Switchoint heating

Technical Manual – Installation of switchpoint heating

Switchpoint Heating 1

VELOX Switchpoint heating is designed for connection to 230 Vac.

Type 1: Self‐limiting heating element (The self‐limiting type decreases the heat output at rising temperature). This reduces the energy consumption and prevents errors due to overheating.

Type 2: Parallel resistive element, two outputs; 70 / 90W per meter can be installed with single or double element partially on the switch to supply extra power on the most sensitive part of the switch.

The elements are double‐insulated and lack protective earthing in order to avoid causing signalling faults if dam‐ aged.

The elements are flexible and are mounted using clips and protective channels in stainless steel, 1 m long.

The elements can be supplied in lengths up to 25 meter

The elements are supplied with water‐tight quick‐connections, IP68, with screw bushing.

Connection is made to adapted 4‐way blocks screwed to sleepers with protective plates.

The installation can be supplied complete with PC‐controlled equipment built to customer design specifications. The system has remote access by means of Internet / Ethernet and separately monitoring of each element.

Address VÄRMEKABELTEKNIK SPH AB Box 190 S‐401 23 GÖTEBORG Sweden

Telephon +46‐(0)301‐418 50 Email info@vkts.se

Org.nr Telefax 556700‐5052 +46‐(0)301‐418 70 Hemsida www.switchpointheating.se

Switchpoint Heating 2

Technical Manual – Installation of switchpoint heating

Index Chapter 1 ....................................... The princip of the system Chapter 2 ....................................... The advantages of the system Chapter 3 ....................................... The placement of the elements Chapter 4 ....................................... Order / What one should do before Chapter 5 ....................................... Delivery check Chapter 6 ....................................... Installation of switchpoint heating Chapter 7 ....................................... Cable channels – in light, armoured concrete Chapter 8 ....................................... Accessories / Supply cable / Mounting clips Chapter 9 ....................................... Installation of control cabinets Chapter 10 ..................................... Control ‐ System Chapter 11 ..................................... Operation Chapter 12 ..................................... Remote control

Technical Manual – Installation of switchpoint heating

1.

Switchpoint Heating 3

The princip of the system

SwitchPoint Heating:s switchpoint heating system are based on heat maintenance of the switch with a relatively low output at a temperature above °C during the winter period and at precipitation the switchpoint heating operates to 100% without control

2.

The advantages of the system

Working switches, free from ice all the year

Low energy consumption

The element can be made in lengths covering all of the length of the switch, only one connection point

Length adapted element with a special plug IP68, with locking with threaded sleeve.

Easy installation with protective channels in stainless steel (length 1m) and mounting clips of spring steel.

Quick installation with short time on the track.

Quick and easy service with plug‐in and barb provided clips just to hock on

Control cabinet complete with a plinth for burial in the ground of impact resistant fibreglass reinforced plastic.

Easy operation and adjustment of values on PC touch‐screen in the control cabinet.

Standard cabinet for 2 or 4 switches where one main cabinet can control a couple of secondary cabinets for expansion.

The control cabinets can be used for other applications where wireless remote control are required.

Remote control via internet and 3G modem

Alarm via mail and Text messages to service personnel

3.

The placement of the heating element

Type of elements Two types of elements are used, both double insulated without protective earth and with an outer sheath of Teflon.

Parallel resistive element 70 or 90W per meter emits a solid output, can be laid double under the same protective channel on exposed parts of the switch (extra element is connected to the end on the pair‐element)

Self‐limiting element 130W/m per meter. The elements decreases automatically emitted output at rising temperature on the rail and thereby saves energy.

Switchpoint Heating 4

4.

Technical Manual – Installation of switchpoint heating

Before you order

Measure the length of the moving rail in that part of the switch which are to be heated, the stock‐rail element is made 0,5 m longer so that the heated part on the stock‐rail projects 0,5 m past the point of the moving rail.

Find out the actual rail profile, choose clips from the table on page 10 or mention the profile.

Shall a point rod cavity be heated? With our switchrod heaters, the point rod and cavity are kept free from ice and snow which improves the functionality at the switch. The switchrod heaters are delivered in two halves in order to simplify the installation, connection is carried out at the ends of the stockrail‐elements.

Determine if an existing control system can be used (230V to element) or if a new shall be purchased.

If a new control system is to be bought, find out which functions are required (control type, logging, remote control with solid wire or 3G).

The array of switches, how many switches lies within a reasonable area to feed from the same control cabinet. These are avail‐ able2 and 4 switches and also as slave cabinet. The slave cabinets are controlled from the master cabinet with a two‐wire signal‐ ling cable. The control cabinets can be combined with a master and one or several slave cabinets which are mounted in a group or separately.

Send an inquiry to info@vkts.se or fax to +46‐301‐418 70

Technical Manual – Installation of switchpoint heating

5.

Switchpoint Heating 5

Delivery check before installation

When the material kit has been received you check that all parts are in and that the marking on the heating cable is equivalent with the length you ordered.

Each heating element has a separate marking on the connection cable so that you easily could replace damaged element.

Compare delivered quantity against the delivery note.

6.

Assembly instruction switchpoint heating element

Prepare the old switch by brushing off the foot of the rail (where the element and clips shall be mounted) with a wire brush in order to obtain a good fit‐up.

Reel out the element with the adapter furthest away from the moving rail tongue and install the cable up to the rail.

Choose the right clips For example: Type 001 for stock rail For example: Type 010 for moving rail

Start by mounting the termination end of the element.

The first channel shall begin a couple of centimetres from the end termination.

Fasten the clips by carefully knocking them in position using a hammer or a plastic club (see illustration).

The clips are mounted 30 cm in between, 2‐3 pcs/meter as evenly distributed as the space permits.

NOTE! In applications where point rod heaters are to be mounted, the element for the stock‐rail has been fitted with a conductor joint.

Fit the next channel tightly against the first one, and it is a good idea to make a clip cover the joint between the chan‐ nels.

Continue until the whole element is covered.

Address VÄRMEKABELTEKNIK SPH AB Box 190 S‐401 23 GÖTEBORG Sweden

Telephon +46‐(0)301‐418 50 Email info@vkts.se

Telefax Org.nr +46‐(0)301‐418 70 556700‐5052 Hemsida www.switchpointheating.se

Switchpoint Heating 6

Technical Manual – Installation of switchpoint heating

For narrow passages flexible channels are used which can be bent to fit.

Here it may also be necessary to use both types of clips to achieve the best possible contact.

At a cut where the width of the rail‐foot decreases, the clip can be used so that the barb provided part point upwards.

Repeat the procedure for the other stock‐rail and for the two moving rails.

In some extreme cases where the switch is in an exposed posi‐ tion with heavy winds or where large amounts of snow can be expected, an extra element is mounted on the moving rail.

This element is mounted on the side facing the stock‐rail.

The length of this element can be approximately half the length chosen for the other lengths.

When all elements has been mounted, the 4‐way block is attached at the sleeper closest to the connections of the element.

Connect each plug and tighten the screw bushing so that a good sealing is obtained. Attach the plug joint with special clips and tighten the hose clamp. Attach the connection ca‐ bles at the sleeper to avoid damages on the cables at packing at the road bed. For the 8 meter long 8‐core cable, a ditch is dug (with suitable depth) next to the sleeper, out from the road bed in direction to the control cabinet. The 8‐core cable is pulled into a protective tube together with sensor cable and is placed in the ditch and covered with the dug away grovel.

Technical Manual – Installation of switchpoint heating

Switchpoint Heating 7

Mount the protective cover (assembly details are supplied) over the 4‐way block and the cables.

Install the sensor under the rail with the special clip, approx. 1 m in on the switch counted from the feed end.

Make sure that the connection cable of the sensor is pro‐ tected.

Now the work as lookout is finished!

IMPORTANT ABOUT THE INSTALLATION! ALL! Cables which are installed nearby the rail has to be attached against the side of the sleeper. The clips shall have such a c/c-distance that the cable do not hang down in the grovel.

In direct proximity of the junction box in the middle of the track, the cable can run freely though.

The reason is that one pack the grovel with machines which penetrates down between the sleepers, the cables can be torn of if they lies loose in the grovel.

Address VÄRMEKABELTEKNIK SPH AB Box 190 S‐401 23 GÖTEBORG Sweden

Telephon +46‐(0)301‐418 50 Email info@vkts.se

Telefax Org.nr +46‐(0)301‐418 70 556700‐5052 Hemsida www.switchpointheating.se

Switchpoint Heating 8

Technical Manual – Installation of switchpoint heating

7.

Cable channels – light in armoured concrete

GRC Cable channels for elongation of cables in track areas manufactured in glass fabric armoured concrete.

Light channels (weighs a fifth of standard pre‐made concrete channels). Decreases handling‐ and transport costs, facilitates the work and halves the labour time for digging and installa‐ tion.

The channel has, despite it’s light weigh, resistance to with‐ stand tough environments.

GRC cable channel is delivered in 2m lengths with a thickness of 10 mm and is available in a number of different sizes (see table below).

Product code

Cat.no Railway

Length (m)

internal width (mm)

Internal depth (mm)

Weight incl. lid Kg

C/1/6

4/090810

2

100

100

22

C/1/7

4/090811

2

130

130

28

C/1/8

4/090812

2

150

210

34

C/1/9

4/090813

2

190

130

34

C/1/10 4/090814

2

250

130

36

C/1/29 4/090815

2

390

125

48

C/1/43 4/090816

2

350

300

64

Technical Manual – Installation of switchpoint heating

8.

Switchpoint Heating 9

Accessories / Supply cable

VX 303

Connection cable between switchpoint heating and control cabinet in standard performance 8 x 2,5mm² (PUR)

VX 303-K

Connection cable between switchpoint heating and control cabinet in standard performance 8 x 2,5mm² with built-in sensor cable (PUR)

VX 303-4

Connection cable between switchpoint heating and control cabinet 8 x 4,0mm²(PUR)

VX 303-4K

Connection cable between switchpoint heating and control cabinet in standard performance 8 x 4,0mm² with built-in sensor cable (PUR)

VX 303-6

Connection cable between switchpoint heating and control cabinet 8 x 6,0mm² (PUR)

VX 303-6K

Connection cable between switchpoint heating and control cabinet in standard performance 8 x 6,0mm² with built-in sensor cable (PUR)

VX313-6

Earth cable 5 x 6mm²

VX313-10

Earth cable 5 x 10mm²

VX313-16

Earth cable 5 x 16mm²

VX314

Earth cable 5 x 25mm²

VX 304-1

Communication cable Screened 2 x 1 mm² (PUR)

VX300X ... Junction box for connection of 4‐way block to ................ existing supply of 4‐5‐core type

With gland, integral deck and heating element VX301 ...... Termination block 8‐core IP 65 VX302 ...... Termination block 2‐core IP 65

VX225 ...... Connection switchpoint heating element Male IP68 VX232 ...... Connection switchpoint heating Female IP68

Address VÄRMEKABELTEKNIK SPH AB Box 190 S‐401 23 GÖTEBORG Sweden

Telephon +46‐(0)301‐418 50 Email info@vkts.se

Telefax Org.nr +46‐(0)301‐418 70 556700‐5052 Hemsida www.switchpointheating.se

Switchpoint Heating 10

Technical Manual – Installation of switchpoint heating

Mounting clips Part.no

Denomination

Length

VX13-43-60

Clips stock-rail 13mm (001) SL

L=60mm

VX13-22-60

Clips stock-rail 13mm (Half clip)

L=60mm

VX13-43-75

Clips stock-rail 13mm

L=75mm

VX13-22-72

Clips stock-rail 13mm (Half clip)

L=72mm

VX16-43-56

Clips moving rail 16mm

L=56mm

VX16-22-56

Clips moving rail 16mm (half clip)

L=56mm

VX20-22-72

Clips moving rail neck 20mm (half clip)

L=72mm

VX22-22-72

Clips moving rail neck 22mm (half clip)

L=72mm

VX18-43-63

Clips moving rail 18 mm (010) SL

L=63mm

VX18-22-63

Clips moving rail 18 mm (half clip)

L=63mm

VX22-43-69

Clips moving rail 22mm (003B) SL

L=69mm

VX26-43-20

C-Clips 26mm for cut-out part

L=20mm

VX30-43-20

C-Clips 30mm for cut-out part

L=20mm

VX20-43-38

Clips moving rail 20mm

L=38mm

Extensionplate for rail welded against stock-rails plate VX0-43-132

VX801 VX802

Protective channel stainless 1m Protective channel stainless 1 m Flexible Flexible Standard

*More types on request 9.

Standard control cabinets for switchpoint heating

Control cabinet with temperature and snow sensor, pc‐controlled system with remote communication. They are supplied with enclosure in glass fabric armoured plastic (sensor included), other type of enclosure (steel, stainless, aluminium) on request.

Technical Manual – Installation of switchpoint heating

Switchpoint Heating 11

The control cabinets can be combined to control larger applications, a master cabinet can control and supervise 20 switchpoint heating applications (80 element), build on with slave cabinets and connect with screened 2 x 1,5 signalling cable.

Standard control cabinet for switchpoint heating can be combined for larger applications 1 ‐ 2 switches

VX2000 Control cabinet for switchpoint heating TYPE‐2 EMI‐MP/LCD

1 ‐ 2 switches

VX2000S Control cabinet ‐ Slave for switchpoint heating TYPE‐2S EMI‐MP/LCD

3 ‐ 4 switches

VX4000 Control cabinet for switchpoint heating TYPE‐4 EMI‐MP/LCD

3 ‐ 4 switches

VX4000S Control cabinet ‐ Slave for switchpoint heating TYPE‐4S EMI‐MP/LCD

Weather station

Supplement with weather station on control cabinet. Logs weather data

Web camera

Supplement with web camera for visual remote supervision

Address VÄRMEKABELTEKNIK SPH AB Box 190 S‐401 23 GÖTEBORG Sweden

Telephon +46‐(0)301‐418 50 Email info@vkts.se

Telefax Org.nr +46‐(0)301‐418 70 556700‐5052 Hemsida www.switchpointheating.se

Switchpoint Heating 12

Technical Manual – Installation of switchpoint heating

10. Assembly instructions control cabinets The control cabinet should be mounted as close to the switch as possible to avoid high costs for supply cables (8‐core) to switchpoint heating element and unnecessarily long sensor cables causing deviations in the values read off.

The enclosure is easily mounted with the build‐in base which is dug down in a pit in direct connection to the cable pit. Pull in all cables, position the enclosure with a water level and refill with sand and broken stone.

Connections to the elements are made using 8‐core conduc‐ tors in polyurethane rubber with separate cable for each ele‐ ment.

The control cabinet is supplied with a Ekkj 5 x 6‐16mm². At 4‐ core system a null separator be provided.

The control cabinet is supplied internally completed. We supply the connection cable between the cabinet and the element in the standard length of 8 meter. If the distance exceeds the standard length, an extra connection lead can be jointed inn a jointing box IP68, supplied by us.

Sensors are ordered in required length.

Cables to the element are connected to to terminal blocks according to connection schedule.

Supply cable to the cabinet is connected direct into line breaker and to zero/earth terminal block.

The control cabinet is constructed around PC‐controlled triac‐ system with units of eight channels (expandable in modules of 8 channels). .... Temperatur sensor (Thermo element type K)

Current transformer for current measuring

Moisture sensor

Remote control via internet Lan / 3G modem

Supervision with alarm via SMS / Mail

Logging of values for: temperature, power consump‐ tion, operation times, etc.

Technical Manual – Installation of switchpoint heating

Switchpoint Heating 13

Control – System The princip of the system is based on keeping the rail foot at a temperature just above 0°C during the cold period of the year, at precipitation a moisture sensor disconnects the temperature control and the heat is switched on with 100%. This status is kept 5 hours after the precipitation ended.

Controlling the heat in a switch is controlled by a PC‐system with a sensor placed under the rail foot.

Normally one sensor is used as a reference for a group of switch‐ es but if required can one or several sensors be connected for each switch.

The cabinet is delivered in two sizes for 2 or 4 switches with mas‐ ter and slave equipment.

A master cabinet can be build with slave cabinet and can control 20 switchpoint applications or other electrical equipment such as surface heating on platforms, illumination etc. With a total of 80 channels per 20A. The control cabinets outlets to the elements is done with triac modules of 8 channels which admits both sequential as soft start.

These functions minimizes fuses on the supply part when using self‐limiting element.

Sensors The sensor cards consists of eight entries each and each system can contain 50 sensor cards. They can measure: current, tem‐ perature, voltage, moisture etc. with a total of 400 measuring points.

Logging of values The sensor cards are supervised and logged by a PC, chosen values can be used to control one or several channels. All values are gathered in a log‐file which can be presented as curves directly in the interface or be downloaded for further treatment /analysis such as operating curves, function analysis, power consumption.

Address VÄRMEKABELTEKNIK SPH AB Box 190 S‐401 23 GÖTEBORG Sweden

Telephon +46‐(0)301‐418 50 Email info@vkts.se

Telefax Org.nr +46‐(0)301‐418 70 556700‐5052 Hemsida www.switchpointheating.se

Switchpoint Heating 14

Technical Manual – Installation of switchpoint heating

11. Operating 1. ....When the automatic cabinet is in place and all the cables are added, the supply voltage can be switched on and the system put into operation 2. ....Put the breakers on the residential‐/commercial protection in position on (upwards).

3. ....Put the operation switch in position Automatic (upwards) 4. ....Put the circuit breakers in position on (upwards) 5. ....Put on the main switch 6. ....Normally the system now starts and the computer. If the computer does not start automatically push on your computer's start button.

7. ....The computer is programmed for normal operation with alarm (if alarm number is given to us in advance, are these also the pre‐programmed). This can otherwise be done on site or via a PC with internet connection according to separate man‐ ual.

8. ....If problems at start‐up can our support be contacted (work hours) at +46‐301‐418 54.

9. ....Provided that the temperature of the rail is below +3 ° C the control cabinet should automatically start the heating = LEDs on Thyristor cards will blink for a few minutes and then have a steady light.

10....If the temperature of the rail is above +3 ° C can reboot be simulated by increasing the operating temperature to a value over the rail temperature (see separate manual) 11....The function of the moisture sensor – the moisture sensor activates the switchpoint heating at precipitation and tempera‐ tures below +3°C, the heat will remain operating during the whole period of precipitation if the temperature is below +3°C. The moisture sensor has a build‐in releasing delay on 5 hours. This means that the smallest melting sequence remains in 5 hours. At operation with moisture sensor the temperature control is disconnected which makes the leds on the thyristor‐ card to go out. Moisture sensor operation is indicated by separate signalling lamps. Logging of temperatures and energy consumption is however done as normal.

12....Test of moisture sensor – Test is easiest done at temperatures below +3°C (simulation of such temperature can be done with cold spray on the temperature sensor of the moisture sensor). Place some snow or water in the “ring” on the upper side of the moisture sensor, activation shall now occur. NOTE! The heat remains connected during 5 hours!

Technical Manual – Installation of switchpoint heating

Switchpoint Heating 15

12. Communication - Supervising Communication The PC of industrial standard for the system can be contacted via modem or Inter‐ net 3G and Team Viewer client.

Supervising, adjustment of values and downloading log‐files can be done anywhere on the earth via a PC / Laptop with a solid or mobile communication.

With team viewer you will be able to see and manage the PC in the control cabinet in the same way as if you really were at the site.

Supervising via internet To supervise your applications connected to our system can be done via an internet site established for your applications. On this page all data can be read off, alarm, temperatures, power consumption etc. the unit downloads data once a hour or at triggered alarm.

Alarm can also be obtained via mail or text‐messages to one of you predetermined mobile telephone.

With the aid of a web camera images can be downloaded to better overview the actual situation.

Support You will get help from our technicians with configuration and interconnections of your system, we also contributes with support and updates of the control system.

Address VÄRMEKABELTEKNIK SPH AB Box 190 S‐401 23 GÖTEBORG Sweden

Telephon +46‐(0)301‐418 50 Email info@vkts.se

Telefax Org.nr +46‐(0)301‐418 70 556700‐5052 Hemsida www.switchpointheating.se

Switchpoint Heating 16

Technical Manual – Installation of switchpoint heating

Notes ....................................................................................................................................................................................................

Technical Manual – Installation of switchpoint heating

Switchpoint Heating 17

.................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... .................................................................................................................................................................................................... ....................................................................................................................................................................................................

Address VÄRMEKABELTEKNIK SPH AB Box 190 S‐401 23 GÖTEBORG Sweden

Telephon +46‐(0)301‐418 50 Email info@vkts.se

Org.nr Telefax 556700‐5052 +46‐(0)301‐418 70 Hemsida www.switchpointheating.se

Switchpoint Heating 18

Technical Manual – Installation of switchpoint heating

Telephone to all office: +46‐301‐418 50, Email info@vkts.se