10041PUB903 Quick Start User Guide 20130722

10041PUB903 Quick Start User Guide 20130722
QUICK START USER GUIDE
t-Boss 7400 ACDC Track Driver
Genesis Technologies Inc.
www.genesisusa.com
10041PUB903 20120925
5812 South 129th E. Ave. • Tulsa, Oklahoma 74134
Thank you for purchasing the t-Boss 7400 ACDC Track Driver.
It is our goal always to provide quality products and service at a fair price, and treat every
customer in a fair and forthright manner. We believe this is the only way to endure in the
railroad industry marketplace over the long-term.
We ask for your suggestions, whether they be criticism, product or service improvement
ideas, or praise. Your feedback will be taken seriously and in good faith. We will work hard
to earn and deserve your business.
The Genesis Team
Quick-Start User Guide
t-Boss 7400 ACDC Track Driver
Product Orientation
Features Summary
Ÿ Four Independent Isolated AC Outputs
Ÿ Exceptionally Efficient, Cool Operation
Ÿ Powered from Signal System Battery Supply
Ÿ Rugged Design and Construction
Ÿ Increased Track Power Output with XP Option
Ÿ Internal Input and Output Surge Protection
Ÿ LED Status Indicator for Battery Input
Ÿ Plug-in Input/Output Connector - Accepts
AWG #10 Wire
Ÿ LED Status Indicator for Each AC Track Output
Ÿ Circuit Breaker Input Overcurrent Protection
Ÿ Inputs and Outputs Fully Isolated
Ÿ Wall or Rack Mount Ventilated Enclosure
Ÿ Clean System Shutdown and Power-up at Low
or High Battery Voltage
About ACDC Track Circuits
ACDC track circuits, also known as “Style-C” or “Ring-10” track circuits, have long enjoyed a reputation
for superior shunting sensitivity. This is partly due to the greater potential (voltage) used to excite the
track circuit. However, studies have shown that to maintain shunting continuity once it is acquired,
sufficient power is required to “burn” through the resistance of railhead rust and contaminants. Each
t-Boss7400 output is capable of outputting in excess of four amperes at full power – easily enough to
maintain shunting with most situations having difficult or poor track conditions.
The t-Boss 7400 ACDC Track Driver is a self-contained and compact unit specifically designed to drive
four independent and electrically isolated ACDC track circuits. The t-Boss 7400 is easily installed and
provides front-panel indicators to aid in troubleshooting track circuit problems and the DC battery
power source.
Why the t-Boss 7400 excels at driving ACDC track circuits
Early technology track drivers were designed using transformers intended to drive 6.3 volt vacuum
tube heater filaments. Because these transformers were inexpensive and readily available, they were
used in the original ACDC track driver designs, thus the voltage applied to most track circuit inputs is
6.3 VAC.
Many ACDC type track circuits can be driven successfully with 6.3 VAC. However, for those that have
poor ballast, are unusually long, or have conditions that result in low resistance between the rails,
higher voltage and amperage are required to power the track circuit. This is especially true during wet
weather conditions and when the roadway surface and the island circuit has been treated with ice and
snow melting chemicals.
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Page 1
Quick Start User Guide
t-Boss 7400 ACDC Track Driver
The t-Boss 7400 ACDC Track Driver is available in two versions:
Ÿ SP (standard power) - each output is approximately 7.5 Volts AC with 3 Amp output load (12.6 VDC
input).
Ÿ XP (extra power) - each output is approximately 10.2 Volts AC with 3 Amp output load (12.6 VDC
input).
Compared to early technology track drivers, the t-Boss 7400SP can provide about 16% greater driving
capability whereas the t-Boss 7400XP can provide about 34% greater driving capability.
t-Boss 7400 Familiarization
The t-Boss 7400 ACDC Track Driver is self-contained in a durable, compact steel enclosure. It is easily
mounted on the equipment wall of a signal bungalow or cabinet. For rack mounting, an adapter plate
is available for standard rack hole spacing. All wiring connections are made via a single 10-position
connector that requires no crimp terminals – simply strip the wire, insert into the connector receiver
clamp and tighten the wire-clamp screw.
The DC power input circuit breaker is intended to disconnect the unit from the DC battery supply if
connected improperly or an internal short-circuit should occur. Please note however, the circuit
breaker cannot always act fast enough to prevent damage to the unit if it is connected improperly.
The t-Boss 7400 includes secondary power surge protection for the 12VDC input and each of the four
track circuit outputs.
The front panel drawing to the left shows the
important features of the t-Boss 7400 ACDC Track
Driver.
(1) 0.25 in. mounting holes (4 places)
(2) 10-position Input/Output Connector
(3) DC BATT - NORMAL or LO/HI VOLTAGE FAULT
Indicator (blue)
(4) T1 - Track 1 Output Status Indicator (green or
red)
(5) T2 - Track 2 Output Status Indicator (green or
red)
(6) T3 - Track 3 Output Status Indicator (green or
red)
(7) T4 - Track 4 Output Status Indicator (green or
red)
(8) 15A Circuit Breaker
The five LED indicators provide status information
regarding the operation of the t-Boss 7400 ACDC
Track Driver.
The t-Boss 7400 senses overvoltage and undervoltage conditions for DC battery power input. When
either of these conditions exist, the unit immediately shuts down.
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Quick Start User Guide
t-Boss 7400 ACDC Track Driver
The purpose of sensing overvoltage or undervoltage and ceasing operation when such conditions exist
is to avoid unpredictable operation when input power is outside the specified operating parameters.
The Genesis t-Boss 7400 provides “clean” shutdown and power-up under all conditions. For example,
should the battery DC input voltage drop below 8.5 VDC, the system immediately shuts down and
remains shut down until the battery voltage recovers to 9.5 VDC. This minimizes the possibility of
erratic signal operation and “gate-pumping” where the signals and gates repeatedly cycle between ON
and OFF, resulting in much confusion to motorists and the risk of damage to vehicles and to the gate
arms.
The track output status LEDs provide indications that reflect the status of each track circuit; normal
non-shunted, normal shunted, open, reversed polarity, near overcurrent threshold and overcurrent.
These LED indicators are primarily intended to aid in troubleshooting track circuit problems. A more
in-depth description is included in the following section, “Using the t-Boss 7400 Front Panel Indicators.”
Application
When and where to use ACDC Track Circuits
ACDC track circuits are well suited where poor rail-wheel shunting for signal operation is expected or
has been experienced due to infrequent train traffic, excess railhead rust and/or contamination, or
lightweight equipment. They are best suited for rail-highway grade crossings where trains are traveling
at or about the same speed and do not stop within the approach circuit before entering the island.
ACDC track circuits are not suitable for signalized crossings where trains or rolling stock are parked or
stopped within the approaches and the signals are required to recover. Also, they must not be overlaid
nor can they be an overlay or wrap with other types of track circuits such as those used with motion
sensors, grade crossing predictors, coded track circuits and other types of track circuits commonly used
in North America.
Using the t-Boss 7400 Front Panel Indicators
Font panel indicator LEDs are intended to help troubleshoot problems with the B12 DC battery input
and the T1, T2, T3 and T4 track circuit outputs and track circuits.
When the t-Boss 7400 is initially powered-up, the LED Front Panel Indicators cycle through a self-test. If
the battery voltage is within the permissible operating range, all track outputs are then powered up.
DC BATT – NORMAL OR LO/HI VOLTAGE FAULT INDICATOR
A single blue LED indicator shows the status of the battery input voltage to the t-Boss 7400.
Ÿ ON continuously - DC battery input voltage is within normal operating limits.
Ÿ FLASHING slowly - DC battery input voltage is near either the low or high acceptable limits operating threshold.
Ÿ STROBED1 - DC battery input voltage is below or above allowable operating limits (system is shutdown and all track outputs are OFF).
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Quick Start User Guide
t-Boss 7400 ACDC Track Driver
DC Battery LED indicator thresholds and their display states are defined in the following table:
DC Input Range or
DCV Change
DC BATT / FAULT LED
T1 - T4 Outputs
After Change
Before Change
OFF
After Change
OFF
OFF
STROBED
OFF
STROBED
FLASH
ON
FLASH
STROBED
FLASH
ON
FLASH
STROBED
STROBED
ON
ON
ON
OFF
OFF
↙ 7.50V Note 2
STROBED
FLASH
ON
FLASH
STROBED
FLASH
ON
FLASH
STROBED
OFF
ON
ON
ON
OFF
OFF
< 7.50V Note 2
OFF
OFF
OFF
<
7.50V Note 2
↗8.00V Note 2
↗9.5V
↗10.5V
↗ 15.0V
↗16.0V
> 16.0V Note 1
↙ 15.5V
↙ 14.5V
↙ 10.0V
↙ 8.5V
OFF
Notes:
1. When the DCV is greater than the DC high-voltage threshold or is less than the DC low-voltage threshold, the
t-Boss 7400 ACDC Track Driver will shut-down.
2. V is approximate.
3. Input DC voltage should never exceed 17.5VDC for more than 1 second.
4. LED Indicator switch threshold accuracy is ±3%.
5. ↗ = DCV is increasing in value.
6. ↙ = DCV is decreasing in value.
T1 THROUGH T4 TRACK STATUS INDICATORS
Four LED indicators each capable of displaying either GREEN or RED are provided for each of the four
t-Boss 7400 track driver outputs. The Track Output Status indicators show the status of each track
circuit and can be used to aid in troubleshooting problems with the track driver or the track circuit.
The TRACK STATUS Indicators show the status of each of the t-Boss 7400 track outputs and its respective track circuit. LED indications are:
Ÿ ON GREEN continuously - NORMAL - NOT SHUNTED. Normal operation with track circuit not
shunted.
Ÿ FLASHING GREEN slowly - SHUNTED. Track circuit is shunted. Occurs when circuit is occupied by a
train, but also may occur if ring-10 diode is shorted, gage rod is shorting track circuit, etc.
Ÿ STROBED GREEN1 - HIGH-RESISTANCE CIRCUIT - Track circuit is open or current output substantially
reduced. May be caused by an open ring-10 diode, a broken or high-resistance bond, a broken rail,
a disconnected track wire or adjustments made to track circuit resistors. Although the track circuit
may appear to operate properly, the cause of such a condition should be discovered and corrected.
See the section ”Selecting and Adjusting Track Limit and Relay Resistors” (page 8) for information
about the selection and adjustment of track and relay resistors.
Ÿ OFF - OPEN CIRCUIT. Track circuit is open and output current is near zero. May be caused by output
not being connected or unused. It also could be caused by an open ring-10 diode, a broken or highresistance bond, a broken rail, or an open track wire.
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Quick Start User Guide
t-Boss 7400 ACDC Track Driver
Ÿ STROBED RED over continuous GREEN - REVERSED POLARITY - Track circuit polarity is reversed and
track circuit is not shunted, open or disconnected. Although a track circuit may appear to function
properly when the polarity is reversed, this is abnormal and should be corrected.
Ÿ FLASHING RED slowly - OVERCURRENT - Track circuit output is near the overcurrent fault threshold
(between 5.0A and 6.5A). The cause may be the track circuit limit resistor is adjusted at too low
resistance. The track circuit limit resistor should never be adjusted to less than 1 Ohm. Although a
track circuit may seem to function properly when operated in an overcurrent condition, this is
abnormal and should be corrected.
Ÿ STROBED RED1 - OVERCURRENT FAULT - Track circuit output exceeds the overcurrent fault
threshold of 6.5A. All track outputs are shut-down when an overcurrent fault occurs. The system
will resume operation once the overcurrent fault is corrected. The cause may be the track circuit
limit resistor is adjusted at too low resistance. The track circuit limit resistor should never be
adjusted to less than 1 Ohm.)
1
A strobed indication is two quick consecutive flashes each second.
IMPORTANT - The usefulness and accuracy of the T1 through T4 track circuit LED indicators will be
significantly improved if the following guidelines are followed:
1. Use the recommended values for the track circuit limit and relay current adjustment resistor. See
the section ”Selecting and Adjusting Track Limit and Relay Resistors” (page 8) for information about
the selection and adjustment of track and relay resistors.
2. Make sure the B12 battery voltage is between 11.0 Volts and 14.5 Volts and does not vary more
than ±5% during normal operation.
3. Adjust the track circuit limit resistor to provide approximately 2.5 to 4.5 VAC (track unoccupied) as
read on a Fluke 87 DVM or equivalent.
4. Adjust the relay current resistor to provide approximately 2.5 to 4 times the specified pick-up
current for the track circuit relay when unoccupied.
5. Never adjust the track circuit limit resistor to less than 1 Ohm.
RESETTING THE T-BOSS 7400 TRACK STATUS BASELINE MEMORY
To determine the status of the T1 through T4 outputs, the t-Boss 7400 monitors each output continuously to establish a normal “baseline.” This is done over a period of time and is used to determine
when track circuit conditions change in such a way that may indicate a track circuit fault, such as a
high-resistance bond, broken rail or a failed ring-10 diode.
If you adjust the track circuit resistors after a baseline has been established, the t-Boss 7400 LED indicator for the track circuit that was adjusted may not indicate the track status correctly. Once you have
finished adjusting the track and relay resistors, you should reset the baseline by removing power from
the t-Boss 7400 for several seconds and then restoring power. This can be done by temporarily unplugging the connector to the t-Boss 7400.
If the track circuit resistors are adjusted properly and all track circuits are functioning normally, the tBoss 7400 will establish a new baseline and the track circuit LED indicators should indicate correctly.
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Quick Start User Guide
t-Boss 7400 ACDC Track Driver
t-Boss 7400 Track Driver - Typical Hookup Wiring Diagram
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Quick Start User Guide
t-Boss 7400 ACDC Track Driver
Installation
Overall Preparation
To better understand the requirements of ACDC track circuits, please refer to the t-Boss 7400 Installation Diagram (page 6).
Each track circuit must be:
Ÿ isolated from adjacent track circuits (including non-circuited track) using suitable insulated joints in
both rails;
Ÿ free from low resistance paths between the rails such as non-insulated gauge rods, non-insulated
metalized frames in roadway crossing surfaces and very poor ballast; (The t-Boss 7400 can drive
track circuits that have a rail-to-rail resistance of less than two Ohms. However, a resistance
exceeding ten Ohms will yield much better results.)
Ÿ electrically bonded at all non-insulated rail joints using one or two bonds from one rail to the next;
Ÿ equipped with a suitable and properly installed diode (also known as a ring-10 diode) at the end of
the track circuit opposite from where the track feed wires are connected;
Ÿ connected from the rails to the field connections in the case or bungalow using wire no smaller
than AWG #6.
Ÿ protected by appropriate primary lightning protection (warranty does not cover lightning damage);
Ÿ equipped with adjustable track limit and a relay resistors suitable for the track driver being used
and the overall application; and
Ÿ equipped with a track driver such as the t-Boss 7400XP or t-Boss 7400SP.
Appropriate primary lightning protection is also required for the 12VDC battery input.
Wiring and Connections
See separate (11” x 17” drawing provided with each unit) wiring diagram for proper hookup or refer to
page 6.
Track circuits should be connected such that polarity and phase are opposite to those of adjacent track
circuits. This helps to ensure that activation of the signals will occur should both insulated joints fail
and the circuits become shorted to each other.
Opposite phase and polarity of adjacent track circuits is accomplished by installing ring-10 track diodes
with opposite polarity to those of adjacent circuits. Also, the t-Boss 7400 track output labeled as “+”
should be connected to the positive side of the circuit. This is best understood by examining the
provided wiring diagram and using it as a guide for your wiring hook-up.
When wiring the t-Boss 7400 plug-in connector, MAKE CERTAIN your wiring is correct BEFORE PLUGGING IN THE CONNECTOR. Damage to the t-Boss 7400 ACDC Track Driver caused by improper hookup
is not covered by the warranty.
The front-panel connector should have ONLY ONE WIRE PER INSERTION POINT. It is not designed to
hold securely more than one wire.
Make sure to use wire of adequate size for the current it must carry. The B12 and N12 inputs may be
required to carry up to 15 amperes under certain conditions. Each output may see currents up to 6.5
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Quick Start User Guide
t-Boss 7400 ACDC Track Driver
amperes. The following table specifies the minimum recommended wire size for wiring inside the
signal bungalow or cabinet. AWG #10 is preferred, which is the maximum wire size the connector will
accommodate.
PIN
01
2
03
04
05
06
07
08
09
10
CONNECTOR WIRING PINOUTS & MINIMUM WIRE SIZE
NAME
FUNCTION
MINIMUM WIRE SIZE
B12
12VDC BATTERY POSITIVE
AWG #12
N12
12VDC BATTERY NEGATIVE
AWG #12
T1+
TRACK 1 POSITIVE OUTPUT
AWG #12
T1TRACK 1 NEGATIVE OUTPUT
AWG #12
T2+
TRACK 2 POSITIVE OUTPUT
AWG #12
T2TRACK 2 NEGATIVE OUTPUT
AWG #12
T3+
TRACK 3 POSITIVE OUTPUT
AWG #12
T3TRACK 3 NEGATIVE OUTPUT
AWG #12
T4+
TRACK 4 POSITIVE OUTPUT
AWG #12
T4TRACK 4 NEGATIVE OUTPUT
AWG #12
Each wire should be stripped of insulation to 5/32” or 7mm. Make certain the wire clamp inside the
connector is gripping the bare wire itself and not the insulation. It is also important that no bare wire is
exposed after it is inserted into the wire clamp inside the connector.
DO NOT OVERTIGHTEN THE SCREWS on the connector. It is best to use a screwdriver with a handle
diameter no larger than about ½”. Test the wires after tightening the screw by pulling on them to make
sure they are securely fastened. If you have tools to measure torque when tightening the screws,
tighten to between 4.4 and 5.3 inch-pounds.
CAUTION! DO NOT WORK ON THE CONNECTOR WITH POWER APPLIED. The wire tightening screws
are at the same potential as the wire clamp, thus when tightening the screw, your screwdriver shaft is
at the same potential as the wire. Avoid inadvertently causing a short by turning off power or disconnecting the other end of the wire.
Field wiring to the rails should be AWG #6. Circuit resistance between the t-Boss 7400 and the rails
should be kept as low as reasonably possible as this helps to ensure adequate rail-wheel shunting.
Selecting and Adjusting Track Limit and Relay Resistors
Track Limit Resistor - Suggested track limit and relay adjust resistor values when using a 4 Ohm track
relay are as follows:
● t-Boss 7400XP - 10 Ohms adjustable (track) and 20 Ohms adjustable (relay)
● t-Boss 7400SP - 5 Ohms adjustable (track) and 10 Ohms adjustable (relay)
Use your railroad’s recommended procedures for adjusting the track limit and relay resistors. A good
starting place is for both resistors to be adjusted to approximately ⅔ of maximum resistance.
Note: To determine the approximate current draw by the track relay, simply read the DC voltage
across the relay coil and divide that value by the resistance value of the relay coil. For example, if the
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Quick Start User Guide
t-Boss 7400 ACDC Track Driver
DC voltage reads 1.0 VDC and the relay coil resistance is 4 Ohms, then 1.0 ÷ 4 = 0.25, or 0.25A (250
milliamps).
About Track Ballast
Good ballast conditions will improve shunting by not absorbing energy provided by the t-Boss 7400
ACDC Track Driver that would otherwise be used for good shunting. We recommend that the
approaches be reasonably free from dirt and other contaminants that would otherwise absorb electrical energy intended to help with shunting.
Pre-cutover Testing and Cutover
Once you have the t-Boss 7400 ACDC Track Driver operating, check the voltage to the rails. In dry
weather conditions with good ballast you should see 2.5 to 4.5VAC, depending on the adjustment of
the track circuit limit resistor. Remember, the track circuit voltage depends on the following three
factors:
1. Rail to rail resistance as affected by ballast, weather, snow and ice melting chemicals, etc.;
2. Settings of the track circuit limit resistor, and to a lesser extent, the relay current adjustment
resistor;
3. Battery input voltage to the t-Boss.
The following tests should be made before cutover:
1. Complete a disarrangement test as required by your railroad’s procedures;
2. Shunt each track circuit with a zero Ohm shunt then check the respective t-Boss 7400 track output
status LED to make sure it is not drawing too much current (LED flashing RED or strobed RED). If it
is, correct the problem before continuing. The problem may be the track circuit limit resistor is set
at too low resistance;
3. Shunt all approaches and the island using an approved 0.06 Ohm shunt to verify proper signal operation;
4. If possible, watch a train through the approaches and island to verify proper signal operation;
5. Complete any additional tests as required by your railroad or other regulatory agencies.
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Quick Start User Guide
t-Boss 7400 ACDC Track Driver
SPECIFICATIONS
TRACK OUTPUTS
(B12 = 12.6V; Load = 2Ω)
SP Version ...................................................................................................... 7.4 VAC
XP Version ...................................................................................................... 9.7 VAC
(B12 = 13.6V; Load = 2Ω)
SP Version ...................................................................................................... 8.0 VAC
XP Version .................................................................................................... 10.5 VAC
Near Current Limit Threshold (OVERCURRENT - LED flashing RED slowly)
Both Versions ................................................................................................ 5.0 A
Current Limit (OVERCURRENT FAULT - absolute maximum - forces system shutdown)
Both Versions ................................................................................................ 6.0 A
INPUTS
DC Battery (minimum for track driver output operation) ................... > 9.5
DC Battery (maximum for track driver output operation).................... < 16
DC Battery (absolute maximum).............................................................. 17.5
DC Battery (minimum recommended for operation) ............................ 11.0
DC Battery (maximum recommended for operation) ........................... 14.0
DC Idle Current (no track load, input = 13.6VDC) ................................. 0.45
DC Battery Overcurrent Circuit Breaker ..................................................... 15
VDC
VDC
VDC
VDC
VDC
Amps
Amps
ENVIRONMENT
Operating Temperature ...................................................... -40 (-40) - 160 (71) ˚F (˚C)
Humidity (non-condensing)....................................................................... 95% Relative
DIMENSIONS (see reference drawings for details)
Height .............................................................................................. 7.00 (17.78)
Width ................................................................................................ 5.56 (14.12)
Length (including connector) ....................................................... 7.70 (25.15)
Weight ................................................................................................ 15.5 (7.03)
Mounting Hole Centers - Width ....................................................... 2.5 (6.35)
Mounting Hole Centers - Height................................................... 6.34 (16.10)
in (cm)
in (cm)
in (cm)
lbs (kg)
in (cm)
in (cm)
CONNECTOR WIRING
Wire size range ........................................................................................ 10 - 24
Screw tightening torque - minimum ................................................... 4.4 (.5)
Screw tightening torque - maximum .................................................. 5.3 (.6)
AWG
in lbs (Nm)
in lbs (Nm)
Three-Year Limited Warranty
Genesis warrants all new products for three-years against parts failure and workmanship unless the warranty
terms are specifically stated otherwise on the invoice and packing slip for that product when shipped. Warranty
is explicitly for parts and workmanship and not for design or function.
Any products we manufacture found to be faulty in any way may be returned for rework, shipping prepaid. If
found to be in warranty, we will correct the fault or failure and return to you at no charge, shipping prepaid.
Warranty does not apply to damage caused by lightning, voltage surges, water, inappropriate storage, handling,
misuse or if the product has been modified or repaired by others.
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