MIDAS IP ENABLED OUTSTATION USER HANDBOOK · PDF fileMIDAS IP Enabled Outstation User Handbook ... MIDAS-IP REAR WIRING TO 600 CABINET (TOP) ... PCM Pulse Code Modulation

MIDAS IP Enabled Outstation

User Handbook

667/HB/32500/000 Page 1 Issue 4

Siemens Mobility, Traffic Solutions Sopers Lane, Poole, Dorset, BH17 7ER United Kingdom +44 (0)1202 782000 http://www.siemenstraffic.com/

MIDAS IP Enabled Outstation User Handbook

Prepared: Simon White/Ruth Davis

Function: Senior Product Engineer/Technical Author

Siemens Part Number

Highways Agency Stores Code

Issue Change Ref.

Date

667/HB/32500/000 MANUAL-0567-1-SPC (Paper) 4 TS005501 30 April 2010

667/TB/32500/000 MANUAL-0566-1-SPC (CD-ROM) 4 TS005501 30 April 2010

667/HB/32500/000 MANUAL-0567-1-SPC (Paper) 3 TS005095 15 September 2009

667/TB/32500/000 MANUAL-0566-1-SPC (CD-ROM) 3 TS005095 15 September 2009

667/HB/32500/010 Installation notes, issued with each MIDAS-IP Outstation

1 N/A 23 August 2007

© Crown Copyright 2009 THIS DOCUMENT IS ELECTRONICALLY HELD AND APPROVED

The names of products of third parties listed in this document may be trademarks of their respective owners.

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User Handbook

Product Support

Technical Support is provided by Siemens Mobility, Traffic Solutions (TS) Engineering for the benefit of the Highways Agency and its installation and maintenance contractors. Technical Support is provided for the items included in the Installation, Commissioning and Maintenance sections of this Handbook. The Telephone Help Line is available between the hours of 9.00 am and 5.00 pm, Monday to Friday (excluding Bank Holidays). Outside office hours use the Fax Help Line or e-mail.

Telephone: (01202) 782626 Fax: (01202) 782545 e-mail: [email protected] or [email protected] Keith Haskell Siemens Mobility, Traffic Solutions Sopers Lane Poole Dorset BH17 7ER

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mailto:[email protected]

mailto:[email protected]


User Handbook

TABLE OF CONTENTS

1. INTRODUCTION ....................................................................................................6 1.1 Purpose..........................................................................................................................................6 1.2 Scope..............................................................................................................................................6 1.3 Related Documents.......................................................................................................................6

1.3.1 Required Documents ...............................................................................................................6 1.3.2 Reference Documents .............................................................................................................7

1.4 Abbreviations ................................................................................................................................8 1.5 SAFETY WARNING .......................................................................................................................9 1.6 Operational Warning.....................................................................................................................9 1.7 Static Precautions.......................................................................................................................10

2. EQUIPMENT DESCRIPTION ...............................................................................11 2.1 Functionality................................................................................................................................11 2.2 System Overview ........................................................................................................................13 2.3 Physical Arrangement ................................................................................................................15 2.4 Power System..............................................................................................................................19 2.5 Cables...........................................................................................................................................20 2.6 PCBs.............................................................................................................................................20

2.6.1 IP CPU Module ......................................................................................................................20 2.6.1.1 IP Core CPU ...................................................................................................................21 2.6.1.2 CPU Carrier card ............................................................................................................22

2.6.2 Loop Detector Card................................................................................................................23 2.6.3 RS485 Lightning Protection Module ......................................................................................24 2.6.4 Ethernet Lightning Protection Module....................................................................................24 2.6.5 IP Address Plug (Type 9300).................................................................................................25

3. INSTALLATION....................................................................................................26 3.1 Physical Installation....................................................................................................................26

3.1.1 Installation List .......................................................................................................................26 3.1.2 Equipment Needed for an Installation....................................................................................26

3.2 Install Battery...............................................................................................................................26 3.3 Connect RS485 Lightning Protection Module..........................................................................27 3.4 Connect Ethernet Lightning Protection Module ......................................................................28 3.5 Fit Local Transponder Lead.......................................................................................................29 3.6 Loop Detector Leads ..................................................................................................................30 3.7 Earthing........................................................................................................................................31 3.8 IP Address Plug...........................................................................................................................32 3.9 Connect Mains Lead to PDU ......................................................................................................32

4. COMMISSIONING................................................................................................33 4.1 Initial Setup..................................................................................................................................33 4.2 Using the Transponder Simulator .............................................................................................35 4.3 Configure the Loop Sensitivities...............................................................................................35 4.4 Presence Switches .....................................................................................................................37 4.5 Final Commissioning Checks....................................................................................................37

5. MAINTENANCE ...................................................................................................38 5.1 Replaceable Parts .......................................................................................................................38 5.2 Routine Maintenance..................................................................................................................38 5.3 Fault Finding................................................................................................................................38

5.3.1 Checking PSU Output............................................................................................................41 5.4 Outstation Reset .........................................................................................................................42 5.5 Fitting and Replacement Procedures .......................................................................................42

5.5.1 Default Settings......................................................................................................................42

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5.5.2 Replacing the IP CPU Module ...............................................................................................44 5.5.3 Replacing a Loop Detector Card ...........................................................................................44 5.5.4 Replacing the Power Supply Unit ..........................................................................................45 5.5.5 Replacing the Power Supply Battery .....................................................................................45 5.5.6 Replacing the Battery Charger ..............................................................................................45 5.5.7 Replacing the RS485 Lightning Protection Module...............................................................46 5.5.8 Replacing the Ethernet Lightning Protection Module ............................................................46 5.5.9 Replacing Fuses ....................................................................................................................46

5.5.9.1 Battery Fuse ...................................................................................................................46 5.5.9.2 Mains Fuse .....................................................................................................................47 5.5.9.3 RS485 Lightning Protection Module Fuses ....................................................................47

6. TECHNICAL SPECIFICATION.............................................................................48 6.1 Physical Characteristics.............................................................................................................48 6.2 Electrical Specification...............................................................................................................48 6.3 Features .......................................................................................................................................48 6.4 Safety............................................................................................................................................49 6.5 EMC ..............................................................................................................................................49 6.6 Environmental Information ........................................................................................................49 6.7 Data Rates....................................................................................................................................49 6.8 Battery Backup............................................................................................................................49 6.9 Lightning Protection ...................................................................................................................49 6.10 Processor .................................................................................................................................49 6.11 Engineer’s Terminal (MOTE) ..................................................................................................50 6.12 Loop Detectors ........................................................................................................................51

APPENDIX A – TECHNICAL DRAWINGS AND FAMILY TREE..................................52

APPENDIX B – PART NUMBERS ................................................................................53

APPENDIX C – OPEN SOURCE LICENCES ...............................................................55

INDEX............................................................................................................................56

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FIGURES FIGURE 1 - SYSTEM OVERVIEW..............................................................................................................12 FIGURE 2 - SYSTEM SCHEMATIC DIAGRAM..........................................................................................14 FIGURE 3 - FRONT PANEL........................................................................................................................15 FIGURE 4 - HARDWARE MODULE ARRANGEMENT (FRONT VIEW, FRONT PANELS REMOVED)...16 FIGURE 5 - REAR VIEW OF MIDAS IP ENABLED OUTSTATION ...........................................................16 FIGURE 6 - MIDAS-IP REAR WIRING TO 600 CABINET (TOP)...............................................................17 FIGURE 7 - MIDAS-IP REAR WIRING TO 600 CABINET (BOTTOM).......................................................18 FIGURE 8 - IP CPU MODULE ....................................................................................................................20 FIGURE 9 - REAR VIEW OF CARRIER CARD SHOWING EXTERNAL CONNECTIONS .......................21 FIGURE 10 - IP CORE CPU .......................................................................................................................22 FIGURE 11 - CPU FRONT PANEL.............................................................................................................22 FIGURE 12 – ST4M LOOP DETECTOR FRONT PANEL ..........................................................................24 FIGURE 13 - IP ADDRESS PLUG ..............................................................................................................25 FIGURE 14 - RS485 LIGHTNING PROTECTION CONNECTIONS ..........................................................27 FIGURE 15 - ETHERNET LIGHTNING PROTECTION UNIT CONNECTIONS.........................................29 FIGURE 16 - DETECTOR BACKPLANE (VIEW FROM REAR).................................................................30 FIGURE 17 - LOOP DETECTOR TERMINAL BLOCK CONNECTIONS ...................................................31 FIGURE 18 - MOTE CONNECTED ............................................................................................................34 FIGURE 19 - LAPTOP RUNNING MOTE ENGINEER’S TERMINAL.........................................................34 FIGURE 20 - SWITCHES 5-8 ON LOOP DETECTOR CARD....................................................................36 FIGURE 21 – PSU TEST POINTS..............................................................................................................41 FIGURE 22 - WIRING DIAGRAM FOR ENGINEER’S TERMINAL TO OUTSTATION CABLE.................50

TABLES TABLE 1 - CABLE CONNECTIONS............................................................................................................20 TABLE 2 - STATUS INDICATION LEDS ....................................................................................................23 TABLE 3 - LOOP DETECTOR BACKPLANE CONNECTIONS..................................................................30 TABLE 4 - DETECTOR SENSITIVITY SETTINGS.....................................................................................36 TABLE 5 - DETECTOR OPERATING FREQUENCY SETTINGS..............................................................36 TABLE 6 - DETECTOR PRESENCE SETTING..........................................................................................37 TABLE 7 - FAULT FINDING........................................................................................................................41 TABLE 8 - MIDAS IP OUTSTATION TEST EQUIPMENT DEFAULT SETTINGS .....................................43 TABLE 9 - FUSE RATINGS ........................................................................................................................46 TABLE 10 - ENGINEER’S TERMINAL CABLE PIN OUT ...........................................................................51 TABLE 11 - MIDAS-IP ST4M LOOP DETECTOR SPECIFICATION..........................................................51

LAST PAGE ..................................................................................................................57

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1. INTRODUCTION

1.1 Purpose This Handbook contains the information needed to install and maintain the Siemens MIDAS-IP Enabled Outstation. In the interests of Health and Safety, when installing, using or servicing the equipment, the instructions in Section 1.5 should always be followed.

1.2 Scope This document covers the general description, installation, commissioning and maintenance instructions for the MIDAS-IP Outstation. The Outstation configuration will determine which sections of the Handbook are relevant. Please note that some of the photographs included in this handbook were taken during the development phase of the project and may therefore differ in small detail from the final version.

1.3 Related Documents

1.3.1 Required Documents The documents in the following table are referred to in the text of this Handbook, and are required when installing, commissioning and maintaining MIDAS-IP equipment.

Document Type Reference Number Description Handbooks 667/HB/26766/ETC MIDAS Transponder System

Handbook Highways Agency Drawings -

MCX 0156 Sheets 1 - 5 NMCS Installation Cabinet 600

incorporated in Volume 3 ‘Highway

MCX 0834 Sheets 1 - 4 600 Cabinet Equipment Configuration

Construction Drawings’ available from The Stationery Office

MCX 0594 Sheets 1 - 4 NMCS2 Midas 600 Cabinet Arrangement

Highways Agency Document

MCH 1957 NMCS Maintenance Instruction General Electrical Tests and Inspections

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1.3.2 Reference Documents The documents in the following table are referred to in the text of the Handbook, but are not required when installing, commissioning and maintaining MIDAS-IP equipment.

No. Publisher Reference Number Document Title 1. Siemens 667/HB/32591/000 Address Plug (Type 9300)

Programmer Handbook 2. Siemens 667/HB/32500/001 MIDAS IP Outstation Open Source

Licences 3. Highways Agency TR 2512 Performance Specification for Below

Ground Vehicle Detection Equipment 4. TR 1100C General Specification for Motorway

Signs, Signalling and Communications Equipment

5. TR 2130C Environmental Tests for Motorway Communications Equipment and Portable and Permanent Road Traffic Control Equipment

6. TR 2146E NMCS2 MIDAS Outstation Link Specification

7.

TR 2169J NMCS2 MIDAS Outstation Specification

8. MCE 1137 IP Address Plug Type 9300 Hardware and Software Requirements

9. MCE 1126C NMCS Internet Interface Specification10. MCH1514 Code of Connection 11. ITU-T K20 (07/2003)

K21 (07/2003) Lightning protection

12. ETSI EN 300 330 Electromagnetic compatibility and Radio spectrum Matters (ERM)

13. British Standards BS EN 41003:1999 Particular Safety Requirements for Equipment to be Connected to Telecommunication Networks

14. BS EN 60950-1:2006 Safety of Information Technology Equipment General Requirements

15. BS EN 50293:2001 Electromagnetic Compatibility - Road Traffic Signal System - Product Standard

16. BS 7671:2001 Requirements for electrical installations. IEE Wiring Regulations. Sixteenth edition

17. BS EN 55024:1998 Information technology equipment. Immunity characteristics. Limits and methods of measurement

18. Other Control of Substances Hazardous to Health Regulations (COSHH) 2002

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19. http://www.dft.gov.uk/pgr/roads/tss/tsmanual/chapter8/trafficsignsmanualchapter8ro4182

Chapter 8 – Traffic Signs Manual

1.4 Abbreviations COBS Control Office Base System CRC Cyclic Redundancy Check EMC Electro Magnetic Compatibility EPA ESD Protected Area ESD Electrostatic Discharge ESDS Electrostatic Discharge Sensitive Device FPGA Field Programmable Gate Array HDLC High level Data Link Control IDC Insulation Displacement Connector I/O Input/Output IP Internet Protocol I2C Inter-Integrated Circuit (serial bus specification) LCC Local Communications Controller MIDAS-IP Motorway Incident Detection and Automatic Signalling - Internet Protocol MIU MIDAS Interface Unit MOTE MIDAS Outstation Test Equipment NMCS2 National Motorway Communications System Mk 2 NRTS National Roads Telecommunications Services OAL Outstation Auxiliary Link PC Personal Computer PCB Printed Circuit Board PCM Pulse Code Modulation PDU Power Distribution Unit PSU Power Supply Unit RMC Regional Maintenance Contractor SDRAM Synchronous Dynamic Random Access Memory TS Traffic Solutions TPR Transponder

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http://www.dft.gov.uk/pgr/roads/tss/tsmanual/chapter8/trafficsignsmanualchapter8ro4182





User Handbook

1.5 SAFETY WARNING When installing, using or servicing this equipment the following safety instructions must be noted and adhered to: i) This equipment must only be used or worked on by competent personnel that are

trained in the current UK electrical safety procedures. 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 MIDAS-IP Outstation including, but not restricted to the following:

a) The equipment must be correctly connected to the specified incoming power supply.

b) Hazardous voltages of mains potential are present within the equipment. Observe any warning labels and do not remove any protective covers unless absolutely necessary. The equipment must be disconnected/isolated from its power source before

removing any protective covers, or working on any part from which protective covers have been removed.

If the equipment has to be operated with safety covers removed, there must be at least two competent persons present.

c) All wiring must be carried out in accordance with the requirements of BS7671 (IEE Wiring Regulations).

d) MIDAS-IP Outstations use Sealed Lead Acid Batteries. Care must be taken in handling these to prevent a short circuit condition occurring between the battery terminals.

e) Exercise care when handling old batteries, which may be leaking. RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. BATTERIES MUST BE DISPOSED OF IN ACCORDANCE WITH THE “CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 2002”. SPENT BATTERIES MUST BE DISPOSED THROUGH AN APPROVED HAZARDOUS WASTE DISPOSAL CONTRACTOR. DO NOT PUNCTURE BATTERIES. DO NOT DISPOSE OF BATTERIES IN ANY FIRE.

f) The Lead Acid Battery used in MIDAS-IP has pressure vents on its top surface. When stored and shipped, these must be uppermost to reduce the likelihood of electrolyte leakage.

g) This product is not designed to withstand high altitude de-pressurisation. Where air freight is necessary, it must be shipped in a pressurised hold.

h) When replacing or exchanging the Outstation for another unit, be sure to connect the safety electrical connection (earth) on the rear of the unit.

1.6 Operational Warning

Resetting a MIDAS-IP unit when it is running from battery with mains not present will prevent it from starting up until mains power is restored.

Mains Voltage must be present to start up a MIDAS-IP unit

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1.7 Static Precautions

Where it is practicable a small Electrostatic Discharge (ESD) Protected Area should be created when handling sensitive devices off-site. If this is not possible then as a minimum the operator should be connected by a wrist strap to a suitable piece of earthed metal on the assembly being modified. The assembly and the ESDS container must have made contact with the operator before ESDS is removed from its protective packaging and inserted into the equipment.

Always hold components by the edges, and try to avoid touching the edge connectors and components directly.

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2. EQUIPMENT DESCRIPTION

2.1 Functionality MIDAS-IP Outstations are physically located adjacent to motorways that have been equipped with inductive loops. Loop pairs are normally sited at 500m intervals along the carriageway. One pair of loops is fitted in each lane. Up to 10 pairs of loops can be controlled and monitored by a single MIDAS-IP Outstation. Each MIDAS-IP Outstation continuously monitors vehicle data on a per lane basis. Vehicle counts, together with speed, headway and length data for individual vehicles are calculated. Time-averaged statistical data, derived from flow information and individual vehicle data, is reported to the Instation as traffic data. Raw vehicle presence data, flows and speeds are used by algorithms which report corresponding MIDAS Alerts to the Instation. The High Occupancy (HIOCC & HIOCC2) algorithm detects slow moving or stationary traffic and generates incident alerts. The System Overview in Figure 1 shows how the Transponder and Outstation interface to one another, and to other traffic control equipment. A serial interface allows connection of an Engineer’s Terminal (MIDAS Outstation Test Equipment, or MOTE), which can give identity, version and status information. Individual Vehicle Data and MIDAS Alerts are also available on this link to allow local monitoring of traffic conditions. An Ethernet network interface is also provided to support an IP enabled engineer’s terminal, for future use. The MIDAS-IP outstation is fitted with two Instation communications interfaces; RS485 and Ethernet. It uses one of these interfaces to communicate its data back to the control room Instation using the NRTS network. An additional auxiliary link (OAL) is also provided and is capable of operating in RS485 or Ethernet mode. It operates in an output only mode and transmits Individual Vehicle Data, Traffic Data and MIDAS Alerts in response to Instation configurable parameters. The unit uses the Highways Agency’s IP Address Plug that is used to address a wide variety of motorway equipment. Further details of MIDAS-IP Outstation functionality may be obtained from the MIDAS Outstation Specification (see section 1.3.2 point 7).

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COBS

RS485 Link

TPR

- O/S Link 2

MIDASLCC

MIDASTRANSPONDE

R

MIDAS

-IP OUTSTATION

Up to 10 Inductive loop pairs

O/S Auxiliary Link RS485 or Ethernet

TPR

-O/S Link 1

LCC-TPR Link MIU

MIDASTransponder or Outstation

ENGINEER’S TERMINAL

MIDASLCC

MIDASTRANSPONDE

R

PCM Link (RS232 interface)

RS485 Link OR

NRTS

Network

MIU

Figure 1 - System Overview

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2.2 System Overview The MIDAS-IP Outstation consists of the following items, as shown in the System Diagram, Figure 2. 19 inch 3U high aluminium rack Power supply unit

Lead acid power fail battery Battery charger unit

Five loop detector cards (four loops per card) MIDAS-IP CPU module RS485 lightning protection module Ethernet comms lightning protection module

Loop cable connection kit Mains cable

The items are supplied in a cardboard box 575mm x 460mm x 220mm, with a total weight of approximately 10.7 Kg including battery. The following items are separately bagged in the box: RS485 lightning protection module Ethernet comms lightning protection module

Loop cable connection kit Mains cable Terminal block, resistors, nuts, screws and washers.

These items are detailed in the Installation Notes supplied in the packaging. There is also the IP Address Plug, supplied separately, which connects to the front of the CPU Module and is described in Section 3.8. The communications link between the Instation and Outstation can be either RS485 via Transponder or Ethernet (in which case the Transponder is not required). When communication is via the Transponder, there is a local RS485 communications link, the use of which is optional. Communications on the Auxiliary link can be either RS485 or Ethernet. Ethernet communications uses the same physical Ethernet port as the Transponder.


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Figure 2 - System Schematic Diagram


User Handbook

Figure 3 - Front Panel

2.3 Physical Arrangement The MIDAS-IP Outstation is mounted in a standard 19” equipment rack of 3U height, which provides a mounting frame and mechanical protection for all the hardware. All the external communications interfaces are routed through the Lightning Protection Modules mounted at the rear of the cabinet. The Outstation may be housed within the same cabinet as the Transponder, in which case the RS485 connection may be made to the link connection socket on the front of the MIDAS-IP CPU Module. For more information, see Section 3.5. A view of the equipment with the front panels removed is shown in Figure 4. A rear view of the equipment is shown in Figure 5.

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Figure 5 - Rear view of Midas IP Enabled Outstation

Figure 4 - Hardware Module Arrangement (front view, front panels removed)

Battery

Power Supply

CPU Carrier card

CPU Core

Loop Detector cards

Battery Charger


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Figure 6 - MIDAS-IP Rear Wiring to 600 Cabinet (top)


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Figure 6 and Figure 7 give an overview of how the rear wiring appears when fully fitted at the rear of the cabinet. For more detailed views, see Figure 14, Figure 15 and Figure 17.

Violet

Orange

Blue

Orange

White

Red

Grey

Red

TBA3

TBA4 TBG5

TBG4

Violet

Red

Blue

Red

White

Brown

Grey

Brown

Violet

Brown

Blue

Brown

White

Green

Grey

Green

Violet

Green

Green

Blue

White

Yellow

Grey

Yellow

Violet

Yellow

Blue

Yellow

White

Orange

Grey

Orange

Loop #01

Loop #02

Loop #03

Loop #04

Loop #05

Loop #06

Loop #07

Loop #08

Loop #09

Loop #10

Loop #11

Loop #12

Loop #13

Loop #14

Loop #15

Loop #16

Loop #17

Loop #18

Loop #19

Loop #20

TBA TBB TBC TBE TBF TBG

Figure 7 - MIDAS-IP Rear Wiring to 600 Cabinet (bottom)


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2.4 Power System The battery, battery charger module and power supply unit are located at the left side of the rack. These three elements satisfy the power requirements of the MIDAS-IP CPU and detectors, whilst providing control and monitoring information to the MIDAS-IP CPU. The battery charger has a heat sink that is fixed to the front panel. The battery charger becomes warm in use, heating this panel; this is part of normal operation and should not be considered a fault. The battery is a 12V sealed lead-acid type. It is capable of providing greater than 8 hours’ battery support in the event of a mains failure. The system operates normally while the battery is being recharged. The battery recharges fully within 12 hours of mains power restoration.

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2.5 Cables The cables are connected as follows:

Cable Connection Mains Via IEC320 connector on the front panel. See Section

3.9. RS485 Via 12-way terminal block. See Section 3.3. Ethernet Refer to Section 3.4. Earths Refer to Section 3.7. Loops Refer to Section 3.6.

Table 1 - Cable Connections The terminal block positions are defined in Highways Agency drawing MCX 0594 (see section 1.3.1).

2.6 PCBs

2.6.1 IP CPU Module The MIDAS-IP processor card consists of two parts: A single extended Eurocard (the carrier card) and a smaller CPU core. The CPU is mounted directly to the carrier card. The two together form the removable MIDAS-IP CPU module as shown in Figure 8 below.

Figure 8 - IP CPU Module

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Figure 9 - Rear View of Carrier Card showing external connections PL4, PL6 and PL8 are finely pitched connectors. It is recommended that a special tool (Molex) be used to remove them to avoid damage. It is not recommended that they be removed and reconnected in the field. The yellow RJ45 connector (SK5) is an interface to connect with RS485 serial interface detectors. It is wired as per the specification TR2512 for serial detectors. It is coloured yellow to distinguish it from the two Ethernet ports on the card that also use RJ45 connectors. The standard MIDAS-IP unit does not at present use this interface to communicate with its detectors. Detector communication is via the 50-way parallel interface ribbon cable that connects to PL5 on the carrier card (see Figure 8).

2.6.1.1 IP Core CPU This provides a Freescale PowerPC processor, 64 Mbytes SDRAM, 32 Mbytes Flash memory, communications interfaces and an FPGA for programmable I/O. The core CPU also provides an I2C interface for peripheral devices on the host card.

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Figure 10 - IP Core CPU

2.6.1.2 CPU Carrier card This card acts as a carrier for the CPU core. It comprises integrated PSUs for the CPU core, detectors and main processor circuitry. This card provides the reset switch, local/remote switch and status indicators. External communications interfaces are included for RS485 transponder/auxiliary links, RS232 Engineer’s Terminal link and Ethernet IP links. The card also has an I2C interface to the IP address plug. A hardware based watchdog is integrated on the card to ensure recovery in the event of software failure. PL7 on the Carrier card (see Figure 8) enables the Real Time Clock and should not have its link removed from the default position of pins 3-4.

Figure 11 - CPU Front Panel

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The LEDs located on the front indicate the following:

LED Function No Fault State Fault Indicated State

W/D FAIL Watchdog Failure Off Lit Red (for approx. 30 seconds, then off)

RUN Software running Flashing Green* 1 second on/1 second off

Off/Steady Green

COMMS Communications established On (flashes off for approx. 1/10 sec on transmit)

Off

DIAG Software status indication Off Lit Green

Table 2 - Status Indication LEDs * For software version 3 and above, the ‘RUN’ LED will follow the sequence below during start-up:

• Power on, 3 LEDs turn on for 13 seconds, then turn off for 13 seconds. • The ‘RUN’ LED then flashes rapidly for 33 seconds during system start-up. • If a valid address plug is attached the ‘RUN’ LED will then flash at the lower rate.

See Table 7 on page 41 for details of the diagnosis and possible remedy when a fault is indicated by one of the LEDs.

2.6.2 Loop Detector Card The Loop Detector detects the presence of vehicles passing over the inductive loops. Each Loop Detector can support up to four loops through four separate loop detector channels. The presence time The operating frequency, sensitivity and presence time of each of the loops is adjusted independently using on-board switches. See section 4.3 for information on setting up the sensitivity of each of the channels and Figure 20 for the position of switches 5-8. See section 4.4 for information on setting up the presence time for each of the channels. See Figure 12 for details of the front panel of the Loop Detector card.

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Figure 12 – ST4M Loop Detector front panel Status LEDs are provided on the front of each loop detector card to aid installation and fault diagnosis. To activate the LEDs press the LED Enable button on each card. When activated, Detector LEDs (D) illuminate when a vehicle is detected, and Fault LEDs (F) extinguish when a fault is detected. To conserve power they automatically switch off after approximately 20 minutes. Presence switches, when off, will raise a fault when a continuous vehicle presence has been detected for four minutes. When the switch is on, a fault is raised when a continuous vehicle presence has been detected for 35 minutes.

2.6.3 RS485 Lightning Protection Module This module provides the Transponder and auxiliary RS485 connections on the Outstation with lightning protection, and connects to the rear of the cabinet.

2.6.4 Ethernet Lightning Protection Module This in-line module protects the MIDAS-IP’s rear Ethernet connection from lightning surges on the communications cabling. It is separate from the main 19” rack and fixes to the rails at the rear of the cabinet, above the RS485 lightning protection module. It is connected in-

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line with the Ethernet cable entering the type 600 cabinet. Fixings are provided to hold the module away from the rails.

2.6.5 IP Address Plug (Type 9300) The IP address plug holds its address electronically in electrically erasable memory. The plug is a common weatherproof design that uses an I2C interface and communicates directly with the processor card assembly. The tag attached to the tether gives the programmed address of the plug and identification information. The plug shown below has not been programmed and therefore does not show an address.

Figure 13 - IP Address Plug

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3. INSTALLATION

3.1 Physical Installation The Outstation is generally supplied fully assembled with the exception of the Address Plug, the mains power cable and the two Lightning protection modules (RS485 and Ethernet). In some circumstances, the battery may be delivered separately, in which case install it as described in section 3.2. All the parts needed for an installation (except the address plug and the RJ45 Ethernet cable) are contained within the packaging. The address plug is supplied separately by the Highways Agency on a site by site basis. The RJ45 cable should also be sourced from the Highways Agency – see Appendix B for part number. Locate the Installation kit of parts which contains all the fixings required to install the unit and check it against Section 3.1.1. No specialised tools are required. Insert the cage nuts into the required positions in the front of the Type 600 frame and mount the Outstation using four screws and washers at the front. The location of the unit within the Type 600 frame is detailed in the Highways Agency installation drawings.

3.1.1 Installation List • Outstation Assembly (19” rack) including battery

• Outstation Installation Kit, consisting of: 4 x M6 Captive nuts, screws and washers 2 x M3 nuts, screws and washers 1 x Terminal block and cable 1 x Mains Power Cable 1 x Detector Loop Cableform 2 x Lightning Protection Modules (RS485 and Ethernet) 2 x 120Ω Resistors*

* Resistors are only required where they are not present on the cable network. Check with HA/NRTS whether they should be installed.

3.1.2 Equipment Needed for an Installation A standard Engineer’s tool kit. A programmed IP Address Plug Type 9300 (HA Stores Code NMCS-0037-2-000). Note that the plug is supplied blank and must be filled with site data prior to beginning the installation. An RJ45 Ethernet cable. A MOTE (MIDAS Outstation Test Equipment) kit supplied by Simulation Systems Limited and a suitable laptop p.c. (see section 6.11 for the minimum specification requirements). The handbooks and drawings referred to in section 1.3.1.

3.2 Install Battery If the battery is not already installed in the unit, proceed as follows:

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1. Remove the Battery Charger Module front panel (with the Supplier label). 2. Disconnect the battery charger and earth lead. 3. Connect the terminals to the battery (+ Red, - Black). 4. Slide the battery into place with the terminals facing forward. 5. Reconnect the earth lead and battery charger. 6. Replace the front panel. 7. Switch on the battery at the Battery Isolation Switch on the front panel.

3.3 Connect RS485 Lightning Protection Module Install the terminal block in position TBC2 as shown in Figure 6 on page 17 and MCX0831. Note that there is a 6 way terminal block installed in the cabinet that must be removed first. Connect the module in accordance with Figure 14 below. It is advisable to fit the RS485 Lightning Protection Module to the terminal block before terminating its earth lead (See Section 3.7). This ensures that the earth lead is long enough to reach the appropriate earthing point in the PDU. Refer to the Highways Agency installation requirements for specific fitting instructions. See also the Highways Agency drawing MCX 0834 sheets 1 and 4 for more details. Note that the termination resistors (where required) should be fitted between pins 1 and 2 (Transponder link) and 7 and 8 (Auxiliary link) of the terminal block as shown below.

Figure 14 - RS485 Lightning Protection Connections The connection from the RS485 lightning protection unit to the CPU module is via a 10-way coloured ribbon cable. It connects to PL2 of the CPU module as follows:

Pin No. Cable colour Fuse

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Pin No. Cable colour Fuse 1 Brown FS1

2 Pink FS2

3-8 Not used FS3 – FS6

9 Green FS7

10 Pink FS8

Note the two cable ties on the rear of the Outstation, below the red Ethernet cable. Thread the ribbon cable and its associated ferrite through these before connecting the cable, and tighten one of the cable ties around the ferrite to provide strain relief.

3.4 Connect Ethernet Lightning Protection Module Fit the Ethernet Lightning Protection Module to the rail TBC in the 600 cabinet, below TBC3, using the integral bolts. It is advisable to fit the module to the cabinet rail before terminating its earth lead (See Section 3.7). This is to ensure that the earth lead is long enough to reach the appropriate earthing point in the cabinet. The Ethernet lightning protection module must be fitted with the external Line In facing downwards, as shown in Figure 15 below. The internal cable connects to the CPU as shown in Figure 5. The RJ45 Ethernet cable is attached to the rear of the Outstation. This cable is connected to the top socket, labelled Line Out on the Ethernet Lightning protection unit. The other end of the cable connects to the top RJ45 connector, marked “IP Transponder (Ethernet)” in Figure 5.

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Figure 15 - Ethernet Lightning Protection Unit connections

3.5 Fit Local Transponder Lead This section only applies if the Outstation is in the same cabinet as the MIDAS Transponder, and there are no other outstations connected to that Transponder link. A special cable is also required, see Appendix B for details. In this case the Outstation may be connected via the ‘D’ type plug on the front of the MIDAS-IP CPU Module instead of via the rear connector and R485 lightning protection module via the special cable. It is important to check that the Transponder connection is not shared with any outgoing line as no lightning protection is provided on the ‘D’ type connection. The switch on the front of the card, marked “Local/Remote”, routes the Transponder link RS485 port either to this front panel ‘D’ type (Local) or to the rear RS485 connector (Remote).

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If no lead is available, mount the Outstation RS485 protection module as usual, wire to the Transponder’s RS485 Protection module and remove the external Transponder line connections.

3.6 Loop Detector Leads The loop connection leads are supplied as a single cableform with three headers on the ‘outstation’ end and four 12-way terminal blocks at the ‘loop feeder’ end. Note that the terminal blocks are not identical - they are ‘handed’, i.e. the blocks for the left hand side of the cabinet are numbered from the opposite end to those on the right. Connect the Berg headers according to the following table and Figure 16:

Backplane Loops PL2 Loops 1-8

PL3 Loops 9–16

PL4 Loops 17-20

Table 3 - Loop Detector Backplane connections

Figure 16 - Detector Backplane (view from rear)

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The shaded terminal blocks shown in Figure 17 are fixed to the Type 600 cabinet rails. The un-shaded terminal blocks are wired to the MIDAS-IP unit and form part of the MIDAS-IP installation kit. Note that in front of the backplane (when viewed from the rear), beneath sockets PL2, PL3 and PL4, are six holes (see Figure 5). Cable ties should be threaded through these and used to secure the ferrites. This gives additional strain relief to these cables.

Violet

Orange

Blue

Orange

White

Red

Grey

Red

TBA3

TBA4 TBG5

TBG4

Violet

Red

Blue

Red

White

Brown

Grey

Brown

Violet

Brown

Blue

Brown

White

Green

Grey

Green

Violet

Green

Green

Blue

White

Yellow

Grey

Yellow

Violet

Yellow

Blue

Yellow

White

Orange

Grey

Orange

Loop #01

Loop #02

Loop #03

Loop #04

Loop #05

Loop #06

Loop #07

Loop #08

Loop #09

Loop #10

Loop #11

Loop #12

Loop #13

Loop #14

Loop #15

Loop #16

Loop #17

Loop #18

Loop #19

Loop #20

12

34

56

78

910

1112

12

34

56

78

910

1112

12

34

56

78

910

1112

12

34

56

78

910

1112

12

34

56

78

910

1112

12

34

56

78

910

1112

12

34

56

78

910

1112

12

34

56

78

910

1112

TBA TBG

Figure 17 - Loop Detector Terminal Block connections

3.7 Earthing The Outstation has a flying earth lead which should be connected inside the PDU. There are also flying earth leads on the RS485 and Ethernet Lightning Protection modules. These leads must be fed down the side of the 600 cabinet, and terminated on the spare earth terminals housed within the PDU.

Safety Warning:

When replacing or exchanging the Outstation for another unit, be sure to connect the safety electrical connection (earth) on the rear of the unit.

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3.8 IP Address Plug The IP Address Plug is delivered separately from the other equipment and must be programmed with the appropriate address by the RMC. See section 1.3.2 point 1 for details of the Address Plug Programming Handbook, which is required to program the plug before attaching it to the equipment. The plug should be fixed to the cabinet by its tether and then plugged into the military style bayonet socket on the front of the unit (see Figure 3). In normal operation, the ‘RUN’ LED will flash at a rate of approximately 1 second on, 1 second off. When the Instation connects to the Outstation and establishes communications, the Comms LED comes on. If the Outstation is started with no plug attached, the ’RUN’ LED will continue rapidly flashing indicating system start-up mode. If a plug is attached that contains corrupted data or no data, the Outstation will behave as if there is no plug. The address plug contains Ethernet and NMCS2 addresses which allow each of the four possible combinations of Ethernet and RS485 operation on the Transponder and Auxiliary links.

3.9 Connect Mains Lead to PDU Safety Warning:

Ensure mains power to the cabinet is turned off at the PDU before wiring the IEC320 power lead to the PDU.

Connect the mains lead in accordance with Highways Agency drawings MCX 0156. The PDU is located in the base of the equipment cabinet. The cover of the PDU has to be removed to access the mains terminal blocks; this can be done with a 4mm flat blade screwdriver. Upon completion of this installation, test the power cable and earth cable to ensure compliance with BS7671.

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4. COMMISSIONING Commissioning may be performed either with connection to the Instation (via an RS485 Transponder or Ethernet) or by use of a suitable simulator. The simulator must be connected to the Outstation in place of the normal line connection, i.e. at the terminal block on the lightning protection module. If a simulator is used, a suitable address plug must be used to match the Outstation address that the simulator is using.

4.1 Initial Setup • Ensure that the switch and link settings on the unit are set to their default values, as

defined in section 5.5.1. • Ensure that both the PDU main switch and the spur switch to the MIDAS-IP unit are

on. Ensure that the red power switch on the front of the MIDAS-IP unit is on and illuminated.

• Make sure that the Battery Isolation Switch is set to Connected. • Set the RS485 Transponder Mode link switch to LOCAL or REMOTE as appropriate

(see Section 3.5). • Ensure the correct address plug is fitted as required for the communications

network location. • After a start-up period of 30 to 60 seconds, check the LEDs. (The Run LED should

be flashing green at a slow rate of 1 second on, 1 second off, the Comms LED should be substantially lit (flashes off when transmitting) and the others should be off.)

• Connect the MOTE as shown in Figure 18 below, select the Engineer’s Terminal mode of operation (Figure 19) and continue as follows:

• Ensure that the MOTE termination resistor is switched in circuit (140Ω). • Check that the baud rates are set to the factory defaults. • Check at the Control Office or Instation that communications have been

established. Communications are established when the Outstation receives site data from the Instation. If the Instation is not ready for communications go to section 4.2. Otherwise skip section 4.2.

• Check the Extended Status Request dialog box. “Transponder Link” should show OK, to indicate that the Outstation is communicating with the Transponder. “Loop Status” should be showing none faulty. If “Battery” shows low, commissioning may continue. It may be necessary to wait for at least one hour for the battery to become sufficiently charged, when the fault should clear.

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Figure 18 - MOTE Connected

Figure 19 - Laptop running MOTE Engineer’s Terminal

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4.2 Using the Transponder Simulator • Connect the RS485 link from the MOTE Transponder Simulator to the Outstation

either by wiring to the LOCAL TRANSPONDER D-type on the front or to the RS485 connection on the lightning protection module. Set the Local/Remote switch on the IP CPU card accordingly.

• Fit the test address plug into the socket labelled ADDRESS on the IP CPU card and reset the Outstation by inserting an insulated probe into the Reset opening.

• Make sure that the Battery Isolation Switch is set to CONNECTED. • Run the Transponder Simulator as required.

4.3 Configure the Loop Sensitivities • When the traffic flow is dense it may be necessary to switch off all but the pair of

channels to be tested by using the sensitivity switches on the loop cards (See Table 4 below and Figure 12 on page 24). If the channels are switched off during testing, they must be re-enabled to the correct sensitivity when steps 1 & 2 below are completed.

• Note that all the presence (P) switches should remain off during this process.

• The RESET button on the detector card must be pressed if the switch settings are changed. Changes in the settings will not take effect until the card is reset.

• Step 1: Enable the logging vehicle data message as described in the MOTE handbook. Check that a vehicle passing a pair of loops in a lane causes the detect LEDs of the corresponding loop detector channels to flash and a vehicle data message appears on the MOTE screen. Record the result.

• Step 2: While monitoring the flow of vehicles in a lane, look for the passage of a vehicle with a known length. Compare the length of this vehicle with the vehicle record. If the vehicle record length is too short, the sensitivity of the pair of loop detector channels should be increased. Conversely, if the length is too great, the sensitivity should be reduced.

• The sensitivity of both loops should be adjusted together.

• Repeat this procedure until the outstation consistently gives the correct length for a known set of vehicles and record the sensitivity.

• Repeat steps 1 and 2 for each pair of detector channels.

• Step 3: Once all detectors are set and enabled, check each channel for spurious loop events or cross-channel interference i.e. any detection of a vehicle not in the same lane as the loop. If spurious loop events occur, select a different detector operating frequency (see Table 5 and Figure 20). Alternatively, reduce the sensitivity of the loop detector channel concerned then repeat step 2 for the channel. Record any changes to the sensitivity against step 3.

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S1 S2 S4 Sensitivity (%ΔL/L) ON ON ON Channel Off OFF ON ON 0.02 ON OFF ON 0.04 OFF OFF ON 0.08 ON ON OFF 0.20 OFF ON OFF 0.50 ON OFF OFF 0.50 OFF OFF OFF 1.00

Table 4 - Detector Sensitivity Settings

SW 5 - 8, Pos 1 SW 5 - 8, Pos 2 Frequency OFF OFF Highest ON ON Lowest OFF OFF Highest ON ON Lowest

Table 5 - Detector Operating Frequency Settings

Figure 20 - Switches 5-8 on Loop Detector Card

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4.4 Presence Switches Time(s) may be selectable (there is 1 presence time switch per channel). The recommended setting (ON) gives a presence time of 35 minutes, and the alternative setting (OFF) gives a presence time of 4 minutes.

P Presence Time OFF 4 Minutes ON 35 Minutes

Table 6 - Detector Presence Setting

4.5 Final Commissioning Checks • Perform a quick battery test procedure:

This is a quick check that the battery is in circuit and that its fuse is intact and functioning before leaving site: i) Switch MIDAS-IP on and press all the loop detector LED Enable buttons. ii) Verify the loop detectors are detecting the changing presence of vehicles via their

status LEDs. iii) Ensure the Battery Isolation switch is set to Connected. iv) Switch the Mains Power switch off and verify the red power switch is extinguished. v) Confirm the unit continues to operate from battery power, and the detector LEDs

are flashing in response to vehicles. vi) Switch the Battery Isolation switch off and confirm the unit powers down. vii) Switch the Battery Isolation switch on – the unit will not switch back on – mains

power has to be present for this to happen. viii) Finally, switch mains power back on and confirm the red power switch is

illuminated.

• Check the Outstation address is correct for the location.

• Contact the Instation to confirm that the Outstation is responding correctly.

• Make sure the Local/Remote switch is set to Remote unless a local lead is fitted – see Section 3.5.

Note: A “Help Line” facility is available. See page 2 of this handbook for details.

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5. MAINTENANCE Before undertaking any maintenance of the equipment, read the Safety Instructions in Section 1.5 and the Operational Warning in Section 1.6. When maintenance and refitting is carried out on other equipment within the cabinet, it may be necessary to move MIDAS-IP equipment, in particular the Lightning Protection Modules. Follow the instructions given for individual items of equipment in Section 5.5. For a diagram of the Outstation internal layout see Figure 4, and for the front and rear connections see Figure 3, Figure 5 and Figure 6. In addition to standard equipment such as tools for dismantling and wiring, an Engineer’s Terminal pc running MOTE software and a MOTE connection unit is required – see Section 6.11.

5.1 Replaceable Parts The following parts are replaceable. Follow the instructions given in section 5.5 for replacing individual parts.

IP Address Plug Loop Detector cards CPU Module Power Supply Unit Battery Charger Module Power Supply Battery RS485 and Ethernet Lightning Protection Modules Fuses Various cable forms

Appendix B gives the part numbers.

5.2 Routine Maintenance The only routine maintenance required is the replacement of the battery and verification that fuses are intact. Before removing or replacing the battery, read the Safety Warning in Section 1.5. Electrical safety checks should be carried out in accordance with the requirements of MCH 1957. The power supply battery backup is a 12V sealed lead-acid type, with an estimated operating life of two years. The battery should be replaced every two years. Instructions for replacing it can be found in Section 5.5.5.

5.3 Fault Finding Listed below are the main faults that might be reported by Outstations. If any fault is reported that is not listed below, or a fault persists after trying the remedy(ies) suggested, consult Siemens (see page 2 for details).

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Symptom Diagnosis Remedy The Mains is disconnected.

Check that the mains supply is connected.

The Mains has failed. Check the mains fuse. Check the mains supply. DO NOT reset the Outstation. See Section 5.4.

A Mains Fail fault is reported at the Instation or in the Fault Report

The PSU has failed. The PSU output should be 16.5V (&0.5V); see section 5.3.1 for details. If not, replace the PSU.

The watchdog has failed. Reset the Outstation. (DO NOT reset if mains voltage is not present. See Section 5.4).

The W/D FAIL LED on the IP CPU Module is lit

Hardware fault. Reset the Outstation. (DO NOT reset if mains voltage is not present. See Section 5.4). If the fault persists, replace the CPU module.

System has not started correctly (indicated by rapid flashing of the run LED).

Check the address plug is correctly programmed and fitted. Then reset the Outstation. (DO NOT reset if mains voltage is not present. See Section 5.4). If the fault persists, replace the CPU module.

The RUN LED on the IP CPU Module is not flashing at normal rate (1 second on, 1 second off).

Software is not running. Reset the Outstation. (DO NOT reset if mains voltage is not present. See Section 5.4). If the fault persists, replace the CPU module.

Hardware fault. Reset the Outstation. (DO NOT reset if mains voltage is not present. See Section 5.4). If the fault persists, replace the CPU module.

The DIAG LED on the IP CPU Module is lit

There is a fault reported in the Fault Log.

Use the MOTE Engineer’s Terminal to examine the Fault Log.

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The battery is not charging.

Check the Battery Isolation Switch is set to Connected. Check the battery is connected and a terminal has not worked loose. Check the battery fuse. Replace the battery. Replace the battery charger.

A Battery Low fault is reported at the Instation or in the Fault Report.

The battery is disconnected.

Check the Battery Isolation Switch is set to Connected. Check the battery is connected and a terminal has not worked loose. Check the battery fuse. Check the battery fuse.

The IP CPU has failed. Replace the IP CPU module.

The Battery is not charging.

Check the battery leads. Check the battery fuse. Change the battery. Replace the battery charger.

A Battery Charger fault is reported at the Instation or in the Fault Report.

The Battery is disconnected.

Check the battery connections. Check the Battery Isolation Switch is set to Connected. Check the battery fuse.

The IP CPU has failed. Replace the IP CPU module.

A road loop is disconnected.

Check terminal block connections and cables (section 3.6). Check the loop detector ribbon cable is correctly connected. Reconnect the road loop. Reset the detector.

A Loop Detector fault is reported at the Instation or in the Fault Report.

A road loop is shorted Remove the short. Reset the detector.

A fault in the Loop Detector Card.

Replace the Loop Detector Card.

The Transponder link has failed.

Check the Transponder link connections. Check the site configuration.

Instation reports Outstation unobtainable

The address is configured incorrectly

Reprogram or replace the address plug.

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The Transponder has failed

See the Transponder System Handbook, as detailed in section 1.3.1.

Any other fault report or message.

Reset the Outstation (DO NOT reset if mains voltage is not present. See Section 5.4). If the fault persists, consult TS Engineering.

Table 7 - Fault Finding

5.3.1 Checking PSU Output To check the PSU output:

1. Leave the Power Switch ON. 2. Set the Battery Isolation Switch to OFF. 3. Pull out the Power Supply Unit without removing the connections, as shown in

Figure 21. 4. Use a multimeter to take the reading; insert the black probe into the white cable

connector and the red probe into the orange cable connector. 5. Replace the PSU and set the Battery Isolation Switch to ON.

Figure 21 – PSU Test Points

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5.4 Outstation Reset Note: Do Not carry out a manual reset during a mains fail, as the equipment will shut down. It can only be restarted with mains present. To carry out a reset of the Outstation, insert an insulated probe into the hole marked “Reset” on the front of the IP CPU module (as shown in Figure 3) and press for two seconds. The system then restarts. Allow 30 to 60 seconds for the system start-up. Note: Loop Detectors at the Outstation also have reset buttons, which are required for resetting latched loop faults and for changing loop sensitivity and presence times.

5.5 Fitting and Replacement Procedures Please note that card switches (other than on loop detectors) are factory set. Check with Section 5.5.1 that the card is the correct one and that the default settings are correct before fitting the replacement. Part numbers for all the replaceable parts are given in Appendix B.

Replacement of some modules within MIDAS requires the disconnection of safety earth leads. It is vital that these earth leads are re-connected after the module has been replaced.

Safety Warning:

5.5.1 Default Settings The following table shows the default settings for the various items of equipment. It is important to ensure that the equipment uses the settings detailed below when it is installed.

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Default Setting

Meaning

CPU Core Storage capacitor link Link set on

pins with silk screen box around them

RTC time is preserved when power is disconnected

Loop Detector cards Front panel switches S1, S2, S4 & P All off Presence time

(section 4.4) and loop sensitivity (section 4.3)

Card 1 Frequency selection switches SW5–8 ⎧

⎩Pos 1 – Off Pos 2 – Off Highest frequency


⎩Pos 1 – Off Pos 2 – On High frequency


⎩Pos 1 – On Pos 2 – Off Low frequency


⎩Pos 1 – On Pos 2 – On Lowest frequency


⎩Pos 1 – Off Pos 2 – Off Highest frequency

MOTE

Link Data Rates

Outstation Auxiliary Link – OAL 4800 Baud speed Engineering Terminal Link – ETR 9600 Baud speed

Transponder Link – Upstream 4800 Baud speed Note: The MOTE cover must be removed

to make Data Rate adjustments

Termination resistor 140Ω RS485 link is terminated with 140Ω

.

Table 8 - MIDAS IP Outstation Test Equipment Default Settings


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5.5.2 Replacing the IP CPU Module 1. Switch off at the main power switch and disconnect the mains lead. See Figure 3. 2. Switch the battery off at the Battery Isolation Switch. 3. Remove the IP Address Plug and any connections to the D-type connectors. 4. Remove the rear connections (Ethernet, etc). 5. Disconnect the 10 way IDC connector on the rear of the carrier card (SK2) and the

remote transponder connector (if fitted). 6. Undo the four screws holding the front panel marked MIDAS-IP CPU Module and slide it

out as far as possible. 7. Slide out the module half way. 8. Disconnect the 50 way IDC on the carrier card (PL5) from the front and remove the

power connector. 9. Replace the IP CPU assembly. Before fitting the new module check that the default

settings correspond with those in Section 5.5.1. 10.Reverse the above procedures to reassemble and reconnect the cards. NB – it is possible to replace the core CPU or the carrier card separately if required. However, this procedure should not be carried out in the field; the unit should be returned to service repair. Follow the instructions above to point 6 and then proceed as follows:

Disconnect the carrier card from the core CPU by undoing the 4 spacer screws. Carefully separate the units. If the carrier card is to be replaced, it must be removed from the front panel by

disconnecting the connectors PL4, PL6 and PL8 (as shown in Figure 8). It is recommended that a special tool (Molex) be used to remove them to avoid damage. It is not recommended that they be removed and reconnected in the field.

Replace the carrier card or core CPU as required and reconnect the units. Check that the default settings on the new card correspond with those in section 5.5.1.

Reassemble the unit by reversing the disconnection instructions.

5.5.3 Replacing a Loop Detector Card 1. Disconnect the mains and isolate the battery using the Battery Isolation Switch on the

front panel (See Figure 3). 2. Undo the two screws on the front panel holding the Detector and slide it forward to

remove. 3. Set all the switches on the new card to the same positions as the old card. 4. Fit the new Detector and screw to the equipment rack. 5. Restore mains power and reconnect the battery. 6. Activate the Detector card LEDs to check it is correctly detecting the changing presence

of vehicles.


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5.5.4 Replacing the Power Supply Unit 1. Remove the IEC320 plug from the front of the unit and isolate the battery using the

Battery Isolation Switch on the front panel (See Figure 3). 2. Remove the front panel marked Power Supply Unit. 3. Disconnect the battery fuse connectors and the power connector. 4. Remove the earth lead. 5. Remove the PSU. 6. Fit the new PSU. 7. Reconnect the mains earth lead. 8. Re-connect the power connector and the battery fuse connectors. 9. Re-fit the front panel. 10.Connect the battery using the Battery Isolation Switch, and re-connect the mains.

5.5.5 Replacing the Power Supply Battery 1. Disconnect the mains and isolate the battery using the Battery Isolation Switch on the

front panel (See Figure 3). 2. Remove the left hand front panel (with the Supplier label) and disconnect the battery

charger. 3. Disconnect the earth lead. 4. Slide out the battery and disconnect the battery terminals. 5. Replace the battery. The terminals should be towards the front of the MIDAS-IP unit. 6. Re-connect the terminals to the replacement battery (+ red, - black). 7. Re-connect the battery charger, reconnect the earth leads and replace the front panel. 8. Switch on the battery at the Battery Isolation Switch on the front panel. 9. Re-connect the mains. 10.Handle and dispose of the battery safely in accordance with the Safety Warning in

Section 1.5.

5.5.6 Replacing the Battery Charger 1. Disconnect the mains and isolate the battery using the Battery Isolation Switch on the

front panel (See Figure 3). 2. Remove the left hand front panel (with the Supplier label) and disconnect the battery

charger. 3. Disconnect the earth lead. 4. Replace the battery charger unit. 5. Reconnect the earth lead and cable to SK1. 6. Replace the front panel. 7. Switch on the battery at the Battery Isolation Switch on the front panel. 8. Re-connect the mains.


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5.5.7 Replacing the RS485 Lightning Protection Module This module protects the equipment against induced voltage transient and excessive line voltages/currents. The fuses will blow if excessive currents are coupled into the lines. It is unlikely that the module will require replacement, but it may need to be moved within the cabinet when rewiring is carried out or new equipment is fitted. Proceed as follows: 1. Disconnect the ribbon cable and the earth lead. 2. Cut the cable ties holding the ribbon cable to the rear of the Outstation. 3. Unscrew the module from the cabinet rails and remove. 4. Fit the new module by screwing to the cabinet rails. 5. Refit the cabling and cable ties as necessary.

5.5.8 Replacing the Ethernet Lightning Protection Module This module protects the rear Ethernet connection to the Instation from lightning surges on the communications cabling. It can be moved or replaced in the same way as the RS485 lightning protection module (see section 5.5.7 above). It is an in-line module, connected in series with the Ethernet cable exiting the type 600 cabinet. Care should be taken to ensure it is installed the correct way round. Its cover is marked with line in and line out. Line out connects to the MIDAS-IP unit. The Ethernet lightning protection unit should be mounted with this connector facing upwards.

5.5.9 Replacing Fuses See Appendix B for part numbers.

Location Fuse Rating Qty Front panel Battery backup fuse 3.15A Q/B 250V 1 Front panel Mains fuse 3.15A 250V Anti-surge (T) 1 RS485 Lightning Protection Module

Lightning Protection module fuse

1A S/B 250V Anti-surge (T)

8

Table 9 - Fuse Ratings

5.5.9.1 Battery Fuse Isolate the battery using the Battery Isolation Switch. Investigate and rectify the cause of the fault. Remove the fuse from the battery front panel and replace with one of the same rating. Re-connect the battery at the Battery Isolation Switch.


User Handbook

5.5.9.2 Mains Fuse Isolate the mains using the Mains Switch. Investigate and rectify the cause of the fault. Remove and replace the fuse in the mains socket. See Figure 3. Re-connect the mains at the Mains Switch.

5.5.9.3 RS485 Lightning Protection Module Fuses Remove the plastic cover from the Lightning Protection Module. Replace fuses FS1 to FS8 as required. Replace the cover.

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6. TECHNICAL SPECIFICATION

6.1 Physical Characteristics

Unpackaged – unit only

Packaged with installation kit

Size height 130 mm 220 mm width 480 mm 575 mm depth 240 mm 460 mm Approx. without battery 3.75 Kg 7.9 Kg Weight with battery 6.5 Kg 10.7 Kg

6.2 Electrical Specification Parameter Conditions Min Typ Max Units Operating voltage

195.5 230.0 253.0 V rms a.c.

230 V rms a.c. input voltage, with loop detector status LEDs in-active

74 mA rms

230 V rms a.c. input voltage, with loop detector status LEDs active

125 mA rms

Operating current

230 V rms a.c. input voltage, battery charging with flat battery

340 mA rms

Frequency 47 50 52 Hz


8.7 W


17.3 W

Power

230 V rms a.c. input voltage, battery charging with flat battery

52 W


0.50 Power factor


0.55

6.3 Features A MIDAS-IP Outstation can sample up to 20 loops. It reports averages for speed, occupancy, headway and flow over a configurable interval. It provides alarms when there is a configurable change in average speed or flow at a site. It provides alarms when there is a high occupancy condition in a lane. It provides RS485 and Ethernet interfaces to the Instation. It functions with the HA IP address plug.


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6.4 Safety

Certified Meets Electrical Safety requirement BS EN 60950 (section 1.3.2 point 14). Meets Telecommunications Safety requirement BS EN 41003 (section 1.3.2 point 13).

6.5 EMC MIDAS-IP Outstations meet the emission and susceptibility requirements of BS EN 50293 (section 1.3.2 point 15). The Detector loop operating frequency complies with EN 300 330 (section 1.3.2 point 12). Loop Detectors meet the emission and susceptibility requirements of TRG 1068 (section 1.3.2 point 4).

6.6 Environmental Information The roadside equipment meets the mechanical and temperature requirements of TR2130C (section 1.3.2 point 5). Operating temperature from -15°C to 60°C. Humidity range 0% - +95% (non-condensing).

6.7 Data Rates Standard baud rates 2400, 4800, 9600. Other rates programmable up to 38,400. Ethernet 10Mbits/sec.

6.8 Battery Backup Lead acid battery support – 8 hour operation at -15°C. The battery is fully recharged within 12 hours of mains power being restored.

6.9 Lightning Protection Meets the requirements of ITU-T K20 and K21 (section 1.3.2 point 11) and BS EN 55024:1998 (section 1.3.2 point 17).

6.10 Processor Freescale PowerPC processor 64Mbytes SDRAM 32 Mbytes Flash memory FPGA for programmable I/O Core CPU provides an I2C interface for peripheral devices on the host card Integrated PSUs for the CPU core, detectors and main processor circuitry


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Lead acid battery charging and monitoring External communications interfaces for RS485 transponder/auxiliary links, RS232 engineer’s terminal link and Ethernet IP links I2C interface to the address plug Hardware based watchdog.

6.11 Engineer’s Terminal (MOTE) The Engineer’s Terminal for use with MIDAS-IP is the MOTE, supplied as a kit by Simulation Systems Limited. The minimum specification IBM-compatible pc needed to run the MOTE (version 4.30) is:

1000+ MHz Pentium (or Pentium compatible) processor 128MB of RAM At least 50MB of hard disk space (more for log files) CD/DVD-ROM At least 1 RS232 COM port (or USB/Serial adapter) At least 1 free PCI slot (desktop PC users only), or 1 free PCMCIA slot (laptop users only) Microsoft Windows 2000/XP

Later versions of MOTE may call for a different minimum specification. Please check with the MOTE handbook for the latest requirement. The wiring for the cable to connect the Engineer’s Terminal to the Outstation is shown in Figure 22 below (the part number for the cable is given in Appendix B). This wiring is that of a null modem cable. Table 10 shows the pin out.

PC end 9 way socket

O/S end 9 way plug

1

5

6

9

6

9

1

5

DTR

CTS

RTS

DSR

GND

TX

RX

Figure 22 - Wiring Diagram for Engineer’s Terminal to Outstation cable


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Signal name Female socket (9 way) Male plug (9 way)

Not connected 1 1

Receive Data (RxD) 3 2

Transmit Data (TxD) 2 3

Data Terminal Ready (DTR) 6 4

Signal Ground (GND) 5 5

Data Set Ready (DSR) 4 6

Request To Send (RTS) 8 7

Clear To Send (CTS) 7 8

Not connected 9 9

Table 10 - Engineer’s Terminal Cable Pin Out

6.12 Loop Detectors Number of loops – 20. Meets the requirements of Inductive Loop Vehicle Detection Equipment specification (see section 1.3.2 point 3 for details). The MIDAS-IP Loop Detector is a (ST4M) scanning 4-channel detector with a single Eurocard outline. It meets the requirements of standard EN 300 330 (section 1.3.2 point 12). Key characteristics of the MIDAS-IP (ST4M) loop detectors are shown in Table 11 below. The front panel has the following features:

• Three sensitivity switches per channel • One presence time switch per channel • Reset button • LED Enable button • Fault and Detect LEDs.

The MIDAS-IP unit provides an RS485 interface for serial data connection with alternative loop detector cards. Power supply and current 5V DC at 60mA current 12V DC at 20mA current Environmental -15°C to 60°C up to 95% humidity Size 160mm x 100mm x 25mm Inductance Tuning Range 50μH to 300μH (plus feeder inductance) Feeder Length 0 – 200 metres Operating Frequency 20kHz to 110kHz Vehicle Speed Range 0 to 195 km/h using loops 2m in direction of

travel

Table 11 - MIDAS-IP ST4M Loop Detector Specification


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APPENDIX A – TECHNICAL DRAWINGS AND FAMILY TREE This Appendix contains the following:

Part Number Description 667/DZ/32500/000 MIDAS-IP Outstation Family Tree

667/GA/32500/000 MIDAS-IP Outstation Assembly

667/GA/26775/ETC Detector Loop Cable Assembly

667/DB/32500/000 MIDAS-IP Wiring Diagram

667/GA/32510/000 PSU PCB Assembly

667/GA/32520/000 CPU Module Assembly

667/DA/32521/ETC CPU Circuit Diagram

667/GA/32521/ETC CPU PCB Assembly

667/DA/20982/ETC RS485 Lightning Protection Circuit Diagram

667/GA/20982/ETC RS485 Lightning Protection PCB Assembly

667/DA/32570/000 Ethernet Lightning Protection Circuit Diagram

667/GA/32575/000 Ethernet Lightning Protection PCB Assembly

667/DA/26761/000 Backplane Circuit Diagram

667/GA/26761/000 Backplane PCB Assembly

667/DA/26759/ETC Outstation Detector Circuit Diagram

667/GA/26759/ETC Outstation Detector PCB


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APPENDIX B – PART NUMBERS

Equipment Description Siemens Part No HA Stores No Midas IP Enabled Outstation Handbook (paper)

667/HB/32500/000 MANUAL-0567-1-SPC

Midas IP Enabled Outstation Open Source Licences

667/HB/32500/001 -

Midas IP Enabled Outstation Handbook (CD-ROM)

667/TB/32500/000 MANUAL-0566-1-SPC

Midas IP Enabled Outstation Installation Notes (paper)

667/HB/32500/010 -

IP Outstation Assembly 667/1/32500/000 MIDAS-0034-1-SPC

Installation Kit 667/1/32565/000 MIDAS-0037-2-SPC

IP Address Plug 667/1/32580/000 NMCS-0037-2-000

IP CPU Assembly 667/1/32520/000 MIDAS-0038-2-SPC

Loop Detector Card assembly 667/1/26758/000 MIDAS-0040-2-SPC

Battery Charger module 667/1/32515/000 MIDAS-0041-2-SPC

Power Supply Unit assembly 667/1/32510/000 MIDAS-0039-2-SPC

PSU Battery - 12V 9Ah1 418/4/42314/024 MIDAS-0044-2-SPC

RS485 Lightning Protection Module PCB 667/1/20982/005 MIDAS-0043-2-SPC

Ethernet Lightning Protection module 667/1/32570/000 MIDAS-0042-2-SPC

Engineer’s Terminal cable 667/1/32535/000 -

Local Transponder cable 667/1/32540/000 -

Mains fuse 3.15A 518/4/90353/008 -

Battery Backup fuse 3.15A 518/4/90285/007 -

RS485 Lightning Protection Module fuse 518/4/90284/005 -

IP Address Plug Programmer 667/1/32595/000 NMCS-0039-3-SPC

IP Address Plug Programmer Handbook 667/HB/32591/000 -

IP Address Plug Programmer Software 667/TZ/32591/000 -

RJ45 Patch Cable 1.5m - CABLE-2301-1-000

RJ45 Patch Cable 2.0m - CABLE-2302-1-000

1 Lead Acid Batteries have a one-year shelf life, if stored at 20°C, at which stage they must be recharged to maintain their efficiency. It is recommended that battery spares should be charged every six months to prevent deterioration. Consult the manufacturer’s data for this recharge procedure. It is recommended that batteries should not be held as spares, but ordered as required.


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User Handbook

APPENDIX C – OPEN SOURCE LICENCES The Midas IP Outstation contains several items of open source software, the licence agreements for which are contained in the document – Midas IP Enabled Outstation Open Source Licences 667/HB/32500/001. The licence document is supplied with this handbook on the CD-ROM 667/TB/32500/000.

667/HB/32500/000 Page 55 Issue 4


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INDEX

—A— Address Plug...................................................... 13, 25

Programming.......................................................... 7 Alarm........................................................................ 48 Alerts........................................................................ 11 Auxiliary link ............................................................. 13

—B— Battery...................................................... 9, 13, 19, 33

Charger ................................................................ 13 Charger fault ........................................................ 40 Fuse ..................................................................... 46 Isolation Switch .............................................. 33, 35 Low fault ............................................................... 40 Replacement ........................................................ 45

Battery Backup Features ............................................................... 49

Battery Charger Replacement ........................................................ 45

Baud rate.................................................................. 33

—C— Cables ...................................................................... 20 Circuit Diagrams....................................................... 52 Comms..................................................................... 23 CPU Carrier Card..................................................... 13 CPU Module............................................................. 13

Defaults ................................................................ 43 CPU PCB

Replacement ........................................................ 44

—D— Data Rates ............................................................... 49 Default settings ........................................................ 42 DIAG .................................................................. 23, 39

—E— Earth .................................................27, 28, 31, 42, 45

Cable.................................................................... 20 Electrical Safety ....................................................... 49 EMC ......................................................................... 49 Engineer’s Terminal ........................................... 33, 50 Environmental Requirements ................................... 49 Ethernet.................................................................... 13

cable..................................................................... 20 Flying Earth Lead ................................................. 31 Line Protection Module

Replacement .................................................... 46 Line Protection Module............................. 13, 24, 28

—F— Faults ....................................................................... 38 Features ................................................................... 48 Flying Earth Lead ..................................See also Earth Frequency Settings ............................................ 36, 37 Functionality ............................................................. 11

Fuses........................................................................ 46

—H— HA Stores Number ................................................... 53 Health and Safety ....................................................... 6

—I— IEC320 ..................................................................... 20 Individual Vehicle Data ............................................. 11

—L— LEDs................................................................... 23, 33 Lightning Protection.................................................. 49 Line Protection Module15, See also Ethernet, See also

RS485 Link Data Rates........................................................ 43 Local......................................................................... 29 Loop

Cable .................................................................... 20 Loop Detector

Cards.................................................................... 13 Fault ..................................................................... 40 Features ............................................................... 51 Leads.................................................................... 30 Operating frequency ............................................. 51 PCB Defaults........................................................ 43 Replacement ........................................................ 44 Specification ......................................................... 51

—M— Mains........................................................................ 32

Cable .................................................................... 20 Fault ..................................................................... 39 Fuse ..................................................................... 47

Maintenance Routine ................................................................. 38

Manual reset............................................................. 42 MIDAS Alerts............................................................ 11 MOTE........................................................... 11, 33, 50 Mounting frame ........................................................ 15

—O— Overview .................................................................. 13

—P— Part Numbers ........................................................... 53 PCB

Switches ............................................................... 42 PCB Assembly drawing ............................................ 52 Power Supply ........................................................... 13

Battery Backup ..................................................... 38 Battery Replacement ............................................ 45 Loop Detector ....................................................... 51 Replacement ........................................................ 45

Processor Features ............................................................... 49

PSU.................................................See Power Supply


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—R— Remote..................................................................... 29 Replaceable parts .................................................... 38 Reset............................................................ 39, 41, 42 RS485 ................................................................ 13, 15

Cable.................................................................... 20 Flying Earth Lead ................................................. 31 Line Protection Module............................. 13, 15, 27

Fuse ................................................................. 47 Replacement .................................................... 46

RUN ................................................................... 23, 39

—S— Safety....................................................................... 49 Safety Instructions.................................................... 38 Sealed Lead Acid Batteries ........................................ 9 Sensitivity Settings ................................................... 36 Size .......................................................................... 48 Software

running ................................................................. 23

status.................................................................... 23 System Overview...................................................... 13

—T— Telecommunications Safety ..................................... 49 Terminal block .................................................... 20, 27 Traffic Data............................................................... 11 Transponder

Link....................................................................... 33

—V— Vehicle Data ............................................................. 11

—W— W/D FAIL............................................................ 23, 39 Watchdog ................................................................. 23 Weight ...................................................................... 48 Wiring ....................................................................... 30

Last page of the MIDAS-IP Enabled Outstation Handbook