Siemens HB 904 Series Specifications

ST750 GENERAL HANDBOOK
Traffic Solutions
Sopers Lane, Poole, Dorset, BH17 7ER
United Kingdom
+44 (0)1202 782000
www.siemens.co.uk/traffic
ST750
General Handbook
PREPARED:
Andy White
FUNCTION:
Engineering Manager
THIS DOCUMENT IS ELECTRONICALLY HELD AND APPROVED
© Siemens plc. 2011 All rights reserved.
The information contained herein is the property of Siemens plc and is supplied without
liability for errors or omissions. No part may be reproduced or used except as authorised by
contract or other written permission. The copyright and the foregoing restriction on
reproduction and use extend to all media in which the information may be embodied.
The names of products of third parties named in this document may be trademarks of their respective
owners.
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ST750 GENERAL HANDBOOK
Change History
Issue
1
2
3
4
5
Change Ref
First Issue
TS004961
TS005209
TS005637
TS005954
667/HB/33750/000
Date
11 February 2009
27 February 2009
28 August 2009
31 August 2010
10 February 2011
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ST750 GENERAL HANDBOOK
SAFETY INFORMATION
HEALTH AND SAFETY AT WORK
DISCONNECT ALL POWER TO THE CABINET BEFORE REMOVING OR
INSTALLING ANY EQUIPMENT INTO THE CABINET.
Safety of Maintenance Personnel
In the interests of health and safety, when using or servicing this equipment the
following instructions must be noted and adhered to:
(i)
Only skilled or instructed personnel with relevant technical knowledge and
experience, who are also familiar with the safety procedures required when
dealing with modern electrical/electronic equipment are to be allowed to use
and/or work on the equipment. All work shall be performed in accordance with
the Electricity at Work Regulations 1989.
(ii) Such personnel must take heed of all relevant notes, cautions and warnings in
this Handbook and any other Document or Handbook associated with the
equipment including, but not restricted to, the following:
(a) The equipment must be correctly connected to the specified incoming
power supply.
(b) The equipment must be disconnected/isolated from the incoming
power supply before removing any protective covers or working on any
part from which the protective covers have been removed.
(c) This equipment contains a Lithium battery that must be disposed of in a
safe manner. If in doubt as to the correct procedure refer to the
instructions contained on page 6 of this document.
(d) Any power tools must be regularly inspected and tested.
(e) Any ladders used must be inspected before use to ensure they are
sound and not damaged.
(f)
When using a ladder, before climbing it, ensure that it is erected
properly and is not liable to collapse or move. If using a ladder near a
carriageway ensure that the area is properly coned and signed.
(g) Any personnel working on site must wear the appropriate protective
clothing, e.g. reflective vests, etc.
In the event of more than one person working on the Controller and its associated
signal heads, the Mains Supply to the Cabinet Assembly must be switched off. If the
master switch has a lock, this should be used to keep the switch locked in the ‘off’
position.
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ST750 GENERAL HANDBOOK
When working on the controller in countries where both sides of the
incoming supply are above earth potential, the Master Switch or Circuit
Warning Breaker on the rear of the Cabinet should be opened, since the
Controller Switch on the front of the ST750 does not isolate both sides
of the supply.
When re-commissioning signals, the following sequence is recommended:
1.
2.
3.
Switch OFF the Cabinet Assembly at the master switch
Switch ON the lamps on-off switch on the manual panel
Switch ON the Cabinet Assembly at the master switch.
More specific safety information is given within the text of the handbook, where it
relates to particular activities or situations.
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ST750 GENERAL HANDBOOK
WARNING
To isolate the equipment the master switch must be in the
“Off” position.
Switching either the Controller or the Manual Panel Signals
On/Off switch to “Off” does not guarantee isolation of the
equipment.
WARNING
These (this) controller(s) require specific configuration to
enable them (it) to function correctly when installed.
The configuration process is a complex activity should
only be carried out by persons who are adequately trained,
have a full understanding of the needs of the county or
region where the controller is to be used and are
experienced in the tasks to be undertaken.
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ST750 GENERAL HANDBOOK
Safety of Road Users
It is important that all personnel are aware of the dangers to road users that could
arise during repair and maintenance of traffic control equipment.
Ensure that the crossing area is coned and signed as necessary to warn motorists
and pedestrians of any dangers and to help protect the personnel working on the
site.
Whilst repairing signals which are in an "all-out" condition, care must be taken to
ensure that no spurious signals are lit during testing which could mislead drivers or
pedestrians. Particular care is required where pedestrian audible devices are
installed, to ensure that no false indications are given during, for example, cable
testing. Personnel should also ensure the safety of pedestrians, especially children,
who may come into contact with parts of the ST750 Rack Assembly, Cabinet
Assembly or signal poles.
Safety Warning - Lithium Battery
This equipment contains a Lithium battery.
Do not short circuit, recharge, puncture, take apart, incinerate, crush, immerse, force
discharge or expose to temperatures above the declared operating temperature
range of the product, otherwise there is a risk of fire or explosion.
Batteries should be handled and stored carefully to avoid short circuits. Do not store
in disorderly fashion, or allow metal objects to be mixed with stored batteries. Keep
batteries between -30°C and 35°C for prolonged storage.
The batteries are sealed units which are not hazardous when used according to
these recommendations. Do not breathe vapours or touch any internal material with
bare hands.
Battery disposal method should be in accordance with local, state and government
regulations. In many countries, batteries should not be disposed of into ordinary
household waste. They must be recycled properly to protect the environment and to
cut down on the waste of precious resources.
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TABLE OF CONTENTS
1. INTRODUCTION................................................................................................................................ 11
1.1 PURPOSE OF THIS HANDBOOK...................................................................................................11
1.2 CONTACT US.................................................................................................................................. 11
1.3 REFERENCE DOCUMENTS........................................................................................................... 11
1.3.1 NON-ESSENTIAL DOCUMENTS – INTERSECTION DESIGN ..............................................11
1.3.2 ESSENTIAL DOCUMENTS – CONTROLLER.........................................................................11
1.3.3 ESSENTIAL DOCUMENTS – CABLING..................................................................................12
1.3.4 ESSENTIAL DOCUMENTS – ANCILLARY EQUIPMENT .......................................................12
1.4 PRE-REQUISITES........................................................................................................................... 12
1.4.1 QUALIFICATIONS.................................................................................................................... 12
1.4.2 REQUIRED TOOLS.................................................................................................................. 13
1.5 DEFINITIONS .................................................................................................................................. 13
1.6 ABBREVIATIONS ............................................................................................................................ 14
2. SPECIFICATION ............................................................................................................................... 15
2.1 EQUIPMENT INTRODUCTION ....................................................................................................... 15
2.1.1 SINGLE PEDESTRIAN CONTROLLER...................................................................................16
2.1.2 DUAL PEDESTRIAN CONTROLLER ......................................................................................16
2.1.3 SMALL NON-UK CONTROLLER .............................................................................................16
2.1.4 CONTROLLER EXPANSION ...................................................................................................16
2.1.5 TYPES OF PEDESTRIAN CONTROLLER ..............................................................................17
2.1.6 DIFFERENCES BETWEEN THE ST750 AND THE ST700 .....................................................17
2.1.7 SPARES COMPATIBILITY BETWEEN THE ST750 AND ST700............................................ 19
2.2 BASIC SYSTEM OVERVIEW .......................................................................................................... 19
2.3 MAINS SUPPLY............................................................................................................................... 20
2.3.1 ELECTRICAL NOISE ............................................................................................................... 20
2.4 DETERMINATION OF LOADING AND POWER CONSUMPTION ................................................21
2.4.1 ST750 SUPPLY REQUIREMENTS..........................................................................................21
2.4.2 LAMP DRIVE CAPABILITY ...................................................................................................... 22
2.4.3 CALCULATION OF AVERAGE SIGNAL LAMP POWER ........................................................23
2.4.4 INTERSECTION’S POWER REQUIREMENTS FOR RUNNING COSTS ESTIMATE............ 24
2.4.5 CONNECTION TO UN-METERED SUPPLIES (UMS) ............................................................25
2.4.6 DETECTOR POWER SUPPLIES.............................................................................................25
2.4.7 AUDIBLE AND TACTILE SUPPLIES .......................................................................................26
2.5 PHASES........................................................................................................................................... 27
2.6 STAGES........................................................................................................................................... 27
2.7 TIMINGS .......................................................................................................................................... 27
2.7.1 TOLERANCE............................................................................................................................ 27
2.8 MASTER TIME CLOCK AND CLF SUMMARY ...............................................................................28
2.9 MODES OF OPERATION................................................................................................................ 28
2.10 CABINET CHARACTERISTICS .................................................................................................... 29
2.11 ENVIRONMENTAL ........................................................................................................................ 30
2.11.1 TEMPERATURE..................................................................................................................... 30
2.11.2 ATMOSPHERIC ..................................................................................................................... 30
2.11.3 HUMIDITY .............................................................................................................................. 30
3. PEDESTRIAN FACILITIES ............................................................................................................... 31
3.1 TYPES OF PEDESTRIAN CROSSINGS.........................................................................................31
3.1.1 PELICAN CROSSING .............................................................................................................. 31
3.1.2 NEAR SIDED PEDESTRIAN CROSSING ...............................................................................31
3.1.3 FAR SIDED PEDESTRIAN CROSSING ..................................................................................32
3.1.4 ON-CROSSING DETECTORS.................................................................................................33
3.2 PEDESTRIAN MODES OF OPERATION .......................................................................................34
3.2.1 FIXED VEHICLE PERIOD ........................................................................................................ 34
3.2.2 VEHICLE ACTUATED .............................................................................................................. 34
3.2.3 VEHICLE ACTUATED WITH PRE-TIMED MAXIMUM (PTM) .................................................35
3.2.4 LINKED OPERATION............................................................................................................... 35
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3.3 PEDESTRIAN DEMAND CONTROL...............................................................................................36
3.3.1 INTRODUCTION ...................................................................................................................... 36
3.3.2 PEDESTRIAN DEMAND ACCEPTANCE ................................................................................38
3.3.3 PEDESTRIAN DEMAND DELAY (PDD) ..................................................................................38
3.3.4 PEDESTRIAN DEMAND CANCEL (PDX)................................................................................39
3.3.5 KERBSIDE DETECTOR (MAT) TESTING ...............................................................................39
4. HARDWARE OVERVIEW ................................................................................................................. 41
4.1 CABINET OPTIONS ........................................................................................................................ 41
4.2 THE ST750 RACK ASSEMBLY....................................................................................................... 44
4.3 ST750 CPU LEDS............................................................................................................................ 46
4.3.1 STATUS LED GROUP ............................................................................................................. 46
4.3.2 SIGNAL LED GROUP .............................................................................................................. 47
4.4 MASTER SWITCH ASSEMBLY ...................................................................................................... 47
4.5 FUSES ............................................................................................................................................. 48
4.6 MAINS DIMMING TRANSFORMER................................................................................................48
4.7 MANUAL PANEL ............................................................................................................................. 48
4.8 DETECTOR MOUNTING................................................................................................................. 49
4.8.1 DETECTOR BACK PLANE IN SMALL OUTER CASE ............................................................49
4.8.2 DETECTOR BACK PLANES IN LARGE OUTER CASE .........................................................51
4.9 2A DETECTOR SUPPLY KIT .......................................................................................................... 51
4.10 GEMINI2 ......................................................................................................................................... 52
4.10.1 GEMINI2 IN SMALL OUTER CASE........................................................................................52
4.10.2 GEMINI IN LARGE OUTER CASE.........................................................................................53
4.11 TC12 OTU...................................................................................................................................... 55
4.11.1 INTEGRAL TC12 OTU IN SMALL OR LARGE OUTER CASES ...........................................55
4.11.2 FREE STANDING TC12 OTU IN SMALL OUTER CASE ......................................................55
4.11.3 FREESTANDING TC12 OTU IN A LARGE OUTER CASE ...................................................57
4.12 SDE/SA .......................................................................................................................................... 58
5. INSTALLATION AND COMMISSIONING.........................................................................................59
5.1 PRE-INSTALLATION CHECKS....................................................................................................... 59
5.1.1 HARDWARE CHECK ............................................................................................................... 59
5.1.2 DIMMING TRANSFORMER TAP SETTING ............................................................................59
5.2 ST750 CABINET PREPARATION ................................................................................................... 60
5.3 SITE SUITABILITY........................................................................................................................... 60
5.4 INSTALLATION OF THE ST750 SMALL CABINET ........................................................................61
5.4.1 INSTALL CONTROLLER CABINET AND STOOL...................................................................62
5.5 INSTALLATION OF THE ST750 LARGE CABINET........................................................................63
5.5.1 REMOVE THE CONTROLLER CABINET FROM THE STOOL ..............................................64
5.5.2 INSTALL THE STOOL.............................................................................................................. 64
5.6 CABLING TO THE ST750 SMALL AND LARGE CABINETS .........................................................65
5.7 ON SITE CABLE TESTING ............................................................................................................. 67
5.8 FIT THE CABINET TO THE STOOL ...............................................................................................68
5.9 BACK FILL AND IN-FILL THE STOOL ............................................................................................68
5.10 SEALING THE BASE OF THE CONTROLLER OUTER CASE ....................................................68
5.11 CABLE ROUTING & TERMINATION ............................................................................................69
5.11.1 PHASE DRIVE PCB TERMINAL BLOCKS ............................................................................70
5.11.2 ST750 CPU PCB TERMINAL BLOCKS .................................................................................79
5.12 REGULATORY SIGNS MONITORING .........................................................................................84
5.13 PCB SWITCHES, FUSES, LINKS AND FIRMWARE....................................................................84
5.13.1 CPU PCB SWITCH AND LINK SETUP..................................................................................85
5.13.2 PHASE DRIVE PCB SWITCHES, LINKS AND FUSES SETUP............................................88
5.14 REFITTING THE LID ..................................................................................................................... 90
5.15 ON-SITE ST750 TESTING ............................................................................................................ 90
5.16 ST750 START-UP SEQUENCE .................................................................................................... 92
5.17 COMMON RETURNS FOR PUSH BUTTON ................................................................................93
5.18 COMMON RETURNS FOR DETECTORS....................................................................................93
6. FITTING THE ST750 RACK ASSEMBLY INTO ALTERNATIVE CABINETS ................................. 94
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7. ROUTINE MAINTENANCE PROCEDURES.....................................................................................95
7.1 ROUTINE INSPECTION OF SIGNAL EQUIPMENT .......................................................................95
7.2 ROUTINE INSPECTION AND ELECTRICAL TESTING OF ST750 ...............................................95
7.3 ROUTINE SETUP CHECK .............................................................................................................. 97
7.4 REPLACEMENT OF PCBS ............................................................................................................. 97
7.4.1 SAFETY REQUIREMENTS......................................................................................................98
7.4.2 GENERAL REQUIREMENTS ..................................................................................................98
7.4.3 ACCESS TO PCBS IN ST750 CABINET ASSEMBLY.............................................................98
7.4.4 ACCESS TO PCBS IN OTHER OUTERCASES......................................................................99
7.4.5 REPLACEMENT OF CPU PCB................................................................................................99
7.4.6 REPLACEMENT OF POWER/PHASE ASSEMBLY ................................................................99
7.4.7 REPLACEMENT OF MANUAL PANEL PCB .........................................................................100
7.4.8 REPLACEMENT OF EXPANSION I/O OR OTU PCB ...........................................................101
7.5 REPLACEMENT OF MAINS POWER SUPPLY UNIT ..................................................................101
7.6 REPLACING OTHER COMPONENTS..........................................................................................101
8. SELF-TEST FACILITY ....................................................................................................................102
APPENDIX A - PART NUMBERS AND SPARES LIST .....................................................................108
A.1 – PART NUMBERS .......................................................................................................................108
A.2 – SPARES LIST.............................................................................................................................109
A.2.1 – PCBS...................................................................................................................................109
A.2.2 – FUSES.................................................................................................................................110
A.2.3 – CABLES ..............................................................................................................................110
A.2.4 – OTHER SPARES ................................................................................................................110
A.3 - FUSE RATINGS AND POSITIONS.............................................................................................110
Table of Figures
Figure 1 –Theoretical Crossing............................................................................................................. 23
Figure 2 – Ped Demand Processing ..................................................................................................... 37
Figure 3 – ST750 in Small Outer Case with Detector Swing Frame .................................................... 41
Figure 4 – ST750 in Small Outer Case configured with optional 11” Swing Frame ............................. 42
Figure 5 – ST750 in Large Outer Case configured with optional 19” Swing Frame............................. 43
Figure 6 – ST750 Rack Assembly ........................................................................................................ 44
Figure 7 – CPU and Phase Driver Cards.............................................................................................. 45
Figure 8 – I.O Expansion Card ............................................................................................................. 45
Figure 9 - CPU LEDs ............................................................................................................................ 46
Figure 10 – Master Switch Assembly.................................................................................................... 47
Figure 11 – Mains Dimming Transformer ............................................................................................. 48
Figure 12 – Manual Panel (full panel shown) ....................................................................................... 48
Figure 13 – Single Detector Backplanes .............................................................................................. 49
Figure 14 – Detector Swing Frame ....................................................................................................... 50
Figure 15 – Detectors in 11” Swing Frame ........................................................................................... 50
Figure 16 – Detectors in a 19” Swing Frame ........................................................................................ 51
Figure 17 - 2A Detector Supply Kit ....................................................................................................... 51
Figure 18 - Gemini in a Detector Swing Frame .................................................................................... 52
Figure 19 - Gemini in an 11" Swing Frame........................................................................................... 53
Figure 20 - Gemini in a Large Outer Case............................................................................................ 53
Figure 21 - Freestanding TC12 OTU in Small Outer Case................................................................... 56
Figure 22 - Free Standing TC12 OTU in Large Outer Case................................................................. 57
Figure 23 - Dimming Transformer Tap Selection.................................................................................. 60
Figure 24 - Stool Installation, Small Cabinet......................................................................................... 63
Figure 25 - Stool Installation, Large Cabinet ........................................................................................ 65
Figure 26 - Termination of Armoured CAble to CET bar ...................................................................... 67
Figure 27 - Allocation of Red Lamp Monitor Channels for ST750 Controllers without LV CLS (NLM)
monitoring ...................................................................................................................................... 73
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Figure 28 - Allocation of Red Lamp Monitor Channels for ST750LED Controllers with LV CLS (NLM)
monitoring ...................................................................................................................................... 74
Figure 29 - Dimming Transformer Tap Selection.................................................................................. 77
Figure 30 - Connector PL5.................................................................................................................... 78
Figure 31 - Connector PL3.................................................................................................................... 81
Figure 32 - Connector PL7.................................................................................................................... 82
Figure 33 - Connector PL2.................................................................................................................... 83
Figure 34 - Connector PL6.................................................................................................................... 84
Figure 35 – CPU PCB ........................................................................................................................... 85
Figure 36 – Flash Rate Settings ........................................................................................................... 86
Figure 37 – Phase Output Flash Selection ........................................................................................... 87
Figure 38 – Relay Output Resistance Selection ................................................................................... 87
Figure 39 – ST750 Phase Drive PCB Assembly .................................................................................. 88
Figure 40 – Links LK1 to LK4................................................................................................................ 90
Figure 41 – Handset............................................................................................................................ 103
Figure 42 - Fuse Ratings .................................................................................................................... 111
Tables
Table 1 – ST750 Supply Requirements ................................................................................................ 22
Table 2 – ST750 Lamp Drive Capability ............................................................................................... 22
Table 3 – ST750 Lamp Load (Watts).................................................................................................... 22
Table 4 – Detector Power Consumption............................................................................................... 23
Table 5 – ST750 Cabinet Assembly Size and Weight .......................................................................... 29
Table 6 – Phase Drive PL6 Connector ................................................................................................. 70
Table 7 – Phase Drive PL7 Connector ................................................................................................. 71
Table 8 – Phase Drive PL8 Connector for ST750 Phase Driver PCB (6 Phase) ................................. 72
Table 9 – Phase Drive SK1 Connector ................................................................................................. 75
Table 10 – Phase Drive PL1 Connector ............................................................................................... 75
Table 11 – Phase Drive SK2 Connector No Dimming .......................................................................... 76
Table 12 – Phase Drive SK2 48V Dimming Connections..................................................................... 76
Table 13 – Phase Drive PL5 Connector ............................................................................................... 77
Table 14 – Processor Card PL3 Connector.......................................................................................... 80
Table 15 – Processor Card PL7 Connector.......................................................................................... 81
Table 16 – Processor Card PL2 Connector.......................................................................................... 82
Table 17 – Processor Card PL6 Connector.......................................................................................... 83
LAST PAGE........................................................................................................................................ 112
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1. INTRODUCTION
1.1 Purpose of this handbook
The purpose of this handbook is to give a general description and specification of the
ST750 Rack Assembly and the procedures for its Installation, Commissioning and
Maintenance in the ST750 Cabinet Assembly and other Cabinets. Also provided is
guidance on testing and maintenance procedures.
Note
Ongoing development means that some of the delivered items may
differ in detail from the information included in this handbook.
1.2 Contact Us
If you have any comments on this handbook, or need any further information, you
can contact us at trafficwebmaster.stc@siemens.com.
1.3 Reference Documents
1.3.1 Non-Essential Documents – Intersection Design
1.
Publisher
Siemens
Reference Number
667/DS/20664/000
2.
Siemens
667/HE/31699/000
3.
Siemens
667/DZ/33750/000
Document Title
Traffic Signal Junction Cable Design &
Certification
Loop Inductance and Turns Calculation
Spreadsheet
ST750 Family Tree
1.3.2 Essential Documents – Controller
4.
Publisher
Siemens
Reference Number
667/SU/32900/000
5.
6.
7.
Siemens
Siemens
Siemens
667/HH/32900/000
667/HB/32900/000
667/HB/33750/000
8.
9.
10.
11.
12.
Siemens
Siemens
Siemens
Siemens
Siemens
667/DA/27880/000
667/DA/27880/006
667/GA/33750/ETC
667/CC/32750/000
667/HB/32921/007
667/HB/33750/000
Document Title
ST900/750 Family Firmware and
Hardware Configurations
ST900/750 Family Handset Handbook
ST900 General Handbook
ST750
General
Handbook
(This
document)
ST750 UK Power Circuit Diagram
ST750 Non-UK Power Circuit Diagram
ST750 ELV Controller Cabinet Cabling
ST750 Family Controller Configuration
Handbook Supplement for Monitoring
Helios CLS (NLM) Signals
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ST750 GENERAL HANDBOOK
1.3.3 Essential Documents – Cabling
13.
Publisher
Siemens
Reference Number
667/HE/20664/000
14.
Siemens
667/HE/20663/000
Document Title
Installation
and
Commissioning
Handbook
Installation
Testing
(General)
Loop Detector and Cable Terminations –
Installation and Commissioning
1.3.4 Essential Documents – Ancillary Equipment
15.
Publisher
Siemens
Reference Number
667/HE/20662/000
16.
Siemens
667/HE/20665/000
17.
18.
19.
20.
21.
22.
Siemens
Siemens
Siemens
Siemens
Siemens
Siemens
667/HB/43100/000
667/HB/32600/000
667/HB/27663/000
667/HB/22380/000
667/CC/29000/002
667/CC/29000/003
Document Title
Installation & Commissioning – Signals
& Poles
Installation
and
Commissioning
Handbook 5 - Above Ground Detectors
TC12 General Handbook
Gemini2 Traffic Outstation Handbook
ST4R/ST4S Loop Detector Handbook
TCSU/TfL IMU Handbook
24 Volt Power Distribution Small Cabinet
24Volt Power Distribution Large Cabinet
1.4 Pre-Requisites
Anyone undertaking installation, commissioning and first line maintenance on the
ST750 controller will also need the ST900/750 Family Handset Handbook
(667/HH/32900/000). This provides details of how to access the controller handset
port through which the user communicates with the controller.
1.4.1 Qualifications
Only skilled or instructed personnel with relevant technical knowledge and
experience, who are also familiar with the safety procedures required when dealing
with modern electrical/electronic equipment, are to be allowed to use and/or work on
the equipment. All work shall be performed in accordance with the Electricity at Work
Regulations 1989 or the relevant local, state and government regulations.
Any personnel working on the ST750 Controller should have completed the following
training courses:
•
M608 – Pedestrian Traffic Controller Maintenance (ST750 & ST750ELV)
•
Personnel should also comply with the Highways National Sector Scheme
Competency Requirements
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Training requirements for non UK users may be different
1.4.2 REQUIRED TOOLS
In addition to a standard Engineer’s tool kit, the following tools are required when
carrying out any work on the ST750 Controller:
T-bar key
S-18 key – Main Cabinet
Serial handset Techterm, or
Old Oyster handset, or
Larger Screened Oyster handset
Manual Panel key Type 900
Part Number
667/2/20234/000
4/MC 289
667/4/13296/001
667/4/13296/000
667/4/13296/002
667/4/13651/000
1.5 Definitions
Cabinet
Assembly
The ST750 Rack Assembly installed in the ST750 Cabinet with
associated equipment mounting frame, mounting stool, mains
distribution, power supplies, electronic control and phase switching.
Configuration
data (also
referred to as
customer’s
data)
and site
specification
Data supplied by customer as to how the ST750 is to function.
EM
Controller identification number (ElectroMatic).
Firmware
EPROM
This goes on the Main Processor Board.
Pedestrian
stream
A group of Red, Amber and Green traffic signals plus their associated
Red Man, Green Man and Waits of the pedestrian signals.
Rack Assembly
This consists of a box like frame with a plate hinge on the front that
acts as an access door. The Phase Drive PCB and PSU are mounted
behind the ST750 CPU PCB.
STS
(Site to Scale)
This is a scale drawing of the intersection including Cabinet Assembly
position, detector loop positions and specification, cable routing and
poles with signal head arrangements.
Works
Specification
Document produced by Siemens, which details the hardware required
for the ST750 and includes Site Data, usually in the form of a printout
of the data entered on the configurator.
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1.6 Abbreviations
AC
AGD
BIT
CET
CLF
CLS
CPU
DC
DFM
ELV
EPROM
FT
IC
IC4
I/O
I/P
LED
LV
ms
NLM
OMU
OTU
PCB
PLD
PROM
PSU
RAM
RCD
RFL
RMS
ROW
RTC
SA
SDE
ST
UTC
UTMC
VA
Alternating Current
Above Ground Detector
Binary digit (i.e. `0' or `1')
Cable Earth Terminal
Cableless Linking Facility
Central Light Source
Central Processing Unit
Direct Current
Detector Fault Monitor
Extra Low Voltage
Erasable Programmable Read Only Memory
Fixed Time
Integrated Circuit
ST800 Configurator
Input/Output
Input
Light Emitting Diode
Low Voltage
milliseconds
No LMF Module
Outstation Monitor Unit
Outstation Transmission Unit
Printed Circuit board
Programmable Logic Device
Programmable Read Only Memory
Power Supply Unit
Random Access Memory
Residual Current Device
Reset Fault Log (handset command)
Root Mean Square
Right Of Way
Real Time Clock
Speed Assessment
Speed Discrimination Equipment
Self Tuning
Urban Traffic Control
Urban Traffic Management and Control
Vehicle Actuated
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2. SPECIFICATION
The Specification that follows is for the ST750 Cabinet Assembly. Where appropriate
it also applies to the ST750 Rack Assembly as supplied for installation in another
Cabinet.
Non-UK specifications
specifications.
are
detailed
where
they
differ
from
standard
UK
2.1 Equipment Introduction
The ST750 is a Pedestrian Controller and Small Non-UK Traffic Controller and can
be supplied in either small or large single-door outer cases.
It can be supplied as
•
•
•
Single Pedestrian controller (2 Phase)
Dual Pedestrian Controller (4 Phase)
Small Non-UK Controller (6 Phase)
Generally it comes as a fully fitted Cabinet Assembly with its own equipment,
mounting stool, mains distribution, power supplies, electronic control and phase
switching
This ST750 Cabinet Assembly can also accommodate Detectors, I/O PCB, OTU
PCB, an OMU Assembly, Manual Panel, Master Switch Assembly and a Dimming
Transformer.
It may also be fitted as a “Cuckoo” into many existing cabinets, when supplied as a
Rack Assembly consisting of the power/phase assembly and a CPU. There are a
number of conversion kits available that enable it to be installed into other cabinets.
The ST750’s electronics consist of three PCBs:
•
The CPU PCB that contains most of the logic, which controls the system and the
extra low voltage inputs and outputs, i.e. detector inputs, audible outputs, etc.
•
The Phase Drive PCB that contains most of the Mains distributions, the triac
phase drive outputs, voltage and current monitoring.
•
The PSU (24V) that provides the main power supply for the ST750.
The CPU PCB operates under the control of both a main and a secondary
processor. The main processor is a Motorola 68340, which runs the firmware
controlling all the functions of the ST750’s operations. The secondary processor is
an Intel 80C31 controlling all the phase output switching and voltage monitoring. The
two processors communicate with each other through shared RAM. This dual
processing provides additional safety features, as each processor continually
667/HB/33750/000
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ST750 GENERAL HANDBOOK
monitors the actions of the other, and independently turns off the lights to the
motorists and pedestrians if either processor causes an error.
The software is written in a powerful high level language that allows the
implementation of the ST750’s extensive facilities. The ST750 offers both Single and
Dual Pedestrian operation and up to a 6 Phase Traffic Controller operation, each
with solid state switching.
The power/phase assembly with its associated ST750 Phase Drive PCB and PSU
can drive up to 18 signal outputs with 230V at 4A. The pedestrian signals are
configurable to supply either 230V or 48V. Each of the two pedestrian streams has
current monitoring on two separate vehicle approaches for Red, Amber and Green
lamps plus one unmonitored approach Red lamp only. This provides TR2500A
compatible Red lamp monitoring for the Red lamps and lamp monitoring for the
Amber and Green lamps.
Note that a new ST750LED Phase Driver PCB provides lower current outputs, and
can monitor Helios LV CLS (NLM) signals. See 667/HB/32921/007 in Section 1.3.2
for further details.
The controller conforms to the UK Highways Agency specification TR2500A.
2.1.1 Single Pedestrian Controller
The ST750 Single Pedestrian Controller consists of one vehicle phase and one
pedestrian phase with a minimal set of I/O to perform all the functions of 2 phase
Pelican, Puffin or Toucan. These consist of 32 buffered inputs, 8 isolated relay
outputs, 2 Audible outputs and 1 Tactile Interlock output.
2.1.2 Dual Pedestrian Controller
The ST750 Dual Pedestrian Controller consists of 2 vehicle phases and 2 pedestrian
phases with a minimal set of I/O to perform all the functions of 4 phase Pelican,
Puffin or Toucan. These consist of 32 buffered inputs, 8 isolated relay outputs, 4
Audible outputs and 2 Tactile Interlock outputs.
2.1.3 Small Non-UK Controller
The ST750 Small Non-UK Controller consists of a 6 Phase Traffic Intersection
Controller. It is similar to the Pedestrian controllers, except in the following areas:
•
•
•
It has 6 Phases
It has no built in current lamp monitoring facilities
It cannot be configured to output 48V from any of its Phase Drive
outputs.
2.1.4 Controller Expansion
Expansion may be achieved by adding combinations of the following equipment:
•
Inputs/Outputs PCB
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ST750 GENERAL HANDBOOK
This board can expand the inputs/outputs as follows:
16 Inputs
16 Outputs
•
Detectors
These can be Siemens, Microsense or Sarasota self tuning units. Up to 4 units
can be accommodated in the ST750 cabinet, each unit having four detector
channels.
•
Ancillary Equipment
OTU – Outstation Transmission Unit for Tele Command 12.
OMU – Outstation Monitoring Unit for Remote Monitoring System.
2.1.5 Types of Pedestrian Controller
A number of different types of pedestrian crossings are available on the ST750. The
following table lists the different types of ‘stand-alone’ pedestrian crossings detailed
in TR2500A:
Type of
Crossing
Ped. Signal
Position
“Pelican”
Far-side
“Puffin”
Near-side
“Pedestrian”
Far-side
“Toucan”
Far-side
“Toucan”
Near-side
Pedestrian to Vehicle
Clearance Period
Vehicle Flashing Amber
Pedestrian Flashing
Green
Vehicle Red
Pedestrian Red
Vehicle Red
Pedestrian Blackout
Vehicle Red
Pedestrian Blackout
Vehicle Red
Pedestrian Red
These are described in more detail in sections 3.1.1 to 3.1.3 titled ‘Pelican Crossing’,
‘Near Sided Pedestrian Crossing’ (which covers both ‘Puffin’ and ‘Toucan’) and ‘Far
Sided Pedestrian Crossing’ (which covers both ‘Pedestrian’ and ‘Toucan’).
The ‘on-crossing detectors’ are described in section 3.1.4, while ‘kerbside detectors’
are described in section 3.3.
2.1.6 Differences between the ST750 and the ST700
The ST750 differs functionally from the ST700 in the following ways:
•
CPU – A new variant of the CPU board is required for operation in the ST750.
Although the ST700 and ST750 CPU Cards look very similar, the ST750 requires
at least 512KB of RAM and only 256KB is fitted to most ST700 CPU Cards.
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Note
The ST750 requires a CPU board with a /003 part number suffix for
UK applications or /007 for Non-UK applications. Earlier i.e. ST700
CPU boards can NOT be used in an ST750
•
PHP – PB801 and the ST750 require PB817 issue 5 or later; PB800 and the
ST700 can use PB817 issue 3 or later (which includes PB817 issue 5).
•
IO – PB801 firmware on the ST750 controller continues to use the I/O built in to
the CPU Card, with the option of adding one ST800 style Expansion I/O Board.
•
SDE – Integral SDE/SA is still used, using the I/O on the CPU Card. The SDE/SA
Card on the Extended System Bus is not supported by the firmware.
•
Config – The standard stand-alone pedestrian configurations have changed. A list
of these can be found in the IC4 ReadMe file (v11) and in this document (section
5.15). A list of the significant changes between a new ST750 standard
configuration and its original ST700 configuration is included in its Special
Instructions (from issue 2).
•
Kerbsides – As required by TR2500A in the UK, pushbuttons now insert a latched
demand if they are pressed while their associated kerbside detector is inactive. If
its associated kerbside detector is active, an unlatched demand is inserted (which
is cancelled when all the kerbside detectors for the phase go inactive).
•
DFM – DFM Faults on the individual I/O lines no longer appear in the Fault Log
Data (FLD) and should be interrogated using the DSF handset command, which
also displays the I/O Line Number and IC4 Name as well as indicating whether
the input failed active (1) or inactive (0).
•
DFM – The ‘Reset DFM’ facility (RDF=1 for example) will now clear the DFM fault
flag (FLF12) and extinguish the System Error LED.
•
Priority – The ‘Automatic Reset’ option of the Priority DFM Facility (PDR) has
been improved so that a number of activations can be specified; the N’th
activation is allowed and the fault is automatically cleared.
•
Handset – The handset now auto-detects Eight Data Bits with No Parity Bit (8N)
as well as continuing to support Seven Data Bits with an Even Parity Bit (7E) and
1200, 9600 and 19200 bps.
•
Handset – Level 2 (PME) and Level 3 (Pushbutton) Access Timeout Periods are
restarted if Level 2 or 3 data is changed (including RFL=1 for example) or the
PME access code is re-entered.
•
Config – The new CID handset command displays the firmware version (as
entered on the IC4 Admin Screen) ‘desired’ by the configuration currently running
a controller. The EM number and issue of the configuration is still visible using
the CIC handset command.
•
Config – The version of firmware required by a new configuration is checked
before the existing configuration is erased. An “FLF 21:255 CPAT” fault logged if
the new configuration requires a later version of firmware. The version required
by the configuration which failed to load can be seen using the new CIE handset
command.
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2.1.7 Spares Compatibility between the ST750 and ST700
With the exception of the CPU board all components of the ST700 system are
compatible with the ST750.
The ST750 requires a CPU board with a /003 part number suffix for UK applications
or /007 for Non-UK applications. Earlier i.e. ST700 CPU boards can NOT be used in
an ST750 due to the difference in RAM requirement.
If required, it is possible to use an ST750 CPU board to replace an existing or faulty
ST700 CPU board but it is NOT possible to use an ST700 CPU board to replace an
existing or faulty ST750 CPU board.
•
To use an ST750 CPU in an ST700 it is required to change the firmware
(PROM) to PB800. In this case, the relevant ST700 configuration will also
need to be downloaded prior to use.
On NO ACCOUNT is it permitted to downgrade an ST750 site to
an ST700 site by changing the CPU board and associated
Warning! firmware as an ST750 needs to conform to TR2500A which the
ST700 DOES NOT and CAN NOT
2.2 BASIC SYSTEM OVERVIEW
Control
Main Microprocessor
Firmware Storage
Working Data Storage
Motorola 68340
PROM (27C4002)
Static RAM (≥512K)
(Battery Backed)
Secondary Microprocessor
Firmware Storage
Working Data Storage
Inter-Processor Communications
Intel 80C31
PROM (27C512)
Internal to Microprocessor Device
Dual Port RAM 71321 (2K x 8)
Hardware Fail Flash
Programmable Logic Device
DIL Switches
Lamp Switching
Triac
Opto isolated, zero crossing
No Load at dimming changeover
Conflict System
Main and Secondary Processors
Self Testing
Physical Hardware CPU Card
Phase Drive Card
667/HB/33750/000
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PCB (244mm x 228mm)
PCB (253mm x 235mm)
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ST750 GENERAL HANDBOOK
2.3 MAINS SUPPLY
The following supply voltages may be used:
Nominal
Voltage
100-240
Minimum
Voltage
85
Maximum
Voltage
264
It is recommended that the signals are supplied at the nominal mains voltage during
Bright. I.e. For a 200V nominal supply, use 200V transformer/bulbs.
THE PROSPECTIVE SHORT CIRCUIT CURRENT OF THE
Note SUPPLY MUST NOT EXCEED 16,000 AMPS
Frequency:
50Hz ±2Hz or
60Hz ±2Hz
Mains Brownout:
Continues operating with up to 50ms loss of mains.
Mains Fail:
Restarts without operator intervention.
Battery Support:
Primary cell Lithium battery provides support for the
following during power failures.
(a) Clock Synchronisation (programmable up to 31
days).
(b) Timing Data (greater than one year).
A large capacitor provides support for a minimum of 4
hours if the battery has failed or is removed for
replacement.
Dimming Voltage:
120V, 140V, 160V RMS **See Note 1
Solar Cell Input:
Dimming cannot be provided at mains supplies below
200V.
Solar input operating voltages are as follows:
Bright to Dim > 80V RMS
Dim to Bright < 40V RMS
**Note 1. 160V is recommended for ST750LED Controllers. See 667/HB/32921/007 in
Section 1.3.2 for further details.
The solar cell enables the ST750 to identify the light level and thus dim the signals
when it is dark. The switch is set to operate at 55 lux and release at 110 lux. There is
an optional time switch that can be used to regulate dimming control if required.
2.3.1 Electrical Noise
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2.3.1.1 Supply Transients
The ST750 has been designed to withstand all the transients as defined in EN50293
on its supply.
2.3.1.2 Electrical Interference
The ST750 has been designed to create very little electrical interference, by the use
of mains filters and solid state lamp switching control. The mains filters protect the
incoming mains supply from any ST750 generated signals. The lamp switches are
switched at zero crossover of the mains supply to reduce any switching transients.
The switching of the signals for dim/bright lamps changeover is controlled carefully to
ensure the inductive switching does not cause interference.
The ST750 design is also extremely tolerant of externally generated electrical
interference. Care is taken to avoid earth loops using a ‘Star’ point earthing system
to which the cabinet, the internal metalwork, the junction cabling and the mains earth
is connected.
The arrangement and partitioning of the equipment is carefully organised to reduce
electrical noise.
The PCBs have two inner layer planes used for noise reduction. One is connected to
zero voltage and the other connected to +5V, to form a complete screen with
extensive capacitive de-coupling across the planes, which form the logic supplies.
Unused inputs are connected to the logic supplies to ensure their logic state.
The phase switching (signal outputs) system has isolation provided by Opto-SCRs
and zero crossing switched Triacs, for the mains switching. The circuit includes a
snubber filter circuit that aids triac switch off and reduces noise when an inductive
circuit is connected.
2.4 Determination of Loading and power consumption
Described below are the methods used to determine:
•
•
how the ST750 supplies the total lamp load required
the overall power used and thus estimate site running costs.
2.4.1 ST750 Supply Requirements
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ST750 GENERAL HANDBOOK
The typical supply requirements for an ST750 are:
Power
(Watts)
Single (2 Phase) or Dual (4 Phase) Pedestrian Controller
40 W
Non-UK Controller (6 Phase)
50 W
Table 1 – ST750 Supply Requirements
These requirements exclude lamp loads, detectors and OTU but include dimming
transformer.
2.4.2 Lamp Drive Capability
Max Current
(Amps)
Maximum lamp current that the ST750 can
supply including short-term illumination, i.e.
red/amber.
8A
Max
Power
(Watts)
1840W
Maximum lamp load for each triac output on
the phase drive PCB.
4A @ 230V
or
4A @ 48V
920W
or
192W
Table 2 – ST750 Lamp Drive Capability
Output Type
230V Halogen
230V Siemens Helios
CLS (With LMF)
230V Siemens Helios
CLS NLM (No LMF)
48V 40W Wait
48V 65W Wait
48V Siemens Led Wait
48V Siemens Nearside
Signal
48V Siemens Demand
Indicator
Lamp Load
(Bright)
63W
Maximum Quantity
per triac output
14
Lamp Monitoring
28W
32
14W
64
Yes (Max 8 per
sensor)
Yes (Max 8 per
sensor)
No*
40W
65W
7W
18W
4
3
>8
>8
Yes
Yes
No
No
6W
>8
No
Table 3 – ST750 Lamp Load (Watts)
*Note – ST750 LED Controllers allow these signals to be monitored.
667/HB/32921/007 in Section 1.3.2 for further details.
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See
Issue 5
ST750 GENERAL HANDBOOK
Power (Watts)
Siemens ST4R/ST4S detectors
2.4 watts per
detector
Sarasota MTS36Z (2 channel) or MTS38Z (4 channel)
detectors. (NB The power consumption is the same for
both 2 and 4 channel units.)
3 watts per
detector
Microsense detectors
6 watts per
detector
Table 4 – Detector Power Consumption
Key:
Traffic Red / Amber / Green Signal (Primary)
Traffic Red / Amber / Green Signal (Secondary)
Pedestrian Red / Green Signal.
Pedestrian Wait Indicator Box (on pole).
2 Detector Cards used but not shown
A
A
B
B
A
A
C
C
D
D
C
C
Figure 1 –Theoretical Crossing
2.4.3 Calculation of Average Signal Lamp Power
Calculate the total average signal lamp power as follows, using the bright figures in
Table 3.
Total average signal lamp power is the sum of the signal lamp power plus the sum of
the Wait indicator power.
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Assuming that HI lamps take 63W each, the theoretical crossing (Figure 1)
calculation would be:
One lamp per signal head @ 63W x 12 signal heads
Wait indicators at 40W x 4
Total average signal lamp power
=
=
=
756W
160W
916W
2.4.4 Intersection’s Power Requirements for Running Costs Estimate
The following worked example is based upon a 230V/240V mains supply.
1. Calculate the total average controller power
2. Calculate the total average lamp power for the junction as shown in 2.4.3
3. Add the total average signal lamp power to the total average controller power
Total average controller power is calculated as follows:
Average Controller power + Average Detector Power. See section 2.4.1.
A controller is rated at 40 watts (single or dual Pedestrian Controller).
For the purposes of this calculation Siemens ST4R/ST4Sdetector cards are rated at
3W per card.
This gives the total average junction power, which may be used to estimate running
costs.
i.e. Total average junction power
=
Total average signal lamp power +
Total average controller power.
Therefore for our theoretical crossing (Figure 1) the total average controller power is:
1 x Controller
2 x Siemens ST detectors
Total average controller power
Note:
40 W
6W
46 W
The controller power should also include any additional equipment supplied
by the controller. This may include, for example, OTU, OMU or Auxiliary
detector power supply.
For the total average junction power to aid with running cost estimates, the total
average lamp power must be added to the total average controller power.
Total average junction power is calculated as follows:
Total average lamp power
Total average controller power
Total average junction power
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916 W
46 W
962 W
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ST750 GENERAL HANDBOOK
If an estimate of running costs is required that includes the period of time that the
signals are dimmed, this can be approximated as follows:
Total average Junction Power (Dimmed) is:
Total average Signal Power x (Dimmed Voltage / Nominal Mains voltage) plus
Total average Controller Power.
Therefore for the theoretical crossing in Figure 1:
Total average Junction Power (Dimmed)
= (916W x (160V/240V)) + 46W
= 657 W
2.4.5 Connection to Un-Metered Supplies (UMS)
If the ST750 is to be connected to an unmetered supply (UMS) equipment codes for
the agreed power consumption of the controller and all associated equipment may
be found on the Elexon web site.
General information may be found at:
http://www.elexon.co.uk/participating/unmeteredSupplies.aspx
The actual charge codes may be found by following the link below, which is correct
at the time of writing:
http://www.elexon.co.uk/documents/Participating_in_the_Market/Unmetered_Supplie
s_-_Operational_Information/Unmetered__Supplies_Operational_charge_codes.xls
Note that a condition of using these codes is the creation of a full site inventory to
create a costing for the supply of electricity. Details on this process may be found by
following the link below, which is correct at the time of writing:
http://www.elexon.co.uk/documents/Publications/Guidance_Notes__Unmetered_Supplies/Charging_Code_Structure_for_UMS.pdf
2.4.6 Detector Power Supplies
The maximum current available for detectors on the ST750 is 0.6A at 24V DC. Refer
to Table 4 or the Detector Handbooks for power consumption of detectors.
If more current is required, then power all detectors from a 24V AC Detector PSU.
See Appendix A for part number. This PSU provides a maximum of 2A at 24V AC
and is in the form of a transformer that can be mounted in three different positions:
• On the side of the Detector chassis using the four appropriate fixing holes
• On the back of the metal outer case frame near the mount position of the
detector chassis, using the four appropriate fixing holes.
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ST750 GENERAL HANDBOOK
•
On the left-hand side flange of the metal outer case frame just above the
Master Switch Panel, using the four appropriate fixing holes.
2.4.7 Audible and Tactile Supplies
The Audible and Tactile power supplies on the ST750 are designed to provide a DC
voltage between 10V and 24V, and typically provide a maximum of 100mA at 18V
DC.
The ST750 provides three audible outputs on each of the 2 pedestrian phases.
These are located on the CPU card PL2 (Phase D) and PL3 (Phase B).
Pin 11 is titled ‘Tactile Phase n’
– This is intended to interlock a tactile unit via
the tactile PSU ‘interlock’ input to prevent
operation on a Pelican during the flashing
green man period where the ‘Loud’ output
is configured to be time-switched.
Pin 12 is titled ‘Audible Phase n Loud’ – This is the normal connections to audibles.
This output can be configured to be timeswitched. If the tactile is also required to
be switched then the tactile PSU ‘interlock’
input signal can be taken from this output.
Pin 13 is titled ‘Audible Phase n Quiet’ - This output is for the secondary physically
muted audible.
Audible and Tactile units used must operate correctly over the voltage range 10 to
24V DC.
The units recommended and supplied by Siemens that meet this requirement are:
Audible:
667/4/04785/000
Highland Electronics type SC628P
(previously Sonalert Mallory SC628P)
Roxborough type SPCI535A4
Tactile:
667/7/17390/000
PELICAN currently Radix RS250 or RS252
667/7/17390/001
INTERSECTION currently Radix RS251 or RS252
NOTE – There are four main situations for audible/tactile control that arise on an
ST750. These are –
1. Normal Audibles – The ‘Loud’ output is used.
2. Switched Audibles – The ‘Loud’ output can be used configured to switch
off at selected times (e.g. at night). If the Tactiles are also to be switched
then the tactile PSU ‘interlock’ input can be connected to this output.
3. A Muted Audible Output – The ‘Quiet’ output can be connected to the
second audible. This audible will require a local physical muting method.
4. A Pelican With Flashing Green Man – The ‘Loud’ output is off during the
flashing period. Thus the ‘Loud’ output is used to connect to the audibles
and the tactile PSU ‘interlock’ signal input. If the ‘Loud’ output is configured
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to be time switched, then the ‘Tactile’ output is used to control the tactile
PSU interlock signal input.
2.5 PHASES
The ST750 Pedestrian Controller supports either 2 ‘Real’ Phases for a single
pedestrian crossing or 4 ‘Real’ Phases for a dual pedestrian crossing.
The ST750 Small Non-UK Controller can support up to 6 ‘Real’ Phases.
The ST750 software can support up 32 phases, which can be any combination of
real and software phases.
2.6 STAGES
The ST750 software supports up 32 stages. Note that Stage 0 is normally ALL RED.
2.7 TIMINGS
All ST750 timings are transferred to battery supported RAM during initialisation.
Once in RAM, most timings can be varied by handset commands. Once the
configuration data has been loaded into the ST750, the same configuration cannot
be loaded again. This prevents the accidental overwriting of any configuration data
that may have been set up using the handset.
In the UK some timings considered to be fixed timings cannot be changed by
handset. These are typically the Amber and Red/Amber periods. These timings can,
however, be specified as alterable at configuration time to suit other signal
sequences, Non-UK requirements etc.
Some timings considered to be safety timings can only be changed by a person at
the ST750 operating the write enable ‘level 3’ push button, e.g. minimum green,
intergreen, blackout timings, etc.
The default timings for the ST750 standard Pedestrian configurations are given in
their IC4 printouts (Special Instructions). These printouts also show the handset
commands that are used to change each of the timings. Some of these timings are
described in Section 3.
A summary of all the timings available within the ST750 Non-UK intersection
controller is contained in the ST900 General Handbook (see Section 1.3 for details).
It also shows their upper and lower limit values and, where applicable, the
configurable limits.
2.7.1 Tolerance
All timings, except CLF and Master Time Clock, are derived from the crystal
frequency which has a tolerance of 35 parts per million. An additional error, due to
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ST750 GENERAL HANDBOOK
random signals not being synchronised to the clock pulse, may add up to 200ms to
the time.
If the result of the above timings is required to change the signal lamps, a further
error may occur up to a maximum of 21ms.
The set-up accuracy of the real time clock and the accuracy of any offsets calculated
from it will be 1 second.
2.8 MASTER TIME CLOCK and CLF SUMMARY
• Master Time Clock
• Timing Sources – 50Hz or 60Hz Mains (automatically detected)
• Standby Timing – On board crystal and battery support programmable up
to 31 days. Accuracy of standby crystal oscillator is 35 parts per million.
• Programmable changeover to mains synchronisation.
• Facility for synchronising the real time clock or group timer from existing
UTC.
• Number of time switch settings – 64
• Number of time switch functions – 3
(a) Isolate controller
(b) Introduce a CLF plan
(c) Introduce time-switch events such as alternative maximum green
periods
• Cableless Link Facility
-
Number of plans:
Number of plan influence tables:
Number of groups per plan:
Number of group influences:
16
16
32
10 types
2.9 MODES OF OPERATION
The following modes are available on the ST750 Pedestrian controller, and are
described fully in Section 3:
• Stand Alone Pedestrian V.A.
• Stand Alone Pedestrian V.A. with pre-timed maximum period
• Stand Alone Pedestrian Fixed Vehicle Period
• Stand Alone Pedestrian Cableless Link (Pedestrian inhibit)
• Stand Alone Pedestrian UTC (‘PV’ control bit)
• Stand Alone Pedestrian Local Link (‘PV1’ control)
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The following intersection modes are available on the ST750 Non-UK controller:
•
Start Up
•
Part-time (Off period)
•
Urban Traffic Control.
•
Emergency Vehicle
•
Priority (Non-emergency vehicle)
•
Hurry Call
•
Manual Operation
•
Manual Step-On, if fitted.
•
VA, CLF or FT Operation (selected via mode switch)
•
Cableless Linking
•
Vehicle Actuated (VA)
•
Fixed Time (FT)
For more information refer to the ST900 Family General Handbook
2.10 Cabinet Characteristics
The ST750 Outer case is a single sided access cabinet with the following
dimensions:
Small outer case –
Height
Width
Depth
Approximate weight of cabinet and stool, including one Gemini, and
two Loop Detector cards
1200mm
466mm
370mm
47Kg
Large outer case Height
Width
Depth
Approximate weight of cabinet and stool, including one Gemini, and
two Loop Detector cards
1157mm
730mm
426mm
50Kg
Table 5 – ST750 Cabinet Assembly Size and Weight
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For more details on the Small and Large cabinets refer to section 4.1
The case is manufactured in grey or black powder coated aluminium.
In addition to the screw-locks, the main controller door is fitted with a S18 lock. There
is a facility to change the S18 lock to a Yale with an RKA27C pattern barrel.
The key lock should not be operated unless the screw locks are tight, i.e.
Note Unlock the case before undoing the screw lock and only lock the case after
tightening the screw locks.
The lock used on the Manual Panel is a small Yale lock with a 900 pattern barrel.
2.11 ENVIRONMENTAL
2.11.1 Temperature
The ST750 in a grey outercase is designed to operate in external ambient
temperatures of –25ºC to +65ºC.
Its use in countries where high levels of solar radiation are expected with longer
periods of exposure may impose power restrictions on the ST750 hardware
configuration. Contact Engineering at Poole for more details on hardware
restrictions.
2.11.2 Atmospheric
The controller is proofed against driving rain and sand, dust conditions and industrial
pollution.
2.11.3 Humidity
The ST750 will withstand a temperature of 45°C with a relative humidity of 95%.
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3. PEDESTRIAN FACILITIES
3.1 Types of Pedestrian Crossings
3.1.1 Pelican Crossing
The vehicle to pedestrian intergreen is controlled by the PAR Pedestrian All-Red
period. The PAR handset command allows different all-red periods to be executed
depending on why the vehicle phase left green. Different times can be specified for
each of the following: fixed vehicle period mode (see section 3.2.1), VA mode ‘gap’
change and VA mode ‘max’ change (see section 3.2.2), a ‘linked’ change (see
section 3.2.4).
The pedestrian to vehicle intergreen is divided into three fixed periods governed by
the PIT Pelican Intergreen Times.
Veh: Green Amber
Ped:
Red
Red
3
Flashing Amber
Green
PAR
MIN
Red
Flashing Green
PIT n 0
PIT n 1
Green
PIT n 2
3.1.2 Near Sided Pedestrian Crossing
The vehicle to pedestrian intergreen on a stand-alone crossing is controlled by PAR.
However if the near-sided pedestrian phase is part of an intersection stream, then
this period is controlled solely by the IGN intergreen command.
The pedestrian to vehicle clearance period consists of:
• a minimum period governed by PBT p,
• an extendable period limited to a maximum governed by CMX p,
• a gap clearance delay CDY p 0, or
• a max clearance delay CDY p 1
where ‘p’ is the pedestrian phase letter.
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Veh: Green Amber
Ped:
Red
Red
3
Red
Green
PAR
Green
R/A
MIN
PBT
CDY0 2
IPX
Gap Change
On-Crossing Detector:
Max Change
R/A Green
Red
Red
CMX
CDY1
2
On intersections, the appearance of the vehicle phase will be delayed further if the
IGN intergreen time is larger than PBT plus the red/amber period.
3.1.3 Far Sided Pedestrian Crossing
The vehicle to pedestrian intergreen on a stand-alone crossing is controlled by PAR.
However if the far-sided pedestrian phase is part of an intersection stream, then this
period is controlled solely by the IGN intergreen command.
The pedestrian to vehicle blackout clearance period consists of:
• a minimum period governed by PBT p,
• an extendable period limited to a maximum governed by CMX p,
• a gap clearance delay CDY p 0*, or
• a max clearance delay CDY p 1
where ‘p’ is the pedestrian phase letter.
Following this blackout clearance period, there is a clearance all-red period CRD p.
* The gap clearance delay CDY p 0 is usually set to zero and hence is not shown on
the following diagram.
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Veh: Green Amber
Ped:
Red
Red
3
Green
PAR
MIN
Green
R/A
Red
Blackout
PBT
CRD 2
IPX
Gap Change
On-Crossing Detector:
Max Change
R/A Green
Red
Red
Blackout
CMX
CDY1 CRD 2
If a fixed black-out period is required, i.e. with no on-crossing detectors, then CMX
should be set to zero so that the black-out period is controlled solely by PBT:
Veh: Green Amber
Ped:
Red
Red
3
R/A
Green
Blackout
MIN
PBT
PAR
Green
Red
CRD 2
On intersections, the appearance of the vehicle phase will be delayed further if the
IGN intergreen time is larger than PBT plus CRD plus the red/amber period whether
CMX is zero or non-zero. But for backwards compatibility, if CMX and CRD are both
zero, then the intergreen is controlled solely by IGN even if PBT is set longer.
3.1.4 On-Crossing Detectors
‘On-Crossing Detectors’ are above ground detectors that are used to determine
whether pedestrians are still crossing. While pedestrians are still crossing, the
extendable clearance period is extended, up to its configured maximum (CMX in the
above diagrams).
The on-crossing detector inputs are configured using IC4 and the extension times
are configured on an input basis (i.e. IPX).
If an on-crossing detector is unused, i.e. where several have been configured by
default on a stand-alone controller, it can be de-allocated using IOA. If no extendable
clearance period is required on a particular phase, then the clearance maximum time
(CMX) can be set to zero. If all of the on-crossing detectors for a phase are deallocated but the clearance maximum time is non-zero, then the clearance period is
extended up to its maximum.
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Also note that if the Continuous Ped Demand (CPD) button on the manual is
pressed, then the red clearance of near-sided signals will be extended to its
maximum as required by TR2500A.
If an on-crossing detector has not been activated from the end of the preceding
pedestrian clearance period to the end of the current pedestrian steady green period,
then the clearance period is forced to run to its maximum.
A fault will not be recorded if this occurs, instead the controller will wait until the
normal DFM time-outs confirm and report a fault.
3.2 Pedestrian Modes Of Operation
A stand-alone pedestrian crossing can run any of the following modes of operation:
3.2.1 Fixed Vehicle Period
The vehicle phase appears at green for at least a fixed period. No vehicle detection
equipment is required.
If the pedestrian phase is demanded while this period is still running, the vehicle
phase remains at green. When the period expires, the vehicle phase loses right of
way and the pedestrian phase subsequently appears at green.
If the pedestrian phase is demanded after this fixed vehicle period has expired, then
the vehicle phase immediately (subject to the pedestrian demand delay see section
3.3.3) loses right of way and the pedestrian phase subsequently appears at green.
When the pedestrian phase has completed its green period and the controller has
executed the required ‘pedestrian to vehicle clearance period’ (see section 3.1), the
vehicle phase returns to green.
The fixed vehicle period is specified by the handset commands MEX, MFX, MGX
and MHX allowing four different times to be called up at different times of the week.
3.2.2 Vehicle Actuated
This mode requires vehicle detection equipment, either inductive loops cut into the
road’s surface or ‘above ground’ detectors (usually microwave detectors) mounted
on the signal poles. Activations on these inputs start (or restart) the ‘extension time’
for the phase and while this is active, the vehicle phase will (normally) remain at
green.
The vehicle phase appears at green for at least a minimum period specified by the
MIN handset command.
If the pedestrian phase is demanded while this period is still running, the vehicle
phase remains at green until at least this period has expired.
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If the pedestrian phase is demanded after this ‘minimum’ period has expired and no
vehicles are present, then the vehicle phase loses right of way immediately.
If the vehicle detectors indicate that vehicles are present, then the vehicle phase will
remain at green until the vehicles are no longer present. This is referred to as a ‘gap
change’ since the vehicle phase loses right of way to service the pedestrian demand
when a gap in the traffic appears.
However, when the pedestrian phase is demanded, the vehicle phase’s ‘maximum
green timer’ is started. If vehicles continue to be present, keeping the vehicle phase
at green, the vehicle phase will lose right of way when this timer expires, even if
vehicles are still present. This is referred to as a ‘max change’ since the vehicle
phase loses right of way when its maximum green time expires.
The maximum green time is specified by the handset commands MAX, MBX, MCX
and MDX allowing four different times to be called up at different times of the week.
When the pedestrian phase has completed its green period and the controller has
executed the required ‘pedestrian to vehicle clearance period’ (see section 3.1), the
vehicle phase returns to green.
3.2.3 Vehicle Actuated with Pre-Timed Maximum (PTM)
This mode is very similar to normal vehicle actuated mode, except that the vehicle
phase’s maximum green timer is started as soon as the vehicle phase appears at
green, regardless of whether there is a demand for the pedestrian phase.
The option is enabled using the PTM handset command.
Therefore, if the vehicle phase has already been at green for longer than its
configured maximum green time when a push-button is pressed, the vehicle phase
loses right of way immediately subject to the pedestrian demand delay (see section
3.3.3) or the pre-timed maximum extra.
Compare this to the normal vehicle actuated mode, where the pedestrian would have
to wait for up to the maximum green time (if vehicles continue to be present) before
the vehicle phase loses right of way.
3.2.4 Linked Operation
With the controller running any of the above three modes, the operation controller
can be further modified by various ‘linking’ options.
These options hold the vehicle phase at green until a specific time when the
pedestrian phase is allowed to appear. During this ‘window’ vehicle extensions are
removed to ensure that any pending demand for the pedestrian phase is serviced.
This is often required, for example, when the pedestrian controller is close to an
intersection where it is beneficial to keep the pedestrian controller at vehicle green
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during certain stages of the intersection controller to help the traffic entering and/or
leaving the nearby intersection.
Cableless Link – Using the controller’s Master Time Clock and CLF facilities, the
controller can be given one or more ‘windows’ during the CLF cycle when it is
allowed to service the pedestrian demands. For the rest of cycle, the vehicle phase
remains at green.
UTC – The ‘PV’ control bit from the instation holds the vehicle phase at green. When
the ‘PV’ bit is de-activated for a short period, the controller will service any pending
demand for the pedestrian phase.
Local Link – The ‘PV1’ input from an adjacent controller holds the vehicle phase at
green. When the ‘PV1’ bit is de-activated for a short period, the controller will service
any pending demand for the pedestrian phase.
3.3 PEDESTRIAN DEMAND CONTROL
3.3.1 Introduction
In addition to pedestrian push buttons, the controller can be configured with ‘cycle
detectors’ and ‘kerbside detectors’. The controller firmware treats ‘cycle detectors’
and ‘push-button inputs’ the same and both should be configured to demand the
phase in the usual way.
‘Kerbside detectors’ allow the controller to cancel the demand (and switch off the
wait / demand indicator) if the pedestrian crosses before the pedestrian phase gains
right of way..
A push button input can be associated with a specific kerbside input in order to
determine the type of pedestrian demand inserted. A kerbside input can be
associated with one or more push button inputs, or it can be associated with none in
which case it is only used to hold and cancel the demand.
Figure 2 – Ped Demand Processing” overleaf shows the pedestrian demand
processing performed by the firmware described in the rest of this section.
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Figure 2 – Ped Demand Processing
SPECIAL
CONDITIONING
READ/WRITE
ACCESS
PUSHBUTTON
ACTIVE
(ENG 254)
OR
NOT
SET
ROW
CLR
KBSACT
KERBSIDE ACTIVE
OR
x4
LATCHED
PUSHBUTTON
PBNLAT
(ENG 284)
(ENG 255)
ALL KERBSIDES
INACTIVE
PUSHBUTTON &
KERBSIDE LATCH
SET
PBKLAT
(ENG 256)
LATCHD
1WTCTRL
(ENG 197)
CLR
PEDBUT
OR
OR
(ENG 29)
ROW
VARIOUS
FACILITIES
UNLPUF
PDX
OR
DEMAND
BUT NOT
KERBSIDE
NOT
IPX
AND
PED DEMAND PROCESSING
LATCHED PHASE DEMANDS
OR
PHASE
DEMAND
PROCESSING
OR
WAIT /
DEMAND
INDICATOR
PBNACT
AND
PDD
IPX
DEMAND AND
KERBSIDE
INPUTS
KERBSIDE
DEMAND
PED INPUT PROCESSING
SPECIAL CONDITIONING ‘WAIT’ CONTROL
The following lines can be used in special conditioning to add pedestrian phase demand and kerbside inputs in addition to those
provided by the firmware:
;xxPB = Pushbutton input, xxKBS = Associated Kerbside input, ‘p’ = Phase letter
xxPB_ext.xxKBS_ext=+PBNACTp
;Pushbutton and Kerbside both active
xxPB.NOT(xxKBS_ext)=+PBNLATp ;Pushbutton active while kerbside inactive
xxKBS_ext=+KBSACTp
;Kerbside extension active
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3.3.2 Pedestrian Demand Acceptance
For the purposes of this section, push button inputs include any demand inputs
assigned to a pedestrian phase, including for example inductive loops for cycles.
If no kerbside detectors are configured on the phase, pressing the push buttons
generates a latched demand for the pedestrian phase, which is only cleared when
the pedestrian phase gains right of way.
If kerbside detectors are configured on the phase, then the operation is as follows:
Every push button input and every kerbside input is configured with its own extension
period (which can be modified using the IPX handset command). The extension
remains active for the configured period after the input goes inactive.
An unlatched demand for the pedestrian phase is accepted and the wait / demand
accepted indicator illuminated when a push button (or its extension) and its
associated kerbside detector (or its extension) are both active at the same time. This
demand will be cancelled when all the kerbside inputs go inactive.
A latched demand for the pedestrian phase is accepted and the wait / demand
accepted indicator illuminated when a push button input is active but its associated
kerbside detector (and its extension) is inactive, or no kerbside detector has been
associated with that push button input. This demand is only cleared when the phase
gains right of way.
3.3.3 Pedestrian Demand Delay (PDD)
The transition from vehicle green to pedestrian green starts with the vehicle
changing to amber. A delay before starting this transition can be configured so that
the vehicle phase does not terminate as soon as the pedestrian push button is
pressed, although the wait indicator is illuminated.
The delay is controlled using the handset command PDD.
The controller uses the following rules:
• In VA mode, if one or more real phases are at right of way (and none of the
phases at right of way have pre-timed maximums configured) the delay is not
applied, since if vehicles are present, their extensions will keep the vehicle phase
at green.
• In VA mode, the controller will examine the maximum green timers of all
conflicting phases which are at right of way which have also been configured to
run a ‘pre-timed maximum’ but no ‘pre-timed extra period’ (see PTM and PTX in
section 3.2.3If any have expired or have less time to run than the delay, the delay
is introduced, otherwise all have more time to run than the delay, so no delay is
introduced and the controller will only allow the stage change if none of the
phases are being extended.
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•
•
In VA mode, if no real phases in the same stream are at right of way, the delay is
introduced, so delaying the appearance of the pedestrian green after a quiescent
all-red period, for example.
In all other modes, the delay will always be introduced. This is to cater for cases
such as ‘fixed vehicle period’ mode, UTC inserting a demand dependant force for
the pedestrian phase, or CLF introducing a demand dependant move just after
the push-button is pressed. Introducing the delay prevents these cases making a
stage move shortly after the push-button is pressed. In most other cases, the
demand delay will have little or no effect.
Note that special conditioning can always be written to ‘short-circuit’ the pedestrian
demand delay if required under certain circumstances by putting in an unlatched
demand for the phase if the wait indicator is lit.
3.3.4 Pedestrian Demand Cancel (PDX)
The unlatched phase demand is cleared when all kerbside detectors and their
extensions for the phase have been inactive for the configured pedestrian demand
extension time for the phase (PDX). The wait / demand accepted indicator will be
extinguished if there are no other demands present for the phase.
Note that the phase may still appear at green if the controller has already started the
move to the stage in which the phase appears.
3.3.5 Kerbside Detector (Mat) Testing
Kerbside detector testing can be performed by the firmware to check the operation of
kerbside ‘mat’ detectors.
Every 60 seconds, if there are no pedestrian phase demands active and no pushbutton (or cycle) inputs active, the controller outputs a 500ms (±50ms) test pulse on
a configured output. If the output is de-allocated using IOA, no kerbside testing will
be performed.
This output is connected to all the kerbside detectors and should result in all of the
kerbside inputs going active during the pulse.
Therefore, the test is not performed while a pedestrian demand exists since this will
extend the pedestrian demand if the kerbside input has just gone inactive and the
controller is timing off the kerbside and demand extension periods.
Nor is the test performed while any push-button or cycle inputs (or their extensions)
are active since the kerbside test will activate the kerbside inputs even though noone may be present and allow these inputs to produce a demand for the pedestrian
phase.
Each configured kerbside detector is sampled twice and if either sample on a
particular kerbside detector indicates the detector is inactive*, the detector is logged
as faulty, the DFM indicator is illuminated and the detector input forced active
(regardless of the setting of the DFM forcing action command ‘DFA’).
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* Note that for the input to be seen inactive at the 200ms processing rate, all ten
20ms samples must have been inactive.
Thereafter, the force is only removed after 5 consecutive tests of the detector have
passed, but the fault log entry remains set and the DFM indicator remains
illuminated, until RFL=1 is entered.
If the maintenance engineer enters RFL=1, the controller will automatically perform a
test. If a kerbside detector which was reported as faulty passes this test, even if this
is the first test that it has passed, the fault log entry for that detector is cleared and
the detector is assumed to be working. This means that when the maintenance
engineer fixes a kerbside detector, they do not have to wait for 5 automatic tests
before they can clear the fault, they just need to enter RFL=1.
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4. HARDWARE OVERVIEW
4.1 Cabinet Options
The ST750 is available in either the T400S (small) or ST900 (Large) cabinet / Outer
Case
ST750 Rack
Assembly
Equipment
Terminal
Panel
Detector
Swing
Frame
Master
Switch Unit
Mains
(Dimming)
Transformer
Figure 3 – ST750 in Small Outer Case with Detector Swing
Frame
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ST750
Rack
Assembly
Detector
PSU Kit
Gemini
Loop
Detectors
11”
Detector
Rack Kit
Rack
11”
Swing
Frame
Mains
(Dimming)
Transformer
Figure 4 – ST750 in Small Outer Case configured with optional 11”
Swing Frame
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19”
Swing
Frame
ST700
Rack
Assembly
19” Rack
Assembly
Figure 5 – ST750 in Large Outer Case configured with optional 19” Swing Frame
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4.2 The ST750 Rack Assembly
HANDSET
PORT
PSU
SIEMENS ST750
PHASE
CONTROL
RIBBON
CABLE BUS
POWER
SUPPLY
ST750 CPU PCB
LED SIGNAL
VISUAL
DISPLAYS
CABLE
ACCESS
OPENING
PHASE
DRIVE PCB
I/O BOARD
OR
OTU BOARD
ON
CONTROLLER
SWITCH
STATUS VISUAL
DISPLAYS
TERMINAL
BLOCKS FOR
ROAD SIDE
CABLES
HEATSINK
COVER
END PLATES SHOWN IN DOT
OUTLINES AND TRANSPARENT TO
PROVIDED BETTER VIEWING
Figure 6 – ST750 Rack Assembly
The ST750 Rack Assembly consists of a box like frame with a plate hinge on the
front that acts as an access door.
The Phase Drive PCB is mounted behind the ST750 CPU PCB in this assembly.
This contains the logic power supply, the mains distribution, Solid State Relay, A
Relay, B Relay, Dimming relays, the mains fusing, and the Phase Drives, along with
the terminal blocks to wire the phase drives directly to the road side cables. The
Phase Drive PCB has a flying 64-way Phase Control Bus ribbon cable attached. This
connects to the ST750 CPU PCB and supplies the power and control signal to that
card.
Mounted on the heatsink cover of the Phase Drive PCB is the mains power supply
unit (24V DC output) that is mains powered from, and supplies 24Volts to, the Phase
Drive PCB via a cableform.
The ST750 CPU PCB is mounted on the outside of the hinged plate. This contains
the Dual Processors and associated logic, LED signals and status visual display,
Handset Port, Modem Port, Manual Panel Port and I/O circuits along with the
terminal blocks to wire the I/O circuits directly to the road side cables.
This leaves space on the inside of the hinged plate to mount an additional I/O PCB
or OTU PCB as and when required. These cards are the same as those used on the
ST800 and thus are connected to the ST750 CPU PCB using an extended system
bus cable that runs along the side.
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Figure 7 – CPU and Phase Driver Cards
I/O
Expansion
Card
Figure 8 – I.O Expansion Card
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4.3 ST750 CPU LEDS
There are 21 LED indicators on the component side of the ST750 CPU PCB in two
groups, Status (see section 4.3.1) and Signal (see section 4.3.2), as shown in Figure
9.
LED SIGNAL
VISUAL
DISPLAYS
VIEW OF PHASE 'F'
A
B
C
D
E
F
PP
RED
AMB
SE
F
GRN
WD
STATUS VISUAL
DISPLAYS
Figure 9 - CPU LEDs
4.3.1 Status LED Group
The top Status LED is green and is labelled ‘PP’ for power present. This LED flashes
giving a heartbeat indication that the ST750 is running normally.
If it does not illuminate there is no power to the CPU PCB. Check that the ST750 is
powered and that the Phase Control ribbon cable is inserted into the socket of the
CPU PCB.
The other two LEDs are red and identify various fault conditions.
The top red LED is labelled ‘SE’ for system error. This illuminates during the powerup sequence and then extinguishes when the ST750 is running normally with no
faults present in its fault log.
The bottom red LED is labelled ‘WD’ for watchdog. This LED is illuminated when the
hardware watchdog circuit times-out. Note that when the firmware detects a serious
fault, it extinguishes the signals and deliberately stops ‘kicking’ the hardware
watchdog so that it times-out and reinforces the signals’ Off or Fail Flashing
condition.
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4.3.2 Signal LED Group
These LEDs are in groups of three, one for each traffic phase A to F. Each group
has a red at the top, amber in the middle and green at the bottom (see View of
Phase ‘F’ in Figure 9) to represent a set of traffic lights. They provide visual
representation of the state of the red, amber and green drives for their respective
phase.
4.4 Master Switch Assembly
The Master Switch Assembly is mounted in the bottom right hand corner of the
controller, refer to Figure 3
With reference to Figure 10 the mains supply voltage is applied to the main ON/OFF
63A circuit breaker, within the Master Switch Assembly, for onward supply to the
ST750 Traffic Controller.
The live supply wire is taken from the main ON/OFF mini circuit breaker and applied
to a Master 20A Mini Circuit Breaker.
The output from the 20A Mini Circuit Breaker is applied a 5A fuse. Output from the
fuse is applied to 300mA Residual Current Device (RCD) for onwards distribution to
the two main outlet sockets. Space is provided on the Master Switch Assembly to fit
an additional 5A fuse; to be utilised as an auxiliary power supply. Controller mains
power Live is taken from the 20A Mini Circuit Breaker and applied to PL1 on the
Phase Drive PCB.
5A
Fuse
63A
Main
ON/OFF
Switch
Position
for
additional
5A Fuse
300 mA
RCD
20A Mini
Circuit
Breaker
Figure 10 – Master Switch Assembly
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4.5 FUSES
Figure 42 on page 111 lists the types and placing of fuses in the ST750. Fuses
should only be replaced by ones of a similar rating and type.
4.6 Mains Dimming Transformer
Mains Dimming Voltages are derived from the Mains Dimming Transformer,
mounted in the bottom left hand corner of the controller, and delivered to SK1 on the
Phase Driver PCB. Please refer to Figure 11.
Figure 11 – Mains Dimming Transformer
4.7 Manual Panel
The Manual Panel is situated on the right hand side of both large and small Outer
Cases. It is mounted within a secure enclosure, please refer to Figure 12. When the
full Manual Panel is not fitted a signals on/off switch is fitted instead.
Figure 12 – Manual Panel (full panel shown)
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4.8 Detector Mounting
The ST750 supports Single Detector Back Planes only - the Intelligent Detector
Backplane as fitted to ST750 ELV / ST900 / ST900 ELV controllers is NOT
supported. For full details on the connection of detectors and power requirements
please refer to ST4R/ST4S Detector Manual 667/HB/27663/000.
Single Detector
Backplane Kits
(rear view)
Figure 13 – Single Detector Backplanes
4.8.1 Detector Back plane in Small Outer Case
The ST750 small outer case can accommodate one of two different swing frame
configurations – Note that both swing frames CANNOT be fitted at the same
time.
If four or less Detector PCBs are required, sufficient room is available in a Detector
Swing Frame.
The lower portion of the Detector Swing Frame accommodates the Single Detector
Backplanes and Detector PCBs, while a Gemini2 unit can be mounted on the upper
portion of the Detector Swing Frame.
Figure 14 shows the Detector Swing Frame with, Detectors and Gemini2 Unit fitted.
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Gemini
Unit
Detectors
Figure 14 – Detector Swing Frame
Note
The Detector swing frame supported in the ST750 is a different part
(667/1/33770/000) to that supported in the ST700.
The detector mounting frame 667/1/27854, as used in the ST700 is
NOT supported in the ST750
If more than four Detector PCBs are required, an 11” Swing Frame will be required in
the cabinet. With the 11” swing frame fitted, the ST750 can support up to a
maximum of eight Detector PCBs and associated Backplanes. With reference to
Figure 15, the 11” Swing Frame must be provided with at least one 11” Detector
Rack Kit. In this case the Gemini unit (if required) is also mounted in the Detector
Rack Kit.
11”
Detector
Rack Kit
Figure 15 – Detectors in 11” Swing Frame
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4.8.2 Detector Back Planes in Large Outer Case
With reference to Figure 16, when a Large Outer Case is used a 19” Swing Frame is
required.
One or more 19” Detector Rack Kits should be specified and mounted to the 19”
Swing Frame, which in turn provides the platform to mount the Detector Back
Planes.
The maximum number of Detector PCBs, which can be specified, is eight. Figure 16
shows the mounting position for the 19” Detector Rack Kit. Power for the Detector
PCBs is provided by the Detector Supply Kit.
19”
Swing
Frame
19”
Detector
Rack Kit
Figure 16 – Detectors in a 19” Swing Frame
4.9 2A Detector Supply Kit
With reference to Figure 17, the ST750 is configured with one detector supply kit,
fitted on the right hand side of the ST750 Rack Assembly, as standard.
An additional Detector Supply kit can be specified and fitted immediately below the
first. The Detector PSU transformer will be configured with conventional main leads
to allow mains supply to be obtained from socket 1 on the Phase Driver PCB.
Figure 17 - 2A Detector Supply Kit
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4.10 Gemini2
4.10.1 Gemini2 in Small Outer Case
When a Gemini2 unit is required, it can be positioned in one of two locations,
depending on the quantity of Detector PCBs fitted. If four or less Detector PCBs are
required then the Gemini2 unit can be accommodated in a Detector Swing Frame,
refer to Figure 18.
Figure 18 - Gemini in a Detector Swing Frame
Warning!
Note
When fitting a Gemini2 in the ST750 Detector Mounting Bracket
Assembly care must be taken to ensure that the internal lead acid
battery terminals point UPWARDS to prevent leakage. This will
require the battery to be re-moved and re-fitted BEFORE installation
as when supplied from the factory the battery will be fitted in the
opposite orientation. Refer to 667/HB/32600/000 for full details.
The Detector swing frame supported in the ST750 is a different part
(667/1/33770/000) to that supported in the ST700.
The detector mounting frame 667/1/27854, as used in the ST700 is
NOT supported in the ST750
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If more than four Detector PCBs are required then an 11” Swing Frames will have to
be fitted to accommodate the Detector PCBs along with the Gemini2. Refer to Figure
19.
Figure 19 - Gemini in an 11" Swing Frame
Warning!
When fitting a Gemini2 unit in a swing frame care must be taken to
ensure that the internal lead acid battery terminals point UPWARDS to
prevent leakage. With a Gemini2 orientated as In Figure 19 it will be
necessary to invert the battery BEFORE installation. Refer to
667/HB/32600/000 for full details.
4.10.2 Gemini in Large Outer Case
The Large Outer Case requires the fitting of a 19” Swing Frame. With reference to
Figure 20, the Gemini unit and any detectors should be mounted in the 19” Rack
Assembly.
Gemini
Loop
Detectors
Figure 20 - Gemini in a Large Outer Case
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Warning!
When fitting a Gemini2 unit in a swing frame care must be taken to
ensure that the internal lead acid battery terminals point UPWARDS to
prevent leakage. With a Gemini2 orientated as In Figure 20 it will be
necessary to invert the battery BEFORE installation. Refer to
667/HB/32600/000 for full details.
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4.11 TC12 OTU
The Outstation Transmission Unit (OTU) based around the Tele 12 (TC12)
Command System, is available in two configurations –
•
•
Integral OTU
Freestanding OTU
4.11.1 Integral TC12 OTU in Small or Large Outer Cases
The Integral Tele 12 OTU PCB occupies the same position as the I/O Expansion
PCB in the Rack Assembly (refer to Figure 8). Therefore, both Integral OTU and I/O
Expansion units cannot be fitted in the same controller.
Power to the Integral
OTU is obtained via the processor data communication ribbon cable.
For full connections
667/HB/43100/000.
details
refer
to
the
Tele
12
General
Handbook
4.11.2 Free Standing TC12 OTU in Small Outer Case
The freestanding OTU must be specified in a 5U 11” rack unit.
With reference to Figure 21, the 5U Rack is mounted at the bottom of an 11” Swing
Frame.
Mains Power to the Freestanding OTU is obtained from the Master Switch Unit.
For full connections and configuration details for the Tele 12 OTU connection
scheme refer to the Tele 12 General Handbook 667/HB/43100/000.
667/HB/33750/000
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ST750 GENERAL HANDBOOK
Freestanding
OTU in 11”
Swing Frame
Figure 21 - Freestanding TC12 OTU in Small Outer Case
667/HB/33750/000
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ST750 GENERAL HANDBOOK
4.11.3 Freestanding TC12 OTU in a Large Outer Case
A freestanding OTU must be specified in a 5U 19” rack unit..
With reference to Figure 22, the 5U Rack is mounted at the bottom of the 19” Swing
Frame. Mains
Power to the Freestanding OTU is obtained from the Master Switch Unit.
For connections and configuration details for the TC12 OTU connection scheme
refer to the TC12 General Handbook 667/HB/43100/000.
Freestanding
O T U in 19”
Swing Frame
Figure 22 - Free Standing TC12 OTU in Large Outer Case
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4.12 SDE/SA
The ST750 does not support the SDE/SA PCB. Instead, the functionality associated
with Speed Discrimination and Speed Assessment is contained within the standard
ST750 controller firmware. Please refer to the doc 667/HH/32900/00 for the
appropriate handset commands.
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5. INSTALLATION AND COMMISSIONING
This section details the procedure for installing and commissioning of the
ST750 pedestrian controller in both the small and large controller cabinet
arrangements.
Refer to section 6 for instructions on installing and commissioning of the ST750 Rack
Assembly into other traffic controller cabinets.
5.1 Pre-installation checks
The following checks should be carried out at the service centre and again on site,
with the exception of the pre-installation self-test which can only be carried out at the
service centre.
The controller cabinet should be visually inspected to check for any damage that
may have occurred in transit. Check the security of all internal wiring, PCBs/boards,
racks and fixings.
5.1.1 Hardware check
Check against the Works Specification that:
-
the correct boards and kits (including the Firmware PROMs and PLD) have been
supplied and fitted correctly.
-
the appropriate links have been made on all the PCBs/boards.
-
all fuses are fitted and are of the correct ratings.
-
the correct interconnection cabling has been installed within the controller
cabinet, e.g. Detectors to Rack Assembly, OTU to Rack Assembly, etc.
-
The dimming transformer taps are set for the required dimming voltage as
described in section 5.1.2.
5.1.2 Dimming Transformer Tap Setting
Connect the brown wire, as shown in Figure 23, to the connector block position as
per this table:
Required Dimming voltage
160V
140V
120V
667/HB/33750/000
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Input Tap
IP2
IP3
IP4
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ST750 GENERAL HANDBOOK
Dimming
tap
positions
Figure 23 - Dimming Transformer Tap Selection
Once the hardware has been checked as above, it is recommended that a self-test is
run (see section 5.16) before leaving the service centre.
5.2 ST750 Cabinet preparation
The controller cabinets are normally delivered from the manufacturing department in
a fully assembled and tested state. However to aid installation, the internal
equipment has been designed to be readily removable. All of the electronics should
be removed from the cabinet if:
-
the controller cabinet cannot be made waterproof
the controller cabinet is un-powered and will suffer from condensation, moisture
ingress and animal/insect infestation.
there is a risk of the equipment being damaged by the contractor.
the controller cabinet will be left un-powered for a prolonged period.
5.3 Site suitability
The ST750 controller cabinet is installed to suit local conditions, but subject to the
following limitations:
(i)
The position of the controller cabinet is as shown on the relevant site plan,
STS.
(ii)
No part of the Cabinet is less than 457mm (18 inches) from the kerbside
unless agreed with the customer.
When it is necessary to site the controller cabinet less than 2 metres from the
outer edge of the kerb, the access panels should not open toward the
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carriageway. Where no pedestrian guard rails are fitted, a clearance of at
least 600mm should be left between the cabinet and the kerb edge so that
guard rails may be installed at a later date without the need to disturb the
cabinet installation.
(iii)
Any person having control over the junction, whether manual control or test
box simulation, MUST have a good view of the intersection.
(iv)
When the ST750 controller cabinet is to be located on unmade ground (e.g. a
grass verge) it is recommended that paving slabs or a concrete standing be
provided at ground level on the manual panel (left) side and the front side.
The hard standing shall extend a minimum distance of 900mm away from the
door, extending the full width of the controller cabinet, and at least 800mm
away from the side of the cabinet with a flap, again extending the full width of
that side. Customers may specify particular requirements.
5.4 Installation of the ST750 Small Cabinet
The following list details the order in which it is recommended that an ST750
installation take place in the ST750 small case, generally known as the ST400S
case.
Warning!
It should be noted that the ST750S case is not designed to have the
controller stool removed. If the two parts are separated the stool will
flex and once concreted in the ground it may NOT be possible to refit
the controller cabinet to the stool or it may result in the case becoming
distorted.
The following list details the order in which it is recommended that an ST750
installation take place.
-
the controller cabinet cannot be made waterproof
Remove the Rack assembly if necessary – section 5.2
Install the stool and controller cabinet into the ground – section 5.4.1
Pull the cables into position – section 5.6
Terminate the armour to the CET connectors – section 5.6
Fit the CET glands to the CET bars – section 5.6
Test the cables – section 5.7
In-fill with kiln dried sand the controller stool/cabinet base and seal the cabinet
base – section 5.9 and 5.10
Refit the Rack Assembly if applicable – section 5.2
Terminate the cables – Section 5.6
Occasionally it may be necessary to terminate the cable prior to sealing the base. In
the case of the ST750 this will result in the necessity of installing the Rack Assembly
into the controller cabinet. It is usually better to seal the base and make provision for
the installation of additional cables such as Telecom or fibre cable by installing a
suitable size flexible duct. This duct itself may then be sealed with expanding foam
sealant.
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5.4.1 Install Controller Cabinet and Stool
A hole should be excavated and a flagstone at least 600mm x 450mm embedded
securely at the bottom of the hole. Refer to Figure 24 for the general method of
installation and dimensions. Care should be taken to ensure the correct orientation of
the controller cabinet. Care must be taken that the controller and stool are not buried
to deep as the controller isolation transformer in this cabinet is very low. Burying the
controller too deep will result in a seal below ground level or excessively close to the
MDU and the isolation transformer.
If the ST750 controller cabinet is being installed on a slope, allowance must be made
for ground level clearance of the door to the uphill side.
The stool is placed in the centre of the flagstone with the bottom edge of the
controller cabinet base between 10 and 20 mm below the final ground level as
shown in Figure 30. Adjustment may be required to ensure that the top of the stool is
horizontal; this should be checked using a spirit level.
Mix up a stiff mixture of concrete (mix: 1 cement, 3 sand, 4 coarse aggregate
(20mm) with no excess water) and cover the flagstone to a height approximately
100mm (4”) above the bottom of the stool. The concrete must be sloped to provide a
run up for the cables. Any cables that already enter the pit must be held away from
the wet concrete. Where there is a risk of freezing, a suitable antifreeze additive
should be incorporated in the concrete mix to ensure proper curing.
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Figure 24 - Stool Installation, Small Cabinet
5.5 Installation of the ST750 Large Cabinet
The following list details the order in which it is recommended that the ST750
installation take place.
-
the controller cabinet cannot be made waterproof
Remove the Rack assembly if necessary – section 5.2
Install the stool and controller cabinet into the ground – section 5.4.1
Pull the cables into position – section 5.6
Terminate the armour to the CET connectors – section 5.6
Fit the CET glands to the CET bars – section 5.6
Test the cables – section 5.7
In-fill with kiln dried sand the controller stool/cabinet base and seal the cabinet
base – section 5.9 and 5.10
Refit the Rack Assembly if applicable – section 5.2
Terminate the cables – Section 5.6
Occasionally it may be necessary to terminate the cable prior to sealing the base. In
the case of the ST750 this will result in the necessity of installing the Rack Assembly
into the controller cabinet. It is usually better to seal the base and make provision for
the installation of additional cables such as Telecom or fibre cable by installing a
suitable size flexible duct. This duct itself may then be sealed with expanding foam
sealant.
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5.5.1 Remove the controller cabinet from the stool
Remove the stool by removing its four fixing nuts and bolts and lift the controller
cabinet off the stool.
5.5.2 Install the stool
A hole should be excavated and a flagstone at least 900mm x 600mm embedded
securely at the bottom of the hole. Refer to Figure 25 for the general method of
installation and dimensions.
If the ST750 controller cabinet is being installed on a slope, allowance must be made
for ground level clearance of the door to the uphill side.
The stool is placed in the centre of the flagstone with the top surface between 50 and
75 mm above the final ground level. It is essential that the stool be fitted the
correct way round with the single centre edge holes to the front and the CET
fixing holes on the right, as shown in Figure 25. Adjustment may be required to
ensure that the top of the stool is horizontal; this should be checked using a spirit
level.
Mix up a stiff mixture of concrete (mix: 1 cement, 3 sand, 4 coarse aggregate
(20mm) with no excess water) and cover the flagstone to a height approximately
100mm (4”) above the bottom of the stool. The concrete must be sloped to provide a
run up for the cables. Any cables that already enter the pit must be held away from
the wet concrete. Where there is a risk of freezing, a suitable antifreeze additive
should be incorporated in the concrete mix to ensure proper curing.
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ST750 GENERAL HANDBOOK
Figure 25 - Stool Installation, Large Cabinet
5.6 Cabling to the ST750 small and large cabinets
All cables into the ST750 controller cabinets should be fed through the ducts and into
the stool/base as close to the controller termination positions as possible. This is to
prevent unnecessary damage being caused should any cables need to be moved
once they are in place. Care must be taken not to obstruct the Electricity Supply
Company cut-out with any cabling.
The outer sheathing must be stripped to expose the armouring. It is suggested that
between 55mm and 65mm of the inner sheathing is left above the Hose Clip and
stripped armour (see Figure 1), which is more than normally required for other
Cabinet Assemblies. This is due to the height of the CET bar and its staggered fixing
nature. The additional height ensures that double insulation is provided where the
cable rests against the metal items. Sufficient further conductor length must also be
allowed to reach the terminal blocks via the proper routing.
The cable is inserted in the CET ring and the armoured wires are bent outwards and
down against the ring. A hose clip is then placed over the armoured wires and
tightened up. The armouring must be stripped, leaving a small amount (approx. 0 to
2mm) below the level of the CET ring.
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The inner sheathing is removed to expose the individual cores that are connected to
associated terminals, leaving sufficient spare length for re-making off the ends
should this become necessary. Unused cores should be left with sufficient length to
enable them to be connected to any terminal should this subsequently become
necessary.
The ST750S, controller cabinet (Small outer-case) has 2 CET bars and the CET bars
are mounted directly to the controller cabinet. Each bar has 8 holes for fixing cables;
4 upper and 4 lower fixing positions. This allows the CET rings and hose clips to
overlap each other. The cables must be identified as to their destinations and
additional Idents may be required on specific contracts.
The ST750L controller cabinet (Large outer-case) has 2 CET bars as standard, but
can be expanded to accommodate additional cables, and the CET bars are mounted
directly to the controller cabinet stool. Each bar has 6 holes on each side for fixing
cables. These holes are staggered to allow the CET rings and hose clips to overlap
each other. The cables must be identified as to their destinations and additional
Idents may be required on specific contracts.
667/HB/33750/000
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ST750 GENERAL HANDBOOK
SIDE VIEW
Mounted at CET Lower Fixing Position
Cores
Inner Insulation
Ident
55mm
to
65mm
Higher CET
Fixing Position
(Armouring not shown at
front of ring for clarity)
Lower CET
Fixing Position
Stud
Hose Clip
Nut
Ident
(Alternative position)
CET Bar
Incoming Cable
CET Ring
(Earthing Band)
PLAN VIEW
Wormdrive Hose Clip
991/4/01375/028
Earthing Band
667/2/02348/000
Figure 26 - Termination of Armoured CAble to CET bar
5.7 On Site Cable Testing
When all the cables have been terminated onto the CET bar they should be checked
and tested as defined in the General Installation and Commissioning Handbook
667/HE/20664/000
667/HB/33750/000
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5.8 Fit the cabinet to the Stool
If the controller cabinet was not installed with the mounting stool then it should be
done as follows:
Clean the top surface of the stool and the lower surface of the cabinet that will be in
contact when the cabinet is fitted.
The cabinet is installed by lowering it onto the stool and fitting the four retaining
bolts.
When fitting the cabinet onto the stool, make sure that all the cables are in their
correct position with regard to the CET bar. Once the cabinet has been secured,
moving of the cables could cause damage.
5.9 Back fill and in-fill the stool
On completion of the cable tests the controller cabinet and stool can be back-filled by
the civils team using the appropriate material for the site layout. Once the back-fill is
completed in-fill with kiln dried sand as per Figure 24and Figure 25, taking care that
the compacted sand is at ground level when finished.
If any of the cables were replaced or moved during the installation of the controller
cabinet then the kiln dried sand in-filling must be made good before the sealing
compound is introduced.
NOTE: The back-fill must be brought to a level such that once the decorative top
surface is completed that the finish is at the surrounding ground level. The site
should be finished to the requirements listed in section 5.3 particularly paying
attention to any hardstanding around the controller base.
5.10 Sealing the base of the controller outer case
To prevent condensation and infestation in the controller cabinet the base MUST be
sealed as soon as possible after the controller has been installed. If any of the
cables were replaced or moved during the installation of the controller the kiln dried
sand in-filling must be made good before the sealing compound is introduced.
NOTE: The in-filling, kiln dried sand, must be brought to ground level or above and
compacted. Make sure that the kiln dried sand is level or slightly sloped down where
it meets the cables so it will not prevent the sealant meeting the cable.
The sealant should be poured all around the cables and to a height which, when the
sealant is set, gives a total covering not less than 6.5mm thick over the base of the
controller cabinet base. Use between 2.0 to 3.0 litres of approved epoxy resin for the
large controller cabinet base and 2.0 Litres for the small controller cabinet base this
will give an adequate and even cover.
This will act as a preventative barrier against the ingress of moisture and
animal/insect infestation.
667/HB/33750/000
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A concrete fillet around the outside of the stool may be completed before or after the
epoxy sealing to suit site conditions.
Refer to Figure 24 and Figure 25 for general method of in-fill, kiln dried sand, sealing
and concrete fillet.
Warning!
Should the controller cabinet base/stool NOT be in-filled with kiln
dried sand and sealed with an approved epoxy resin the
controller electronics/electrical circuits may be damaged.
5.11 CABLE ROUTING & TERMINATION
The following guidelines apply when the ST750 Rack Assembly is installed in the
ST750 Cabinet Assembly or any other controller cabinet.
All intersection cables and their wires must secured within the cabinet using ty-wraps
once terminated.
Note: No wire runs or looms should be positioned directly above the ST750 Rack
Assembly, as this would prevent its removal for maintenance or replacement. In the
back of the metal frame across the top of the ST750 Rack Assembly, securing holes
are provided to secure the detector wire looms. These holes ensure that there is
sufficient room to allow the removal of the ST750 Rack Assembly.
Wiring runs should be made neatly and routed to allow enough spare cables for
possible changes/additions at a later date.
Spare cores are to be bundled and routed to a convenient position clear of mains.
The ends are to be insulated to make the loom secured. Spare cores of ELV cables
are to be loomed separately from the cores of LV cables.
If cable idents are required then these are fitted to cores before termination.
Signal and Detector terminations to the ST750 Rack Assembly should be as per
the Works Specification, leaving sufficient spare wire to enable joints to be remade
when necessary. The ‘Pair’ cable used for connection from the loops should be
terminated using the appropriate kit.
OMU must monitor the Controller Lamp Supply at the screw terminal on SK2 Pin
6.
Note: The following connectors’ identification, signal allocation, coding information
(when required) and Softwire colours (when used) are given as guidance to assist
the installation engineer, when wiring to the Works Specification. No Softwire Kit is
required to wire an ST750 Rack Assembly into an ST750 Cabinet as the Intersection
Cables can be wired directly to the ST750 terminals. Softwire Kits are available to
install an ST750 in other Cabinets. If the Softwire kit is used in the ST750 cabinet
assembly, then their associated terminal blocks are mounted on the right hand side
667/HB/33750/000
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ST750 GENERAL HANDBOOK
and back of the cabinet’s inner metal frame. The position of these terminal blocks
means that a short screwdriver (No1 Pozidriv) is required to terminate the wires due
to the proximity of the dimming transformer (if fitted). If there are many cables,
access to the terminal blocks becomes restricted.
5.11.1 Phase Drive PCB Terminal blocks
For installation in an ST750 Cabinet, wire the intersection cables directly to the
specified connector in the following tables (using the respective mating half
contained in the attached plastic bag) on the Phase Drive PCB.
The connectors must be wired as follows:
•
•
•
•
Ensure 10mm of wire insulation is stripped back
Make sure that the connector is fully undone (open) before inserting the stripped
wire end
Insert the stripped wire end fully to the back stop
Firmly tighten the connector’s terminal screw ensuring that the wire’s conductor is
firmly positioned correctly in the connector
Warning: The above method must be used. Failure to do so could result in
the wires coming loose or falling out over a short period of time.
For installation in another cabinet, a Softwire Kit is required. Wire the loose ends of
the Softwire kit Cableform to the cabinet terminal blocks. Use the relevant signals as
defined by the works specification and shown in the tables that follow. Figure 27 also
provides further information on PL6, PL7 and PL8.
Table 6 – Phase Drive PL6 Connector
PL6
Pin No
Signal Phase Drive O/P
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Red Phase A (Unmonitored)
Monitored Red Phase A Approach 1
Monitored Red Phase A Approach 1
Monitored Amber Phase A Approach 1
Monitored Green Phase A Approach 1
Monitored Red Phase A Approach 2
Monitored Red Phase A Approach 2
Monitored Amber Phase A Approach 2
Monitored Green Phase A Approach 2
Not used (for isolation purposes)
Red Phase B
Not used (for isolation purposes)
Amber Phase B
Amber Phase B
667/HB/33750/000
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Softwire kit
Cableform
667/1/27877/000
Colour
Ident
Red
RAU
Red
Yellow
Green
RA1
YA1
GA1
Red
Yellow
Green
RA2
YA2
GA2
Red
RB
Yellow
YB
Issue 5
ST750 GENERAL HANDBOOK
Softwire kit
Cableform
667/1/27877/000
15
16
Not used (for isolation purposes)
Green Phase B
Green
GB
Coding Details: The plug mount connector on the Phase Drive board PL6 has
coding pins 2 and 15 fitted, with the cable fitted socket connector
that mates with PL6 having coding pins 1 and 16 fitted. This
coding prevent the incorrect connection between PL6 and PL7.
For more details see the following diagram:
Mating Half PL6
1
16
2
PCB
15
PL6
Table 7 – Phase Drive PL7 Connector
PL7
Pin No
Signal Phase Drive O/P
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Red Phase C (Unmonitored)
Monitored Red Phase C Approach 1
Monitored Red Phase C Approach 1
Monitored Amber Phase C Approach 1
Monitored Green Phase C Approach 1
Monitored Red Phase C Approach 2
Monitored Red Phase C Approach 2
Monitored Amber Phase C Approach 2
Monitored Green Phase C Approach 2
Not used (for isolation purposes)
Red Phase D
Not used (for isolation purposes)
Amber Phase D
Amber Phase D
Not used (for isolation purposes)
Green Phase D
667/HB/33750/000
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Softwire kit
Cableform
667/1/27877/000
Colour
Ident
Red
RAU
Red
Yellow
Green
RA1
YA1
GA1
Red
Yellow
Green
RA2
YA2
GA2
Red
RB
Yellow
YB
Green
GB
Issue 5
ST750 GENERAL HANDBOOK
Coding Details: The plug mount connector on the Phase Drive board PL7 has
coding pins 1 and 16 fitted, with the cable fitted socket connector
that mates with PL7 having coding pins 2 and 15 fitted. This
coding prevent the incorrect connection between PL7 and PL6.
For more details see the following diagram:
Mating Half PL7
2
15
1
PCB
16
PL7
Table 8 – Phase Drive PL8 Connector for ST750 Phase Driver PCB (6 Phase)
PL8
Pin No
1
2
3
4
5
6
Signal Phase Drive O/P
Red Phase 5 (Unmonitored)
Amber Phase 5 (Unmonitored)
Green Phase 5 (Unmonitored)
Red Phase 6 (Unmonitored)
Amber Phase 6 (Unmonitored)
Green Phase 6 (Unmonitored)
Softwire kit
Cableform
667/1/27877/050
Colour
Ident
Red
RED5
Yellow
YLW5
Grey
GRN5
Red
RED6
Yellow
YLW6
Grey
GRN6
Coding Details: This connector has no coding element, as it is the only 6-way
connector.
Table 9 – Phase Drive PL8 Connector for ST750LED Phase Driver PCB
PL8
Pin No
Signal Phase Drive O/P
1
2
Monitored Red Phase A RLM Channel 3
Monitored Red Phase A RLM Channel 4
Softwire kit
Cableform
667/1/32756/000
Colour
Ident
Red
RA3
Red
RA4
Coding Details: This connector has no coding element, as it is the only 2-way
connector.
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ST750 GENERAL HANDBOOK
PL6
Vehicle
Supply
240v
Phase A
R
A
G
Triacs
and
Monitors
RAU
RA1
Vehicle RLM
YA1 Channel 1
GA1
5
33
RLM
LMU+RLM
37
RA2
Vehicle RLM
YA2 Channel 2
GA2
6
Vehicle RLM
Channel 3
Vehicle RLM
Channel 4
RLM
LMU+RLM
Pedestrian
Supply
240/48V
Wait
Supply
240/48V
Current sensor number,
in this case sensor 6.
Phase B
RB
GB
YB
R
G
W
Red Man
Green Man
34
LMU ONLY
Triacs
and
Monitors
38
Wait
LMU ONLY
PL7
Phase C
Vehicle
Supply
240v
Ped
Supply
240/48V
Wait
Supply
240/48V
Vehicle
Supply
240v
Vehicle
Supply
240v
R
A
G
Triacs
and
Monitors
Phase D
RAU
RA1
Vehicle RLM
YA1
Channel 1
GA1
7
39
RA2
Vehicle RLM
YA2
Channel 2
GA2
8
R
A
G
Vehicle RLM
Channel 3
RLM
LMU+RLM
Vehicle RLM
Channel 4
RLM
LMU+RLM
RB
GB
YB
R
G
W
Triacs
and
Monitors
Phase E
35
Red Man
Green Man
36
LMU ONLY
40
PL8
Wait
LMU ONLY
RED5
YLW5
GRN5
Phase F
RED6
YLW6
GRN6
R
A
G
Figure 27 - Allocation of Red Lamp Monitor Channels for ST750 Controllers
without LV CLS (NLM) monitoring
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PL6
Phase A
Vehicle
Supply
230V
R
A
G
Triacs
and
Monitors
RAU
RA1
5
YA1
Vehicle RLM
Channel 1
GA1
LMU + RLM
RA2
6
YA2
Vehicle RLM
Channel 2
GA2
Pedestrian
Supply
230/48V
Wait
Supply
48V
Phase B
R
G
W
LMU + RLM
RB (Red Man)
34
GB (Green Man)
LMU only
38
YB
Triacs
and
Monitors
Wait
LMU only
PL7
Phase C
Vehicle
Supply
230V
R
A
G
Triacs
and
Monitors
RAU
No external RLM on Phase C
RA1
7
YA1
Vehicle RLM
Channel 1
GA1
LMU + RLM
RA2
8
YA2
Vehicle RLM
Channel 2
GA2
Pedestrian
Supply
230/48V
Wait
Supply
48V
Phase D
R
G
W
LMU + RLM
RB (Red Man)
36
GB (Green Man)
LMU only
YB
Triacs
and
Monitors
40
Wait
LMU only
PL8
33
RA3
Vehicle RLM Channel 3
RA4
Vehicle RLM Channel 4
RLM
37
RLM
Figure 28 - Allocation of Red Lamp Monitor Channels for ST750LED
Controllers with LV CLS (NLM) monitoring
667/HB/33750/000
Page 74
Issue 5
ST750 GENERAL HANDBOOK
Table 9 – Phase Drive SK1 Connector
SK1
Pin No
Signal Phase Drive Returns,
Solar Cell, Detector and AUX
mains supplies
1
2
3
4
5
6
7
8
9
10
11
12
13
Signal Lamp Supply Return
Signal Lamp Supply Return
Signal Lamp Supply Return
Signal Lamp Supply Return
Signal Lamp Supply Return
Signal Lamp Supply Return
Signal Lamp Supply Return
Aux Mains Supply
Aux Mains Supply 2 ( not used)
230V Detector Supply
Solar Cell Live
Solar Cell Input
Not used (for isolation purposes)
14
15
16
17
Softwire kit
Cableform 667/1/27872/000
Colour
Ident
TB1
Blue
None
4
See note 1
See note 1
See note 1
See note 1
See note 1
Blue
None
12
Pink
Pink
Pink
DET
SOLAR LIVE
SOLAR CELL
2
3
1
Softwire kit
Cableform 667/1/27864/000
Colour
Ident
TB1
Orange
None
6
See note 2
See note 2
Orange
None
12
48V Lamp Supply Return
48V Lamp Supply Return
48V Lamp Supply Return
48V Lamp Supply Return
Note 1 These neutrals are not used as TB1 block part of cable form is linked
between terminals 4 to 12, but these outputs can be used when wired direct
in an ST750 cabinet installation.
Note 2 These 48V returns are not used as TB1 block part of cable form is linked
between terminals 6 to 12, but these outputs can be used when wired direct
in an ST750 cabinet installation.
Coding Details: Connector SK1 has no coding elements as it is the only 17-way
connector and can only be inserted one way.
Table 10 – Phase Drive PL1 Connector
PL1
Pin No
Controller Mains I/P
1
2
3
Live 230V Mains Supply
Neutral 230V Mains Supply
Earth Connection
667/HB/33750/000
Page 75
Softwire kit Cableform
667/1/27874/000 or /001
Colour
Pink
Blue
Green/Yellow
Issue 5
ST750 GENERAL HANDBOOK
Coding Details: Connector PL1 has no coding elements, as it is the only 3-way
connector and can only be inserted one way.
Table 11 – Phase Drive SK2 Connector No Dimming
If the installation has no Dimming Transformer, then insert the Cableform
667/1/27868/002. This cable is provided as standard with rack assemblies. Cabinet
assemblies have a dimming transformer fitted as standard, which includes the cable
667/1/27868/000. See Table 12 below for details.
SK2
Pin No
1
2
3
4
5
6
7
8
9
10
Softwire kit
Cableform 667/1/27868/002
Connection
Short to pin 6
Short to pin 5
Short to pin 4
Short to pin 3
-
Table 12 – Phase Drive SK2 48V Dimming Connections
Normally the ST750 in its own cabinet is fitted with the cable 667/1/27868/000
described below (see also Figure 28):
SK2
Pin No
1
2
3
4
5
6
7
8
9
10
48V Dimming Transformer’s I/P
Dim I/P 1
Dim I/P 2, 3 or 4
Dim Relay Common
Dim Relay n/c
B Relay O/P
Lamp Supply
Neutral
Not used
48V Supply
48V Return
667/HB/33750/000
Softwire kit
Cableform 667/1/27868/000
Colour
Dim Transformer
Connection
Red
I/P1
Brown
I/P 2 etc
Short to pin 5
Short to pin 6
Short to pin 3
Short to pin 4
Black
Neutral
Yellow
Orange
Page 76
48V
0V
Issue 5
ST750 GENERAL HANDBOOK
Figure 29 - Dimming Transformer Tap Selection
Dimming
tap
positions
Required Dimming voltage
160V
140V
120V
Input Tap
IP2
IP3
IP4
If the ST750 is installed in another cabinet, the 667/1/27868/001 cable should be
used with connections as shown above. This cable is provided with the cabinet
modification kit.
Note 1:
Note 2:
The links between pins 3 to 6 need to be rearranged.
The Screen (SCR) and 48V Return connections on the Dimming
Transformer need to be linked together and connected to the Earth
Star point in the controller cabinet with a length of yellow/green wire.
Coding Details: Connector SK2 has no coding elements, as it is the only 10-way
connector and can only be inserted one way.
Table 13 – Phase Drive PL5 Connector
PL5
Pin No
1
2
3
4
5
6
7
8
External Lamp Monitoring Sensors
External Sensor 33 – Red
External Sensor 33 – White
External Sensor 34 – Red
External Sensor 34 – White
External Sensor 35 – Red
External Sensor 35 – White
External Sensor 36 – Red
External Sensor 36 – White
667/HB/33750/000
Page 77
Issue 5
ST750 GENERAL HANDBOOK
9
10
11
12
13
14
15
16
External Sensor 37 – Red
External Sensor 37 – White
External Sensor 38 – Red
External Sensor 38 – White
External Sensor 39 – Red
External Sensor 39 – White
External Sensor 40 – Red
External Sensor 40 – White
Note that the ST750LED Phase Driver PCB with LV CLS (NLM) monitoring only has
connections on PL5 for External Sensors 38 and 40 (Phase B and Phase D Waits).
Coding & Wiring Details: Connector PL5 is a 20-way Berg connector that has a
side flange coding element, which mates with the
associated slot of the IDC board mounted 16-way
connector. The pin positions 1, 2, 19 & 20 on the Berg
connector are not used for wiring purposes but are used
to provide a stop for the IDC board mounted connector
locking levers. See the following diagram:
Connector PL5 and its Mating Half (Berg
Connector) Viewed from the Top
Pin 1
Coding
Slot
PCB Mounted
IDC Connector
Free Standing
Berg Connector
Four Shaded
Pin Positions
are not used
Coding
Flange
Figure 30 - Connector PL5
Instead of driving all the signals at the 230V nominal supply, the ST750 is capable of
driving the Wait indicators or all the pedestrian phase signals directly with an ELV
48V lamp supply.
Switching the supply from 230V to 48V requires fuses and links on the lamp switch
card to be re-arranged as detailed in Section 5.13. The required arrangement also
needs to be configured (using the ELV handset command) and affects what sensors
34 and 38 (or 36 and 40 on the second stream) can monitor. See the following table:
667/HB/33750/000
Page 78
Issue 5
ST750 GENERAL HANDBOOK
ELV:0 – All signals at
230v
34/36 – Monitor
Red+Green
38/40 – Not Required
Wait
(all cables thro’ toroid
twice)
Note
ELV:1 – Waits at 48v
34/36 – Monitor
Red+Green
(Red & Green thro’ toroid
twice)
(Wait cables thro’ toroid
once)
38/40 –Monitor Wait
(Wait cables thro’ toroid
once)
ELV:2 – All ped signals at
48V
34/36 – Monitor Red+Green
(all cables thro’ toroid once)
38/40 –Monitor Wait
(all cables thro’ toroid once)
At the time of writing, the controller is unable to monitor the current
waveform generated by the low power near-sided signals currently on
the market.
Wiring of external toroids
All drive cables supplying signals at 230V should be wound around the toroid so the
cable passes through the centre twice. (N.B. This includes vehicle aspects as well as
pedestrian aspects.)
All drive cables supplying signals at 48V should only pass through the centre of the
toroid once.
5.11.2 ST750 CPU PCB Terminal Blocks
When installing in an ST750 cabinet, wire the intersection cables directly to the
specified connector in the following tables (using the respective mating half
contained in the attached plastic bag) on the ST750 CPU PCB.
The connectors must be wired as follows:
• Ensure 9mm of wire insulation is stripped back
• Make sure that the connector is fully undone (open) before inserting the stripped
wire end
• Insert the stripped wire end fully to the back stop
• Firmly tighten the connector’s terminal screw ensuring that the wire’s conductor is
firmly positioned correctly in the connector
Warning: The above method must be used. Failure to do so could result in
the wires coming loose or falling out over a short period of time.
Also, the connectors PL2, PL3, PL6 and PL7 require a small-ended
(2.5mm) screwdriver. Use a Phoenix Screwdriver Part Number SZS
0.4 x 2,5 or equivalent (see note at the top of each table).
667/HB/33750/000
Page 79
Issue 5
ST750 GENERAL HANDBOOK
When installing in any other cabinet, a Softwire kit is required. Wire the loose wire
ends of the Softwire kit cableform to the terminal blocks in the cabinet, using the
relevant signals as defined by the works specification and shown in the tables that
follow:
Table 14 – Processor Card PL3 Connector
Note: These terminals must be tightened correctly, using Phoenix Screwdriver Part
Number SZS 0.4 x 2,5 or equivalent.
PL3
PCB
Connector
Pin No
1
2
3
4
5
6
7
8
9
10
11
12
13
Controller Isolated O/P,
Tactile and Audible
Circuits
O/P 88 Common
O/P 88 Closed Contact
O/P 89 Common
O/P 89 Closed Contact
O/P 90 Common
O/P 90 Closed Contact
O/P 90 Open Contact
O/P 91 Common
O/P 91 Closed Contact
O/P 91 Open Contact
Tactile Phase B
Audible Phase B Loud
Audible Phase B Quiet
Softwire Kit Cableform
667/1/27863/100
Colour
Terminal Block
Pin No
Brown
TBX1
Red
TBX2
Orange
TBX3
Yellow
TBX4
Green
TBX5
Blue
TBX6
Not used
Slate
TBX7
White
TBX8
Not used
Red/Orange
TBX10
Red/Green
TBX11
Red/Brown
TBX12
Coding Details: The plug mount connector on the CPU PCB PL3 has coding pins 2,
8 and 13 fitted, with the cable fitted socket connector that mates with
PL3 having coding ridges 2, 8 and 13 removed. This coding prevent
the incorrect connection between PL3 and PL2. For more details see
the following diagram:
667/HB/33750/000
Page 80
Issue 5
ST750 GENERAL HANDBOOK
Coding for PL3
Mating Half PL3
2
Coding Ridge
Removes in 3
positions
8
Coding Pin
Inserted in
3 Positions
13
PL3 on PCB
Figure 31 - Connector PL3
Table 15 – Processor Card PL7 Connector
Note: These terminals must be tightened correctly using Phoenix Screwdriver Part
Number SZS 0.4 x 2,5 or equivalent.
PL7
PCB
Connector
Pin No
Controller
I/P
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Input 0
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
Input 8
Input 9
Input 10
Input 11
Input 12
Input 13
Input 14
Input 15
Softwire Kit Cableform
667/1/27863/100
Colour
Terminal Block
Pin No
Brown
TBG1
Red
TBG2
Orange
TBG3
Yellow
TBG4
Green
TBG5
Blue
TBG6
Violet
TBG7
Slate
TBG8
White
TBH1
Black
TBH2
Red/Orange
TBH3
Red/Green
TBH4
Red/Brown
TBH5
Green/Orange
TBH6
Green/Brown
TBH7
Green/Slate
TBH8
Coding Details: The plug mount connector on the CPU PCB PL7 has coding pins 2,
8 and 16 fitted, with the cable fitted socket connector that mates
with PL7 having coding ridges 2, 8 and 16 removed. This coding
667/HB/33750/000
Page 81
Issue 5
ST750 GENERAL HANDBOOK
prevents the incorrect connection between PL7 and PL6. For more
details see the following diagram:
Coding for PL7
Mating Half PL7
2
Coding Ridge
Removes in 3
positions
8
Coding Pin
Inserted in
3 Positions
16
PL7 on PCB
Figure 32 - Connector PL7
Table 16 – Processor Card PL2 Connector
Note: These terminals must be tightened correctly using Phoenix Screwdriver Part
Number SZS 0.4 x 2,5 or equivalent.
PL2
PCB
Connector
Pin No
1
2
3
4
5
6
7
8
9
10
11
12
13
Controller Isolated O/P,
Tactile and Audible
Circuits
O/P 92 Common
O/P 92 Closed Contact
O/P 93 Common
O/P 93 Closed Contact
O/P 94 Common
O/P 94 Closed Contact
O/P 94 Open Contact
O/P 95 Common
O/P 95 Closed Contact
O/P 95 Open Contact
Tactile Phase D
Audible Phase D Loud
Audible Phase D Quiet
Softwire Kit Cableform
667/1/27863/100
Colour
Terminal Block
Pin No
Brown
TBY1
Red
TBY2
Orange
TBY3
Yellow
TBY4
Green
TBY5
Blue
TBY6
Not used
Slate
TBY7
White
TBY8
Not used
Red/Orange
TBY10
Red/Green
TBY11
Red/Brown
TBY12
Coding Details: The plug mount connector on the CPU PCB PL2 has coding pins 1,
6 and 12 fitted with the cable fitted socket connector that mates
with PL2 having coding ridges 1, 6 and 12 removed. This coding
prevent the incorrect connection between PL2 and PL3. For more
details see the following diagram:
667/HB/33750/000
Page 82
Issue 5
ST750 GENERAL HANDBOOK
Coding for PL2
Mating Half PL2
1
Coding Ridge
Removes in 3
positions
6
Coding Pin
Inserted in
3 Positions
12
PL2 on PCB
Figure 33 - Connector PL2
Table 17 – Processor Card PL6 Connector
Note: These terminals must be tightened correctly using Phoenix Screwdriver Part
Number SZS 0.4 x 2,5 or equivalent.
PL6
PCB
Connector
Pin No
Controller
I/P
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Input 16
Input 17
Input 18
Input 19
Input 20
Input 21
Input 22
Input 23
Input 24
Input 25
Input 26
Input 27
Input 28
Input 29
Input 30
Input 31
Softwire Kit Cableform
667/1/27863/100
Colour
Terminal Block
Pin No
Brown
TBJ1
Red
TBJ2
Orange
TBJ3
Yellow
TBJ4
Green
TBJ5
Blue
TBJ6
Violet
TBJ7
Slate
TBJ8
White
TBL1
Black
TBL2
Red/Orange
TBL3
Red/Green
TBL4
Red/Brown
TBL5
Green/Orange
TBL6
Green/Brown
TBL7
Green/Slate
TBL8
Coding Details: The plug mount connector on the CPU PCB PL6 has coding pins 1,
7 and 15 fitted, with the cable fitted socket connector that mates
with PL6 having coding ridges 1, 7 and 15 removed. This coding
667/HB/33750/000
Page 83
Issue 5
ST750 GENERAL HANDBOOK
prevent the incorrect connection between PL6 and PL7. For more
details see the following diagram:
Coding for PL6
Mating Half PL6
1
Coding Ridge
Removes in 3
positions
7
Coding Pin
Inserted in
3 Positions
15
PL6 on PCB
Figure 34 - Connector PL6
5.12 REGULATORY SIGNS MONITORING
The ST750 Rack Assembly does not cover regulatory signs and their associated
monitoring. There is a fuse position labelled ‘F3 Detector’ which could be used to
supply regulatory signs if required. Their monitoring would require standard current
coils to be connected to the external analogue inputs.
5.13 PCB SWITCHES, FUSES, LINKS AND FIRMWARE
The switches, fuses and link settings are related to the hardware options; their
locations and option selections are shown in Sections 5.13.1 and 5.13.2.
To aid the location identification an overview of each card is also given:
667/HB/33750/000
Page 84
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ST750 GENERAL HANDBOOK
5.13.1 CPU PCB Switch and Link Setup
See the following pages for switch and link settings.
Switches and Link
Setting Positions
Controller O/P
92 to 95
Manual Panel
Connector PL1
S1
A
E
F
Status
LED
Displays
PL3
DIL Sw
D
S4
DIL Sw
C
S3
DIL Sw
Phase
Control
Bus
PL4
Phase
LED
Displays
S2
DIL Sw
B
Controller
I/P 16 to 31
PL2
PL6
LK1
Controller
I/P 0 to 15
EPLD
PP
SE
WD
PL7
Detector
PL8 Supply
FUSE
RS232
Handset
Port
SK1
Modem
Port
PL12
Controller
O/P 88 to 91
BATTERY
FUSE
Phase Bus
Processor &
Firmware
Main
Processor
Firmware
1st
2nd
Extended
System
Bus
PL11
Main
Processor
Figure 35 – CPU PCB
667/HB/33750/000
Page 85
Issue 5
ST750 GENERAL HANDBOOK
5.13.1.1 DIL Switch S4 Settings
For use in the UK, the hardware fail flash facility should be disabled. The settings are
shown in Figure 36.
For use in Non-UK versions, the flash rate can be set to different speeds for 40ms to
600ms (on 50Hz operation) by setting the right combination of S4 switches to the off
position. The set-up is detailed as follows:
Flash ‘OFF’ time
50Hz
60Hz
All On = 40ms All On = 33ms
+320ms if Off
+160ms if Off
+80ms if Off
+40ms if Off
S4
LK1
Fail Flash Enabled
Link 2-3 Disabled
3 2 1 Link 1-2 Enabled
(Link 2-3 must always
be selected for UK use)
+267ms if Off
+133ms if Off
+66ms if Off
+33ms if Off
OFF ON
Flash ‘ON’ time
50Hz
60Hz
All 0n = 40ms All On = 33ms
+320ms if Off
+160ms if Off
+80ms if Off
+40ms if Off
+267ms if Off
+133ms if Off
+66ms if Off
+33ms if Off
Flash Rate Selection
Flash rate depends on mains frequency
Minimum flash period is 40ms (50Hz) & 33ms (60Hz)
To ‘add’, turn Off appropriate switch
OFF ON
Figure 36 – Flash Rate Settings
5.13.1.2 DIL Switch S2 & S3 Settings
For use in the UK these switches should be set to the OFF position. The settings are
shown in Figure 37.
For Non-UK versions, each of the six phases can be set individually to flash either
Red (using S2) or Amber (using S3), or both Red and Amber when the hardware fail
flash is activated.
The set-up of each phase to the required colours is detailed as follows:
667/HB/33750/000
Page 86
Issue 5
ST750 GENERAL HANDBOOK
S2
Phase:-
S3
Phase:-
1
1
RED
AMBER
6
6
7&8
not used
OFF
7&8
not used
ON
OFF
ON
Figure 37 – Phase Output Flash Selection
5.13.1.3 DIL Switch S1 Settings
The value of the series resistance for the relay contacts can be set to either 182
ohms or 22 ohms and is set on switch S1 as follows:
S1
Relay Output: 5
6
7
8
1
2
3
4
ON = 22 Ohms
OFF = 182 Ohms
OFF
ON
Figure 38 – Relay Output Resistance Selection
667/HB/33750/000
Page 87
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ST750 GENERAL HANDBOOK
5.13.2 Phase Drive PCB Switches, Links and Fuses Setup
External Analogue I/Ps
Connector (Current Coil)
L
K
2
L
K
3
Phase 1 & 2 Drive O/Ps Connector
L
K
1
1
L
K
4
PL6
Ribbon cable connected
to 64-way connector on
Controller Board
PL5
LK15
24V O/P
LK16
LK17
24v Power Supply Unit
Mains I/P
LK18
LK19
PL3
Phase 3 & 4 Drive O/Ps Connector
1
PL7
MAP 140 PSU
Connector
PL2
ST700 PSU
Connector
16
16
F4
F8
SK2
TAG2
F1
F7
Phase 5 & 6 Drive O/Ps Connector
TAG1
LK20
1
TAG4 TAG3
PL8
F9
F10
F2
6
F6
F11
LK21
LK22
F3
SK1
PL1
External Mains and
48V Connections
Mains I/P
Connector
Dimming
Transformer
Connector
F6 and F8 are
Pedestrian Wait/
Vehicle Ambers
FUSE
F10 and F11 are
Pedestrian Red/
Green
= 48v
Figure 39 – ST750 Phase Drive PCB Assembly
667/HB/33750/000
Page 88
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ST750 GENERAL HANDBOOK
5.13.2.1 Fuse/Dummy Fuse Settings
The output voltage for the Pedestrian Red and Pedestrian Green can be set to either
230V or 48V operation. Fitting the fuse and dummy fuse as follows sets the voltage:
•
For 230V operation fit the 10A fuse in F10 and the dummy fuse in F11.
•
For 48V operation fit the 10A fuse in F11 and the dummy fuse in F10.
The output voltage for the Pedestrian Waits can be set to either 230V or 48V
operation. Fitting the fuse and dummy fuse as follows sets the voltage:
•
For 230V operation fit the 10A fuse in F8 and the dummy fuse in F6.
•
For 48V operation fit the 10A fuse in F6 and the dummy fuse in F8.
Note that the ST750LED Phase Driver PCB with LV CLS (NLM) monitoring always
provides Waits at 48V, so F8 does not exist, and F6 is always fitted.
Note: The dummy fuse is a plastic spacer, the same size as the fuse it replaces. It is
used to prevent service personnel inserting an extra fuse and thus causing damage
to occur to the ST750.
5.13.2.2 Blue and Red Handbag Links Settings
The output voltage monitoring circuits for the Pedestrian Red and Pedestrian Green
can be set to monitor either 230V or 48V. Inserting the correct coloured handbag
links on the board sets the voltages for the Monitoring circuit. The positions and
colours are as follows:
•
For 230V operation fit only a Red Link in position LK22 (large pitch).
•
For 48V operation fit only Blue Links in positions LK22 (small pitch), LK15 and
LK17. On 4 phase units fit LK18 and LK20.
Note: Links LK15, LK17, LK18 and LK20 are accessed through the two rectangular
cut outs in the heatsink cover. See Figure 39 for details. A pair of long nose pliers is
required to insert and extract the handbag links.
The output voltage monitoring circuits for the Pedestrian Wait can be set to monitor
either 230V or 48V. Inserting the correct coloured handbag links on the board sets
the voltages for the Monitoring circuit. The positions and colours are as follows:
•
For 230V operation fit only a Red Link in position LK21 (large pitch).
•
For 48V operation fit only Blue Links in positions LK21 (small pitch), LK16 and
LK19.
667/HB/33750/000
Page 89
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ST750 GENERAL HANDBOOK
Note that the ST750LED Phase Driver PCB with LV CLS (NLM) monitoring always
provides Waits at 48V, so LK16, LK19 and LK21 do not exist.
Note: Links LK16 and LK19 are accessed through the two rectangular cut outs in
the heatsink cover. See Figure 39 for details. A pair of long nose pliers is required to
insert and extract the handbag links. Both the Red and Blue links are wire shorting
links in the form of a handbag, with a handle to aid insertion and extraction. They fit
into PCB mounted sockets and use spring clips in the socket to make the connection
and fit. These spring clips also retain the link to the PCB; the contacts are gold
plated for low resistance and reliability.
5.13.2.3 Links LK1, LK2, LK3 and LK4 Settings
The links LK1 to LK4 have handbag links fitted as shown below. These should not be
changed. Note that later versions of this PCB do not have any of these links
present.
LK4
LK3
LK2
LK1
Connector PL5
Figure 40 – Links LK1 to LK4
5.14 Refitting the LID
Reconnect the earth lead by fitting the Faston connector to the Faston Tag. Replace
the Lid carefully on the equipment mounting frame and secure the Lid to the frame
using the ‘T’ key.
5.15 ON-SITE ST750 TESTING
Connect a suitable handset to the 25-way D-type connector on the ST750 Phase
Drive PCB.
Replace each of the 4 off 10A fuses in the fuse holders F6 to F11 on the Phase
Drive PCB with 3.15A fuses, leaving the dummy fuses in place. See Figure 42 and
Figure 39 for details. This protects the individual circuits whilst the self-test is being
performed in the event of a short circuit in any of the cables.
667/HB/33750/000
Page 90
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ST750 GENERAL HANDBOOK
Select and run the self-test – see section 8.
If the self test passes, replace the 10A fuses in the Phase Drive PCB.
The ST750P stand-alone pedestrian controllers normally run one of the standard
configurations generated by Siemens Poole that are listed below:
EM30700 Single/dual stand-alone Pelican crossing
EM30701 Single/dual stand-alone crossing with a red clearance period, i.e. nearsided Puffin or Toucan crossing.
EM30702 Single/dual stand-alone crossing with a blackout clearance period, i.e.
far-sided Pedestrian or Toucan crossing.
EM30703
Single stand-alone crossing with a red clearance period, i.e. near-sided
Puffin or Toucan crossing, with centre island blackout option.
These configurations are available on the IC4 CD. Other configurations may be
produced by Siemens Poole in order to meet the particular requirements of an area
or of one particular site.
These configurations need to be customised for particular installations using the
handset and the information in the special instructions of the configuration printout.
The commands to customise the ST750 are described in the Handset Handbook and
in the Special Instructions. These allow facilities such as kerbside and on-crossing
detectors and speed discrimination/assessment to be enabled or disabled. However,
the fundamental lamp sequence (i.e. flashing green-man, red-man or blackout
clearance periods) cannot be changed using the handset and is fixed in each of the
default configurations.
The configuration data for a stand-alone pedestrian crossing ST750 is loaded
through the handset port from a PC running IC4.
The configuration data could be loaded while the ST750 is still in the depot rather
than using a PC on the street. Provided the battery isolators are removed, the
configuration data will still be present in the battery backed-up RAM when the ST750
is installed.
The procedure for loading the configuration data is given in the Handset Handbook.
Once the configuration data has been loaded, ensure the Signals ON/OFF switch on
the manual panel is in the off position and connect a suitable handset to the 25-way
D-type connector on the ST750 CPU PCB.
With all signals covered (bagged), use the LMP handset command, which causes
each colour on each phase to illuminate in turn, whilst other persons are checking
the aspects. Care must be taken to ensure that any traffic on the junction does not
mis-read the signals and cause an accident. In addition, a visual check of the wiring
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must be carried out, to ensure that the individual approaches are wired correctly as
shown in Figure 27.
The ST750 signals can now be switched on (using the switch on the manual panel)
and the ST750 powered up normally.
If the solar cell and signal dimming are not required then the following test can be
ignored.
1. Cover the photoelectric cell for at least one minute to exclude any light and
check that the signals are dimmed.
2. Remove the cover from the photoelectric cell and after at least one minute
the signals should revert to the bright condition.
If detectors are installed then they should be set up as defined in the Detector
Information Handbook.
Set up the date and time.
Check that the Lamp Monitor has correctly learnt all the lamp loads, using the KML
and KEL handset commands, described in the Controller Handset Handbook.
Check that there are no unexplained errors in the fault log.
This completes the testing and the site should be ready for Customer acceptance.
5.16 ST750 START-UP SEQUENCE
When the ST750 is initially powered up, it performs various internal checks before
starting normal operation. While these checks are being performed the green
heartbeat LED flickers and the red system error LED remains on.
If these tests fail then there is a serious fault on the CPU PCB and the PCB should
be replaced. The error message is repeatedly written to the handset display at 1200
baud, and no other handset operations can take place. Refer to the ST900/750
Handset Handbook for full detail of error messages (section 1.3.2)
In addition to the above internal checks, the ST750 goes on to check the contents of
its battery backed RAM, e.g. the fault log and checksum on the timings data, before
attempting to switch on the signals.
Once the ST750 is running normally, it extinguishes the red system error LED and
the green heartbeat LED flashes.
If the red system error LED remains illuminated then a handset should be connected
and the fault log checked to see what errors exist. The fault log is described in the
Handset Handbook.
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5.17 COMMON RETURNS FOR PUSH BUTTON
For the connections for the common returns see the following drawings :ST750 in small outer case - 667/CC/29000/002
ST750 in large outer case - 667/CC/29000/003
5.18 COMMON RETURNS FOR DETECTORS
For the connections for the common returns see the following drawings :ST750 in small outer case - 667/CC/29000/002
ST750 in large outer case - 667/CC/29000/003
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6. FITTING THE ST750 RACK ASSEMBLY INTO ALTERNATIVE CABINETS
Warning!
DISCONNECT ALL POWER TO THE CABINET BEFORE
REMOVING OR INSTALLING ANY EQUIPMENT INTO THE
CABINET.
The ST750 Rack Assembly may be fitted into enclosures other than the ST750
Cabinet Assembly. In the UK, the Cabinet must be one that has previously been
approved with a different controller. Some examples are:
ST800
T400S
T400L
GEC110/125
CST – McQue
T110
T500P
GEC125 in 25 Case
Microsense Midi
The procedure for each type of Cabinet depends largely on the type and condition of
the existing equipment. For this reason it is not possible to define in detail exactly
what should be undertaken, but generally the procedure follows that defined in
sections 5.1 to 5.14.
For some Cabinets, conversion kits of parts are available. These provide brackets
and other equipment that may be helpful during the installation. Part numbers for the
spares available at the time of issue of this handbook are listed in Appendix A.
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7. ROUTINE MAINTENANCE PROCEDURES
This section contains a list of checks to be performed at an ST750 on a regular basis
(normally annually).
If for any reason, the power is switched off to the ST750, then a total installation
Megger test should be carried out, as defined in the General Testing Handbook.
7.1 ROUTINE INSPECTION OF SIGNAL EQUIPMENT
Check all signal heads/aspects for damage and take any necessary corrective
action.
Check all signal heads for correct alignment with their respective approaches.
Check all pole top cable connections; ensure that they are sound, secure and not
seriously corroded.
Check that all top caps are fitted and are not damaged.
Check that all poles are secure in the ground and are not leaning or damaged.
7.2 ROUTINE INSPECTION AND ELECTRICAL TESTING OF ST750
It is suggested that these procedures be performed in the order listed.
Examine the cabinet and equipment mounting frame for serious damage. The
cabinet would normally only be replaced if it has been damaged to the extent that its
security has been breached or that water or dirt is entering.
Check the base seal for integrity. If damaged, perform repair or advise customer
dependent on the terms of the contract which is in place.
Open the door(s), both the main (if the cabinet has one) and the manual panel;
check that the screw-locks, lock and hinges operate freely. Inspect the door and
lock, and check the lock and catch-plate for security. Replace or tighten as
necessary. Lubricate as necessary with good quality penetrating type oil.
Inspect the manual panel gasket, ensuring it is intact and in the correct position.
Replace as necessary ensuring that the surface is clean before fitting.
Check the manual panel for any damage and replace if necessary. Check that all
functions operate correctly. Press the lamp test keypad and check that all LEDs are
operational.
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Warning!
The following tests will result in the signals extinguishing.
• Test the 300mA RCD (if fitted) by pressing the test button. The breaker should
operate immediately. If the contract specifies the testing of RCD speed, then this
test should be performed using the appropriate equipment. If the RCD is faulty
then the results should be recorded the unit replaced. Any replacement unit is to
be similarly tested to ensure correct operation before leaving site.
• Check the termination panel(s) and master switch panel within the Cabinet and
ensure that there are no loose fixings, or damage to these panels. Tighten any
loose fixings and carry out any repairs that are necessary.
• Check the logic assembly and other assemblies within the ST750 are securely
fixed. Retighten loose fixings as necessary.
• Check that all fuses are secure in their holders..
It is strongly recommended that the ST750 supply is isolated
Warning! before any fuses are checked
• Check wiring and cableforms, particularly ribbon cables for damage. Replace or
re-route as appropriate.
• The battery on the ST750 CPU PCB must be replaced if it has failed. Any
replacement battery should be suitably marked with an appropriate date label.
Having done this, the ST750 records should be updated accordingly.
The following tests require the ST750 to be powered and running normally.
• Tests of the Voltage Drop of Neutral Conductors. This test should be carried out
during each periodic/annual inspection as a simple check of neutral cables, which
can also provide a good indication of the state of the intersection cabling.
(i) Take a digital multi-meter or voltmeter and set it to measure 240 volts AC
(RMS).
(ii) Select a phase and wait until its green has just terminated. Measure the
voltage between the Cabinet Assembly neutral and the green feed; the
voltage should be no greater than 4 volts (RMS) throughout the signal
cycle, except when the phase next goes to green. If the voltage between
the green feed and neutral is greater than 4 volts then do the following:
(1) Check all joints in the appropriate neutral cable run, ensure that they are
all tight and none are seriously corroded, replace or tighten them as
necessary.
Re-test cable
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If the fault still persists then:
(2) Increase the number of conductors/cable cores used for the neutral.
Or
(3) Replace the cable that has failed the test.
Re-test the cable to ensure that corrective action taken has removed the
problem.
• With the handset, check that all inputs used are operating correctly.
• Test the maintenance socket RCD by pressing the test button. The breaker should
operate immediately (See notes on RCD testing earlier in this section).
The following checks should be carried out before leaving the site.
• Check the manual panel gasket is intact and in the correct position. Replace as
necessary ensuring the surface is clean before fitting.
• Inspect the cabinet base seal. If damaged, the affected area should be filled with
sand and re-sealed. For details see section 5.10.
7.3 ROUTINE SETUP CHECK
Check that the real time clock is set correctly as described in the Controller Handset
Handbook.
Use the time of day TOD command to check that the real time clock is running the
correct time. A true measurement of the accuracy of the real time clock can only be
gained if the clock with which it is compared has been accurately set up.
It is essential that the time be compared with an adjacent installation using a clock
that has been synchronised to that installation within the last 30 minutes.
7.4 REPLACEMENT OF PCBS
This section covers the removal and fitting of PCBs in the ST750. Safety
requirements and procedures are described to ensure that the board functions
correctly when fitted (e.g. PROM fitting).
When replacing PCBs only approved spares must be used. Use of any other
components may invalidate the Type Approval of the equipment.
Note that PCBs are not generally available separately as spares, but are included in
kits. If a PCB fails a new board may be taken from the replacement kit, or the whole
kit may be replaced. See Appendix A for part numbers.
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7.4.1 Safety Requirements
Warning!
Before replacing any fuses, PCBs etc., IT IS ESSENTIAL THAT THE
POWER TO THE ST750 IS ISOLATED. See the Safety Warning on
page 2 for details.
Failure to isolate the supply before changing parts may result in
Warning! damage to the ST750
7.4.2 General Requirements
When replacing PCBs the original PCB should be inspected and the following points
checked:
(a) Check the connectors on the PCB. Are any pins bent, broken or damaged in any
way? If there are, make a note of the PCB and pin number in the Controller Visit
Log Book as the ribbon backplanes may have been damaged.
(b) Check any ICs that are mounted in sockets and ensure that they are the correct
ones for the position and are securely fitted. Refer to the works specification for
further details.
A problem with a loose fitting IC or use of an incorrect one can usually be
rectified easily without having to fit a replacement PCB.
(c) Do not forget to record the replacement in the Controller Visit Log Book.
7.4.3 Access to PCBs in ST750 Cabinet Assembly
The ST750 CPU PCB is mounted directly on the outside of the ST750 Rack
Assembly hinged front plate and is easy to access once the Lid is removed from the
equipment mounting frame.
If a fault is suspected with the Phase Drive PCB, the whole Power/Phase assembly
is replaced as described in section 7.4.6.
If fitted, the I/O Board or OTU Board are fitted inside the ST750 Rack Assembly,
behind the CPU PCB.
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To open the hinged plate, the 64-way Phase Control Ribbon cables at
the front of the ST750 Rack Assembly must be disconnected.
Disconnection of the cable disconnects all logic power from the CPU
Warning and therefore prevents the ST750 operating the lights, but it does not
switch the incoming mains off. The mains must be isolated at the
master switch before any disconnection of cables or fuse replacement
takes place.
7.4.4 Access to PCBs in other Outercases
All ST750 Rack Assemblies installed in cabinets with 19” mounting kits provide full
access to the front face of the ST750 and have sufficient room to allow the hinged
front plate to swing open, giving access to the internal PCBs.
Access to the PCBs is the same as described in section 7.4.3.
7.4.5 Replacement of CPU PCB
Ensure that the replacement PCB has the correct firmwares fitted and they are of
the correct variant and issue. Refer to the Works Order Specification for details.
Important
See notes on CPU compatibility between ST750 and ST700
contained in section 2.1.7
On NO ACCOUNT is it permitted to downgrade an ST750 site to
an ST700 site by changing the CPU board and associated
Warning! firmware as an ST750 site will conform to TR2500A which the
ST700 DOES NOT and CAN NOT
The mounting pillars on the CPU are a nylon clip type and only require the clipping
mechanism to be released to allow the board to be removed. The pillars are retained
on the hinge plate by means of an integral clipping mechanism on the other end.
When the CPU is replaced, make sure that the clipping mechanism of the mounting
pillar is fully engaged.
Warning Care must be exercised when removing or inserting the green connectors
and their cables from the PCB, as strong extraction and insertion forces are required.
Be careful not to over flex the board, which could cause tracks to fracture and the
board to fail.
7.4.6 Replacement of Power/Phase Assembly
The Power/Phase assembly may be removed once the following have been carried
out:
•
•
Isolate the Mains to the ST750 at the master switch
Disconnect the 64-way Phase Control ribbon cable from the CPU
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•
•
•
•
•
Unclip the earth lead from the hinged front plate
Remove the front plate 1 holding the CPU (and I/O or OTU) and store carefully
Disconnect the earth wires from the fixing point in the assembly
Disconnect PL6, PL7, PL8 and SK2
Disconnect PL1 and SK1.
Warning Care must be exercised when removing or inserting the green connectors
and their cables from the PCB, as strong extraction and insertion forces are required.
Be careful not to over flex the board, which could cause tracks to fracture and the
board to fail.
Using a 10” Pozidriv No.1 screwdriver, loosen (do not remove) the four screws
holding the Power/Phase assembly to the equipment mounting plate. Lift the
assembly off the mounting plate.
Replace with the new Power/Phase assembly, checking that the part numbers are
the same, i.e. 2 phase, 4 phase or 6 phase unit.
Ensure that all links and fuses are set correctly (i.e. in the same position as the
original unit) as described in section 5.13.
Reconnect PL1, PL6, PL7, PL8, SK1, SK2 and the earth wires.
Replace the hinged front plate holding the CPU PCB and, if fitted, the I/O or OTU
PCB.
Replace all the cables to the CPU. Clip the earth lead to the front plate.
Restore power to the ST750.
Note: The new Power/Phase assembly is supplied with a chassis door fitted. It is not
necessary to replace the door when the Phase Drive PCB has failed. The old
Power/Phase assembly should be returned to Siemens Poole with the replacement
door.
7.4.7 Replacement of Manual Panel PCB
First unplug the cable connecting the manual panel to the CPU PCB.
The manual panel is held to the main Cabinet Assembly by a number of screws that
need to be removed. After removing these screws the panel may remain held in
place by the sealing strip. Ease the panel away from the housing, gradually working
from one corner, taking care not to scratch or otherwise damage it.
The replacement panel should be mounted with a new sealing strip to prevent water
ingress. After fitting, reconnect the cable to the CPU PCB.
1
The front plate needs to be at 90º when it is fitted or removed. Push the front plate
up and remove from the bottom hinge pin. Pull down to release the front plate from
the top hinge pin.
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Where an Internal Manual panel is fitted, it may be removed directly by removal of
the screws holding it to the 19 inch panel; it may be easier to remove the 19 inch
panel from the rack first. No sealing is required on refitting.
7.4.8 Replacement of Expansion I/O or OTU PCB
Removal of the I/O or OTU PCB may be done once the Mains to the ST750 Rack
Assembly has been isolated at the master switch, the 64-way Phase Control ribbon
cable has been disconnected from the CPU and the hinged front plate has been
opened.
Ensure that the replacement PCB has the correct firmware and PLD fitted at the
correct variant and issue. Refer to the Works Order Specification for details.
The I/O or OTU PCB is removed by removal of the screw fixings (4 off) which secure
it to the inside surface of the hinge plate. Ensure all the cables are fully disconnected
before the board is removed, and fully inserted following the replacement of the
board.
7.5 REPLACEMENT OF MAINS POWER SUPPLY UNIT
The spare Mains Power unit is provided as part of the Power/Phase Assembly. It is
not necessary to replace the whole assembly if the power unit has failed, providing
the failure has not damaged other components.
The Mains PSU may be removed once the following have been carried out:
•
•
•
The Mains to the ST750 Rack Assembly has been isolated at the master switch
The 64-way Phase Control ribbon cable has been disconnected from the CPU
The hinged front plate has been opened.
Remove the cables and connectors connected to the PSU, then release the nylon
mounting pillar clips that attach the PSU to the heatsink cover of the Phase Drive
PCB. The clips are retained on the heatsink cover by means of an integral clipping
mechanism on the other end.
When the PSU is replaced, ensure that the clipping mechanism of the mounting pillar
is fully engaged and all the cables and connectors are securely fitted.
Re-assemble the Rack Assembly.
7.6 REPLACING OTHER COMPONENTS
Only approved spares must be used when replacing any components. Use of any
other components may invalidate the Type Approval of the equipment.
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8. SELF-TEST FACILITY
The self-test facility can be used to check the hardware fitted to the controller, even
before a configuration is loaded. It is designed to be used both in the factory by
production and on the street by installation/ maintenance engineers.
Self-test is initiated by holding down the level 3 access button while switching on the
power to the controller. The button should be released once the green heartbeat
LED starts to flash.
The green heartbeat LED continues to flash during the self-test unless a fault is
detected when the red system error LED illuminates.
Connecting a 20 character by 4 line handset displays information about the checks it
is performing, such as the firmware issue and the lamp supply voltage, both dim and
bright, and detail any faults found.
Self-test performs the checks detailed on the following pages and produces error
messages if faults are detected.
While the self-test is running, the manual panel can be checked. Pressing each
button on the panel should illuminate the associated LED. To distinguish this from
normal operation, the LED flashes at a fast rate while the button is depressed. Note
that the ‘Lamp Test’ button illuminates all the LEDs, as it does for normal operation.
To test the signals on/off switch and the cabinet alarm LED, switching the switch to
the signals ‘on’ position illuminates the cabinet alarm. Switching it to the ‘off’ position
extinguishes the cabinet alarm indicator. Note that the signals on/off switch does not
affect the self-test in any other way.
• Resolving problems with lamp switch cards and triacs:
When various tests fail, the handset may display information such as:
No voltages on:
R-00000000+00000000
A-00000002+00000002
G-00000000+00000000
-ve Peak +ve Peak
←
←
←
←
identifies the test which has failed
outputs from the red voltage monitors
outputs from the amber voltage monitors
outputs from the green voltage monitors
The numbers are in hexadecimal notation and so each of the eight digits encodes
four phases, as follows:
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Figure 41 – Handset
0 = - 1 = - E
0000
00
2 = F –
3 = F E
0
1
2
3
4
5
6
7
=
=
=
=
=
=
=
=
-
C
C
C
C
B
B
–
B
B
A
–
A
A
–
A
8
9
A
B
C
D
E
F
=
=
=
=
=
=
=
=
D
D
D
D
D
D
D
D
–
–
C
C
C
C
B
B
–
B
B
A
–
A
A
–
A
0000 00 0 2
So in the above example, there are no voltages on Phase B amber (or Wait). Has
the wait fuse blown?
• On power-up, the self-test facility checks the integrity of the main processor
board:
RAM
DPR
PRG
XTL
DPR
FAULT
RAM FAULT
PROM FAULT
FAULT
R/W FAULT
All the above faults point to problems internally on the main processor card.
• Checks communications with the secondary / phase bus processor:
P/Bus CPU....
If the processor cannot be detected, then the self-test will wait indefinitely at this
point with the red system error LED illuminated. Check that the processor and its
firmware are fitted.
• Examines the lamp switch cards to see how many are fitted:
No L/S Cards Found
No cards were detected. Either the lamp switch or the processor PCB could be
faulty.
• Waits for ZXO synchronisation and checks the mains frequency:
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ZXO Sync’d...
If the phase bus processor cannot synchronise to the mains zero cross-over signal,
then self-test will wait indefinitely at this point with the red system error LED flashing.
Mains Freq Error
If the mains frequency is more than 5% out from either 50Hz or 60Hz.
• Checks all the ADC test voltages on all of the lamp switch cards:
ADC Tests....Failed
ADC Test Readings
0.0V 2.5V 5.0V
B0+ nnnn nnnn nnnn
B0- nnnn nnnn nnnn
... .... .... ....
If the test fails, then the readings from each board, taken at both the positive and
negative mains peaks for each of the two test voltages (0V and 2.5V) are displayed
on the handset.
Ideally the values should be 0 and 128.
• Checks that the lamp supply and voltage monitors are detecting no mains:
L/Supply Off=240V
L/Supply Stuck On
If a lamp supply is being detected, then this implies that the lamp supply relays are
all switched on (very unlikely) or the lamp supply monitoring transformer (on the
power distribution card) has failed.
V/Mons Off...Failed
R-00000000+00000001
A-00000000+00000000
G-00000001+00000000
If any of the voltage monitors appear to be detecting mains, even though the lamp
supply and all the triacs are switched off, then this implies a problem with the
hardware on the lamp switch card.
• Initialises the phase bus processor:
P/Bus Init...
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Bad L/S Cards
Once initialised, the phase bus processor performs more thorough checks on the
lamp switch card and may detect faults.
• Checks the monitor validation signal:
M/V Test ....Failed
Mon Val Failed
The monitor validation signal is generated by the main processor to check the phase
bus processor, so a failure is probably due to a faulty processor card.
• Step 1 Complete, Start Step 2:
At this point, the self-test has successfully checked-out the logic side of the cards. It
then displays a scrolling pattern on the amber LEDs to show that the first part of the
self-test is complete.
This pattern remains until the operator presses the level 3 button to confirm that the
self-test may switch on the lamp supply and continue its tests.
After the level 3 button is pressed, self-test switches on the lamp supply.
Towards the end of this second sequence of tests, it tests all the triacs by switching
each one on in turn for a very short period of time.
If standard HI 12V halogen lamps are used (with a transformer in the signal head),
then this pulse will not be seen on the street and so the signals need not be covered.
However it may be possible to see the pulse on lamps that are not driven by any
transformer, i.e. that run directly off the 240V.
If in doubt, all non-HI signal heads, i.e. 240V lamps, LED
Warning! Signals and 48V ped signals, should be covered before
proceeding any further with the self-test.
• Self-test switches on the lamp supply and then checks that the voltage
monitors still show no mains (triacs still switched off):
V/Mons Off...Failed
R-00000000+00000001
A-00000000+00000000
G-00000001+00000000
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If any of the voltage monitors appear to be detecting mains, then it would imply that
those triacs are not holding off the mains and the lamp switch card should be
replaced.
• L/S Supply Failure:
L/S Monitor Fault
The lamp supply can be detected on the voltage monitors, but no signal is present
from the lamp supply monitoring transformer. Replace the lamp switch card.
L/Supply Failure
No lamp supply has been detected by the lamp supply monitoring transformer but
further investigations by the self-test facility cannot determine the cause. Check the
lamp supply circuits relays, fuses, etc., in and around the power distribution unit.
Also check that the dim connector SK2 is connected. N.B. Links are required on this
connector even if no transformer is required.
• Checks that each lamp supply relay can switch off the lamp supply
independently:
SSR Fault
Relay A Fault
Relay B Fault
Failure of any of these tests implies that the relay is not switching off, i.e. that it is
either welded closed or the control signals from the main processor card are stuck
active.
• Checks that the dimming relay is functioning:
Dimming Fault
A fault is only logged on the dimming relay if the dim lamp supply is more than 75%
of the normal lamp supply, i.e. that the dimming relay seems to have no effect on the
lamp supply.
Note that this test does not fail if there is no dim lamp supply, e.g. if no dimming
transformer is fitted, since self-test may be performed on the just the controller rack.
Therefore, the dim voltage should be checked manually, e.g.
Dim L/Supply=160V
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• Checks all of the triacs in turn by applying a very short pulse to each
phase’s colour:
A/Red:Extra Sigs On
R-00000001+00000001
A-00000001+00000001
G-00000001+00000001
A fault will be logged if extra signals are detected as on when one particular aspect is
pulsed. This would normally imply a short-circuit in the street cabling or a open
neutral connection.
No Voltages On...
R-00000000+00000000
A-0000000A+0000000A
G-00000000+00000000
A fault will also be logged if no voltages were detected, e.g. when one of the fuses
has blown.
In the example above, 0000000A represents phases B and D (see Figure 41), so
Amber (from RAG down the left-hand side) shows that the pedestrian Wait indicators
have no voltages present. Check the fuses F6 and F8 and the 48V output from the
dimming transformer for example.
If the link on the CPU Card selects the 'fail to flashing' option, the controller flashes
the red and amber phase mimic LEDs on the CPU card (section 4.3) for five seconds
before displaying the multicoloured scrolling pattern.
At the end of the test, the self-test switches off the lamp supply and displays a
multicoloured scrolling pattern on the LEDs to show that all the tests have passed
successfully.
It also illuminates a series of LEDs to identify which cards on the extended system
bus have been detected. A full list is displayed on the handset.
After a few seconds, self-test will repeat the second part of the self-test allowing the
controller to be soak tested.
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Appendix A - PART NUMBERS AND SPARES LIST
Use of components other than those listed, or modifications or enhancements
that have not been authorised by Siemens Traffic may invalidate the warranty
or safety of this product.
A.1 – PART NUMBERS
Listed below are the currently available parts that make up the ST750
Description
ST750 UK SINGLE PED IN ST900 CAB GREY
ST750 UK SINGLE PED IN ST900 CAB BLK
ST750 UK DUAL PED IN ST900 CAB GREY
ST750 UK DUAL PED IN ST900 CAB BLK
ST750 UK SMALL NON UK INT IN ST900 CAB GREY
ST750 LED UK SINGLE PED IN ST900 CAB GREY
ST750 LED UK SINGLE PED IN ST900 CAB BLK
ST750 LED UK DUAL PED IN ST900 CAB GREY
Siemens Part Number
667/1/33750/014
667/1/33750/015
667/1/33750/024
667/1/33750/025
667/1/33750/154
667/1/33750/214
667/1/33750/215
667/1/33750/224
ST750 UK SINGLE PED IN T400S CAB GREY
ST750 UK SINGLE PED IN T400S CAB BLK
ST750 UK DUAL PED IN T400S CAB GREY
ST750 UK DUAL PED IN T400S CAB BLK
ST750 LED UK SINGLE PED IN T400S CAB GREY
ST750 LED UK DUAL PED IN T400S CAB GREY
667/1/33750/010
667/1/33750/011
667/1/33750/020
667/1/33750/021
667/1/33750/210
667/1/33750/220
ST750 UK RACK SINGLE PED ASSY
ST750 UK RACK DUAL PED ASSY
ST750 NON UK RACK SMALL INT ASSY
ST750 LED UK RACK SINGLE PED ASSY
ST750 LED UK RACK DUAL PED ASSY
667/1/33750/513
667/1/33750/523
667/1/33750/653
667/1/33750/813
667/1/33750/823
Kit Termination Detector Cable
Detector Single Backplane Kit
Locking Kit
I/O Kit
Integral OTU Kit
SDE Facility Kit
GPS Module Mod Kit
667/1/15854/000
667/1/15990/003
667/1/21923/001
667/1/27003/000
667/1/27004/000
667/1/27005/000
667/1/27014/000
Manual Panel (Ped full panel)
Manual Panel (Blank)
Manual Panel (Sigs On/Off)
P/E Manual Panel + DFM Assembly
667/1/27056/002
667/1/27056/050
667/1/27056/300
667/1/27056/301
DFM Lens Kit
667/1/27104/000
667/HB/33750/000
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ST750 GENERAL HANDBOOK
Description
Manual Panel RS232 Kit
300mA RCD Kit
Lightning Suppression Kit
24V AC Detector PSU Kit
Dimming/48V Transformer Kit
Controller Handset
Current Monitoring Transformer
Siemens Part Number
667/1/27110/000
667/1/27117/000
667/1/27118/000
667/1/27853/000
667/1/27867/000
667/4/13296/000
667/7/25171/000
GEC125/104 Conversion Kit
CST – McQue Conversion Kit
T110 Pole Mount Conversion Kit
T500P Conversion Kit
GEC125 in 25 Case Conversion Kit
T400S/T500S Conversion Kit
Microsense Midi Conversion Kit
T400L/T500L Conversion Kit
667/1/27855/000
667/1/27855/001
667/1/27855/002
667/1/27855/003
667/1/27855/004
667/1/27855/005
667/1/27855/006
667/1/27855/007
ST750 LED 2 PHASE UPGRADE KIT
ST750 LED 4 PHASE UPGRADE KIT
667/1/32755/752 **
667/1/32755/754 **
11” Swing Frame
19” Swing Frame
11” 3U Detector Rack
19” 3U Detector Rack
Freestanding TC12 OTU in 11” 5U Rack
Freestanding TC12 OTU in 19” 5U Rack
667/1/27087/411
667/1/27087/000
667/1/20690/000
667/1/20690/001
667/1/22691/001
667/1/22691/002
** See 667/HB/32921/007 in Section 1.3.2 for further details.
A.2 – SPARES LIST
Listed here are the parts that should be used when replacing components. In
addition to the spares listed here, many of the parts included in section A.1 above
may be ordered as replacements. Contact Siemens Poole for details.
A.2.1 – PCBS
ST750 2 Phase Drive PCB with chassis
ST750 4 Phase Drive PCB with chassis
ST750 6 Phase Drive PCB with chassis
ST750 LED 2 Phase Drive PCB with chassis
ST750 LED 4 Phase Drive PCB with chassis
CPU PCB (UK Pedestrian)
CPU PCB (NON-UK Small Int)
ST750 2 Phase Drive PCB
ST750 4 Phase Drive PCB
ST750 6 Phase Drive PCB
ST750 LED 2 Phase Drive PCB
ST750 LED 4 Phase Drive PCB
667/HB/33750/000
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667/1/27870/751
667/1/27870/752
667/1/27870/755
667/1/27870/756
667/1/27870/757
667/1/27831/003
667/1/27831/007
667/1/27833/002
667/1/27833/004
667/1/27833/006
667/1/33790/002
667/1/33790/004
Issue 5
ST750 GENERAL HANDBOOK
A.2.2 – FUSES
See Appendix A.3 for details of where these fuses are used
0.5A cartridge fuse
16A HRC cartridge fuse (Pre Nov 2003)
20A MCB SP C Type (Post Nov 2003)
5A HRC cartridge fuse
3.15A fuse
5A HRC cartridge fuse
10A cartridge fuse
5A cartridge fuse
16A HRC cartridge fuse
518/4/90285/004
518/4/90352/005
516/4/97076/010
518/4/90638/000
518/4/97020/115
518/4/97052/017
518/4/90301/013
518/4/90301/010
518/4/97056/012
A.2.3 – CABLES
CPU I/O Softwire kit
Solar and Neutral Softwire kit
Phase Softwire kit 2/4 phases (incl audio drives)
Phase Softwire kit 5/6 phases (incl audio drives)
667/1/27863/100
667/1/27872/000
667/1/27877/000
667/1/27877/050
A.2.4 – OTHER SPARES
Lithium 3V Battery
Isolator Locking KOP
Manual Panel – signs on off only
CET Bar Kit
Door Switch KOP
Detector Mounting Frame
Manual Panel Gasket
Sealant Stool to Case
418/4/39829/000
667/1/21923/001
667/1/27056/010
667/1/27845/000
667/1/27852/000
667/1/33770/000
667/7/27129/000
996/4/05032/003
A.3- FUSE RATINGS AND POSITIONS
Electricity Company Cut-out Fuse
Master Switch Panel - MCB
516/4/97076/010
Maintenance Socket Fuse
518/4/90638/000
Aux. Supply Fuse (If Din Rail
Mounted) e.g. OTU/OMU
518/4/90638/000
Aux. Supply Fuse (If Phase Drive
PCB Mounted) e.g. OTU/OMU
518/4/97052/017
667/HB/33750/000
The maximum size of this fuse should not
exceed 45A (without reference to Poole).
Maximum prospective short circuit current must
not exceed 16,000A. Rating depends on
application but 25A min is recommended up to
18A load
20A MCB SP C Type on the Master Switch Panel
5A HRC cartridge fuse to BS1361 marked
‘MAIN,T’ on Master Switch Panel.
5A HRC cartridge fuse to BS1361 marked
‘OTU/AUX’ on Master Switch Panel.
5A HRC cartridge fuse size 0 (32mm x 6.4mm)
marked ‘F4’ on Phase Drive PCB
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ST750 GENERAL HANDBOOK
Controller Switch Fuse
518/4/97056/012
16A HRC cartridge fuse size 0 (32mm x 6.4mm)
marked ‘F1’ on Phase Drive PCB
AC Detector Fuse
518/4/90301/010
5A cartridge fuse (20mm x 5mm) marked ‘F3’ on
Phase Drive PCB.
Solar Cell Fuses
518/4/90301/010
5A cartridge fuse (20mm x 5mm) marked ‘F2’ on
Phase Drive PCB.
230V R/A Supply Fuse
518/4/90301/013
10A cartridge fuse (20mm x 5mm) marked ‘F9’
on Phase Drive PCB.
230V Green Supply Fuse
518/4/90301/013
10A cartridge fuse (20mm x 5mm) marked ‘F7’
on Phase Drive PCB.
230V R/G Supply Fuse
518/4/90301/013
10A cartridge fuse (20mm x 5mm) marked ‘F10’
on Phase Drive PCB.
48V R/G Supply Fuse
518/4/90301/013
10A cartridge fuse (20mm x 5mm) marked ‘F11’
on Phase Drive PCB.
230V Amb/Wait Supply Fuse
518/4/90301/013
10A cartridge fuse (20mm x 5mm) marked ‘F8’
on Phase Drive PCB.
48V Wait Supply Fuse
518/4/90301/013
10A cartridge fuse (20mm x 5mm) marked ‘F6’
on Phase Drive PCB.
Input Protection
Supply Fuse
518/4/90285/004
Handset Fuse
518/4/90285/004
and
Audible 0.5A cartridge fuse (20mm x 5mm) marked ‘F1
and Inputs’ on CPU PCB.
0.5A cartridge fuse (20mm x 5mm) marked ‘F2
and Handset’ on CPU PCB.
TEST Phase Drive PCB Fuses
518/4/97020/115
4 off 3.15A fuses used for initial testing on a
rewired junction for self test. These fuses are for
the temporary replacement of the fuses in
positions F6 to F11 on the Phase Drive PCB.
Figure 42 - Fuse Ratings
667/HB/33750/000
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LAST PAGE OF THE
ST750 GENERAL HANDBOOK
667/HB/33750/000
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