helios cls retrofit handbook

Transcription

Handbook Supplement for Monitoring
Helios LV CLS (NLM) Signals
Siemens Plc
Mobility Division
Traffic Solutions
Sopers Lane
Poole, Dorset
BH17 7ER
United Kingdom
+44 (0) 1202 782000
http://www.siemens.co.uk/traffic
Handbook Supplement For Monitoring
THIS DOCUMENT IS ELECTRONICALLY HELD AND APPROVED
Prepared By
Company/Dep Traffic Solutions / Engineering
t.
Name
Paul Cox
Function
Lead Engineer
Signature
[ELECTRONICALLY APPROVED]
Checked and Released
Traffic Solutions / Engineering
Dave Martin
Engineering Manager
[ELECTRONICALLY APPROVED]
Date
July 2016
July 2016
COPYRIGHT STATEMENT
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
Copyright  Siemens plc 2016 All Rights Reserved
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SAFETY WARNING
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 or the relevant local, state and
government regulations.
(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.
(iii) Any power tools must be regularly inspected and tested.
(iv) Any ladders used must be inspected before use to ensure they are sound and
not damaged.
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.
(v) Any personnel working on site must wear the appropriate protective clothing,
e.g. reflective vests, etc.
In the event of any person working elsewhere on the junction the Mains Supply to the
controller must be switched off and the master switch locked in the ‘off’ position.
In countries where both sides of the incoming supply are above earth potential, the
Master Switch or Circuit Breaker on the rear of the controller should be opened, since
the Controller Switch on the front of the controller does not isolate both sides of the
supply.
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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 junction 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.
When re-commissioning signals, the following sequence is recommended:
1.
2.
3.
Switch OFF the controller at the main switch
Switch ON the lamps on-off switch on the Manual Panel
Switch ON the controller at the main switch.
More specific safety information is given in the text of the handbook, where it relates
to particular activities or situations.
WARNING
To isolate the equipment, the master switch must be in the “Off”
position.
Removal of the Electricity Board Fuse or Switching the Controller
switch or the Manual Panel Signals On/Off switch to “Off” does not
guarantee isolation of the equipment.
WARNING
These controllers require specific configuration to enable them to
function correctly when installed.
The configuration process is a complex activity and should only be
carried out by persons who are adequately trained, have a full
understanding of the needs of the county or region were the
controller is to be used and are experienced in the tasks to be
undertaken.
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CONTENTS:
1. Introduction ........................................................................................................... 6
1.1 Purpose ................................................................................................................ 6
1.2 Scope ................................................................................................................... 6
1.3 Document Specific Abbreviations and Definitions ................................................ 7
1.4 References ........................................................................................................... 7
2. Overview .............................................................................................................. 10
2.1 The LV CLS Facility ............................................................................................ 10
2.2 Upgrade Prerequisites ........................................................................................ 10
2.3 PB801 / PB815 Compatibility .............................................................................. 11
2.4 Upgrade Procedure ............................................................................................ 12
3. Upgrade Details .................................................................................................. 16
3.1 New LED Lamp Switch / Phase Driver Card Variants......................................... 16
3.2 Signal Types that can be Lamp Monitored ......................................................... 19
3.3 Deciding Which Signals to Upgrade ................................................................... 21
3.4 Upgrading the Signals ........................................................................................ 25
3.5 ST800 Mains Filter.............................................................................................. 29
3.6 Replace the ST700/ST750 Phase Driver PCB ................................................... 35
4. Handset Command Changes ............................................................................. 38
4.1 Fault Log Changes ............................................................................................. 38
4.2 Handset Command Changes ............................................................................. 40
5. Signal Upgrades – Detailed Options ................................................................. 43
5.1 Red / Amber / Green Signals .............................................................................. 44
5.2 Near-Side Peds (Puffin / Toucan) ....................................................................... 45
5.3 Far-Side Peds with Wait Indicators [ST700/ST750 Controllers] ......................... 45
5.4 Far-Side Peds with Wait Indicators [ST800/ST9XX Controllers] ......................... 45
5.5 Monitoring Wait Indicators [ST800/ST9XX Controllers] ...................................... 48
6. Appendix A: Upgrade Kits for Peek Elite Signals ............................................ 54
6.1 Introduction ......................................................................................................... 54
6.2 Part Numbers ..................................................................................................... 55
6.3 Wiring modifications............................................................................................ 55
6.4 Door Locking Options ......................................................................................... 56
7. Appendix B: Part Numbers ................................................................................ 57
FIGURES:
Figure 1 – ST700/ST750 LED Phase Driver Overview ............................................. 18
Figure 2 – Upgrade Strategy Flowchart (Part 1) ....................................................... 23
Figure 3 – Upgrade Strategy Flowchart (Part 2) ....................................................... 24
Figure 4 – Futurit Signal (left) / Dialight Signal (right) ............................................... 28
Figure 5 – PL1 MDU Connections ............................................................................ 30
Figure 6 – Rack Cabling ........................................................................................... 30
Figure 7 – Completed Filter Installation .................................................................... 32
Figure 8 – DIN Rail Terminal Block Assembly 32 Phase .......................................... 33
Figure 9 – Relocated DIN Rail Terminal Block Assembly 32 Phase ......................... 33
Figure 10 – ST700/ST750 LED Phase Driver PCB .................................................. 37
Figure 11 – Front view of HELIOS Peek Elite Retro-fit door ..................................... 54
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Figure 12 – HELIOS Peek Elite Retro-fit door assembled to Peek Elite Housing ..... 54
Figure 13 – Cam locking option 1: a) Unlocked, b) Locked ...................................... 56
Figure 14 – Cam locking option 2: a) Unlocked, b) Locked ...................................... 56
TABLES:
Table 1 – Change History ........................................................................................... 5
Table 2 – Abbreviations and Definitions ..................................................................... 7
Table 3 – Essential Documents .................................................................................. 8
Table 4 – Other Documents........................................................................................ 9
Table 5 – ST700/ST750 Sensor Changes ................................................................ 17
Table 6 – Signal Types that can be Lamp Monitored (ST800/ST9XX) ..................... 20
Table 7 – Signal Types that can be Lamp Monitored (ST700/ST750) ...................... 20
Table 8 – Helios CLS (NLM) Upgrade Kits ............................................................... 27
Table 9 – Signal Upgrades – RAG Signals ............................................................... 44
Table 10 – Signal Upgrades – Far-Side Peds (Enabled) .......................................... 46
Table 11 – Signal Upgrades – Far-Side Peds (Disabled) ......................................... 47
Table 12 – Wait Lamp Configuration Options ........................................................... 48
Table 13 – Peek Elite Retro-Fit Part Numbers.......................................................... 55
Table 14 – Part Numbers.......................................................................................... 57
CHANGE HISTORY:
Version Date
Author
Change
1
Apr 2009 Paul Cox
2
May 2009 Paul Cox
Minor improvements (ref 0005447)
3
Jun 2009 Paul Cox
Minor improvements (ref 0006501)
4
Nov 2009 Dave
Filter DIN plate detail addition for 32 phase
Brocklehurst controllers (ref TS005309)
4a
May 2010 Kevin Wass
Addition of Appendix A for Peek Elite retro-fit
5
July 2010 Kevin Wass
Formal issue of Appendix A (Ref TS005499)
6
Aug 2010 Paul Cox
Added ST700/ST750 Controllers
Removed the option to monitor Helios LED
and Helios CLS+LMF using on-board sensors.
Implemented RFC TS005351 (Neutrals).
7
Sep 2014 David
Hoslett
Updated KLV and KLT values and added
KRW handset command, to support Lamp
Monitoring for Panasonic and Ketc LED
Signals on ST800 Controller for Hong Kong
(ref TS006655)
Paul Cox
8
Mar 2016 Jim
Ballantine
First Release.
Add ST950 Controller and CLS Waits (ref
TS007682)
Reference ST900 firmware issue 14 for KRW
command.
Table 1 – Change History
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1. Introduction
1.1 Purpose
The purpose of this document is to detail the installation and operation of Traffic
Controllers upgraded to lamp monitor ‘Helios CLS (NLM)’ LED Traffic Signals.
1.2 Scope
This document covers the facility that allows these Traffic Controllers to lamp monitor
‘Helios CLS (NLM)’ LED Traffic Signals.
 ST700 Single/Dual Pedestrian Controller
 ST750 Single/Dual Pedestrian Controller
 ST800 Intersection Traffic Controller
 ST900 (LV) Intersection Traffic Controller
 ST950 (LV) Intersection Traffic Controller
It does not replace the original documentation provided for those controllers.
The documents listed in section 1.4.1 are still essential for installation, commissioning
and maintenance of these controllers. All normal installation and commissioning
procedures must be adhered to.
To use the facility, the controller must be fitted with “LED Lamp Switch Card”
(ST800/ST9XX) or “LED Phase Driver” (ST700/ST750). If upgrading existing sites,
the firmware may need to be updated, but in most cases, a new IC4 configuration is
not required; the original configuration can be used.
This facility is not available on the ST800P Pedestrian Controllers, or the ST700SE /
ST750SE Small Intersection controllers.
The ST9XX-ELV and ST750-ELV Controllers are capable of monitoring the
equivalent Central Light Source LED Signals ‘Helios ELV’ at their ELV supply
voltages.
IMPORTANT: Compatible types of LED Signal – At the time of writing, these LV
Controllers can only monitor 230V LED Signals supplied by Siemens and listed in the
appropriate 667/SU/xxxxx/000 document for the controller. These controllers cannot
monitor LED signals from other manufacturers, nor can they monitor 48V LED
Signals such as LED Wait Indicators and Near-Side Puffin Signals. Refer to section
3.2 on page 19 for full details.
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1.3 Document Specific Abbreviations and Definitions
Abbreviation
Explanation
ELV
Helios CLS
‘Extra Low Voltage’ (nominally below 50V AC)
Central Light Source; marketing name for Siemens LED traffic
signals. Helios CLS signals contain a small number of high-power
LED devices.
‘Helios CLS (NLM)’ refers to a CLS module without the LMF module
‘Helios CLS+LMF’ refers to a CLS module with the LMF module.
Siemens LED Traffic Signals prior to the introduction of the CLS
type. Each module contains a large number of individual standard
LED devices. It also simulates a halogen lamp load for Siemens
lamp monitoring equipment in a similar way to an LMF.
Lamp Monitoring Facility; add-on unit that simulates a halogen lamp
load for Siemens lamp monitoring equipment so they can monitor
Helios CLS Signals as normal incandescent lamps.
‘Low Voltage’ (includes 230V; contrast with ELV)
Lamp Switch Card
No LMF Module
Red Lamp Monitor[ing]
Pedestrian Controller version of the ST800 Controller
Pedestrian Controller version of the ST900 Controller
Siemens Traffic Controller product prior to 2007
Siemens Traffic Controller product from 2007 to 2013
Siemens Traffic Controller product from 2013 onwards
Applies both ST900 and ST950 Controllers
Helios LED
LMF
LV
LSC
NLM
RLM
ST700
ST750
ST800
ST900
ST950
ST9XX
Table 2 – Abbreviations and Definitions
1.4 References
1.4.1 Essential Documents
No. Part Number
Title
Version
ST800 Traffic Controller Documents
1. 667/HB/27000/000
ST800 Traffic Controller General Handbook
Issue 7
or later
2. 667/HE/27000/000
ST800 Installation, Commissioning and
Maintenance Handbook
Issue 9
or later
3. 667/HH/27000/000
Handset Handbook for the Siemens Type 800
& Type 700 Traffic Controllers
Issue 9
or later
4. 667/CI/32921/007
ST800 Helios CLS NLM Retrofit Installation
Note
Latest
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5. 667/HB/27880/000
Siemens ST700 General Handbook
Latest
6. 667/HH/27000/000
& Type 700 Traffic Controllers
Issue 9
or later
7. 667/CI/32755/000
ST700 Helios CLS NLM Retrofit Installation
Note
Latest
8. 667/HB/32900/000
General Handbook for the ST900 Family of
Traffic Controllers
Issue 5
or later
9. 667/HE/33900/000
Issue 3
or later
10. 667/HH/32900/000
and Type 750 Family of Traffic Controllers
Issue 5
or later
11. 667/HB/33750/000
General Handbook for the ST750
Issue 4
or later
12. 667/HH/32900/000
and Type 750 Family of Traffic Controllers
Issue 7
or later
13. 667/HB/46000/000
ST950 General Handbook
Latest
14. 667/HE/46950/000
Latest
15. 667/HH/46000/000
ST950 Handset Command Handbook
Latest
General Traffic Controller Documents
16. 667/HE/20664/000
Installation and Commissioning handbook:
Installation Testing (General)
Latest
17. 667/HB/30000/000
Helios General Handbook
Latest
Table 3 – Essential Documents
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1.4.2 Other Documents
No. Part Number
Title
Version
ST800/ST700 Traffic Controller Documents
18. 667/SU/27000/000
Use of ST800/ST700 Firmware and Hardware
Configurations
Latest
ST900/ST750 Traffic Controller Documents
19. 667/SU/32900/000
Use of ST900 and ST750 Firmware and
Hardware Configurations
Latest
20. 667/CC/32900/000
ST900 Family Controller Configuration
Latest
21. 667/CC/32750/000
ST750 Family Controller Configuration
Latest
22. 667/SU/46000/000
Use of ST950 Firmware and Hardware
Configurations
Latest
Table 4 – Other Documents
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2. Overview
2.1 The LV CLS Facility
In order to lamp monitor Helios CLS signals without an LMF module both the
firmware and hardware within the Controller need to be upgraded. The new
ST800/ST9XX “LED Lamp Switch Card” (LSC) and ST700/750 Phase Driver Card
are described in section 3.1.
It should be noted that the ST800 Retrofit Kit can not be used to upgrade an ST800
fitted with a ‘high-current’ 30A kit. Contact Siemens Engineering in Poole for upgrade
options in this case.
Once these changes have been made, the ST800/ST9XX Controllers will monitor
both low-power ‘Helios CLS (NLM)’ and continue to monitor incandescent signals,
although the number of signals that can be monitored by each on-board sensor is
reduced. For ST700/750 Controllers, the only incandescent signals that can be
monitored are WAIT lamps. This is covered in more detail in section 3.2.
Note that when a lamp monitor sensor is configured to monitor LED Signals, the ‘Bulb
Watts’ value configured on the IC4 screens is ignored. The KLT ‘Load Type’ includes
all the information required by the controller to monitor those LED Signals; no
information on power consumed by those signals is required from IC4.
2.2 Upgrade Prerequisites
It is vital that all the following steps have been undertaken BEFORE WORK TO
UPGRADE THE SITE BEGINS.
1) Obtain the correct number of new variant Lamp Switch Cards; section 3.1
2) Determine which signals are to be upgraded; sections 3.2 and 3.3
3) Obtain the required signal upgrade kits; section 3.4
4) [ST800 ONLY] Obtain Mains Filter Upgrade Kit; section 3.5
5) [ST800 ONLY] If the controller is wired 32 phases and fitted with a DIN rail
mounted terminal block in place of the ‘Hedgehog’ obtain an ST800 32 Phase
Retrofit DIN Rail Mounting Panel Kit; section 3.5
6) [ST700/750 ONLY] Check no more than 2 RLM channels are required on the
second pedestrian stream; section 3.1.5 starting on page 17.
7) Check firmware version / obtain new firmware PROM; section 2.4 Step 8)
8) [ST900 ONLY] Ensure “SIC:PB815 issue 4” or later is fitted, see section 2.3 that
follows.
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2.3 PB801 / PB815 Compatibility
From PB801 issue 7 onwards, the ST900 main processor firmware insists that the
Phase Bus Processor firmware 667/TZ/12815/000 “PB815” is issue 4 or later. This
is the issue used in most ST900 Controllers. However, issue 2 may be fitted to some
early ST900 CPU Cards. Use the handset command 'SIC' to determine which version
of firmware is fitted.
If PB815 issue 2 is fitted, it must be upgraded to PB815 issue 4 or later at the
same time as the PB801 firmware PROM is upgraded. If it is not, the signals will
not illuminate and the fault “FLF 2:253” will be logged.
For this reason, the latest versions of both the PB801 and PB815 firmware PROMs
are supplied in the ST900 Retrofit Kit (see page 57 for the part number).
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2.4 Upgrade Procedure
This section summarises the steps to be followed when upgrading a controller to
‘Helios CLS (NLM)’.
IMPORTANT: Before starting the upgrade, consider using ‘IC4 View Differences’
to extract any changes to the controller’s configuration data before changing the
Firmware PROM or the IC4 Configuration PROM. Changes may have been made
to the controller’s configuration data using handset commands and these will be
erased when either the Firmware* or IC4 Configuration are changed.
* On an ST950, the firmware upgrade procedure does not erase handset changes; all
settings changed using handset commands or the web interface are preserved.
Step 1) Prerequisites for Upgrade
BEFORE WORK TO UPGRADE THE SITE BEGINS, refer to section 2.2
for steps that must be performed first.
Step 2) Switch Off the mains power at the Master Switch
Ensure that the Master Switch is locked in the OFF position.
Ensure that the mains supply has been isolated.
Step 3) Upgrade the traffic signals; refer to section 3.4 (page 25).
After upgrading the signals, if any changes are made to the earth
connections, ’Minor Works’ electrical testing as required in
667/HE/20664/000 must be completed.
Step 4) ST700/ST750 Only: Remove or Bypass 230/48V WAIT Transformers
The ST700/ST750 LV CLS Controller only provides 48V drive outputs for
WAIT signals; the option for 230V has been removed on safety grounds.
Step 5) ST700/ST750 Only: Check External Toroid Sensors
External (off-board) lamp monitoring toroid sensors for additional vehicle
RLM channels and Pedestrian Red/Green signals must be removed as
these are now on-board. If monitoring of incandescent WAITs is required,
use sensors 38 and 40. Refer to section 3.1.5 (page 17) for more
information.
Step 6) Replace lamp switch / phase driver card; refer to section 3.1 (page 16)
For the ST700/ST750, instructions on how to change the Phase Driver
Card are in Section 3.6 (page 35).
Step 7) (ST800 only) Fit the Mains Filter to the back of the controller rack
Refer to section 3.5 (page 29)
ST9XX controllers already have a Mains Filter fitted near the Master
Switch. ST700/750 controllers already have Mains Filter fitted in their
‘biscuit tin’. An additional filter is not needed.
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Step 8) Upgrade the Firmware
On an ST800 Controller the firmware must be PB800 issue 26 or later.
The ST800 firmware PROMs may be labelled "PB800" or "667/TZ/12800/000".
On an ST900 Controller the firmware must be PB801 issue 8 or later but
issue 14 (or later) is required for CLS Waits (the KRW settings).
The PHS daughter card needs to be removed to gain access to the firmware PROM.
In both cases, the firmware PROM is located near the centre of the PCB.
IMPORTANT: If the ST900 firmware needs to be upgraded, also check the
Phase Bus Processor firmware is PB815 issue 4 or later;
see section 2.3 on page 11.
On an ST950 Controller all firmware versions support LV CLS monitoring,
but issue 6 (or later) is required for CLS Waits (the KRW settings).
Step 9) If necessary, change configuration PROM
Confirm that the configuration has been generated by a competent person
in accordance with the required procedures in place for the county and
region.
NOTE: A controller can usually be upgraded to LV CLS without changing
the IC4 Configuration PROM; it depends on the signals types and
monitoring required. This is covered in section 3.3 (page 21).
Step 10) Power on
Switch the Signals On/Off switch to the OFF position.
Switch the power to the controller back on.
Step 11) ST700/750 – Download the IC4 Configuration
If the firmware PROM has been changed in Step 8), an IC4 configuration
will need to be downloaded from a PC into the CPU PCB and customised
using the handset mnemonics detailed in the Special Instructions. Follow
your usual procedures for configuring the ST700 and ST750 Controller.
Step 12) Enter any Timing Changes
Make any adjustments to the controller’s timings and settings identified by
the IC4 View Differences (recommended on page 12) and marked-up on
the IC4 Printout in the controller cabinet.
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Step 13) Change the KLV setting
The fault FLF 2:10 will be logged if the type of Lamp Switch / Phase Driver
Card fitted does not match the KLV setting, see section 4.1.1 on page 38.
If the KLV value is zero, select the one KLV value that is most applicable:
If Siemens/Dialight Helios CLS signals are fitted:
 Use KLV=3 if there are no far-side peds or these remain incandescent, or
 Use KLV=4 if far-side peds are also changed to ‘Helios CLS (NLM)’.
If Siemens/Futurit Helios CLS signals are fitted:
 Use KLV=5 if there are no far-side peds or these keep their LMF units, or
 Use KLV=6 if LMF units are removed from the far-side peds.
For information on how to distinguish between Dialight and Futurit signals,
refer to section 3.4.8 on page 28. For information on the options for far-side
peds, see section 3.3 (page 21).
Step 14) Review and if necessary correct the KLT settings for ALL the sensors
The KLT handset command is described in section 4.2.2 (page 41).
KLT s:0 ........ Monitoring disabled on sensor <s>.
KLT s:1 ........ Siemens/Dialight Helios CLS (default after KLV=3 or KLV=4).
KLT s:10 ...... Siemens/Futurit Helios CLS (default after KLV=5 or KLV=6).
KLT s:255 .... Incandescent lamps, Helios LED, Helios CLS+LMF, tubes.
Tip!
On the ST950, rather than using the KLV, KLT and KRW handset
commands, consider using the LMU-General web page to alter the ‘Lamp
Supply Voltage Type’ and the LMU-Sensors page to set up each sensor.
Step 15) Check the KRW settings
For a sensor configured to monitor both Pedestrian LED Red and Wait, two
options are available, selected using the KRW handset command
described in section 4.2.3 (page 42):
0: Auto (Default) – Monitoring of the Pedestrian LED Red is automatically
suspended while the Wait indicator is illuminated on the assumption that
the Wait indicator is not the same LED signal type as the Red.
1: Enabled – Monitoring of the Pedestrian Red and Wait is enabled. The
sensor monitors all the states and the LED Red and LED Wait signal types
must be the same Load Type, i.e. require the same KLT setting, for
example Helios CLS Red and CLS Wait.
Step 16) Reset the Lamp Monitor if any KLT/KRW values are changed
Use KLR=1 to reset the lamp monitor if any KLT or KRW settings are
changed.
Step 17) Illuminate the signals
Enter RFL=1 and Power off/on to clear the FLF 2:10 fault (if present) and
illuminate the traffic signals.
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Step 18) Calibrate the lamp supply voltage reading
Carefully measure the bright lamp supply using a calibrated multi-meter.
If this differs from the value displayed by the handset command ‘KEV’,
enter the correct value, e.g. KEV=235, to calibrate the controller’s reading.
It is important that the controller has an accurate reading of the lamp
supply voltage because it has to suspend monitoring of the LED signals
(except those monitored for RLM) when the supply is outside of the normal
working range to avoid reporting erroneous lamp faults.
Step 19) Check the dim lamp supply voltage
If dimming is required, set transformer output to the 160V tap.
Measure the actual dim voltage and check that it is no higher than 160V. If
dim voltage is higher, move the input to the next higher tap, e.g. from the
230V input tap to the 240V input tap.
If the dimming voltage is still too high, then the 140V tap can be used to
reduce the dimming voltage further.
IMPORTANT: The use of the 120V tap is not supported by Helios CLS
signals.
Step 20) Reset the Lamp Monitor if the dimming voltage is changed
If any changes are made to the transformer connections; enter KLR=1 to
reset the lamp monitor and relearn the loads.
Step 21) Check lamp monitoring learning
This is detailed in Handset Handbook (/HH/) for the Controller.
Check using the KEL handset command that the number of watts learnt
equates to the correct number of signals fitted; ‘Helios CLS (NLM)’
consume between 10W and 15W.
NOTE: The KES and KEL handset commands will show 0mA and 0W
respectively for sensors configured to monitor both Pedestrian Red and
Wait (Red,Wt) if ‘Helios CLS (NLM)’ signals are fitted on the pedestrian
phase; monitoring is suspended while the Wait indicators are lit. This is the
default operation, but may have been changed using the KRW settings
(Step 15).
Step 22) Upgrade Complete
Follow usual commissioning procedures for completion of site installation.
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3. Upgrade Details
3.1 New LED Lamp Switch / Phase Driver Card Variants
3.1.1 Why is a new version of the card required?
In order to reliably monitor the low currents of these low power ‘Helios CLS (NLM)’
signals, a new version of the ST800/ST9XX Lamp Switch Card or ST700/ST750
Phase Driver Card is required.
The current consumed by these signals is typically around 20mA when dimmed. The
new variants of the PCBs are capable of monitoring these lower currents but as a
result there is a lower current limit for the on-board sensors.
The ‘off-board’ sensors continue to monitor up to 4 amps; these cannot be used to
monitor ‘Helios CLS (NLM)’ signals.
Section 3.2 starting on page 19 lists the type of signals (and quantity) that can be
lamp monitored.
IMPORTANT: Do not fit a mix of different variant Lamp Switch Cards in a controller.
For the controller to monitor any Helios CLS (NLM) signals, all the Lamp Switch
Cards must be ‘LED Lamp Switch’ variants, even if the signals on other phases
remain incandescent.
3.1.2 Identification of the new variants – ST800/ST9XX Lamp Switch Card
The new variants of the ST800/ST9XX Lamp Switch Card are clearly distinguishable
from the original cards by a label on the front of the cover stating ‘LED Lamp Switch’.
The part numbers of the PCBs are:
667/1/33905/312 – UK Variant (Fail to Blackout)
667/1/33905/302 – Non-UK Variant (with ‘Fail to Flashing’ option)
The PCB’s are provided as part of a kit. The kit part numbers are listed in section 7
on page 57.
3.1.3 Identification of the new variants – ST700/ST750 Phase Driver Card
The new variant of the ST700/ST750 Phase Driver Card is clearly distinguishable
from the original cards by the “ST700/ST750 LED Phase Driver” title on the Heatsink
Cover. For details on this Phase Driver Card, see section 3.1.5.
The part numbers of the PCBs are:
667/1/33790/002 – ST700/750 LED 2 Phase Driver – Single Pedestrian Stream
667/1/33790/004 – ST700/750 LED 4 Phase Driver – Dual Pedestrian Stream
The PCB’s are provided as part of a kit. The kit part numbers are listed in section 7
on page 57.
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3.1.4 Controller Self-Test
When the controller asks ‘All Cards Working?’ it illuminates amber LEDs in a scrolling
pattern down the phase output mimic LEDs:
For standard controllers, only one amber LED is illuminated at a time on each card.
For LV CLS controllers, the pattern will illuminate two amber LEDs.
Also note that the ADC Test voltage of 2.5V on the normal variant LSC is replaced by
a test at 3.6V on the new variant LSC.
3.1.5 ST700/ST750 LED Phase Driver Card
Compared to the ‘standard’ ST700/ST750 Phase Driver Card, the LED variant has
twice as many on-board sensors to allow it to monitor the LV CLS Signals.
External toroid sensors for monitoring Vehicle RLM Channels 3 & 4 and the
Pedestrian Red/Green signals are no longer supported, with most of these features
now provided by on-board sensors. External toroid sensors are only required to
monitor incandescent WAIT lamps.
Phase
Colour
Sensor
Standard
Variant
LED
Variant
A
R1 A G
R2 A G
R3
R4
5
6
33
37
On-Board
On-Board
Toroid
Toroid
On-Board
On-Board
On-Board
On-Board
B
R,G
W
34*
38
Toroid
Toroid
On-Board
Toroid
C
R1 A G
R2 A G
R3
R4
7
8
35
39
On-Board
On-Board
Toroid
Toroid
On-Board
On-Board
n/a
n/a
R,G
W
36*
40
Toroid
Toroid
On-Board
Toroid
D
Comments
Now on-board
Now on-board
Now on-board
No longer available
No longer available
Now on-board
Table 5 – ST700/ST750 Sensor Changes
* Existing Controllers may use off-board toroid sensors 34 (Phase B) and 36 (Phase
D) to monitor all the pedestrian signals (Red, Green and Wait). In this case,
physically re-arrange those sensors so they become sensors 38 (Phase B Wait only)
and sensor 40 (Phase D Wait only).
For safety reasons and to reduce complexity, the LV CLS variant only provides 48V
Ped Amber outputs for the WAIT / Demand Accepted indicators; the option for 230V
Ped Amber outputs has been removed. As a result, Fuse F8 and links LK16, LK19
and LK21 have been removed from the PCB.
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PL6
Phase A
Vehicle
Supply 230V
R
A
G
Triacs
and
Monitors
5
Pedestrian
Supply
230/48V
R
G
W
Wait Supply
48V
34
Triacs
and
Monitors
Pedestrian
Supply
230/48V
R
G
W
Wait Supply
48V
RA2
YA2
GA2
Phase A RAG
Vehicle RLM
Channel 2
RB
GB
Phase B
Red / Green Man
YB
PL7
7
38
Wait
LMU
only
RAU
Phase C Red
Unmonitored
RA1
YA1
GA1
Phase C RAG
Vehicle RLM
Channel 1
RA2
YA2
GA2
Phase C RAG
Vehicle RLM
Channel 2
RB
GB
Phase D
Red / Green Man
LMU + RLM
8
Phase D
Phase A RAG
Vehicle RLM
Channel 1
LMU only
Phase C
R
A
G
RA1
YA1
GA1
LMU + RLM
Triacs
and
Monitors
Vehicle
Supply 230V
Phase A Red
Unmonitored
LMU + RLM
6
Phase B
RAU
LMU + RLM
36
LMU only
YB
Triacs
and
Monitors
PL8
33
40
LMU
only
Wait
RA3
Phase A Red
Vehicle RLM
Channel 3
RA4
Phase A Red
Vehicle RLM
Channel 4
RLM
37
RLM
Figure 1 – ST700/ST750 LED Phase Driver Overview
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3.2 Signal Types that can be Lamp Monitored
These tables list the signal types that can be lamp monitored. Separate tables are
provided for the ST800/ST9XX Controllers and the ST700/ST750 Controllers. The
tables indicate how many signals can be lamp monitored by the On-Board and OffBoard sensors.
The ‘Can be Lamp Monitored’ column indicates whether the type of the signal can be
monitored by the LV CLS Controller, but is subject to other restrictions:
 Lamp monitoring must be enabled in the IC4 configuration. Lamp monitoring of a
phase can only be modified or disabled by handset commands; it cannot be
enabled using handset commands alone.
 Where a lamp monitor sensor is configured to monitor a pedestrian phase with
Wait Indicators, refer to section 3.3 (page 21).
 All signals of a phase that are monitored by one lamp monitor sensor must have
the same ‘load type’, i.e. require the same KLT setting. DO NOT install a mix of
CLS signals and other signal types on the same sensor, or fit both types of Helios
CLS (NLM) signals on the same sensor.
 Dialight CLS (NLM) Red/Green and CLS Wait indicators can be fitted to a
pedestrian phase and monitored by the same on-board sensor (ST800/ST950) by
changing the KRW setting.
 ‘Helios CLS (NLM)’ Signals can only be lamp monitored by the built-in on-board
sensors; the external off-board sensors are not capable of monitoring these
signals.
 The on-board sensors are not capable of monitoring Helios CLS+LMF or Helios
LED Signals.
 The ST700/ST750 LED Phase Driver Card is limited to two RLM channels on the
second pedestrian stream (but there remain four on the first ped stream); refer to
section 3.1.5 (page 17).
The KLT handset command (section 4.2.2 on page 41) sets the ‘load type’ for each
lamp monitor sensor, informing the controller the type of signal attached.
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Can be Lamp
Monitored?
ST800/ST9XX
Signal Type
Helios CLS (NLM) [Dialight]
Includes Vehicle and Far-Side Ped & Cycle Signals
Helios CLS (NLM) [Futurit]
2
Incandescent / Filament lamps*
Fluorescent Tubes*2
Helios LED and Helios CLS+LMF
LED Near-Side Puffin, Toucan, etc.
LED Wait & Demand Indicators
CLS Wait Indicators
Number of signals
that can be monitored
per Sensor*1
On-board
Off-board
KLT
Yes
8
NONE
1
Yes
8
NONE
10
Yes
Yes
Yes
No
No
Yes
4
16
12
16
255
255
255
0
0
1
NONE
NONE
NONE
NONE
4*
3
NONE
Table 6 – Signal Types that can be Lamp Monitored (ST800/ST9XX)
Can be Lamp
Monitored?
*1 On-board sensors: built-in to the LSC, one per phase, limited to 240W (approx). Off-board sensors:
external toroid sensors with flying leads that can be added, four per LSC, starting with sensor 33.
*2 Refer to the General Handbook for full details on the types of incandescent, filament and
fluorescent signals that can be driven and lamp monitored by the controllers.
*3 In addition, the total number of Helios CLS Red (Pedestrian/Cycle) plus CLS Wait Indicators
monitored by the same sensor must not exceed eight, e.g. four Red + four Wait is the maximum.
ST700/ST750
Signal Type
Helios CLS (NLM) [Dialight]
Helios CLS (NLM) [Futurit]
40W 48V Wait Lamps
65W 48V Wait Lamps
Incandescent Ped Red/Green
Helios LED and Helios CLS+LMF
LED Near-Side Puffin, Toucan, etc.
LED Wait & Demand Indicators
CLS Wait Indicators
Number of signals
that can be monitored
per Sensor*4
On-board
Off-board
KLT
Yes
6
NONE
1
Yes
6
NONE
10
Yes
Yes
No
No
No
No
No
NONE
NONE
4
3
NONE
NONE
NONE
NONE
255
255
0
0
0
0
0
NONE
NONE
NONE (*5)
Table 7 – Signal Types that can be Lamp Monitored (ST700/ST750)
*4 On-board sensors: built-in to the Phase Driver Card. There are more on-board sensors on the LED
variant Phase Driver Cards than the standard types (see page 17). Off-board sensors: external
toroid sensors with flying leads that can be added to monitor 48V incandescent WAIT lamps.
*5 The external toroid sensors used to monitor Wait signals on the ST700/ST750 are not capable of
monitoring CLS Wait signals.
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3.3 Deciding Which Signals to Upgrade
As mentioned in previous sections, limitations to the monitoring scheme influence the
possible upgrade paths.
This section provides a brief overview of the signal upgrade options available without
changing the IC4 configuration and changing controller’s configuration PROM. If you
are prepared to reconfigure the controller, there are additional upgrade options. Full
details of the signal upgrade options that can be attained are to be found in section 5,
which starts on page 43.
For details of how to physically upgrade the signals, see section 3.4, which follows
and starts on page 25.
IMPORTANT: In all cases there are limits on the number of signals that can be
monitored by a sensor; refer to section 3.2 on page 19.
For information on the KLV and KLT handset commands, see section 4.2 that starts
on page 40.
Figure 2 and Figure 3 on pages 23 and 24 provide an overview of possible routes to
upgrade.
The upgrade options depend on the type of the phase and the controller type:
 Vehicle Signals
 Near-Side Pedestrian Signals
 Far-Side Pedestrian Signals on ST700/ST750 Controllers
 Far-Side Pedestrian Signals on ST800/ST9XX Controllers
 Regulator Signs and Fluorescent Tubes
 Vehicle Signals (and all phases without WAIT / Demand Accepted indicators):
o Upgrade from incandescent to ‘Helios CLS (NLM)’.
o If ‘Helios LED’ signals are fitted, upgrade to ‘Helios CLS (NLM)’ (refer to
section 3.4.4).
o If ‘Helios CLS+LMF’ signals are fitted, then usually the Helios CLS aspects
can continue to be used without the LMF unit (refer to section 3.4.2)
o If ‘Helios CLS (NLM)’ signals are already fitted, then monitoring has
probably been disabled in the configuration; refer to section 5.1 for
information on how the controller should be reconfigured.
The recommended KLV value to use depends on the pedestrian signals (see
below). If there are no pedestrian signals, use either KLV value for the type of
LED signals fitted, e.g. either KLV=3 or KLV=4 if Dialight CLS Signals are
fitted.
 Near-Side Pedestrian Signals:
o No upgrade possible; these cannot be monitored. Use the KLV=3/5
command, which disables monitoring of the pedestrian phases.
 Far-Side Pedestrian Signals (ST700/ST750):
o Treat the pedestrian red/green signals as for Vehicle Signals above and
use the KLV=4/6 command, which enables monitoring of the pedestrian
phases.
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o Use 40W 48V Wait lamps or 48V LED Waits. The LED Phase Driver only
supports 48V Wait signals, not 230V signals. If monitoring of the 40W Wait
lamps is required, retain/fit the external lamp monitoring toroid.
 Far-Side Pedestrian Signals (ST800/ST9XX):
If the controller firmware supports the KRW command (section 4.2.3, page 42),
consider using ‘Helios CLS (NLM)’ for the Pedestrian Red/Green Signals and
‘CLS Wait’ for the Pedestrian Wait Indicators.
o Upgrade the pedestrian red/green signals to Dialight ‘Helios CLS (NLM)’.
o Upgrade the pedestrian wait signals to ‘CLS Waits’.
o Use the KLV=4 command enable monitoring of pedestrian phases.
o Use the KRW s=1 command to enable monitoring during the ‘Red+Wait’
period for each sensor ‘s’ monitoring a pedestrian phase.
The limits for each sensor are four Red signals plus four CLS Waits.
Where more than two Pedestrian Red Lamps or more than two Wait Lamps are
monitored on a phase (limit of four incandescent per sensor):
o Upgrade the pedestrian red/green signals to ‘Helios CLS (NLM)’ as for
Vehicle Signals above and use the KLV=4/6 command, and
o Continue to use incandescent Wait lamps or upgrade to LED Waits.
The limitation is that monitoring of the Waits is not possible, and neither is
monitoring of the Pedestrian Red whilst the Waits are ON. Reconfiguring the
controller could remove these limitations; refer to section 5.4.
Where no more than two Pedestrian Red and two Wait Lamps are monitored on a
phase (limit of four incandescent per sensor):
o Leave as incandescent signals and use the KLV=3/5 command.
This option allows both the pedestrian red and wait lamps to be monitored
because the number of aspects does not exceed the one amp current limit.
IMPORTANT: If the on-board sensor is used to lamp monitor these signals,
the pedestrian signals must be true incandescent lamps. The on-board
sensors cannot monitor Helios LED or Helios CLS+LMF.
For other signal upgrade options for pedestrian phases, refer to section 5, which
starts on page 43. Note however that some of those options will require a change
to the configuration PROM.
 Regulator Signs and Fluorescent Tubes:
Leave the signals monitored by ‘Reg. Sign’ and ‘Sw. Tube’ as Fluorescent Tubes.
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Start
ARE VEHICLE
SIGNALS EITHER
YES
INCANDESCENT,
HELIOS LED OR
CLS +LMF?
YES
ARE CLS + LMF
BEING USED?
NO
ARE ANOTHER
MANUFACTURERS
YES
VEHICLE LED ASPECTS
BEING USED?
NO
NO
MONITORING
WILL HAVE
BEEN
DISABLED
RECONFIGURE
IF HELIOS CLS (NLM)
ARE ALREADY FITTED
MONITORING HAS
PROBABLY BEEN
DISABLED
RECONFIGURE
BYPASS LMF
USE APPROPRIATE
KITS/PARTS TO
CONVERT TO CLS (NLM)
FOR DIALIGHT
SET KLV=3
& CHECK
TRAFFIC KLT s:1
FOR EACH SENSOR
FOR FUTURIT
SET KLV=5
& CHECK
TRAFFIC KLT s:10
FOR EACH SENSOR
NO
ARE THERE
PEDESTRIAN
FACILITIES?
FOR DIALIGHT
SET KLV=3
& CHECK
TRAFFIC KLT s:1
PED KLT s:0
FOR FUTURIT
SET KLV=5
& CHECK
TRAFFIC KLT s:10
PED KLT s:0
YES
NO
ARE THE
PEDESTRIAN
SIGNALS
FAR-SIDED?
NEAR-SIDED SIGNALS
CANNOT BE LAMP
MONITORED BY
LV CONTROLLERS.
YES
Continue to Part 2
for Far-Sided Ped
Signals
Figure 2 – Upgrade Strategy Flowchart (Part 1)
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Part 2 – Far-Side Pedestrian Signals
From Part 1
(SEE NOTE 2)
YES
IS THE CONTROLLER
AN ST700 OR ST750?
NO
YES
ARE THE PED SIGNALS
HELIOS LED OR CLS+LMF?
NO
YES
ON ANY PHASE ARE THERE
MORE THAN 2 PED RED
OR MORE THAN 2 WAITS?
NO
YES
DO THE RED &
GREEN MEN NEED TO
BE CLS (NLM)?
UPGRADE RED/GREEN TO
CLS (NLM), AND CONTINUE
WITH INCANDESCENT WAITS
OR UPGRADE TO CLS WAITS,
MAY NOT MONITOR WAITSNB1
CONSULT HANDBOOK.
NO
CONTINUE TO USE
INCANDESCENT PEDS.
IF WAITS ARE
INCANDESCENT
THEY CAN BE
MONITORED
BETTER TO GO THIS
ROUTE AS CAN
MON RM & GM
YES
LED
WAITs?
NO
HELIOS CLS PEDs
PED MONITORING DISABLED
INCANDESCENT PEDs
FOR DIALIGHT SET KLV=4
& CHECK TRAFFIC KLT s:1
& CHECK PED KLT s:1
& CHECK PED KLT s:0
& CHECK PED KLT s:255
FOR FUTURIT SET KLV=6
& CHECK PED KLT s:0
NB1 FOR OPTIONS AVAILABLE FOR PEDESTRIAN PHASES WITH WAITS, CONSULT THE HANDBOOK.
NB2 THIS PART OF THE FLOW CHART DOES NOT COVER OTHER MANUFACTURERS LED FAR-SIDED SIGNALS –
THESE CANNOT BE LAMP MONITORED AND THE CONTROLLER WILL NEED TO BE RECONFIGURED.
Figure 3 – Upgrade Strategy Flowchart (Part 2)
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3.4 Upgrading the Signals
To upgrade a signal head to ‘Helios CLS (NLM)’ follow the instructions in this section.
The part numbers of the upgrade kits are listed in section 3.4.7; the individual
instructions indicate whether a complete signal head is required or just a door
upgrade kit.
The master switch must be locked in the off position and isolation confirmed (as
defined in the IEE regulations BS7671) before starting to upgrade the signals.
3.4.1 From Helios (Halogen) to ‘Helios CLS (NLM)’
Use the ‘Helios CLS (NLM)’ door/aspect assembly kits (see section 3.4.7).
Cut the incoming power (brown and blue cables) from the lamp transformer.
Prepare and connect the cables to the retrofit connector (supplied).
In most cases the lamp transformer and associated earth wiring can be left in place.
Where it becomes necessary to remove the lamp transformer it is essential to ensure
that the earth wiring and any earth chaining is maintained. Re-terminate the earth
wiring as necessary. Note that all metallic items, transformers, power supplies, LMFs
etc. must have adequate Earthing.
When upgrading to LED Signals, it is recommended that individual neutral returns are
used for each green signal if spare cores are available. Refer to Engineering Change
Bulletin ECB10-0124 for more information.
Remove Helios Halogen door assembly.
Fit the new complete ‘Helios CLS (NLM)’ door/aspect assembly.
Connect the retrofit connector to the mating connector on the aspect cable.
3.4.2 From ‘Helios CLS+LMF’ to ‘Helios CLS (NLM)’
Disconnect the incoming power lead to the LMF.
Disconnect power feed to the CLS from the LMF.
Connect these two connectors together so incoming power goes straight to the CLS
signal, bypassing the LMF.
In most cases the LMF can be left in place and earth wiring can remain unaltered.
Where it becomes necessary to remove the LMF it is essential to ensure that the
earth wiring and any earth chaining is maintained. Re-terminate the earth wiring as
necessary. Note that all metallic items, transformers, power supplies, LMFs etc. must
have adequate Earthing.
IMPORTANT: Where a mix of ‘Helios CLS+LMF’ and incandescent lamps are fitted
on a phase, the Futurit CLS signals normally supplied in ‘Helios CLS+LMF’ signals
MUST BE REPLACED with new Dialight ‘Helios CLS (NLM)’ signals. A sensor must
not monitor a mix of Futurit and Dialight signals. Only if all the signals monitored by a
sensor are ‘Helios CLS+LMF’, can those CLS signals be retained with the LMF
bypassed as described above.
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3.4.3 From existing ‘Helios CLS (NLM)’ to ‘Helios CLS (NLM)’
If Siemens Helios CLS (NLM) signals purchased prior to the year 2009 are already
fitted on the site, then these signals can remain in place. The controller will be able to
monitor these signals in the same way as ‘newer’ Helios CLS (NLM) signals.
However, it should be noted that optically these signals look slightly different to newly
purchases Helios CLS (NLM) and this should be taken in to consideration if a mixture
of old and new signals are fitted at the site.
IMPORTANT: Do not install a mix of old (Futurit) and new (Dialight) CLS signals
monitored by the same sensor, e.g. fitted on the same phase. The controller has to
be configured as to which type of Helios CLS signal is monitored by each sensor and
one sensor is unable to monitor a mixture (see the KLT command).
3.4.4 From ‘Helios LED’ to ‘Helios CLS (NLM)’
Use the ‘Helios CLS (NLM)’ door/aspect assembly kits (see section 3.4.7).
Unplug all connectors from the Helios LED door assembly and from the PSU /
Transformer assembly.
Undo the three screws (keyhole) that secure the PSU / Transformer assembly.
Remove the PSU / Transformer assembly.
Disconnect the earth cabling from the PSU / Transformer assembly. Re-terminate the
earth cabling using the screw, nut and associated washers previously removed,
ensuring that earth continuity is preserved. Tidy and secure the screw / nut assembly
using a cable tie. Note that all metallic items, transformers, power supplies, LMFs
etc. must have adequate Earthing.
Disconnect the Brown (pin 4) and Blue (pin 3) cables from the Helios LED connector
PL1. Connect the brown and blue cables to the retrofit connector (supplied).
Remove the Helios LED door assembly.
Fit the new complete ‘Helios CLS (NLM)’ door/aspect assembly.
Connect the retrofit connector to the mating connector on the aspect cable.
3.4.5 From Peek Elite to ‘Helios CLS (NLM)’
Refer to Appendix A: Upgrade Kits for Peek Elite Signals, starting on page 54.
3.4.6 From non-Helios head to ‘Helios CLS (NLM)’
Use complete ‘Helios CLS (NLM)’ signal heads. If the existing signals do not use
Siemens Helios traffic signal heads, then the whole signal head needs to be
replaced. Follow the normal instructions for installing and replacing traffic signal
heads.
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3.4.7 Signal Upgrade Kits
To upgrade to ‘Helios CLS (NLM)’ usually requires the door/aspect assembly to be
replaced. Where only door/aspect assemblies are needed, use the following part
numbers:
Door/Aspect Assembly Kit
667/1/31500/964
667/1/31500/965
667/1/31500/966
Description
Standard RAG Signal – Red
Standard RAG Signal – Amber
Standard RAG Signal – Green
667/1/31500/968
667/1/31500/963
667/1/31500/967
Pedestrian Signal – Red
Pedestrian Signal – Amber (Non-UK)
Pedestrian Signal – Green
667/1/31500/970
667/1/31500/961
667/1/31500/962
Cycle Signal – Red
Cycle Signal – Amber
Cycle Signal – Green
667/1/31500/939
667/1/31500/959
667/1/31500/980
Ahead Green Arrow
Left Green Arrow
Right Green Arrow
Table 8 – Helios CLS (NLM) Upgrade Kits
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3.4.8 Distinguishing between Futurit and Dialight LED Signals
Two types of Siemens Helios CLS LED Signals are in circulation; one manufactured
by Futurit and one by Dialight.
Figure 4 – Futurit Signal (left) / Dialight Signal (right)
Futurit aspects were supplied in Helios CLS+LMF Signals and Dialight aspects are
supplied in new Helios CLS (NLM) Signals.
Electrically, optically and physically there are subtle differences between these two
types of LED signal.
The electrical differences mean that the controller must be configured with the correct
Load Type using the KLV and KLT handset commands (see section 4.2 starting on
page 40). This means that a mix of Dialight and Futurit signals must not be used on
the same lamp monitor sensor. All aspects monitored by a sensor must be Dialight or
all must be Futurit.
It should also be noted that optically these signals look different and this should be
taken in to consideration if a mixture of signals are fitted at the site.
The physical differences between the aspects make it easy to distinguish between
the types.
Futurit aspects can be identified by their ribbed plastic case. The Dialight aspects
have a smooth plastic case.
Dialight aspects have an integral fixing ring and lugs that mate directly with the Helios
door. The Futurit aspects require separate clips to hold them in place against the
Helios door. One white clip is clearly visible in the above picture.
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3.5 ST800 Mains Filter
3.5.1 Mains Filter Upgrade Kit (ST800)
Where the upgrade is to an ST800 system, a mains filter will need to be fitted.
The filter is supplied as a kit including bracket assembly and supplementary wiring.
The kit part number is 667/1/33907/000, although the filter is usually called up in the
ST800 Retrofit Kit 667/1/27000/800.
NOTE: ST9XX Controllers already have a Mains Filter fitted near the Master Switch.
ST700/750 Controllers already have Mains Filter fitted in the ‘biscuit tin’. In these
cases, this filter upgrade kit is not needed.
3.5.2 Mains Filter Fitting Instructions (ST800)
IMPORTANT
Dangerous voltages may be present at the rear of the controller rack.
Ensure that the mains supply to the controller is isolated at the Master Switch
before commencing the fitting process.
Note: The addition of the filter bracket to the controller rack assembly will increase
the depth of the rack assembly. Ensure that any transformers fitted to the rear panel
of the controller cabinet will not clash with the filter bracket. Reposition the
transformers as necessary.
The fitting procedure is as follows.
1) Ensure the mains supply to the controller is isolated at the master switch.
The master switch must be locked in the OFF position and isolation confirmed
(as defined in the IEE regulations BS7671).
2) Remove the MDU from the rack.
3) If the controller is wired with 32 phases and fitted with a DIN rail mounted
terminal block in place of the ‘Hedgehog’, it will be necessary to reposition the
terminal block using an ST800 32 Phase Retrofit DIN Rail Mounting Panel
667/1/33908/000. See section 3.5.3
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4) Disconnect the blue and pink power cables from the rear of the MDU (top right
connector bank) z28, z24, d30, d26 (See Figure 5).
Figure 5 – PL1 MDU Connections
5) Referring to Figure 6, cut the top cable tie (if present) securing the power
cables.
Figure 6 – Rack Cabling
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6) Remove the existing faston receptacles from the pink and blue cables. Trim
the cables back by approximately 8cm (3”).
7) Terminate the blue pair with a single yellow faston receptacle (fully insulated).
Terminate the pink pair with a single yellow faston receptacle (fully insulated).
Note two cables per faston receptacle.
IMPORTANT: Take great care when crimping these cables to ensure a secure
connection with no bare conductors or loose strands of wire.
8) Attach the pink power cables (now paired) to the bottom of the filter, to the
terminal marked “P LINE”.
9) Attach the blue power cables (now paired) to the bottom of the filter, to the
terminal marked “N LINE”.
10) Attach the flying earth cable on the bracket to the earth stud on the back of the
rack.
11) Connect the pre fitted blue and pink cables coming from the filter to the
connector PL1 on the back on the rack; pink to d30 and z28; blue to d26 and
z24 (see Figure 5).
12) Fit the filter assembly to the rack assembly using the pre-existing holes
marked “INSERT” in Figure 6.
13) Use the washers and nuts provided to secure the bracket from the inside of
the rack.
14) Ensure all cables are neatly routed and not trapped, use cable ties and the
cable standoffs on the bracket.
15) ’Minor Works’ electrical testing as required in 667/HE/20664/000 must be
completed.
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Figure 7 – Completed Filter Installation
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3.5.3 ST800 32 Phase Retrofit DIN Mounting Panel
Some controllers wired with 32 phases use a DIN rail mounted terminal block
assembly in place of the ‘Hedgehog’. The mounting position for this assembly
clashes with the mounting position of the new filter bracket. An ST800 32 Phase
Retrofit DIN Mounting Panel 667/1/33908/000 has been designed to relocate the
terminal blocks clear of the filter bracket.
Figure 8 – DIN Rail Terminal Block Assembly 32 Phase
Figure 9 – Relocated DIN Rail Terminal Block Assembly 32 Phase
Figure 8 shows the original position of the DIN Rail Terminal Block Assembly whilst
Figure 9 shows the DIN Rail Terminal Block Assembly repositioned by fitting the
ST800 32 Phase Retrofit DIN Mounting Panel. Figure 9 also shows the filter bracket
in situ. The fitting instructions are on page 34.
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3.5.4 ST800 32 Phase Retrofit DIN Mounting Panel Fitting Instructions
IMPORTANT
Dangerous voltages may be present at the rear of the controller rack.
before commencing the fitting process.
The fitting procedure is as follows.
1) Ensure the mains supply to the controller is isolated at the master switch.
The master switch must be locked in the OFF position and isolation confirmed
(as defined in the IEE regulations BS7671).
2) Remove the MDU from the rack.
3) Detach the terminals, separator and end-stops from the DIN Rail.
4) Drill out the rivets securing the DIN Rail to the rack assembly.
5) Remove the DIN Rail and ensure that any swarf is removed.
6) Fit the ST800 32 Phase Retrofit DIN Mounting Panel assembly
(667/1/33908/00) to the rack using the holes previously occupied by the rivets.
7) Secure the panel assembly in place using the fixings supplied.
8) Re-attach he terminals, separator and end-stops to the new DIN Rail. Ensure
that the end-stops are firmly secured.
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3.6 Replace the ST700/ST750 Phase Driver PCB
3.6.1 ST750 LED Upgrade Kits (ST700/ST750)
There are four different Upgrade Kits, including either a ST700 or ST750 Firmware
PROM, and either a 2-Phase or 4-Phase Driver PCB. See section 7 (Page 57) for
details of the 667/1/32755/xxx Part Numbers.
The kits include some mounting hardware, so the PSU mounted on the existing
Phase Driver PCB can be removed and fitted to the new Phase Driver PCB.
Phase Driver PCB replacement is best achieved by removing the Power/Phase
Assembly (‘Biscuit Tin’) from the Controller, and then replacing the Phase Driver PCB
in a suitable work area. It is understood that some Installation Teams will carry this
out on site, and some will want to carry out this work at a Depot.
Traffic Solutions, Siemens Mobility want to assist in the Retrofit process, and have
therefore introduced the option of a basic ‘Biscuit Tin’, 667/1/27870/799, (see section
7), so that Depots can purchase one or two basic ‘Biscuit Tin’ units, and use them to
prepare ‘Biscuit Tins’ with new Phase Driver PCBs for subsequent site installation.
The basic ‘Biscuit Tin’ includes the Toggle Switch and EMC Filter with associated
wiring, and fixings required for the new Phase Driver PCB.
The new Phase Driver PCB includes a new PL8 connector that offers Red Lamp
monitored connections for Phase A Vehicle Channels 3 and 4, as explained in
Section 3.1.5, and as shown in Figure 1 on page 18. It is recognised that only a few
sites want to use this facility, and the Soft Wire Kit 667/1/32756/000 (see section 7) to
connect to PL8, is therefore an option that can be purchased, when needed.
3.6.2 Power/Phase assembly (‘Biscuit Tin’) removal and re-fitting
IMPORTANT
Dangerous voltages may be present inside the Power/Phase assembly.
before commencing the removal process.
The removal procedure is as follows.
1) Isolate the Mains to the ST750 at the master switch.
2) Disconnect the 64-way Phase Control ribbon cable and other cables from the
CPU.
3) Unclip the earth lead from the hinged front plate.
4) Remove the front plate holding the CPU (and I/O or OTU) and store carefully.
5) Disconnect the earth wires from the fixing point in the assembly.
6) Disconnect PL6, PL7, and SK2.
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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) Disconnect PL1 and SK1.
8) Using a medium crosshead 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.
9) Replace the Phase Drive PCB, as detailed in Section 3.6.3, checking that the
end part numbers are the same, i.e. /002 for 2-phase, and /004 for 4-phase.
10) Ensure that all links and fuses are set correctly (i.e. in the same position as the
original unit), noting that Wait links and fuses are not present on the new
Phase Driver PCB, as explained in section 3.1.5.
11) Reconnect PL1, PL6, PL7, SK1, SK2 and the earth wires.
12) Replace the hinged front plate holding the CPU PCB and, if fitted, the I/O or
OTU PCB.
13) Replace all the cables to the CPU. Clip the earth lead to the front plate.
14) Restore power to the ST750.
3.6.3 Phase Driver PCB replacement
The removal procedure is as follows. Figure 10 (page 37) shows a ST700/ST750
LED Phase Driver PCB mounted in a Power/Phase Assembly.
1) Undo the EMC Filter fixings (M5 stainless screw, shake proof washer and nut),
so the EMC Filter is free to move.
2) Remove the Mains Live/Neutral connections to and from the EMC Filter and
Switch.
3) Remove the M3 Hex Spacers that retain the Phase Driver PCB.
4) Lift out the Phase Driver PCB, noting that it has to disengage PL1 and SK1.
5) Cut the tie wraps holding the PSU cables, and unplug the cables from PL2.
6) Remove the PSU from the nylon PCB supports.
7) Fit the new nylon PCB supports to the new Phase Driver PCB.
8) Fit the PSU onto the new Phase Driver PCB.
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9) Plug the PSU cables into PL2, and tie wrap the cables to the Heatsink/Cover.
10) Fit the Phase Driver PCB into the Power/Phase assembly.
M3 Hex
Spacers
Tie
wraps
Nylon PCB
Supports
for PSU
EMC
Filter
fixings
M3 Hex
Spacers
Earth
strap to
Door
Mains Live/Neutral from EMC Filter
Mains Live/Neutral to Switch/EMC Filter
Figure 10 – ST700/ST750 LED Phase Driver PCB
11) Fit the M3 Hex Spacers to retain the Phase Driver PCB.
12) Re-fit the Mains Live/Neutral connections to and from the EMC Filter and
Switch, being very careful to fit them correctly with respect to polarity and Filter
input/output, as shown below.
Fast-on Tag
TAG1
TAG2
TAG3
TAG4
Wire Connection
Mains Live from EMC Filter Output (Load)
Mains Neutral from EMC Filter Output (Load)
Mains Live to Switch
Mains Neutral to EMC Filter Input (Line)
13) Secure the EMC Filter using the fixings (M5 stainless screw, shake proof
washer and nut).
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4. Handset Command Changes
The LV CLS facility has made some changes to the handset interface:
4.1 Fault Log Changes
4.1.1 FLF 2:10 PBUS
This existing fault code will be set and the signals will not illuminate if the variant of
Lamp Switch / Phase Driver Card fitted does not match the KLV setting (see page
40).
This fault will also be logged if a mix of different variants of Lamp Switch Card is fitted
in the controller. All the cards fitted must be the same variant.
FLF 2:10 PBUS ...... Phase Bus Processor Checks Fail
FLD 10:0 ................. (Data latch test ok)
FLD 11:0 ................. (Address test ok)
FLD 12:1 ................. ADC Tests Failed!
4.1.2 FLF 55:255 LAMP
The ‘load dropped’ as seen using the KLD and LOG handset commands will show a
value of between 10 and 15 watts for each ‘Helios CLS (NLM)’.
The rolling log (LOG) / ST950 System Log also logs the lamp supply voltage when
lamp faults and replacements (and more serious faults) are confirmed.
If spurious lamp faults are reported (or no lamp fault reported when a signal fails):
 Carefully check the incoming mains supply. Is it within 10% of 230V (207-253V)?
 Check the dim lamp supply voltage as instructed by ‘Step 19)’ in the upgrade
procedure (page 15).
 Check the log for supply voltage entries.
E.g. “229-231V(230)” – Shows the minimum, maximum and average lamp supply
voltage seen by the software (for diagnostic purposes).
Are the voltages significantly different from the nominal 230V ‘Bright’ voltage
during the daytime and the 160V ‘Dimmed’ voltage during the night?
For example, entries showing the lamp supply is below 200V logged during
daylight hours implies problems with the incoming mains supply, such as ‘brownouts’.
 Check the log for entries showing an unexpected load increase.
An unexpected load increase, e.g. “A/Red+7W”, implies a problem with an LED
Signal and it is consuming more power than before. A typical fault is when the
LED Signal remains Bright when the controller switches the supply Dim. Visually
inspect the signals on this phase/colour to ensure that the brightness of the signal
changes as the controller switched between the Bright and Dim voltages. If this
does not identify the faulty signal, consider swapping the individual signals with
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others at the site and monitor where the fault ‘moves to’ to identify the faulty
signal.
 The Lamp Monitor diagnostic log KTE/KTR (Trace Records) may help identify the
cause of spurious lamp faults. See the description of those commands in
667/HH/32900/000 for details. On the ST950, the KTR Trace Records can also be
obtained using the Export Site Information (‘PI Dump’).
 The recommended method for identifying a faulty LED Signal on a particular
phase/colour, where there is nothing obviously wrong with its light output uses the
KES handset command to measure the current. Temporarily remove each aspect
in turn noting the drop in current each time. This is quicker with two engineers. If
safe to do so, also repeat this with the signals forced Dim. Replace any signal that
consumes more than 150% or less than 75% of the typical current.
 If Red Lamp Monitoring is enabled, consider changing the Low Lamp Supply
settings. Consider setting the low lamp supply thresholds to LBT=200 and
LDT=120. The controller will extinguish all the signals while the lamp supply is
below 200V (or the dimmed lamp supply is below 120V). This will help prevent
spurious lamp faults from being logged. See “FLF 17” and “LBT” in the Handset
Handbook for more details of this ‘Low Lamp Supply’ facility.
4.1.3 FLF 56:255 LMUC
This fault log entry is set whenever lamp monitor configuration data is changed using
the handset and a lamp monitor reset is required before the changes will be fully
implemented. It will be set when any KLT values are changed for example.
Enter KLR=1 to reset the lamp monitor and automatically clear this fault. As normal, if
Red Lamp Faults (FLF 22) are set, it may be necessary to enter KRD=1 first. KLR will
indicate when this is necessary: ‘KLR:USE KRD’.
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4.2 Handset Command Changes
This section contains a copy of the descriptions for the KLV and KLT handset
commands. Minor changes were also made to other handset commands (KES, KEV,
SLL, KTE and KTR) as part of this and related developments. Refer to the relevant
controller Handset Handbook 667/HH/xxxxx/000 for details on the commands.
4.2.1 KLV – Lamp Supply Voltage Type
KLV
3
KLV : <Lamp Supply Voltage Type: 0 to 8>
The configured Lamp Supply Voltage Type.
This single value configures the whole controller to expect signals of a particular type.
The following table shows the options available.
Value
KLV:0
KLV:1
KLV:2
KLV=3
KLV=4
KLV=5
KLV=6
KLV=7
KLV=8
KLV=9
KLV=10
KLV=11
KLV=12
KLV=13
KLV=14
KLV=15
KLV=16
Description
200-240V (incandescent)
100-120V (incandescent)
48V (ST9XX-ELV & ST750-ELV only)
230V Siemens/Dialight ‘Helios CLS (NLM)’ Traffic
230V Siemens/Dialight ‘Helios CLS (NLM)’ Traffic and Ped***
230V Siemens/Futurit ‘Helios CLS (NLM)’ Traffic
230V Siemens/Futurit ‘Helios CLS (NLM)’ Traffic and Ped***
230V Siemens SILUX 1.230d Traffic
230V Siemens SILUX 1.230d Traffic and Ped***
Spare
Siemens Helios LV CLS (Futurit)
SILUX LV CLS
Hong Kong Panasonic 210 with Panasonic Peds
Hong Kong Panasonic 300 with Panasonic Peds
Spare
Hong Kong Ketc 210 with Ketc Peds
Hong Kong Ketc 300 with Ketc Peds
*** See section 3.3 starting on page 21.
Changing the value will result in a lamp monitor reset and relearn.
‘KLV:2’ is specific to the ST9XX-ELV and ST750-ELV Controllers.
If the command KLV=3 (or higher) is used, always review all the KLT settings
afterwards.
Note: ‘Incandescent’ includes fluorescent tubes as well as LED signals that simulate
an incandescent lamp load, e.g. ‘Helios CLS+LMF’ and ‘Helios LED’ Signals.
For information on how to distinguish between Dialight and Futurit signals, refer to
section 3.4.8 on page 28.
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4.2.2 KLT – Lamp Load Type
KLT KLT <Sensor 1 to 48> : <Load type 0-255>
3
Load Type for each lamp monitor sensor.
All these values are set up by IC4, or may be changed if KLV=3 (or higher) is entered, and
can be viewed and modified using this handset command. Changing a KLT value will
result in the fault “FLF 56:255 LMUC” being set to act as a warning. This fault will be
cleared when a lamp monitor reset and relearn is requested using KLR=1.
The currently defined types are shown in this table. The types available depend on the
controller type, the firmware issue and the version of the LED Signal; refer to the controller
handbook 667/SU/xxxxx/000 for version information.
KLT
0
1
10
11
12
13
14
15
16
17
18
255
Signal Types
Monitoring Disabled
Siemens / Dialight Helios CLS (NLM)
Siemens / Futurit Helios CLS (NLM)
230V Siemens SILUX 1.230d LED Signals
Hong Kong Panasonic 210mm LED Signals
Hong Kong Panasonic 300mm LED Signals
Hong Kong Panasonic Ped LED Signals + Audibles
Hong Kong Ketc 210mm LED Signals
Hong Kong Ketc 300mm LED Signals
Hong Kong Ketc Ped LED Signals + Audibles
Sagemcom DIOFIT WE D300
Original **
** ‘Original’ includes HI lamps, Helios LED, Helios CLS+LMF and fluorescent tubes. Only this Load Type uses
the IC4 configured ‘Bulb Watts’ value.
*** If an on-board sensor is configured to monitor pedestrian Red and Wait with an “LED Lamp Switch” or “LED
Phase Driver” PCB, refer to section 3.3 starting on page 21 and the following applies:
 The 'KLT s:255' option allows the controller to monitor two incandescent Pedestrian Red Man Signals and
two 40/60W Wait lamps. This is the default when KLV = 3, 5 or 7 is entered on an ST800 or ST9XX-LED
Controller.
 The ‘KLT s:0’ option disables monitoring of the pedestrian phase. This is the default when KLV = 3, 5 or 7 is
entered on an ST750LED Controller.
 With other KLT values, unless the KRW settings are changed, monitoring of the Pedestrian Red LED
Signals will only occur while the Waits are OFF and monitoring of the Waits will be disabled allowing LED
Waits to be fitted. KES will display "CLS:R+W" while both the Red and Wait signals are illuminated. This is
the default when KLV = 4, 6 or 8 is entered.
For all other sensor types, the setting applies to all colours monitored by that sensor.
IMPORTANT: All signals monitored by a particular sensor must be of the same type, i.e.
require the same KLT value. Do not fit different signal types on the same sensor.
On a wide screen terminal device (see WID), this command also shows the phase and
colours monitored by this sensor.
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4.2.3 KRW – Allow Lamp Monitoring when Wait Indicators lit
KRW KRW <Sensor 1 to 96> : <Enabled (1) or Auto (0)>
3
Enables Red and Wait monitoring when it is disabled by default on LVCLS controllers.
For a sensor configured to monitor both Pedestrian LED Red and Wait, two options
are available:

0: Auto – Monitoring of the Pedestrian LED Red is automatically suspended
while the Wait indicator is illuminated on the assumption that the Wait
indicator is not the same LED signal type as the Red. KES will display
"CLS:R+W" while both the Red and Wait signals are illuminated to highlight
that monitoring is suspended. As a result, the sensor only monitors the
Pedestrian Red and Green and not the Wait.

1: Enabled – Monitoring of the Pedestrian Red and Wait is enabled. The
sensor monitors all the states and the LED Red and LED Wait signal types
must be the same Load Type, i.e. require the same KLT setting, for example
Helios CLS Red and CLS Wait. This setting can also be used where no load
is connected to the Wait (Amber) drive monitored by this sensor.
This setting has no effect on sensors that are not configured to monitor both LED Red
and Wait.
The KRW is available with the following firmware versions:
 ST800/ST700 – PB800 issue 31 onwards
 ST900 – PB801 issue 14 onwards
 ST950 – 46059 issue 6 onwards
IMPORTANT: After changing these settings, request a lamp monitor reset and
relearn. As a reminder, changing these settings will set the fault entry “FLF 56:255
LMUC”, which will be automatically cleared by a Lamp Monitor Reset.
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5. Signal Upgrades – Detailed Options
This section covers in detail the various options that are available for upgrading the
different types of traffic signals. For a simple overview and what we recommend, go
to section 3.3 on page 21.
This section is divided in to the following sub-sections covering the different types of
signals:
5.1) Red / Amber / Green Signals (page 44)
5.2) Near-Side Peds (Puffin / Toucan) (page 45)
5.3) Far-Side Peds with Wait Indicators [ST700/ST750 Controllers] (page 45)
5.4) Far-Side Peds with Wait Indicators [ST800/ST9XX Controllers] (page 45)
5.5) Monitoring Wait Indicators [ST800/ST9XX Controllers] (page 48)
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5.1 Red / Amber / Green Signals
Do not use this table for sensors monitoring the red, green and wait signals of a
pedestrian phase. Refer to sections 5.2 to 5.4 instead.
Original
Signal
Types 
Incandescent
Helios LED
Helios LMF+CLS
Helios CLS (NLM) [Not Monitored]
Incandescent
New Signal
Types 

-
Helios CLS (NLM)
This table indicates what upgrade options are possible without the configuration
needing to be modified by IC4, i.e. handset only changes.




Table 9 – Signal Upgrades – RAG Signals
Key
-
This upgrade combination is not recommended.
The IC4 configuration does not need to be changed. Requires the load type to be
set to incandescent using KLT s=255. Limited to four signals (1 Amp) per on board sensor.
This option is NOT available on the ST700/ST750 LV CLS controller; always
upgrade the signals, i.e. the  option.

The IC4 configuration does not need to be changed. This is the default assumed
by the firmware and the recommended upgrade step.
The IC4 configuration needs to be modified to enable monitoring because
monitoring will have been disabled; these signals could not have been monitored

by the original controller. Monitoring cannot be enabled using the handset. The
signals themselves may not need to be changed (see section 3.4.3 on page 26).
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5.2 Near-Side Peds (Puffin / Toucan)
For Near-Side LED Signals (Puffin, etc.) lamp monitoring is not currently possible.
Lamp Monitoring of these phases should have already been disabled in the IC4
configuration. If monitoring has been enabled in error, monitoring can be disabled
using the handset command KLT s=0 (see section 4.2.2 on page 41).
On the ST700/ST750 Controllers, use the KLV=3 (Dialight) or KLV=5 (Futurit) options
to disable monitoring of the pedestrian phase. Note that the sensors for monitoring
the pedestrian red/green signals are now built-in and thus need to be explicitly
disabled (using KLV or KLT). Previously, monitoring may only have been disabled
because no external off-board toroid sensors were fitted.
5.3 Far-Side Peds with Wait Indicators [ST700/ST750 Controllers]
On ST700 and ST750 LV CLS Controller, the far-side pedestrian red/green signals
should be upgraded to CLS in the same way as the vehicle phases (see section 5.1
on page 44).
If off-board toroid sensors 34 (Phase B) and 36 (Phase D) were fitted to monitor the
pedestrian phase, these must be removed; on-board sensors are provided on the LV
CLS Controller.
The ST700 and ST750 LV CLS Controllers can monitor up to four 40W 48V WAIT
lamps (per ped stream), and monitoring for these is enabled by default using offboard toroid sensors 38 and 40.
For more details, see 3.1.5 starting on page 17.
5.4 Far-Side Peds with Wait Indicators [ST800/ST9XX Controllers]
5.4.1 Introduction
By default, an ST800 or ST9XX Controller normally monitors the pedestrian Red,
Green and Wait Indicators of one phase using one on-board sensor. These phases
need special consideration because it is not possible for the controller to monitor
different types of signal by the same lamp monitor sensor.
The upgrade options depend on whether monitoring of the phase was enabled in the
original configuration.
If the controller is already configured to monitor pedestrian red, green and wait using
incandescent signals, or LED signals that mimic an incandescent load, then refer to
section 5.4.2.
Where monitoring had been disabled because either ‘Helios CLS (NLM)’ and/or LED
Wait indicators were fitted, the IC4 configuration must first be modified to enable
monitoring because monitoring cannot be enabled using handset commands. In this
case, refer to section 5.4.3.
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Incandescent & 40/60W Wait
Helios LED & 40/60W Wait
Helios CLS+LMF & 40/60W Wait

-




-
Helios CLS (NLM)
CLS Wait
Incandescent
LED Wait
Original
Signal
Types 
Helios CLS (NLM)
40/60W Wait
Incandescent
40/60W Wait
5.4.2 Far-Side Peds – Monitoring Originally Enabled [ST800/ST9XX Controllers]
The following options are available if the controller is already configured to monitor
pedestrian red, green and wait using incandescent signals, or LED signals that mimic
an incandescent load.
New Signal
Types 



Table 10 – Signal Upgrades – Far-Side Peds (Enabled)
Key
-
The IC4 configuration does not need to be changed.
Use KLV=3/5 and KLT s=255 to select ‘Original’ load type.
 The on-board sensor has a limit of two red and two wait signals (four in total). If
more signals are fitted, change to ‘Helios CLS (NLM)’ (i.e. the  options) or
disable lamp monitoring using KLT s=0.
Use KLV=4/6 and KLT s=1 to select ‘Helios CLS (NLM)’ load type.
The on-board sensor has a limit of eight red and eight green signals. Monitoring
 is not possible using an Off-board sensor.
By default the Wait Indicators will not be monitored and neither will the
pedestrian Red while the Wait indicators are illuminated. If this is not acceptable,
see section 5.5 for other options, which starts on page 48.
The on-board sensor has a limit of four red signals, four CLS Waits and up to
 eight green signals. Monitoring is not possible using an Off-board sensor.
pedestrian Red while the Wait indicators are illuminated, but this can be changed
using the KRW setting, see section 4.2.3 on page 42.
Use KLT s=0 to disable monitoring (because of the mix of Incandescent and LED
Waits). Alternatively, make an IC4 configuration change to utilise Option 4 (page
 53) moving the LED Waits to a switched sign, leaving the controller to monitor
the ped signals with the phase’s on-board sensor (limited to four Red and four
Green).
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5.4.3 Far-Side Peds – Monitoring Originally Disabled [ST800/ST9XX Controllers]
Where monitoring had been disabled because either ‘Helios CLS (NLM)’ and/or LED
Wait indicators were fitted, the IC4 configuration must first be modified to enable
monitoring because monitoring cannot be enabled using handset commands.
Helios CLS (NLM)
40/60W Wait
Incandescent
LED Wait
Helios LED
LED Wait
Helios CLS+LMF
LED Wait
Helios CLS (NLM)
LED Wait
Helios CLS (NLM)
CLS Wait
In this case, the following options become available when the IC4 configuration is
modified:
New Signal
Types 

-
-
-
-

Incandescent with LED Wait
Helios LED with LED Wait
Helios CLS+LMF with LED Wait
-

-
-
-
-

-
-
-
-







Helios CLS (NLM) with LED Wait
-
-
-
-


Original
Signal
Types 
Helios CLS (NLM) with 40/60W Wait
Table 11 – Signal Upgrades – Far-Side Peds (Disabled)
Key
-
Select ‘Helios CLS (NLM)’ load type. On-board sensor is limited to eight red and
eight green signals. Monitoring is not possible using an Off-board sensor.
 By default the Pedestrian Red and Wait Indicators will not be monitored while the
Wait indicators are illuminated. If this is not acceptable, see section 5.5 for
options, which starts on page 48, or consider replacing the LED Waits with CLS
Waits, i.e. the  options.

The on-board sensor has a limit of four red signals, four CLS Waits and up to
eight green signals. Monitoring is not possible using an Off-board sensor.
pedestrian Red while the Wait indicators are illuminated, but this can be changed
using the KRW setting, see section 4.2.3 on page 42.

Monitoring is not possible using the on-board sensor (because of the use of LED
Waits).
Leave monitoring disabled in the IC4 configuration.
Consider changing the signals to ‘Helios CLS (NLM)’, i.e. the  options.
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5.5 Monitoring Wait Indicators [ST800/ST9XX Controllers]
To monitor the Wait Lamps of a pedestrian phase that has ‘Helios CLS (NLM)’ fitted,
or to enable monitoring of the Pedestrian Red signals while the Wait Indicators are
illuminated, there are a number of options available.
This issue only affects phases where the amber output of the pedestrian phase is
used to drive the Wait Indicators and it is required that the built-in on-board sensor is
used to monitor the pedestrian red and green man signals. The problem is the amber
output used for the Wait Indicators is also monitored by that built-in on-board sensor.
There are pro’s and con’s with each option as summarised in the table below.
To find the best option, firstly decide how many Wait signals need to be monitored
and whether monitoring of the Pedestrian Red while the Wait signals are illuminated
is required. Then select the option that meets these requirements to determine
whether a switched sign needs to be configured and/or an external toroid sensor
needs to be configured and fitted. If lamp monitoring of the Wait Indicators is not
required or is not possible, e.g. because LED Wait Indicators are used, then select
Option 4.
No.
Wait
Lamps
Ped Red
Always
Monitored
Wait Indicator Option
Switched
Sign
External
Toroid
Sensor
4 CLS
Waits

Use the KRW setting – Page 42
-
-
4 Lamps
(1A)

Option 1) – Page 49
Switched sign (no external sensors)

-
16 Lamps
(4A)
-
External sensor (no switched sign)
-

16 Lamps
(4A)

Switched sign (with external sensor)


N/A

Unmonitored Wait (with switched sign)

-
Table 12 – Wait Lamp Configuration Options
Adding a switched sign is relatively easy to do, but it should be noted that:
 A controller has a limited number of switched sign facilities.
 Each switched sign uses one phase output on an LSC and thus it may require
another LSC to be fitted.
 A simple line of special conditioning is required to control the switched sign in
sympathy with the pedestrian phase amber/wait, detailed overleaf.
When adding an external toroid sensor it should be noted that:
 A controller has a limited number of external toroid sensors; four per LSC.
 External sensors may already be needed to monitor other signals, such as
Regulatory Signs.
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A
G
SPECIAL
CONDITIONING
(SW. SIGN)
R
A
G
ON-BOARD
SENSOR
R
ON-BOARD
SENSOR
5.5.1 Option 1) Monitored Wait – Switched Sign (No External Sensors)
Summary:
 Limited to 4 wait lamps and 1A rms
 Will monitor ped red while wait indicator lit
 Complications of adding a switched sign
 Does not require the fitting of an external lamp monitor sensor toroid
R
G
G
WAIT
Add a switched sign to the configuration and control it from Special Conditioning
using the following as an example:
;Use Switched Sign 0 for B/Wait (A=Amber, B=Phase B)
PRSLMPAB=SESYN0
On the lamp monitor screens, change the settings for the pedestrian phase:
 change lamp monitor ‘Sensor Type’ from ‘As Seq.’ to ‘R,G’ (because the controller
can monitor the red current while the phase amber is illuminated since no wait
lamps are connected to that output) and enable monitoring of ‘Helios CLS (NLM)’
and set up the switched sign phase:
 change lamp monitor ‘Sensor Type’ from ‘As Seq.’ to ‘G’ (Switched sign uses the
green output) and do not enable monitoring of ‘Helios CLS (NLM)’
In the example below, Phase B is the ped phase and Phase C is the switched sign
phase:
Make it clear in the Special Instructions:
 Connect the Wait Indicator lamps to the switched sign output (green) on the LSC.
 DO NOT connect any signals to the pedestrian phase’s amber output on the LSC.
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R
A
R
A
G
OFF-BOARD
SENSOR
G
ON-BOARD
SENSOR
5.5.2 Option 2) Monitored Wait – External Sensor (No Switched Sign)
Summary:
 Limited to 16 wait lamps and 4A rms
 Still won’t monitor ped red while wait indicator lit
 No complications of adding a switched sign
 Requires the fitting of an external lamp monitor sensor toroid
WAIT
Configure a new lamp monitor external sensor:
 Drive = ‘B-Amber’ (assuming ped phase is Phase B)
 Sensor Type = ‘Sw. Sign/Bulb…’
 Bulb Watts = ‘40W’ (this is acceptable for either 40W or 60W Lamps)
Leave the lamp monitor ‘Sensor Type’ for the pedestrian phase as ‘As Seq.’ (not
shown above).
 Connect the Wait Indicator lamps to the pedestrian phase’s amber output on the
LSC.
 Fit external sensor; feed ped phase amber cables through this new toroid.
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R
A
G
R
G
R
A
G
G
OFF-BOARD
SENSOR
SPECIAL
CONDITIONING
(SW. SIGN)
ON-BOARD
SENSOR
5.5.3 Option 3) Monitored Wait – Switched Sign (With External Sensor)
Summary:
 Limited to 16 wait lamps and 4A rms
 Requires the fitting of an external lamp monitor sensor toroid
WAIT
PRSLMPAB=SESYN0
Change the lamp monitor ‘Sensor Type’ for:
 the pedestrian phase from ‘As Seq.’ to ‘R,G’ (the controller can monitor the red
current while the phase amber is illuminated since no wait lamps are connected to
that output)
 the switched sign phase from ‘As Seq.’ to ‘None’ (use off-board sensor, not onboard)
Option 3 continues over the page…
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Configure a new lamp monitor external sensor:
 Drive = ‘S1’ (the first switched sign is used)
 Sensor Type = ‘Sw. Sign/Bulb…’
 Bulb Watts = ‘40W’ (this is acceptable for either 40W or 60W Lamps)
 Connect the Wait Indicator lamps to the switched sign output (green) on the LSC.
 Fit external sensor; feed switched sign cable (switched sign phase green) through
this new toroid.
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R
A
G
SPECIAL
CONDITIONING
(SW. SIGN)
ON-BOARD
SENSOR
5.5.4 Option 4) Unmonitored Wait – Switched Sign (No External Sensors)
Summary:
 Does not require the fitting of an external lamp monitor sensor toroid
Use this option if it is required to monitor the pedestrian red while the wait indicators
are illuminated and monitoring of the Wait indicators is not possible or not needed,
e.g. LED Wait indicators are fitted.
R
G
R
A
G
G
WAIT
PRSLMPAB=SESYN0
Change the lamp monitor ‘Sensor Type’ for:
 the pedestrian phase from ‘As Seq.’ to ‘R,G’ (the controller can monitor the red
current while the phase amber is illuminated since no wait lamps are connected to
that output)
 the switched sign phase from ‘As Seq.’ to ‘None’ (to disable monitoring)
In the example below, Phase B is the ped phase and Phase C is the switched sign
phase.
IMPORTANT: The above example shows ‘Helios CLS (NLM)’ monitoring enabled on
the pedestrian phase (Phase B). Option 4 can also be used with ‘incandescent’ type
pedestrian signals (see section 5.4.2), and in these cases, the ‘Helios CLS (NLM)’
option would not be ‘ticked’.
 Connect the Waits to the switched sign output (green) on the LSC.
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6. Appendix A: Upgrade Kits for Peek Elite Signals
6.1 Introduction
A series of doors are available to upgrade an existing Peek Elite signal to ‘Helios
CLS (NLM)’ which requires the door/aspect assembly to be replaced.
Figure 11 – Front view of HELIOS Peek Elite Retro-fit door
Figure 12 – HELIOS Peek Elite Retro-fit door assembled to Peek Elite Housing
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6.2 Part Numbers
Door/Aspect
Assembly Kit
667/1/33540/964
667/1/33540/965
667/1/33540/966
Description
Standard Peek Elite Retro-Fit Signal – Red
Standard Peek Elite Retro-Fit Signal – Amber
Standard Peek Elite Retro-Fit Signal – Green
667/1/33540/968 Pedestrian Peek Elite Retro-Fit Signal – Red
667/1/33540/963 Pedestrian Peek Elite Retro-Fit Signal – Amber (Non-UK)
667/1/33540/967 Pedestrian Peek Elite Retro-Fit Signal – Green
667/1/33540/970 Cycle Peek Elite Retro-Fit Signal – Red
667/1/33540/961 Cycle Peek Elite Retro-Fit Signal – Amber
667/1/33540/962 Cycle Peek Elite Retro-Fit Signal – Green
667/1/33540/939 Peek Elite Retro-Fit Signal - Ahead Green Arrow
667/1/33540/959 Peek Elite Retro-Fit Signal - Left Green Arrow
667/1/33540/980 Peek Elite Retro-Fit Signal - Right Green Arrow
Table 13 – Peek Elite Retro-Fit Part Numbers
6.3 Wiring modifications
Existing signal head wiring is to be retained and modified using the supplied
connector, as per instructions in main section of this handbook.
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6.4 Door Locking Options
The door locking cams on the existing head are to be retained. There are two types
of cam available, see figures below for details. The cams can be operated using a
small Allen key, or similar tool as shown. Important Note: Ensure that the door is
pressed fully shut to compress the seal before attempting to lock the cams.
Figure 13 – Cam locking option 1: a) Unlocked, b) Locked
Figure 14 – Cam locking option 2: a) Unlocked, b) Locked
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7. Appendix B: Part Numbers
Listed below are a summary of the part numbers referred to in this document.
Part Number
Description
667/TZ/12800/000 PB800 ST800/ST700 Main Processor Firmware PROM
667/TZ/12801/000 PB801 ST800/ST750 Main Processor Firmware PROM
667/TZ/12815/000 PB815 Phase Bus Processor Firmware PROM
667/1/33907/000 ST800 Mains Filter Upgrade Kit
667/1/27000/800 ST800 Retrofit Kit (includes the above and PB800 PROM)
667/1/33908/000 ST800 32 Phase Retrofit DIN Mounting Panel
667/1/33900/900 ST900 Retrofit Kit (includes the PB801 and PB815 PROMs)
667/1/33905/312 ST800/ST9XX LED Lamp Switch PCB – UK Variant (Fail to Blackout)
667/1/27002/002 ST800/ST9XX LED Lamp Switch Kit – UK Variant (includes the above)
667/1/33905/302 ST800/ST9XX LED Lamp Switch PCB – Non-UK (Fail to Flashing option)
667/1/27002/102 ST800/ST9XX LED Lamp Switch Kit – Non-UK Variant (incl. the above)
667/1/33790/002 ST700/ST750 LED 2 Phase Driver PCB – Single Pedestrian
667/1/33790/004 ST700/ST750 LED 4 Phase Driver PCB – Dual Pedestrian
667/1/32755/702 ST700 2-Phase Retrofit Kit (incl. Phase Driver PCB and PB800 PROM)
667/1/27870/799 ST750 LED Power/Phase Modification Kit (basic ‘Biscuit Tin’)
667/1/32756/000 ST750 Phase A Vehicle RLM Cable
667/1/31500/xxx Helios CLS (NLM) Door/Aspect Assembly Kits (see page 27)
667/1/33540/xxx Upgrade Kits for Peek Elite bodies (see page 55)
Table 14 – Part Numbers
Last Page of the Handbook
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helios cls retrofit handbook

Transcription

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