Document Name: ENG****
Document Description: APC Operating and Maintenance Manual
Document Issue: 1d
Document Owner: Craig Payne [Lead Engineer]
Issue 1d First Draft 23/01/2019
Document Revision History
THIS DOCUMENT IS CONTROLLED IN THE MORS SMITT
ELECTRONIC DOCUMENT CONTROL SYSTEM
REVIEW & APPROVAL RECORDS ARE STORED IN THE ELECTRONIC DOCUMENT CONTROL SYSTEM
Mors Smitt UK Ltd :: Graycar Business Park, Barton under Needwood, Burton on Trent, Staffordshire, DE13 8EN, United Kingdom.
This document is proprietary and confidential.
No part of this document may be disclosed in any manner to a third party without the prior written consent of Mors Smitt UK Ltd
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CONTENTS
1 INTRODUCTION ............................................................................................................................................4
1.1 Purpose .................................................................................................................................................4
1.2 Scope ....................................................................................................................................................4
1.3 Abbreviations........................................................................................................................................4
2 SAFETY INSTRUCTIONS .................................................................................................................................5
2.1 General Safety ......................................................................................................................................5
2.2 Human Health.......................................................................................................................................5
2.2.1 Risk of Injury from Electrocution ..................................................................................................5
2.2.2 Risk of Injury due to Dropping the Equipment .............................................................................6
3 SYSTEM OPERATION DESCRIPTION ..............................................................................................................7
3.1 APC Receiver .........................................................................................................................................7
4 TRANSPORT AND STORAGE ..........................................................................................................................8
5 RE-ASSEMBLY................................................................................................................................................9
6 MAINTENANCE ...........................................................................................................................................10
6.1 Corrective Maintenance Instruction...................................................................................................10
6.1.1 General .......................................................................................................................................10
6.1.2 Replacement of the APC Receiver ..............................................................................................10
6.2 Test Equipment...................................................................................................................................11
7 OPERATION .................................................................................................................................................12
8 PREVENTATIVE MAINTENANCE ..................................................................................................................13
8.1 General ...............................................................................................................................................13
8.2 APC Receiver .......................................................................................................................................13
8.2.1 Visual Inspection .........................................................................................................................13
8.2.2 Cleaning ......................................................................................................................................13
8.2.3 Position Check ............................................................................................................................13
[Link] Measuring Conditions.............................................................................................................14
[Link] APC Receiver Position .............................................................................................................14
9 DECOMMISSIONG.......................................................................................................................................15
10 DISMANTLING .............................................................................................................................................16
11 DISPOSAL ....................................................................................................................................................17
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12 ERROR IDENTIFICATION ..............................................................................................................................18
13 APPENDIX....................................................................................................................................................19
14 SUBJECT INDEX ...........................................................................................................................................20
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1 INTRODUCTION
1.1 Purpose
This document comprises the APC System Maintenance Manual and includes maintenance, fault tracing,
corrective maintenance and testing and has been prepared to satisfy the Maintenance requirements within
the RSSB Railway Group Standard (RGS) GE/RT2111 [Ref. Error! Reference source not found.].
1.2 Scope
The scope of this document is limited to providing guidance on the vehicle maintenance for the APC system.
The Line Replaceable Units (LRU’s) included in the scope of this installation specification are listed in Table 1
below.
Table 1: APC LRUs
LRU Part Number
APC Receiver TY294/GRP72
1.3 Abbreviations
APC Automatic Power Control LRU Line Replaceable Unit
ARL Above Rail Level MSUK Mors Smitt United Kingdom
BS British Standard OTMR On-Train Monitoring Recorder
ESD ElectroStatic Discharge RGS Railway Group Standard
IEC International Electrotechnical Commission
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2 SAFETY INSTRUCTIONS
2.1 General Safety
The following safety instructions should be followed when undertaking any servicing, maintenance or
commissioning work on the APC System:
• To avoid accidental damage, power to the APC Receiver shall be switched off before
disconnecting and reconnecting ANY part of the System.
• System LRUs shall not be opened - All faulty units shall be replaced.
• To achieve safe operation of the APC System, all equipment shall be correctly installed and tested
as per the relevant specifications and documentation.
• Servicing and maintenance activities shall only take place when the vehicle is NOT in operation
(with or without passengers).
• Test equipment shall NOT be connected when the vehicle is in operation (with or without
passengers).
• The test personnel shall be familiar with service and maintenance of rolling stock in general, and
in particular with the equipment described herein. Appropriate training of personnel associated
with undertaking maintenance on the APC System is considered the responsibility of the
organization conducting the work.
2.2 Human Health
There are two health hazards pertinent to the APC System, these are:
• Risk of injury from electrocution
• Risk of injury due to dropping equipment
2.2.1 Risk of Injury from Electrocution
All components of the APC system are classified as Extra Low Voltage system according to the International
Electrotechnical Commission (IEC 60038). The input supply power to the APC Receiver is 110VDC.
Power should be removed and confirmed that there is no voltage present from the APC System before
equipment is disconnected and re-connected.
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2.2.2 Risk of Injury due to Dropping the Equipment
A table displaying the weight of each individual system component of the APC System is shown in Table 2
below.
Note: When handling any system component of the APC System, appropriate Personal Protective Equipment
must be worn, particularly protective footwear, to protect against the risk of falling equipment.
Table 2: APC System Weights
System Component Weight (Max.)
APC Receiver
TBC
(including conduit)
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3 SYSTEM OPERATION DESCRIPTION
The Automatic Power Control system cuts the incoming power supply to a traction unit for short periods. This
is required where power supplied from one part of a power distribution system in separated from another by
a neutral section. Its fitment prevents damage to the power distribution system or the vehicle. The system
detects a track magnet positioned shortly before the beginning of the neutral section and sends a signal to the
incoming power circuit breaker controller to open the circuit breaker. Once the system detects a second
magnet positioned after the neutral section a second signal is sent to close the circuit breaker. The APC
Receiver is a very robust unit and can be mounted on the vehicle main underbody or a bogie.
3.1 APC Receiver
The APC Receiver comprises a single LRU assembly with flying lead. The APC Receiver is located externally
beneath the train to detect the magnetic flux emanating from the trackside magnet placed shortly before the
beginning of the neutral section break and sends a signal to the incoming power circuit breaker controller to
open the circuit breaker.
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4 TRANSPORT AND STORAGE
There are no special transportation requirements (Hoisting gear or cranes etc.), or special storage conditions
that are required for the APC Reciever. However, MSUK recommend that all LRU’s are kept in their original
packaging and stored within a dry, safe environment when not in use on a train.
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5 RE-ASSEMBLY
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6 MAINTENANCE
Displayed in Table 3 are the replaceable LRU’s for the APC system.
Table 3: APC LRUs
LRU Part Number
APC Receiver TY294/GRP57
6.1 Corrective Maintenance Instruction
6.1.1 General
The safety instructions in chapter 2 continue to apply to this section. In the event that a vehicle is equipped
with multiple APC Systems and more than one unit of the same kind is to be replaced, then the following
procedures shall be completed for each unit before replacing the next.
Always rectify the fault with one unit before moving on to the second unit. This will avoid the mixing up of
serviceable and unserviceable units.
When replacing any unit, verify with the applicable Product Version document for the APC System that the
resulting system (APC Receiver Hardware) constitutes an approved combination of product numbers and
versions (has verified interoperability).
6.1.2 Replacement of the APC Receiver
The APC Receiver shall be replaced in the following manner:
1. Switch off power from the APC Controller connected to the APC Receiver that is to be replaced
2. Unplug the connector at the end of the APC Receiver cable harness
3. Loosen the four M12 mounting bolts with a suitable spanner
4. Remove cable clamps holding APC Receiver cable harness and retain
5. Fully remove the four M12 bolts (retaining all bolts, washers and spacers) and remove the faulty
unit from its position
6. Mount the new unit with the four retained M12 mounting bolts, washers and spacers, according
to Figure 1 below, and torque to the relevant torque value
7. Attach the cable connector at the end of the APC Receiver cable harness
8. Attached retained cable clamps to hold APC Receiver cable harness in place
9. Undertake visual inspection of the APC Receiver
10. Switch on power to the APC Control Unit
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Spacer
M12 Form A
Plain Washer
M12 Spring
Washer
M12 Bolt or M12
Full Nut to Suit
Application
Figure 1: APC Receiver mounting assembly
6.2 Test Equipment
Test equipment TY392-GRP001 – APC/ATR Test Kit is available as an option. Please contact MSUK for additional
details.
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7 OPERATION
Refer to chapter 3. System OPERATION Description for information about the system operation. APC System
is entirely automated therefore the train operator doesn’t have to interact with it once the system has been
correctly installed, tested and commissioned.
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8 PREVENTATIVE MAINTENANCE
8.1 General
Maintenance of the APC System shall be undertaken at regular intervals, or whenever physical damage is
suspected with the equipment. MSUK recommends following interval duration as presented on the
recommended maintenance plan in Table 4 below.
Table 4: Recommended Maintenance Plan
Frequency Visual Inspection Cleaning
Equipment Every 3.5 Months Every 3.5 Months
APC Receiver X X
8.2 APC Receiver
8.2.1 Visual Inspection
The purpose of the visual inspection is to check the fastenings and to establish if there is any mechanical
damage to the following parts:
• APC Receiver
• APC Receiver conduit
• Cable connectors
• Cable clamp
If the visual inspection identifies any damage, which is considered to have an adverse effect on the APC System
functionality and Safety, then the unit shall be replaced. In addition, anything which is considered to impact
upon the environmental protection shall be considered as damage and the unit shall be replaced.
The APC Receiver shall not be disassembled; a damaged unit (including the cable harness) should be replaced
completely.
Note: The replacement of the APC Receiver is described within section 6.1.2 of this document.
8.2.2 Cleaning
Due to the external location of the APC Receiver, cleaning the outside surface of the APC Receiver mechanical
enclosure is necessary to undertake a visual inspection. A water jet (of less than 70 bars at a distance of at
least 1 meter), or brush and mild detergent can be used to clean the unit from the outside. Pressurised air or
vacuum system can also be utilised if necessary. Removal of the unit from its application to access the top side
is only necessary if the equipment is considered suspect.
IMPORTANT
• Never use chemical solvents for cleaning
• Never open the enclosure
8.2.3 Position Check
To check that the APC Receiver is correctly positioned relative to the rail, the following measurements shall be
done:
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[Link] Measuring Conditions
When performing any measurements, the vehicle shall be positioned on a straight, level plane track and with
the wheels centered on the rails.
The measurement points at the APC Receiver are to be measured from the x, y and z axis reference marks
according to Figure 2 below. (note: axes drawing for reference only – connector composition may vary)
X axis
Y axis
Z axis
Figure 2: APC receiver reference axes
[Link] APC Receiver Position
Mors Smitt recommends that the APC Receiver is installed as per the requirements set in GE/RT2111 as
following:
Figure 3: GE/RT2111 installation requirements
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9 DECOMMISSIONG
When the fault is located, the instructions within chapter 0 shall be followed to replace the faulty item.
If the fault is isolated to a unit, the unit shall NOT be disassembled for further fault tracing. Faulty units are to
be sent back to the supplier’s customer support department together with a description of the fault and with
a reference to which project and vehicle the unit was taken from. MSUK operate a RMA system which can be
accessed through the MSUK website.
The unit shall be sent back in an ESD safe package and protected from mechanical damage during transport.
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10 DISMANTLING
There are no dismantling requirements for any LRU stated within this document. Under no circumstance
should a unit be dismantled/disassembled. All Units shall be replaced in their entirety and returned to MSUK
for investigation and repair. Any damage to train side connectors shall be replaced.
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11 DISPOSAL
All units shall be disposed of responsibly at the end of life. This includes adhering to rules on recycling or safe
disposal of components (i.e. adhering to Waste Electrical & Electronic Equipment regulations etc.).
No hazardous materials are used in the APC System LRUs.
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12 ERROR IDENTIFICATION
Table 5: Error Identification Table
Fault / Problem Possible Causes Action
APC Receiver
Impact Damage Damage caused by impact to the Receiver Replace LRU and return for repair
Damaged cabling
No response to APC signal Replace LRU and return for repair
Damaged APC Receiver
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13 APPENDIX
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14 SUBJECT INDEX
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