with respect to the installation diagrams or rail

markings. 31. Check that the rail contact sleeve covers have been fitted correctly. 32. Switch on the power supply after ensuring that the installation has been correctly re-

instated. Check that the UPS is also switched on. 33. Switch the track equipment back on. Check that the system auto-configures and

starts working. 34. Check the system status [NR/SMS/HO12]. 35. Place the cable in ducts and guides, using fasteners and clips. Replace lids. 36. IF PRACTICABLE:

Observe system operation the passage of a train. APPENDIX A Order of Sensor Components

The following is a checklist on the order of re-application of the sensor mounting components. The correct order of their re-application is critical to ensure that the optical geometry of the sensor is maintained.

a) 2 X Bodywork washers (First Applied) b) 1X Spacer c) 1 X Lower rubber buffer d) Sensor e) 1X Upper rubber buffer f) 1 X Bodywork washer g) 1 X Spring washer h) 1 X M10 nut (Last Applied)

Then tighten to 50NM.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/LD52 Replace a BR843 Level Crossing Barrier Pedestal Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2

Different hydraulic packs are fitted to ABCL level crossings, A hydraulic pack intended for an ABCL (coloured blue) shall not be fitted to any other type of level crossing. Any other hydraulic pack other that one coloured blue shall not be fitted to an ABCL. See NR/SMS/LC00 for more details on the two types. The auto/manual valve on the hydraulic pack shall be in the Auto position for automatic crossing and manual for manually controlled crossings. See NR/SMS/LC11 for more details.


1. Check replacement unit is Not Damaged and is Correct Type. (Mode of Operation)

2. Check existing concrete Pedestal base is capable of under going the proposed renewals.

3. Check all fixing bolts are secure, free from corrosion and capable of sustaining load.

4. Check existing earth clamps / conductors are in place and there is continuity to an effective earth.

5. EARTH TEST all existing circuits to ensure they are free from any existing earth faults. [Earth tests (NR/SMS/Test/051-052-053)]

6. Check any circuits that can be isolated to the diagrams and isolate any incoming supplies at source.

7. WIRE COUNT all terminated wiring / cables to the diagrams.

8. Check any cabling corresponds to the diagrams and the cores are Correctly Labelled (individually) and are unambiguous with other cables.

9. Remove any detachable units i.e. hydraulic power packs, barrier boom arm, counter balance weights (noting positioning and quantity) and store in the transit box provided.

10. Check any Damp proof Membrane (DPC) is in place.


11. Check Pedestal is sitting squarely on base and is level.

12. Check Pedestal is held firmly by all four fixing bolts / anchors.

13. Check Barrier Boom is correctly fitted and secure. [see NR/SMTH/Part 04/ LD01 and EL11]

14. Check the EARTH Continuity conductors are refitted, clearly labelled and effective.

Includes: BR843 Level Crossing Barrier Pedestals. Excludes: Any other type of Level Crossing Barrier Pedestal.



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/LD52 Replace a BR843 Level Crossing Barrier Pedestal Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

15. WIRE COUNT all terminated wiring / cables to the diagrams.

16. CORRELATION CHECK cable core/wire to the wiring diagram (Where more than cable core/wire has been removed at once)

17. Check hydraulic pack is Correctly Installed, is the Correct Type for the crossing type, it is secure and any damping devices are effective. [see NR/SMTH/Part 04/LD02].

18. Check trunnion bolts and spiral pins have been Correctly Installed for the hydraulic pack to pedestal fastenings.

19. Check that the Boom CR plug units are effective for each boom.

20. Check that any counter balance weights are correctly positioned and effective.

21. Check all fuses, links and red dome nuts are correctly re-installed and supplies to the pedestal are properly reinstated.

22. Check any contacts / Bands in all circuits are effective to the final function using an angle meter.

23. Check that any contacts controlled by the relative position / angle of the boom arm are set correctly with angle meter.

24. EARTH TEST all circuits to ensure they are free from any earth faults. [Earth tests (NR/SMS/Test/051-052-053)].

25. Check (if provided) any Earth Leakage Detectors (ELD) are reset ‘clear’ at the source location / REB

26. Check wires and cables are secure and clear of any moving parts or gearing.

27. Check exterior doors of pedestal are secured and any ‘Tamper’ devices are effective. [see NR/SMTH/Part 04/EL11]

28. Check Barrier skirt is fitted correctly and linkage to pedestal is secured. [see NR/SMTH/Part 04/LD01]

29. Fully Test all Barrier functions and operation [NR/SMS/LC21 and NR/SMS/LC10].

30. Check (if provided) protection cage is in place and secure.

31. Check and local control functions are restored to remote or auto working.

32. If practical Observe passage of trains in each direction.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/LD58 Replace a Level Crossing Filament Light Unit Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 1

Includes: Road signal filament light unit, Miniature Stop Light (MSL) unit.

Excludes: LCU Door lock keylock, and Gate drive equipment. Road signal LED SLM light unit, Miniature Stop Light (MSL) unit.


1. Check replacement unit is Not Damaged and is Correct Type.

2. WIRE COUNT existing unit to the wiring diagram.

3. Check existing wiring has Safe Insulation.

4. Check existing wiring is Correctly Labelled.

5. Check existing unit is Isolated from the supply.


6. Check replacement unit is Correctly Installed.

7. Check wiring is replaced as labelled.

8. WIRE COUNT replacement unit to the wiring diagrams.

9. Check any links, and red dome nuts or equivalent, are correctly replaced and secure.

10. Check lenses are of correct type (colour) and are correctly installed in the replacement unit. (Any rubber seals are seated correctly.)

11. Check that the hoods are correctly fitted and are secure in the replacement unit.

12. Check that the correctly rated lamps are installed.

13. Check that all the lamps (main and any auxiliary) illuminate correctly and test for correct voltages [Lamp voltage (NR/SMS/Part/Z01)]. Record the test measurements on the appropriate NR/SMS record card, together with the reason for the test.

14. Check the alignment and height of replacement unit for public use (see HMRI guidance and crossing section order). Check that the coloured lights cannot be misread as signal aspects by train drivers.

15. Check flashing rate of lights [Level Crossing Reference Values (NR/SMS/Part/Z04)]. (RED ROAD LIGHTS ONLY).

16. EARTH TEST supply throughout operation cycle.

17. Test that the red road lamps are proved [(NR/SMS/LX series)]. (RED ROAD LIGHTS ONLY)

18. If proved, Check all indications back to the relevant signal box.

19. Check or arrange for Correct Labelling of unit.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/PC51 Replace a Complete Point Machine Issue No. 01 Issue Date: 01/12/10 Compliance Date: 01/03/11

Page 1 of 2

Includes: Electric and electro–pneumatic point machines, Chair locks, Separate AC point controller units

Excludes: Any other type of point operating equipment (POE)


1. Check replacement unit is Not Damaged and is Correct Type (internal configurable wiring and straps).



4. Check existing wiring (and hoses for EP machines and chair locks) are Correctly Labelled.

5. Check replacement controller contacts are in the correct position (matching existing). (SEPARATE AC POINT CONTROLLER UNITS ONLY).

6. Check existing unit is isolated from the electrical supply.

7. Check air supply is disconnected (ELECTRO-PNEUMATIC MACHINES AND CHAIR LOCKS ONLY).


Where any plug coupler is used Check that no metallic dust exists between the two halves before reconnecting the plug couplers.

8. Check replacement unit is Correctly Installed.

9. Check wiring (and hoses for EP machines and chair locks) are replaced as labelled.

10. WIRE COUNT replacement unit to the wiring diagram.


12. Check terminations are secure and suitably protected.

13. Check wires and cables are secure and clear of moving parts.

14. EARTH TEST circuits and supplies during normal and reverse operation.

15. Test (gauge) point detection [Detection test (NR/SMS/Test/011)] and Record the test measurements on the appropriate NR/SMS record card, together with the reason for the test. (CHAIR LOCKS, ELECTRIC AND ELECTRO-PNEUMATIC POINT MACHINES ONLY).



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/PC51 Replace a Complete Point Machine Issue No. 01 Issue Date: 01/12/10 Compliance Date: 01/03/11

Page 2 of 2

16. Test facing point lock [Facing point lock test (NR/SMS/Test/001)] and Record the test measurements on the appropriate NR/SMS record card, together with the reason for the test. (CHAIR LOCKS, ELECTRIC AND ELECTRO-PNEUMATIC POINT MACHINES ONLY).

17. POINT DETECTION AND CORRESPONDENCE TEST affected ends.

Separate AC point controller units shall be treated as a separate affected end for correspondence and detection tests.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG51 Replace a Filament Light Type Signal Head Issue No. 02 Issue Date: 03/03/18 Compliance Date: 31/05/18

Page 1 of 2

Includes: Filament lamp Colour light signals, Position light signals (PLS), Position light junction indicators (PLJI) , Theatre type indicators (SARI), stencil type indicators (MARI)

Excludes: Mechanical searchlight signal, Banner repeater signal, Electro-mechanical types, Fibre optic types, Dichroic mirror types, and Light emitting diode (LED) types.


1. Check replacement signal head is Not Damaged and is Correct Type.

2. Check replacement signal head internal wiring corresponds to the internal wiring of the existing signal head.

3. WIRE COUNT existing signal head to the wiring diagram.


5. INSULATION TEST replacement signal head (minimum 2M ohms terminals to case).


7. Check existing signal head is Isolated from the supply. AFTER INSTALLATION WORK

8. Check replacement signal head is correctly installed and within structure gauge. 9. Check filters are of Correct Type (colour) and are Correctly Installed. 10. Check wiring is replaced as labelled. 11. WIRE COUNT replacement signal head to the wiring diagram. 12. Check any links, and red dome nuts or equivalent, are correctly replaced and

secure. 13. Check terminations are secure and suitably protected. 14. Check that correctly rated lamps of the Correct Type are fitted in all aspects. 15. Check entry cable is secured and the signal head wiring is not susceptible to

mechanical damage. 16. Check correct hoods fitted.



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG51 Replace a Filament Light Type Signal Head Issue No. 02 Issue Date: 03/03/18 Compliance Date: 31/05/18

Page 2 of 2

17. EARTH TEST circuits if designed to be earth free.

18. Test each signal lamp [Signal lamp test (NR/SMS/Test/021)] and Record the test measurements along with the other details required on the appropriate NR/SMS record card, together with the reason for the test.

19. Check for correct signal sighting SMS/Test/302 and beam alignment

[(NR/SMS/SG00)].

Signal sighting forms include specific details on signal alignment and configuration. Otherwise, see NR/GN/SIG/19032 for generic details.

20. ASPECT TEST signal. 21. Check or arrange for Correct Labelling of unit. 22. Check signal head door fits correctly (Door seal intact, no case damage, no

extraneous light enters).

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG52 Replace an Electro-Mechanical Signal Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 1

Includes: Banner repeater signal, Solenoid shunt signal, Motor driven signal. Excludes: Electro-mechanical searchlight mechanisms.


1. Check replacement signal is Not Damaged and is Correct Type.

2. WIRE COUNT existing signal to wiring diagram.

3. Check existing wiring has safe insulation.

4. INSULATION TEST replacement signal (minimum 2M ohms terminals to case).


6. Check existing signal is Isolated from the supply.


7. Check replacement signal is Correctly Installed and within structure gauge.


9. WIRE COUNT replacement signal to wiring diagram.



12. Check replacement signal lamps are Correct Type.

13. Check replacement signal wiring is not susceptible to mechanical damage.

14. Check replacement signal door fits correctly (Door seal intact, no case damage).

15. Check for correct alignment of signal ([NR/SMS/SG00]).

16. Test signal mechanism operates freely.

17. EARTH TEST supply if designed to be earth free.

18. ASPECT TEST replacement signal.

Sighting forms include specific details on signal alignment and configuration.

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG53 Replace an Electro-Mechanical Indicator Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 1

Includes: Electro-mechanical indicators connected in series with relay coils. Excludes: Any other type of indicator.


1. Check replacement indicator is Not Damaged and is Correct Type.

2. WIRE COUNT existing indicator to the wiring diagram.




5. Check replacement indicator is Correctly Installed.


7. WIRE COUNT replacement indicator to the wiring diagram.

8. EARTH TEST supply if designed to be earth free.

9. Test for correct operation and correspondence between the equipment and the indicator.


End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG54 Replace a Fibre Optic Signal Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 1 of 2

Includes: Alphanumeric indicators, Banner repeater signal, Position light signal, Preliminary route indicator, Points indicator, Fibre optic harness, Fibre optic light box.

Excludes: Filament types, Dichroic mirror types and Light emitting diode types.

Replacement fibre optic harness and signal heads are supplied already connected together.


1. Note whether the existing ‘on’ aspect has two red lights or one red and one white.(POSITION LIGHT SIGNAL ONLY)

2. Check replacement fibre optic unit is Not Damaged and is Correct Type.

3. Check replacement unit has correct coloured filters. (LIGHT BOX ONLY)

4. Check replacement signal head lens has correct Hot Strip setting. (SIGNAL HEADONLY)

Signal light boxes contain specific information on Hot Strip setting.

5. Check replacement fibre optic harness is colour coded at the light box end.



8. INSULATION TEST replacement signal head heater terminals (minimum 2M ohmsterminals to case). (SIGNAL HEAD ONLY)


10. Check existing unit is Isolated from the supply.


11. Check replacement unit is Correctly Installed and within structure gauge.


13. WIRE COUNT replacement unit to the wiring diagram.


15. Check replacement fibre optic harness is not kinked or damaged and colour codesmatch the light box. (HARNESS TYPE ONLY)

16. Check correctly rated lamps are Correctly Installed. (LIGHT BOX ONLY)

17. Check fibre optic cable is secured and not susceptible to mechanical damage.



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG54 Replace a Fibre Optic Signal Issue No. 01 Issue Date: 05/03/11 Compliance Date: 03/09/11

Page 2 of 2

18. Check correct hoods are fitted. (SIGNAL HEAD ONLY).

19. EARTH TEST electrical circuits.

20. Test each signal lamp. [Signal lamp test (NR/SMS/Test/021)] and Record the test measurements along with the other details required on the appropriate NR/SMS record card together with the reason for the test.

21. Check correct signal sighting and beam alignment [(NR/SMS/SG00)]. (SIGNAL HEAD ONLY)

Signal light boxes contain specific information on signal alignment.

22. ASPECT TEST signal.


End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG55 Replace a Light Emitting Diode (LED) Signal Issue No. 03 Issue Date: 03/03/18 Compliance Date: 31/05/18

Includes: LED type main signal head, LED type position light junction indicator (PLJI), LED type position light signal (PLS), PLS fitted with LED Signal Lamp Modules (SLMs). LED Style MARI and SARI units.

Excludes: Filament types, Fibre optic types, Dichroic mirror types, Replace a filament type signal head with a LED type, Work that includes a data change, Individual LED SLMs.


1. Note whether the existing ‘on’ aspect has two red lights or one red and one white. (PLS ONLY).

2. Check replacement signal head is Not Damaged and is Correct Type. Different alignments of the SLM front screen are provided for the signal configuration circumstances; see NR/SMS/SG00 for more details.

3. Check replacement signal head internal wiring corresponds to the internal wiring of

the existing signal head or revised installation drawing.

4. WIRE COUNT existing signal head to the wiring diagram.

5. Check existing wiring has safe insulation.

6. INSULATION TEST replacement signal head (minimum 2M ohms terminals to case).


8. Check existing signal head is Isolated from the supply. AFTER INSTALLATION WORK

9. Check replacement signal head is Correctly Installed and within structure gauge.

10. Check LED SLMs, or equivalent, are correct type and colour, and are correctly orientated for their application.

11. Check that hoods are correctly installed and are correct type.


13. WIRE COUNT replacement head to the wiring diagram or revised installation drawing.



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http://oc.hiav.networkrail.co.uk/sites/ml/Master%20Documents/NRSMTH%20%20issue%209/NRSMTH%20Part03%20Test%20B03.pdf

http://oc.hiav.networkrail.co.uk/sites/ml/Master%20Documents/NRSMTH%20%20issue%209/NRSMTH%20Part03%20Index.pdf

NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG55 Replace a Light Emitting Diode (LED) Signal Issue No. 03 Issue Date: 03/03/18 Compliance Date: 31/05/18



16. Check cable entry is secured and the signal head wiring is not susceptible to mechanical damage.


18. Test the supply to each SLM and Record the test measurements along with the other details required on the appropriate NR/SMS record card, together with the reason for the test.

19. Check for correct signal sighting SMS/Test/302 and beam alignment [(NR/SMS/SG00)].


21. Check or arrange for Correct Labelling of the unit.

22. Check signal head door fits correctly (Door seal intact, no case damage).

End



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http://oc.hiav.networkrail.co.uk/sites/ml/Master%20Documents/NRSMTH%20%20issue%209/SMS%20Part%20C/NRSMS%20PartC%20SG00.pdf

http://oc.hiav.networkrail.co.uk/sites/ml/Master%20Documents/NRSMTH%20%20issue%209/NRSMTH%20Part03%20Test%20B07.pdf

NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part 07/SG56 Signal House Fibre Optic Banner to LED conversion – Style “Off 1 / On 2” Issue No. 01 Issue Date: 03/03/18 Compliance Date: 31/05/18

Includes: Signal House full size Fibre Optic Banner Signal fitted with conventional 55W Halogen lamps (for 1 OFF, 2 ON signal types)

Excludes: All other types of banner signal BEFORE INSTALLATION WORK

1 Check replacement LED illuminator is Not Damaged, is the Correct Type and free of contamination.

2 EARTH TEST supplies where designed to be Earth free.

3 WIRE COUNT existing lamp holder to the wiring diagram

4 Check existing wiring has safe insulation

5 Check existing wiring is correctly labelled

6 Check fibre optic harness is correctly labelled

7 Check replacement LED Illuminator is Correctly Labelled.

8 Check signal head is isolated from the supply

INSTALLATION WORK

Before commencing any work on the Banner Signal, confirm that you have the

correct retrofit kit for Banner signal type to be converted (Kit SHRK-BAN-312).

Signal Identification

There are up to four types of Signal House fibre optic banner repeater signals lit by

halogen light lamps. The types are determined by the number of power feeds to the

banner signal and thus the number of lamp powered up in the signal.

These types fall into the following groups:

A. Two separate feeds, 1 OFF, 1 ON.

B. Three separate feeds, 1 OFF, 2 ON.

C. Three separate feeds, 2 OFF, 1 ON.

D. Four separate feeds, 2 OFF, 2 ON.



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The number of feeds directly relates to the number of halogen lamps, and also the

types of fibre optic used for the banner display.

Group A

With two feeds [OFF 1 and ON 1] - has two halogen lamp each in single light boxes,

with two fibre optic arms one for each banner display OFF and ON to each light box.

Retrofit Kit required - SHRK-BAN-312

Group B

With three feeds [OFF 1, ON 1 and ON 2] - has three halogen lamps with one lamp

in one single light box, and two in one dual light box, with three fibre optic arms,

one for the OFF display from the single light box, and two arms making up the ON

display from the dual light box. Retrofit Kit required - SHRK-BAN-312

Group C

Is reverse of Group B - Two lamps for the OFF in the twin light box, one lamp for the

ON in the single light box, however very rare, and is not covered in this document.

Retrofit Kit required - No Kit available

Group D

With four feeds [OFF 1 and OFF 2, ON 1 and ON 2] - has four halogen lamps with

two in each dual light box with four fibre optic arms, two for the OFF display from

one dual light box, and two for the ON display from one dual light box. Retrofit Kit

required - SHRK-BAN-322

Retrofit Kit SHRK-BAN-312 Contents:

Item 1 Led Light Source Frame

Item 2 Retrofit Signal Label

Item 3 Retrofit LED light source wiring diagram.

Item 4 Led 55W Illuminator Light units [3 off]

Item 5 Label Sheets.

Item 6 Connection Leads [3 off].

Item 7 M6 mounting kit [bolts, nyloc nut for items 2 & 3].

Item 8 Plastic feather clips [10 off]



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Item 9 Bag with Led light source maintenance sheet

Item 10 Marker Pen

Item 11 Document sheet and Return Label.

METHODOLOGY 9 Check the signal to be retrofitted is in full operational order. 10 From the Equipment Housing [using the lineside wiring diagrams], isolate all the

feeds to the signal. 11 Release all 4 catches and open the Banner Signal door and confirm that all the

signal feeds have been isolated. Note - Allow at least 10 minutes for the Halogen lamps to cool down.

12 During this cooling period fit the new retrofit signal label [Item 2], and new retrofit LED light source wiring diagram [Item 3], to the signal rear door.

13 On the rear door of the signal, the hinges are held in place with two M6 bolts [and

possibly lock nuts on the inside].

14 The top hinge is where the two labels Items 2 & 3 will be fitted. If present undo the nyloc M6 lock nuts from inside the rear door top hinge, and discard.

15 Close the door and secure the 4 catches. Undo from the outside the two M6 bolts

and washers and discard.

Figure 1 – Identification Label Figure 2 – Wiring Diagram

16. Referring to Figure 1a, and using the new M6 bolts/washers from the mounting kit

Item 7, feed them through the hinge plate, then the retrofit signal label [item 2] into

the door thread, and tighten.



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17. The door can now be opened by releasing the 4 catches. Working on the inside,

locate the Retrofit LED light source wiring diagram, item 3, and fit over the M6

threaded bushes,[ Figure1b] so it fits flat on the inside of the door.

18. Fit the over washers, then the M6 plain washers, and then the nyloc nuts and

tighten.

For Group 2 Banner, 1 OFF, 2 ON Only:

19. Identify the three separate feeds and on which terminal block they are connected.

Affix one of the ‘OFF’ labels [label sheet item 5] to the terminal block area on the

chassis next to the terminals that the ‘OFF’ feed leads connect to, see Figure 3.

Figure 3 – “Off” Terminals Figure 4 - “On” Terminals

20. Affix the ‘ON 1’ label to the terminal block area on the chassis next to the terminals, see Figure 3 that the first pair of ‘ON’ feed leads connect to.

21. Then affix the second ‘ON 2’ label to the terminal block area on the chassis next to

the second pair of ‘ON’ feed leads connect to.

22. From the identified OFF terminal block, follow the wires from the ‘S’ terminals [right hand side of terminal block] to the Light box.

23. This light box has the OFF display fibre optic plugged into it, fit the second OFF label to the fibre optic arm body, see Figure 5.



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Figure 5 – “Off” Fibre Optic Plug Figure 6 - “On” Fibre Optic Plugs 24. From the identified ON terminal blocks, follow the wires from the ‘S’ terminals [right

hand side of terminal block] to the dual light box that has two lamps fitted. 25. This dual light box has the two ON display fibre optics plugged into it. Fit the ‘ON 1’

label to the one of the fibre optic arm body, the ‘ON 2’ label to the second fibre optic arm body see Figure 6.

Note - Now that the terminal blocks and the fibre optic arms have been identified and marked, the old halogen light sources can be removed.

26. Disconnect all the lamp leads from the terminal blocks using the 2BA-nut runner,

retain the nuts. 27. Remove the fibre optic arms from the light box’s, by holding the body firmly and

jerking the arm down [it is held in by a spring, and needs to be released from the spring by the snap action].

28. Lay the arm down gently onto the transformers. Remove the light boxes and the plastic spacers and plastic plate, by undoing all the light box fasteners [M4].

Note - The light boxes should be retained and disposed of correctly to current regulations [see step 25].

29. Locate the OFF fibre optic arm, and remove, if fitted, the ‘optical filter’ from the end

[see Figure 7]. Repeat this operation for both the ON 1 & ON 2 fibre optic arms.



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Figure 7 – Sequence showing the removal of the Optical Filter 30. Locate again the OFF fibre optic arm, and now working away from the body down

the fibres, locate the ‘spare’ fibres. There should be at least three, possibly more, which have a black plastic cap, fitted to them.

31. Confirm the spare fibres are part of the OFF fibre optic arm, and on any one, remove the plastic cover and clip [ref diagram 1].

Diagram 1 – Fibre Termination Point

32. Feed this fibre back through the bundle straps so it sits next to the fibre optic body.

Fit the ‘Fibre OFF’ label [peel off the backing first] around the fibre [see figure 8], and leave next to the arm body.



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Figure 8 – Fibre optic body and a single fibre 33. Locate the ON 1 fibre optic arm, and now working away from the body down the

fibres, locate the ‘spare’ fibres. There should be at least three, possibly more, which have a black plastic cap, fitted to them. Confirm the spare fibres are part of the ON 1 fibre optic arm and on any one, remove the plastic cover and clip [see diagram 1].


Fit the ‘Fibre ON 1’ label [peel off the backing first] around the fibre [reference Picture 7], and leave next to the arm body.

35. Locate the ON 2 fibre optic arm, and now working away from the body down the

fibres, locate the ‘spare’ fibres. There should be at least three, possibly more, which have a black plastic cap, fitted to them. Confirm the spare fibres are part of the ON 2 fibre optic arm and on any one, remove the plastic cover and clip [see diagram 1].

36. Feed this fibre back through the bundle sstraps so it sits next to the fibre optic body.

Fit the ‘Fibre ON 2’ label [peel off the backing first] around the fibre [reference Picture 7], and leave next to the arm body

Note - These ‘spare’ fibre single optics are later referred to the ‘feedback’ fibre optics.

37. Locate the LED light source frame item 1; this is fitted onto the top of the chassis

where the old light units were.

It is fitted with the ‘studs’ up, with the label at the back [rear of signal], place onto chassis such that all the ten holes line up, see figure 9.



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38. Fit the 10 plastic feather clips [Item 8] into each hole and firmly push into place.

Figure 9 - Chassis

39. Take the 55W Led Illuminator light units, Items 4, and remove the Red insert

covers, then fit the 55W Led Illuminator light units to the light source frame studs, such that the ‘metal guards’ face the rear door [see figure 10]

Figure 10 – Light units mounted the chassis 40. The mounting screws are cross point types and captive in the unit. Connect the

three leads [Items 6] to the 55W Led light units, and then connect lead to the nearest terminal block below the particular Led light unit [ref picture 9].

41. Connect shorter wire identified as ‘0S’ to ‘0S’ terminal, and the longer wire identified

as ‘12S’ to the ‘12S’ terminal, using the 2BA nut runner and using the 2BA nuts retained earlier.

Note - The cable lengths are designed to set lengths making them easy to connect to the terminal block below the Led light source fitted to, and difficult to fit otherwise.



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42. Taking the OFF fibre optic arm, held at the body insert it into the LED light source

whose cable is connected to the previously labelled OFF terminal block. The fibre optic arm body should snap into place with a positive click.

43. Insert the single fibre labelled ‘fibre OFF’ into the small hole next to the OFF fibre

optic arm body, and push home until it clicks into place. 44. Taking the ON 1 fibre optic arm, held at the body insert it into a LED light source

whose cable is connected to the previously labelled ON 1 terminal block. The fibre optic arm body should snap into place with a positive click.

45. Take the ON 2 fibre optic arm, held at the body insert it into the remaining LED light

source whose cable is connected to the previously labelled ON 2 terminal block. The fibre optic arm body should snap into place.

Feedback, Single Fibres. 46. Insert the single fibre labelled ‘Fibre ON 1’ into the small hole next to the ON 2 fibre

optic arm body, and push home until it clicks into place. Insert the single fibre labelled ‘Fibre ON 2’ into the small hole next to the ON 1 fibre optic arm body, and push home until it clicks into place.

Note - the single fibres are swapped over, such that if either one of the ON 1 or ON 2 LED light sources fail, the other is also set to unlit, giving a ‘Black’ ON display, rather than just a confusing ‘half’ display. Note - This ‘swapped over’ feedback does affect testing of the individual ON 1 and ON 2 lineside circuits, in such a way that the ON 1 and ON 2 circuits cannot be tested independently. Both ON 1 and ON 2 circuits must be activated at the same time, as activating only one will cause both circuits to give a ‘Fail’ condition, with NO signal aspect being displayed.

47. Using the marker pen supplied [Item 10], write the date on the install/commissioning

date label on top of all three 55W LED light source units. 48. Place the plastic bag with the manual [Item 9] in the signal down the side of the

chassis.

49. Check all steps above have been completed correctly.

AFTER INSTALLATION 50. Check replacement LED illuminator is correctly installed



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51. Check optical filters have been removed. 52. Check the feedback fibres / cross proving fibres (where two illuminators are

provided for a single aspect) are correctly installed.

53. By making sure that the single fibre labelled ‘Fibre ON 1’ is inserted into the small hole next to the ON 2 fibre optic arm body and pushed home into place.

54. The single fibre labelled ‘Fibre ON 2’ is inserted into the small hole next to the ON 1 fibre optic arm body, and pushed home into place

55. Check wiring is replaced as labelled 56. WIRE COUNT LED Illuminator to the wiring diagram 57. Check the Signal Head wiring is not susceptible to mechanical damage 56. Check fibre optic harness is not kinked or damaged and replaced as labelled 57. Check fibre optic harness is secure and not susceptible to mechanical damage 58. Check terminations are secure and suitably protected 59. Reconnect supply to the signal head 60. Check any links / red dome nuts or equivalent are correctly replaced and secure 61. Check LED illuminator correctly lights 62. EARTH TEST supplies where designed to be Earth free 63. Test LED Illuminator [Signal Lamp Test – SMS Test 21] and record the test

measurements on the appropriate Record Card, together for the reason of the test. 64. Test that lamp proving is effective for each LED Illuminator [Lamp proving test

(SMS test 22)] and record on the appropriate record card together with the reason for the test.

65. Test the feedback fibres / cross proving fibres (where two illuminators are provided

for a single aspect) extinguish the associated illuminators when the fibre is removed.

66. Carry out an ASPECT TEST

67. Check signal house door is correctly fitted ( Retrofit label is affixed, door seal intact,

no case damage, no extraneous light enters).



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68. Fill in the Banner Signal Serial Number and Location details on the document sheet [Item 11] with date, and place all removed items [old light units, screws etc] into the box.

69. Fit the return address label to box and seal box ready for return to Signal House

Ltd. Signal House will dispose to current regulations. Appendix A – Ordering Details

Part Description Signal House Product Number BR Cat Number Signal House Retro-fit 55W LED illuminator Kit

SHRK-BAN-312 0086/001348

Signal House LED Illuminator (single unit)

X11200 0086/001349

End



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Includes: Signal House full size Fibre Optic Banner Signal fitted with conventional 55W Halogen lamps (for 2 OFF, 2 ON signal types)

Excludes: All other types of banner signal BEFORE INSTALLATION WORK

1 Check replacement LED illuminator is Not Damaged, is the Correct Type and free of contamination.

2 EARTH TEST supplies where designed to be Earth free.

3 WIRE COUNT existing lamp holder to the wiring diagram.

4 Check existing wiring has safe insulation.

5 Check existing wiring is correctly labelled.

6 Check fibre optic harness is correctly labelled.

7 Check replacement LED Illuminator is Correctly Labelled.

8 Check signal head is isolated from the supply.

INSTALLATION WORK

Before commencing any work on the Banner Signal, confirm that you have the

correct retrofit kit for Banner signal type to be converted (Kit SHRK-BAN-312).

Signal Identification

There are up to four types of Signal House fibre optic banner repeater signals lit by

halogen light lamps. The types are determined by the number of power feeds to the

banner signal and thus the number of lamp powered up in the signal.

These types fall into the following groups:

A. Two separate feeds, 1 OFF, 1 ON.

B. Three separate feeds, 1 OFF, 2 ON.

C. Three separate feeds, 2 OFF, 1 ON.

D. Four separate feeds, 2 OFF, 2 ON.

The number of feeds directly relates to the number of halogen lamps, and also the

types of fibre optic used for the banner display.



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Group A

With two feeds [OFF 1 and ON 1] - has two halogen lamp each in single light boxes,

with two fibre optic arms one for each banner display OFF and ON to each light box.

Retrofit Kit required - SHRK-BAN-311

Group B

With three feeds [OFF 1, ON 1 and ON 2] - has three halogen lamps with one lamp

in one single light box, and two in one dual light box, with three fibre optic arms,

one for the OFF display from the single light box, and two arms making up the ON

display from the dual light box. Retrofit Kit required - SHRK-BAN-312

Group C

Is reverse of Group B - Two lamps for the OFF in the twin light box, one lamp for the

ON in the single light box, however very rare, and is not covered in this document.

Retrofit Kit required - No Kit available

Group D

With four feeds [OFF 1 and OFF 2, ON 1 and ON 2] - has four halogen lamps with

two in each dual light box with four fibre optic arms, two for the OFF display from

one dual light box, and two for the ON display from one dual light box. Retrofit Kit

required - SHRK-BAN-322

Retrofit Kit SHRK-BAN-322 Contents:

Item 1 Led Light Source Frame.

Item 2 Retrofit Signal Label

Item 3 Retrofit LED light source wiring diagram

Item 4 Led 55W Illuminator Light units [4 off]

Item 5 Label Sheet

Item 6 Connection Leads [4 off]

Item 7 M6 mounting kit [bolts, nyloc nut for items 2 & 3]

Item 8 Plastic feather clips [10 off]

Item 9 Bag with Led light source maintenance sheet

Item 10 Marker Pen

Item 11 Document sheet and Return Label. Copyright Network Rail Provided by IHS Markit under license with Network Rail Licensee=Resourcing Solutions Limited /1121226001, User=Christopherson, Joseph


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METHODOLOGY 9 Check the signal to be retrofitted is in full operational order. 10 From the Equipment Housing [using the lineside wiring diagrams], isolate all the

feeds to the signal. 11 Release all 4 catches and open the Banner Signal door and confirm that all the

signal feeds have been isolated. Note - Allow at least 10 minutes for the Halogen lamps to cool down.

12 During this cooling period fit the new retrofit signal label [Item 2], and new retrofit

LED light source wiring diagram [Item 3], to the signal rear door. 13 On the rear door of the signal, the hinges are held in place with two M6 bolts [and

possibly lock nuts on the inside]. 14 The top hinge is where the two labels Items 2 & 3 will be fitted. If present undo the

nyloc M6 lock nuts from inside the rear door top hinge, and discard. 15 Close the door and secure the 4 catches. Undo from the outside the two M6 bolts

and washers and discard.

Figure 1 – Identification Label Figure 2 – Wiring Diagram

16. Referring to Figure 1a, and using the new M6 bolts/washers from the mounting kit

Item 7, feed them through the hinge plate, then the retrofit signal label [item 2] into

the door thread, and tighten.

17. The door can now be opened by releasing the 4 catches. Working on the inside,

locate the Retrofit LED light source wiring diagram, item 3, and fit over the M6

threaded bushes,[ Figure1b] so it fits flat on the inside of the door. Copyright Network Rail Provided by IHS Markit under license with Network Rail Licensee=Resourcing Solutions Limited /1121226001, User=Christopherson, Joseph


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18. Fit the over washers, then the M6 plain washers, and then the nyloc nuts and

tighten.

For Group 4 Banner, 2 OFF, 2 ON Only:

19. Identify the three separate feeds and on which terminal block they are connected.

Affix one of the ‘OFF1’ labels [label sheet item 5] to the terminal block area on the

chassis next to the terminals that the ‘OFF1’ feed leads connect to, see Figure 3.

20. Then affix the second ‘OFF2’ label to the terminal block area on the chassis next to

the second pair of ‘OFF2’ feed leads connect to.

Figure 3 – “Off” Terminals Figure 4 - “On” Terminals

21. Affix the ‘ON 1’ label to the terminal block area on the chassis next to the terminals, see Figure 4 that the first pair of ‘ON1’ feed leads connect to.

22. Then affix the second ‘ON 2’ label to the terminal block area on the chassis next to

the second pair of ‘ON2’ feed leads connect to. 23. From the identified OFF terminal block, follow the wires from the ‘S’ terminals [right

hand side of terminal block] to the duel light box that has two lamps fitted. 24. This dual light box has the two OFF display fibre optic plugged into it. Fit the OFF1

label to the fibre optic arm body, the ‘OFF2’ label to the second fibre optic arm body see picture 5.



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Figure 5 – “Off” Fibre Optic Plugs Figure 6 - “On” Fibre Optic Plugs 25. From the identified ON terminal blocks, follow the wires from the ‘S’ terminals [right

hand side of terminal block] to the dual light box that has two lamps fitted. 26. This dual light box has the two ON display fibre optics plugged into it. Fit the ‘ON 1’

label to the one of the fibre optic arm body, the ‘ON 2’ label to the second fibre optic arm body see Figure 6.

Note - Now that the terminal blocks and the fibre optic arms have been identified and marked, the old halogen light sources can be removed.

27. Disconnect all the lamp leads from the terminal blocks using the 2BA-nut runner,

retain the nuts. 28. Remove the fibre optic arms from the light box’s, by holding the body firmly and

jerking the arm down [it is held in by a spring, and needs to be released from the spring by the snap action].

29. Lay the arm down gently onto the transformers. Remove the light boxes and the

plastic spacers and plastic plate, by undoing all the light box fasteners [M4].

Note - The light boxes should be retained and disposed of correctly to current regulations [see step 25].

30. Locate the OFF 1 fibre optic arm, and remove, if fitted, the ‘optical filter’ from the

end [see Figure 7]. Repeat this operation for OFF 2, ON 1 & ON 2 fibre optic arms.



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Figure 7 – Sequence showing the removal of the Optical Filter

31. Locate again the OFF 1 fibre optic arm, and now working away from the body down

the fibres, locate the ‘spare’ fibres.

There should be at least three, possibly more, which have a black plastic cap, fitted to them.

32. Confirm the spare fibres are part of the OFF 1 fibre optic arm, and on any one,

remove the plastic cover and clip [ref diagram 1].

Diagram 1 – Fibre Termination Point


Fit the ‘Fibre OFF 1’ label [peel off the backing first] around the fibre [see figure 8], and leave next to the arm body.

34. Repeat for the OFF 2 fibre optic arm using the ‘Fibre OFF 2’ label.

Figure 8 – Fibre optic body and a single fibre 35. Locate the ON 1 fibre optic arm, and now working away from the body down the

fibres, locate the ‘spare’ fibres.



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There should be at least three, possibly more, which have a black plastic cap, fitted to them. Confirm the spare fibres are part of the ON 1 fibre optic arm and on any one, remove the plastic cover and clip [see diagram 1].


Fit the ‘Fibre ON 1’ label [peel off the backing first] around the fibre [reference Picture 7], and leave next to the arm body.

37. Locate the ON 2 fibre optic arm, and now working away from the body down the

fibres, locate the ‘spare’ fibres.

38. There should be at least three, possibly more, which have a black plastic cap, fitted to them. Confirm the spare fibres are part of the ON 2 fibre optic arm and on any one, remove the plastic cover and clip [see diagram 1].


Fit the ‘Fibre ON 2’ label [peel off the backing first] around the fibre [reference Picture 7], and leave next to the arm body

Note - These ‘spare’ fibre single optics are later referred to the ‘feedback’ fibre optics.

40. Locate the LED light source frame item 1; this is fitted onto the top of the chassis

where the old light units were.

It is fitted with the ‘studs’ up, with the label at the back [rear of signal], place onto chassis such that all the ten holes line up, see figure 9.

41. Fit the 10 plastic feather clips [Item 8] into each hole and firmly push into place.

Figure 9 - Chassis 42. Take the 55W Led Illuminator light units, Items 4, and remove the Red insert

covers, then fit the 55W Led Illuminator light units to the light source frame studs, such that the ‘metal guards’ face the rear door [see figure 10]



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Figure 10 – Light units mounted the chassis

43. The mounting screws are cross point types and captive in the unit. Connect the three leads [Items 6] to the 55W Led light units, and then connect lead to the nearest terminal block below the particular Led light unit [ref picture 9].

44. Connect the shorter wire identified as ‘0S’ to ‘0S’ terminal, and connect the longer

wire identified as ‘12S’ to the ‘12S’ terminal, using the 2BA nut runner and using the 2BA nuts retained earlier.

Note - The cable lengths are designed to set lengths making them easy to connect to the terminal block below the Led light source fitted to, and difficult to fit otherwise.

45. Taking the OFF1 fibre optic arm, held at the body insert it into the LED light source

whose cable is connected to the previously labelled OFF 1 terminal block. The fibre optic arm body should snap into place with a positive click.

46. Take the OFF 2 fibre optic arm, held at the body insert it into the remaining LED

light source whose cable is connected to the previously labelled OFF 2 terminal block. The fibre optic arm body should snap into place.

47. Taking the ON 1 fibre optic arm, held at the body insert it into a LED light source

whose cable is connected to the previously labelled ON 1 terminal block. The fibre optic arm body should snap into place with a positive click.

48. Take the ON 2 fibre optic arm, held at the body insert it into the remaining LED light

source whose cable is connected to the previously labelled ON 2 terminal block. The fibre optic arm body should snap into place.

49. Feedback, Single fibres. 50. Insert the single fibre labelled ‘Fibre OFF 1’ into the small hole next to the OFF 2

fibre optic arm body, and push home until it clicks into place. Insert the single fibre labelled ‘Fibre OFF 2’ into the small hole next to the OFF 1 fibre optic arm body, and push home until it clicks into place.



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51. Insert the single fibre labelled ‘Fibre ON 1’ into the small hole next to the ON 2 fibre

optic arm body, and push home until it clicks into place. 52. Insert the single fibre labelled ‘Fibre ON 2’ into the small hole next to the ON 1 fibre

optic arm body, and push home until it clicks into place.

Note - the single fibres are swapped over, such that if either one of the OFF 1 or OFF 2 LED [and ON 1 or ON 2] light sources fail, the other is also set to unlit, giving a ‘Black’ ON display, rather than just a confusing ‘half’ display.

Note - This ‘swapped over’ feedback does affect testing of the individual OFF 1 and OFF 2 lineside circuits, in such a way that the OFF 1 and OFF 2 circuits cannot be tested independently. Both OFF 1 and OFF 2 circuits shall be activated at the same time, as activating only one will cause both circuits to give a ‘Fail’ condition, with NO signal aspect being displayed. This is also true for the ON 1 and ON 2 lineside circuits.

53. Using the marker pen supplied [Item 10], write the date on the install/commissioning

date label on top of all three 1814 55W LED light source units. 54. Place the plastic bag with the manual [Item 9] in the signal down the side of the

chassis. 55. Check all steps above have been completed correctly.

AFTER INSTALLATION 56. Check replacement LED illuminator is correctly installed 57. Check optical filters have been removed. 58. Check the feedback fibres / cross proving fibres (where two illuminators are

provided for a single aspect) are correctly installed. By making sure that the single fibre labelled ‘Fibre ON 1’ is inserted into the small hole next to the ON 2 fibre optic arm body and pushed home into place.

The single fibre labelled ‘Fibre ON 2’ is inserted into the small hole next to the ON 1 fibre optic arm body, and pushed home into place

59. Check wiring is replaced as labelled 60. WIRE COUNT LED Illuminator to the wiring diagram 61. Check the Signal Head wiring is not susceptible to mechanical damage 56. Check fibre optic harness is not kinked or damaged and replaced as labelled



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57. Check fibre optic harness is secure and not susceptible to mechanical damage 58. Check terminations are secure and suitably protected 59. Reconnect supply to the signal head 60. Check any links / red dome nuts or equivalent are correctly replaced and secure 61. Check LED illuminator correctly lights 62. EARTH TEST supplies where designed to be Earth free 63. Test LED Illuminator [Signal Lamp Test – SMS Test 21] and record the test

measurements on the appropriate Record Card, together for the reason of the test. 64. Test that lamp proving is effective for each LED Illuminator [Lamp proving test

(SMS test 22)] and record on the appropriate record card together with the reason for the test.

65. Test the feedback fibres / cross proving fibres (where two illuminators are provided

for a single aspect) extinguish the associated illuminators when the fibre is removed.

66. Carry out an ASPECT TEST

67. Check signal house door is correctly fitted (Retrofit label is affixed, door seal intact,

no case damage, no extraneous light enters). 68. Fill in the Banner Signal Serial Number and Location details on the document sheet

[Item 11] with date, and place all removed items [old light units, screws etc] into the box.

69. Fit the return address label to box and seal box ready for return to Signal House

Ltd. Signal House will dispose to current regulations. Appendix A – Ordering Details

Part Description Signal House Product Number BR Cat Number Signal House Retro-fit 55W LED illuminator Kit

SHRK-BAN-322 0086/001352

Signal House LED Illuminator (single unit)

X11200 0086/001349

End



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NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part M07/SG51X Replace a Missing Filament Lamp Signal Head Issue No. 02 Issue Date: 03/03/18 Compliance Date: 31/05/18

Page 1 of 2

Includes: Colour light signal, position light signal, Position light junction indicator (PLJI), standard (theatre type) indicator (SARI), miniature (stencil) indicator (MARI).

Excludes: Searchlight signal, banner repeater signal, electro-mechanical types, fibre optic types, Dichroic mirror types and light emitting diode (LED) types.

BEFORE REPLACEMENT 1. Check supply is disconnected.

2. Check for evidence on site and on diagram that the signal was previously fitted.

3. Check existing wiring/cable has Safe Insulation.

4. Check any existing wiring is Correctly Labelled.

5. INSULATION TEST existing cable if re-used.

6. Check replacement signal is not damaged and is correct type.(refer to diagram for

correct type).

7. INSULATION TEST replacement signal head.

AFTER REPLACEMENT 8. Check replacement signal is Correctly Installed and within structure gauge.


10. Check filters are of Correct Type (colour) and are Correctly Installed.

11. WIRE COUNT replacement signal to wiring diagram.

12. Check all links, and red dome nuts or equivalent, are correctly replaced and secure.

13. Check all terminations and cables are secure and suitably protected.

14. Check that correctly rated lamps of the correct type are fitted in all aspects.

15. Check entry cable is secured and signal head wiring is not susceptible to

mechanical damage.

16. Check correct hoods are fitted.


18. Test each signal lamp. [Signal Lamp Test (NR/SMS/Test/021)] and Record the test measurements on the appropriate NR/SMS record card, together with the reason for the test.



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../../Working%20Documents/App%20Update/Part-01/NRSMTH%20Part01%20AppendixE(01D).doc

NRSMTH%20Part03%20Test%20B03.pdf



NRSMTH%20Part03%20Index.pdf

SMS%20Part%20B/NRSMS%20PartB%20021.pdf

NR/L3/SIG/11231 Signal Maintenance Testing Handbook NR/SMTH/Part M07/SG51X Replace a Missing Filament Lamp Signal Head Issue No. 02 Issue Date: 03/03/18 Compliance Date: 31/05/18

Page 2 of 2

19. Check for correct signal sighting SMS/Test/302 and beam alignment [(NR/SMS/SG00)].

Signal sighting forms include specific details on signal alignment and configuration. Otherwise, see NR/GN/SIG/19032 for generic details.



22. Check signal head door fits correctly (door seal intact, no case damage, no extraneous light).

End



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SMS%20Part%20C/NRSMS%20PartC%20SG00.pdf
