Dual Inventive ZKL 3000 RC Manuale utente

Manual for installing

ZKL 3000 Remote Control (RC) Line Blockage System

ZKL 3000 RC

November 2016

1. Introduction 3

2. Deﬁnitions & technical speciﬁcations 3

a. Application of ZKL 3000 RC 3

3. Conditions & safety instructions 4

a. Conditions of use 4

b. Instructions 4

4. Components 5

a. ZKL 3000 RC and Ancillaries 5

b. The ZKL 3000 RC Unit 6

c. Batteries and Chargers 6

5. Charging the batteries 7

a. Instructions prior to use 7

b. Charging a backup battery 7

c. Charging an external battery 7

6. Testing the ZKL 3000 RC 8

a. Preparations 8

b. The override key switch 8

c. Function test for installation 9

7. Installing the ZKL 3000 RC 10

a. Installing the ZKL 3000 RC in the track 10

b. Functional test in the track 11

c. LED Indications 13

d. Replacing external battery 13

e. Removing the ZKL 3000 RC from the track 14

8. Troubleshooting 15

a. Error and Alerts 15

9. Transport & storage 17

a. Transport 17

b. Storage 17

10. Maintenance & service 17

a. Maintenance 17

b. Service 18

11. Environment & recycling 18

In conclusion 18

CONTENTS

1. INTRODUCTION

This manual details the correct method for installing the ZKL 3000 Remote Control (RC) Line

Blockage System safely. The ZKL 3000 RC system protects a section of track efﬁciently and effectively

by producing and monitoring a short circuit in the track, simulating a train in the section. This causes

the track circuit to be ‘OCCUPIED’, thus placing the protecting signals danger. This section is

immediately closed to rail trafﬁc, enabling rail workers to perform work on the infrastructure safely.

The ZKL 3000 RC can be operated using either the Remote Switch (RS) 3000 or through the web

interface MTinfo 3000 .

2. DEFINITIONS & TECHNICAL SPECIFICATIONS

a. Application of ZKL 3000 RC

The ZKL 3000 RC can be applied in track types with a width of 1,435mm, such as:

• NP46

• UIC54

• UIC60

• 95 lb RBS

• 85 lb RBS

• 109 lb

• 110 lb

• 113 lb

Additionally, the ZKL 3000 RC can be used for mains voltage of both 1500 V and 25kV.

The ZKL 3000 RC can be used with the following track circuit systems:

• Jeumont-Schneider Peak Voltage track circuit section

• Classic track circuit: 12V alternating voltage 75 Hz

• Siemens electronic ripple control track circuits FTGS46 & FTGS917

• GRS Overlay Track Circuit (OTC)

• Alstom Jade system

• Bi-rail type CV50B3P

• High power pulses type CVTHBG

• TI21 type track circuits (EBI track 200)

• TI21-M type track circuits (EBI track 300)

• Aster SF 15 type track circuit

You must NOT use a ZKL 3000 RC in locations with any of the following:

• Level crossings and/or service roads (or alongside)

• Axle counters

• Switches and Points

ZKL 3000 RC

index

4ZKL 3000 RC

3. CONDITIONS & SAFETY INSTRUCTIONS

WARNING!

Please read all safety instructions carefully before using the ZKL 3000 RC, ensuring you

fully understand the system and how it works. When precautionary measures and safety

instructions are not followed properly there is a risk of electric shock, ﬁre or even death.

a. Conditions of use

You are only allowed to install the ZKL 3000 RC if:

• you hold the ZKL 3000 RC competencies, and they are in date

• you have been assigned the appropriate user rights on MTinfo 3000

• you have been authorised to install the ZKL 3000 RC

As a competent user you are responsible for:

• the RS 3000 during use (including the installation phase)

• any relevant paperwork, user names and passwords (and any authorisation codes via text

message or PIN that you have been assigned)

• managing your password and (if applicable) your PIN. You must never share this

information with others

b. Instructions

Other important instructions

• There are certain situations where it is not possible to switch the ZKL 3000 RC.

Please see the “Troubleshooting” section for more information should you encounter

any problems

• Never perform any repairs to a ZKL 3000 RC. Please contact Dual Inventive for maintenance

and repairs

• Override keys must only be handed out to those who hold the ZKL 3000 RC competency

• Please take good care of the ZKL 3000 RC override keys by organising proper key management

to ensure they are not lost, stolen or damaged

Instructions for first use

• Check whether the ZKL 3000 RC has the correct certiﬁcation. Please consult our website

for the required certiﬁcates: www.dualinventive.eu

• Always take care of your own safety within the railway environment using the most current

applicable legislation

• Always visually inspect the ZKL 3000 RC for damage and perform a function test

DO NOT USE any ZKL 3000 RC if any damage or defects are detected. Please apply a label,

quarantine and return to your stores to be sent to Dual Inventive

• Always use the installation procedure set out in this manual for the ZKL 3000 RC

• Always start the installation with two fully charged batteries



index

ZKL 3000 RC

4. COMPONENTS

A complete ZKL 3000 RC set consists of the following:

• Case including ZKL 3000 RC and ancillaries

• Batteries for ZKL 3000 RC with chargers

a. ZKL 3000 RC and Ancillaries

A ZKL 3000 RC set contains:

1. The ZKL 3000 RC including bypass clamps and override keys

2. Transport case

3. Backup battery

4. Battery compartment key

5. Manual

6. Key ring

7. Carrying strap

8. Test-Tool

9. Backup battery charger

10. USB (contains manual)

11. ZKL Clamp

12. Padlock

13. External battery

14. Charger external battery

15. Connection cable external battery

131415

1 2

index

6ZKL 3000 RC

4. CONTINUATION COMPONENTS

b. The ZKL 3000 RC Unit

1. A hinged frame

2. SWITCH 3000

3. Electronics casing (LEDs, GPS and black box recorder)

4. Battery compartment

5. Contact points

6. Locking mechanism

c. Batteries and Chargers

1. Backup battery

2. Charger backup battery

3. External battery

4. Charger external battery

3 4

6 3 425

index

ZKL 3000 RC

5. CHARGING THE BATTERIES

The ZKL 3000 RC uses two types of batteries and chargers, which are displayed below

a. Instructions prior to use

• The chargers only have an IP20 protection level, so always charge the batteries in a dry,

indoor environment

• ALWAYS place the chargers at least 50mm apart for adequate cooling

• Always check the charger and cables for visible damage before use. DO NOT USE the charger

if any damage is detected

• The charger of both the backup battery and the external battery may only be repaired and

maintained by Dual Inventive

• Always transport and store the chargers in a dry environment

• Only use the charger that was supplied for that particular model

b. Charging a backup battery

• Plug the charger into a power socket. The green LED will illuminate to indicate mains power

• Connect the battery to the charger. The red LED on the charger will illuminate to indicate the

backup battery is being charged

• When the red LED switches off, the battery is fully charged

• The backup battery can stay connected to the charger without causing damage, although

after a period of time the red LED may illuminate again

c. Charging an external battery

• Connect the power cable to the battery and then connect the charger to the mains.

The two red LEDs on the charger will illuminate

• The fan in the charger should start at this point

• Both LEDs on the charger will remain red when the external battery is being charged

• When charged, one LED will turn green indicating this

• The external battery can stay connected to the charger, however it will not trickle charge

ATTENTION:

If you are to re-use the charger on another battery, please remove the charger from the

power before connecting the new battery.

index

8ZKL 3000 RC

6. TESTING THE ZKL 3000 RC

a. Preparations

Before you start, check whether the ZKL3000 RC system’s calibration is still in date.

You can ﬁnd the “Next calibration date” sticker on the measuring unit.

Discharge and charge the batteries at least twice before the ﬁrst use to ensure full power capacity.

See section “Charging the batteries”.

Before installation, the user should check the ZKL 3000 RC for defects and perform a function test.

Testing the ZKL 3000 RC should always be done in a position of safety.

• Before testing, clean the contact points with a wire brush to ensure the best possible connection

• Before use, place two fully charged batteries into the ZKL 3000 RC

• Open the battery cover with the compartment key

• ALWAYS place the power cable on the notched side of the battery compartment

• Insert the batteries and pull the rubber fastener over the battery ends to lock them in position

• Close the battery cover and lock it with the compartment key

• Wait at least 10 seconds after installing the batteries to allow the ZKL 3000 RC to switch on

• Using the override key switch, switch the ZKL 3000 RC on

b. The override key switch

The override key switch has three positions:

Key up (fully clockwise) = ON

The ZKL 3000 RC has now been activated in an overruled

manner and produces a short circuit. The unit cannot be

operated remotely.

Key horizontal = OPERATIONAL

The ZKL 3000 RC is now operational and can be operated

remotely by either the RS 3000 or MTinfo 3000.

Key down (fully counter-clockwise) = OFF

The ZKL 3000 RC has now been activated in an overruled

manner and will not produce a short circuit. The unit

cannot be operated remotely.

index

ZKL 3000 RC

6. CONTINUATION TESTING THE ZKL 3000 RC

The override key switches the ZKL 3000 RC ON or OFF without using either an RS 3000 or

MTinfo 3000. Use of the override key will overrule commands sent by both the RS 3000 and

MTinfo 3000 as the key switch always takes priority. Usually, the key switch would only be used

as a last resort.

Attention! The OPERATIONAL position has two settings.

OPERATIONAL - ON: When switched from the ON to OPERATIONAL (one turn to the left),

the ZKL 3000 RC remains activated creating a short circuit. However, it will now be possible to

remotely operate the ZKL 3000 RC using either an RS 3000 or MTinfo 3000.

OPERATIONAL - OFF: When switched from OFF to OPERATIONAL (one turn to the right), the ZKL

3000 RC remains deactivated. Again, it will now be possible to remotely operate the ZKL 3000 RC

using either an RS 3000 or MTinfo 3000.

c. Function test for installation

• Ensure that the contact points and the Test-Tool are clean

• With the Test-Tool present (as shown below), press the contact points together and switch

the ZKL 3000 RC ‘ON’ using the override key

• The green LED should start ﬂashing (twice per second), indicating that a short circuit has

been detected. Check this status for at least ﬁve seconds

• If all is OK and the green LED continues to ﬂash, switch the ZKL 3000 RC ‘OFF’ using the

override key. The LED should stop ﬂashing. Again, check this for at least ﬁve seconds

• If the LED remains off, remove the Test-Tool. The ZKL 3000 RC is ready to be deployed

ATTENTION: If the ZKL 3000 RC does not pass the functional test before installation,

do NOT use the unit. Apply a label to the ZKL 3000 RC, quarantine it and return to your

depot/warehouse to be returned to Dual Inventive for repair.

index

10 ZKL 3000 RC

7. INSTALLING THE ZKL 3000 RC

a. Installing the ZKL 3000 RC in the track

After you have successfully tested the ZKL 3000 RC in a safe location, you can install the ZKL 3000

RC in the track as follows:

• Ensure that the distance between the bottom of the ZKL 3000 RC and any ballast is at least 3cm

• Set the override key switch of the ZKL 3000 RC to ‘ON’

• Unfold the ZKL 3000 RC and place the contact points on the web of the rail

• Partially insert and remove the ZKL 3000 RC during installation several times (being careful

to keep it in the same location) before the ﬁnal placement of the ZKL 3000 RC. The contact

points will scrape the rust away from the rail web ensuring a better contact

• Using your hand or foot (and being careful to avoid trapping in the hinge), push the

ZKL 3000 RC down until it locks

• The green LED should start ﬂashing (twice per second), indicating that a short circuit has

been detected. Check this status for at least ﬁve seconds

• Place the locking clamp over the hinge of the ZKL 3000 RC

• Insert the two metal locking plates in the base of the locking clamp

• Next, place the clamp around the two pins and lock with a padlock (as shown below)

• Place the external battery outside of the track in a safe location and secure it.

No padlocks or chains have been supplied for this purpose

• Pass the cable under the rail (on the side of the battery cover where possible) to

the ZKL 3000 RC

• Open the battery cover and connect the plug of the external battery with the ZKL 3000 RC using

the connection cable to battery slot 2. Otherwise, the ZKL 3000 RC will not function properly

ATTENTION! You should always place the power cable to the side of the notch in the

battery compartment.

index

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