Klaxon Turbo 2, Turbo 3, ES-2, ES-3, ES-4 Assembly Guide

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Page 1

KLAXON SIGNALS

KLAXON

ES SIREN MAST

ASSEMBLY

GUIDELINES

Klaxon Signals

Wrigley St

Oldham

Lancs

OL4 1HW

Phone: ++ 44 (0) 161 287 5555

Fax: ++ 44 (0) 161 287 5511

Email: [email protected]

SG001a Issue 1 Dec 06

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KLAXON SIGNALS

CONTENTS

1. SIREN HORN CABLE(S) MANUFACTURE......................................... 2

1.1 Cable Specification............................................................................2

2. SIREN CABLE CONSTRUCTION TABLES......................................... 3

2.1 Turbo 2 (2 Horn / 1 Cable).............................................................. 3

2.2 Turbo 3 (3 Horn / 2 Cable).............................................................. 4

2.3 ES-2 (6 Horn / 1 Cable).................................................................. 5

2.4 ES-3 (12 Horn / 1 Cable)................................................................ 5

2.4 ES-3 (12 Horn / 1 Cable)................................................................ 6

2.5 ES-4 (18 Horn / 2 Cable)................................................................ 7

3. CABLE JUNCTION BOX ASSEMBLY INSTRUCTIONS ..................... 9

3.1 PURCHASED COMPONENTS....................................................10

4. MAST ASSEMBLY INSTRUCTIONS................................................. 11

5. HORN ARRAY DIMENSIONS & WEIGHT......................................... 22

6. HORN ASSEMBLY TESTING............................................................ 22

7. STANDARD SIREN MAST INFORMATION ...................................... 23

7.1 Mast Lengths, Weights and Number of Horns.............................. 23

7.2 Mast Fixing Bolts..........................................................................23

7.3 Mast Base Construction ............................................................... 23

7.4 Standard Mast Drawings.............................................................. 24

7.4.1 3 Metre Mast (18-185938) ..................................................... 25

7.4.2 4.5 Metre Mast (18-185939) .................................................. 26

7.4.3 6 Metre Mast (18-185940) ..................................................... 27

7.4.4 12 Metre Support Mast (18-185941)......................................28

7.4.5 12 Metre Support Mast Mounting Flange 1 (18-185942) .......29

7.4.6 12 Metre Support Mast Mounting Flange 2 (18-185943) .......30

7.4.7 Turbo 2/3 & ES2 Siren Horn Cable Box Bracket (18-186209)31

7.4.8 ES3 & ES4 Siren Horn Cable Box Bracket (18-186210)........ 32

SG001a Issue 1 1 of 32 Apr 07

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KLAXON SIGNALS

1. SIREN HORN CABLE(S) MANUFACTURE

1. Identify the siren type for which the cable is to be constructed and use the tables appended to the bottom of this section for connection information.

2. Determine the length of the cable required and cut cable to length. (Length of mast + 1 metre + the length of the longest conductor stated in the siren type table).

3. Cut the protective sheath back to the length of the longest required conductor specified in the siren type table and remove.

4. Cut the respective conductors to the lengths specified in the siren type table and remove.

5. If a single cable is being used then loom the conductors as specified in the siren type table.

6. Crimp the connector plug onto the individual conductors and then insert the crimped connectors into the connector housings.

Note: When the wires are inserted into the connectors the orientation of odd or even numbered wires to the left hand or the right hand side does not matter as long as they are all orientated in the same manner.

1.1 Cable Specification

Siren Type Cable Required

Turbo 2, Turbo 3 4 Core 1.5mm2 YY Cable ES-2, ES-3, ES-4 25 Core 1.5mm2 YY Cable

SG001a Issue 1 2 of 32 Apr 07

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2. SIREN CABLE CONSTRUCTION TABLES

Dependent on the number of horns associated with the siren one or two cables will be required. The tables below identify specific requirements based on the siren type.

2.1 Turbo 2 (2 Horn / 1 Cable)

Length of individual wires from

Horn Number

& Amplifier

1/ Amp 1 1 & 2 240 2/ Amp 1

Note: Cable to be used is a four core cable with three cores being numerically identified and the remaining core being the green/yellow earth core.

GREEN/YELLOW

Wire

Identification

Numbers

3 &

Turbo 2 Horn Arrangement

the point where the outer sheath

of the multi-core cable is

terminated.

(mm)

240

Horn 1Horn 2

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2.2 Turbo 3 (3 Horn / 2 Cable)

CABLE 1

Length of individual wires from

Horn Number

& Amplifier

Wire

Identification

Numbers

the point where the outer sheath

of the multi-core cable is

terminated.

(mm)

1/Amp 1 1 & 2 240 2/Amp 1

GREEN/YELLOW

3 &

880

CABLE 2

Length of individual wires from

Horn Number

& Amplifier

Wire

Identification

Numbers

the point where the outer sheath

of the multi-core cable is

terminated.

(mm)

3/Amp 1 1 & 2 240

Note: Cable to be used is a four core cable with three cores being numerically identified and the remaining core being the green/yellow earth core.

Horn 1

Horn 2

Horn 3

Turbo 3 Unidirectional Horn Arrangement

SG001a Issue 1 4 of 32 Apr 07

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2.3 ES-2 (6 Horn / 1 Cable)

CABLE 1

Length of individual wires from

Horn Number

& Amplifier

Wire

Identification

Numbers

the point where the outer sheath

of the multi-core cable is

terminated.

(mm)

1/Amp 1 1 & 2 240 (Loom in cable loom 1) 2/Amp 1 3 & 4 880 (Loom in cable loom 1) 3/Amp 1 5 & 6 1520 (Loom in cable loom 1) 4/Amp 2 11 & 12 240 (Loom in cable loom 2) 5/Amp 2 13 & 14 880 (Loom in cable loom 2)

15 & 16

6/Amp 2

(All unused

1520 (Loom in cable loom 2)

wires)

Note: Cable to be used is a 25 core cable with 24 cores being numerically identified and the remaining core being the green/yellow earth core.

Horn 4

Horn 5

Horn 6

Horn 1

Horn 2

Horn 3

ES-2 Horn Arrangement

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2.4 ES-3 (12 Horn / 1 Cable)

CABLE 1

Length of individual wires from

Horn Number

& Amplifier

Wire

Identification

Numbers

the point where the outer sheath

of the multi-core cable is

terminated.

(mm)

1/Amp 1 1 & 2 240 (Loom in cable loom 1) 2/Amp 1 3 & 4 880 (Loom in cable loom 1) 3/Amp 1 5 & 6 1520 (Loom in cable loom 1) 4/Amp 3 7 & 8 2160 (Loom in cable loom 1) 5/Amp 3 9 & 10 2800 (Loom in cable loom 1) 6/Amp 3 11 & 12 3440 (Loom in cable loom 1) 7/Amp 2 13 & 14 240 (Loom in cable loom 2) 8/Amp 2 15 & 16 880 (Loom in cable loom 2)

9/Amp 2 17 & 18 1520 (Loom in cable loom 2) 10/Amp 4 19 & 20 2160 (Loom in cable loom 2) 11/Amp 4 21 & 22 2800 (Loom in cable loom 2)

23 & 24

12/Amp 4

(Plus unused

3440 (Loom in cable loom 2)

wires

Horn 07

Horn 08

Horn 09

Horn 10

Horn 11

Horn 12

Horn 01

Horn 02

Horn 03

Horn 04

Horn 05

Horn 06

ES-3 Horn Arrangement

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2.5 ES-4 (18 Horn / 2 Cable)

CABLE 1

Length of individual wires from

Horn Number

& Amplifier

Wire

Identification

Numbers

the point where the outer sheath

of the multi-core cable is

1/Amp 1 1 & 2 240

2/Amp 1 3 & 4 880

3/Amp 1 5 & 6 1520

4/Amp 3 7 & 8 2160

5/Amp 3 9 & 10 2800

6/Amp 3 11 & 12 3440

7/Amp 5 13 & 14 4080

8/Amp 5 15 & 16 4720

17 & 18

9/Amp 5

(Plus unused

wires

CABLE 2

Length of individual wires from

Horn Number

& Amplifier

Wire

Identification

Numbers

the point where the outer sheath

of the multi-core cable is

1/Amp 2 1 & 2 240

2/Amp 2 3 & 4 880

3/Amp 2 5 & 6 1520

4/Amp 4 7 & 8 2160

5/Amp 4 9 & 10 2800

6/Amp 4 11 & 12 3440

7/Amp 6 13 & 14 4080

8/Amp 6 15 & 16 4720

17 & 18

9/Amp 6

(Plus unused

wires

terminated.

(mm)

5360

terminated.

(mm)

5360

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Horn 10

Horn 11

Horn 12

Horn 13

Horn 14

Horn 15

Horn 01

Horn 02

Horn 03

Horn 04

Horn 05

Horn 06

Horn 16

Horn 07

Horn 17

Horn 08

Horn 18

Horn 09

ES-4 Horn Arrangement

SG001a Issue 1 8 of 32 Apr 07

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3. CABLE JUNCTION BOX ASSEMBLY INSTRUCTIONS

1. Select the correct enclosure for use as a cable junction box and associated mounting bracket.

Siren Type Enclosure

Turbo 2 190mm x 190mmx 100mm Small Turbo 3 190mm x 190mmx 100mm Small

ES-2 190mm x 190mmx 100mm Small ES-3 250mm x 200mmx 100mm Large ES-4 250mm x 200mmx 100mm Large

2. Cut a length of top hat section DIN rail to fit the enclosure and fit using screws and nuts supplied with the enclosure.

3. Drill holes in enclosure for the attachment of cable glands. The number and type are as specified in the table below. For a one cable siren assembly two cable glands will be required in the side face of the unit either side of the DIN rail strip. For a two cable assembly two further cable glands would be required on the opposite face of the enclosure to the first two cable glands.

Siren Type

No of

Glands

Gland Size

(mm)

Turbo 2 2 9.0 15.5 4 Turbo 3 4 9.0 15.5 6

ES-2 2 21.0 29.0 12 ES-3 2 21.0 29.0 24 ES-4 4 21.0 29.0 36

Enclosure Mounting

Bracket

Hole Size

(mm)

Connectors

No of

SG001a Issue 1 9 of 32 Apr 07

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KLAXON SIGNALS

3.1 PURCHASED COMPONENTS COMPONENT ADDITIONAL INFO PART No

Enclosure 190mm x

190mmx 100mm

Enclosure 250mm x

200mmx 100mm

2.5mm Screwless Feed Through Connectors

Enclosure Mounting

Bracket Small

Enclosure Mounting

Bracket Large

For use on Turbo 2/3

& ES2 Sirens

For use on ES3 &

ES4 Sirens

18-186678

RS 174-820

18-186679

RS 174-836

5 per pack RS 225-9894

For use on Turbo 2/3

& ES2 Sirens

For use on ES3 &

ES4 Sirens

18-186209 18-186210

Connector End Cover 5 per pack RS 225-9923

End Supports 5 per pack RS 821-633 Din Rail (Top Hat section Punched)

Blank Terminal

Markers

1 Metre Length RS 606-838

RS 425-409

7-13mm Cable Gland 5 per pack RS 365-8438

11-21mm Cable Gland 5 per pack RS 362-0001

SG001a Issue 1 10 of 32 Apr 07

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4. MAST ASSEMBLY INSTRUCTIONS

1. Support the mast during the attachment of the horn units in a horizontal position approximately 1 metre off the ground by the use of three suitable load bearing trestles and a support beam. The trestles are to be deployed in the following manner.

At the base end of the mast position one trestle and at the other end position the remaining two trestles, one at either side with a support beam between them on which the mast is supported. This support beam should be between 500 – 600 mm from the end of the mast.

SG001a Issue 1 11 of 32 Apr 07

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2. Prepare the mast for the fitting of the cable junction box and attachment bracket by positioning the bracket at a convenient height above the base of the mast and carefully marking on the mast the position of the bracket mounting holes.

Remove the bracket and using a 5.0 mm drill bit, drill the four mounting holes and then tap with an M6 thread.

Attach the bracket to the mast using four M6 x 15mm bolts and then attach the junction box to the bracket using two M6 x 15mm bolts and associated nuts and washers.

SG001a Issue 1 12 of 32 Apr 07

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3. Pass the previously prepared multi-core horn driver cable(s) through the inside of the mast. The end of the cable with the connectors to be connected to the siren horn drivers to exit the mast at the top.

4. Identify the multi-core cables if more than one by the use of either a red or blue identification marker or tape applied to the outer sheath at both ends of the cables.

5. Attach the cabling restraint bracket to the cable(s) at the top of the mast at a point approximately 15mm below from where the outer sheaths of the cable(s) are terminated.

SG001a Issue 1 13 of 32 Apr 07

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6. Pull the cable(s) from down from the bottom of the mast until the cable support bracket seats neatly in the mast.

7. Temporarily tape the made off ends of the siren driver cables down their respective sides of the mast, roughly in the position they would be when the assembly is complete.

SG001a Issue 1 14 of 32 Apr 07

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8. Secure the first horn or pair of horns to the top of the mast using four M10 bolts and associated nuts, spring and plain washers, (facing in opposite directions for omni-directional use and facing in the same direction for uni-directional use), remembering also to attach the mast cover mounting brackets at the same time. (These mounting brackets are held in place by the top two horn assembly to mast fixing bolts).

When secured in position thread the appropriate driver wires and associated connectors into the horn assemblies via the holes provided in the horn assembly flanges.

Note: Omni-directional horn assembly depicted in the picture above.

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9. Repeat the process of adding horn assemblies down the mast by initially securing the horn assemblies loosely around the mast before inserting the U-shaped cable protection covers between the horn assemblies. Then using a mallet gently tap the loosely attached siren assembly pairs into position and align with previously fitted horn assembly prior to securing firmly.

Recheck the horn alignment when the assembly is securely positioned and if necessary adjust securing bolts to attain the correct alignment.

Note: Ensure the cabling does not become pinched by the horn assembly flanges or cable covers.

SG001a Issue 1 17 of 32 Apr 07

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10. Secure the mast top cover to the brackets on the uppermost horn assembly using four M8 x 15mm bolts and washers.

SG001a Issue 1 18 of 32 Apr 07

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11. Carefully screw the sounder driver units into the horn assemblies ensuring that at least one O ring rubber sealing gasket is used, against which the driver is firmly hand tightened. When tightened the driver water drainage hole must be positioned in the vertical plane towards the base of the mast. (If this is not possible with the gasket used, then change the gasket for either a thicker or thinner one.

1.5mm or 3.0mm).

SG001a Issue 1 19 of 32 Apr 07

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12. Attach the driver cable connectors to the driver connectors and then carefully position the connectors under the driver. When this is done secure the driver covers to the horn assemblies using four M4 x 30mm Allen key bolts.

13. Identify which horns are connected to which cable by the use of either a red or blue identification marker as appropriate applied to the outer case of each horn driver cover.

SG001a Issue 1 20 of 32 Apr 07

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14. At the base of the mast feed the cable(s) that are exiting at the base through the holes in the sides of the mast approximately 100mm above the base.

15. Feed the cable(s) into the cable junction through an appropriate gland, cut to size and inserting into the feed through connectors contained in the junction box.

Remember to keep the cable identification marking.

SG001a Issue 1 21 of 32 Apr 07

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5. HORN ARRAY DIMENSIONS & WEIGHT

Horn Array

Siren Type

Turbo 2 27 1012 x 500 x 430 730 x 1000 x 430 Turbo 3 41 - 730 x 1500 x 430

ES-2 82 1012 x 1500 x 430 730 x 1500 x 430 ES-3 162 1012 x 3000 x 430 730 x 3000 x 430 ES-4 243 1012 x 4500 x 430 730 x 4500 x 430

Note: Weight and dimensions listed does not include mast.

Weight

(Kg)

Omni-Directional

(WxHxD/mm)

Dimensions

Uni-directional

(WxHxD/mm)

6. HORN ASSEMBLY TESTING

Using a multi-meter measure the resistance between each pair of horn driver conductors at the cable junction box and between each conductor and the mast metalwork to ensure there are no cable breaks or trapped conductors.

The resistance measured between conductors should be in the region of 4.8 to 5.2 ohms and there should be no connection between the conductors and the siren metalwork.

SG001a Issue 1 22 of 32 Apr 07

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7. STANDARD SIREN MAST INFORMATION

7.1 Mast Lengths, Weights and Number of Horns

MAST

Type

18-185938 50 3.0 Up to 6 18-185939 75 4.5 Up to 12 18-185940 100 6.0 Up to 18

18-185941 280 12.0 Support Mast Only

Note:

• Horn Masts are constructed from 114.3mm x 6 CHS galvanised steel.

• Support Mast is constructed from 193.7mm x 5 CHS galvanised steel.

Weight

(Kg)

Length

(metres)

No. of Horns

7.2 Mast Fixing Bolts

Function Mounting Bolts

Securing siren mast or

support mast to the

ground.

Securing siren mast to

support mast

7.3 Mast Base Construction

Typical base construction for a 12 metre support mast with siren horn mast array mounted on top would be a concrete base of 2.1 x 1.5 x 0.8 metre deep construction reinforced at the bottom with a layer of A393 mesh.

Note: The base construction suggested is only typical and each installation will be required to be evaluated by the installer taking into consideration the specific ground conditions where the mast is to be erected.

Medium carbon steel zinc plated grade

8.8, 20mm diameter, 300mm length

Medium carbon steel zinc plated grade

8.8, 20mm diameter, 75mm length

SG001a Issue 1 23 of 32 Apr 07

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