Unipart Dorman CLS LITE Operation & Maintenance Manual
CLS LITE
Operation & Maintenance Manual
C64.65201
Issue 3
June 2019
INTELLIGENT ENGINEERING UNIQUE PEOPLE WORKING TOGETHER
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Document Reference C64. 65201 I ssu e 3 Apr 2019
Table of Contents
Document Control ................................................................................................ 2
Cautions and Warnings in This Document .............................................................. 2
Introduction......................................................................................................... 2
Specifications ....................................................................................................... 3
Storage ............................................................................................................... 4
Safety ................................................................................................................. 4
Pre Installation Checks ......................................................................................... 5
CLS LITE Variants ................................................................................................ 5
Detachable Alignment Scope ................................................................................ 6
INSTALLATION AND ALIGNMENT OF CLS LITE HEADS ON ALL STRUCTURES EXCEPT
THE UNIPART DORMAN ASSI STED LIFT TRUNNION .............................................. 8
Preparing and Mounting the Signal Hea d ............................................................... 9
Backboard Arrangement ....................................................................................... 9
Signal Alignment ................................................................................................ 11
INSTALLATION AND ALIGNMENT OF CLS LITE HEADS USING THE UNIPART
DORMAN ASSISTED LIFT TRUNNION .................................................................. 18
Preparing and Mounting the Signal Hea d ............................................................. 20
Backboard Arrangement ..................................................................................... 23
Alignment at the ALT ......................................................................................... 25
INSTRUCTIONS COMMON T O B O TH VARIANTS ................................................... 27
Electrical Connection .......................................................................................... 27
Changing the Door Opening Side ........................................................................ 30
Door Preparation................................................................................................ 31
Frame Preparation ............................................................................................. 33
Refitting the Door .............................................................................................. 34
Maintenance Activity .......................................................................................... 34
Signal Husbandry ............................................................................................... 35
Service and Repair ............................................................................................. 35
Module Replacement .......................................................................................... 35
End of Life Disposal ............................................................................................ 37
Contact Us ......................................................................................................... 38
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Issue Number
Dated
Reason
1
May 13
Initial Issue
2
Jan 19
Rewrite of Signal Alignment Section
Various Clarifications Based on Customer
Feedback
Document Control
It is the reader’s responsibility to ensure they have the correct version of this
document. If in doubt, please contact Unipart Dorman to verify the current issue
status.
3 Jun 19
Cautions and Warnings in This Document
To highlight items in this document that warrant extra vigilance the following two
alert formats are used:
Activities identified as needing extra c are are highlighted using the Caution Symbol
ACTIVITIES WHICH ARE OR HAVE THE POTENTIAL TO BE HAZARDOUS TO
PERSONNEL AND/OR EQUIPMENT ARE HIGHLIGHT ED W ITH THE
WARNING SYMBOL
Introduction
Following the introduction of the Unipart Dorman Integrated Lightweight Signal (iLS)
which is a versatile yet simple signal li ng solution for installatio n in a wide variety of
applications, a requirement for the enhanced optics and better maintenance
characteristics of the iLS module but housed in a c lassic Unipart Dorman Colour Light
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Signal frame was identified. The new signal is designed to retain the same interface
with all standard modular, route relay, geographical and solid state interlocking
systems and infrastructure used in the UK; and the use of modular based
construction with plug coupled electrical components reduces test and
commissioning time to a minimum.
The new lens/hood arrangement gives excellent protection against phantom aspects
and is designed to be self-clea ning. This allows maintenance cost r educt ions to be
made over the lifetime of the signal. The new module configuration also includes a
Voltage Free Contact Proving capability where specified and the signals can be
adapted to either single or double cut proving contacts.
Where Volt Free Contact Proving i s used, a less power hungry signal drawing just
45mA is available giving a consumption of just 5 Watts. A low current 24Vdc signa l
head may also be specified, please contact Unipart Dorman for more informat ion on
these energy saving options.
The CLS LITE can be installed anyw here a Classic CLS or Filament Head is currently
fitted or by using the Unipart Do r man A ssisted Lift Trunnion range as standalone
maintenance free signals, where all work is carried out from ground level.
Specifications
Nominal Voltage (AC) 110V
Operating Voltage Max 121V, Min 88V
Nominal Voltage (DC) 120V
Operating Voltage Max 145V, Min 88V
Operating Temperature Range -25OC to +40OC
Flashing Aspects Flashing controlled by the
Interlocking
Current Proving Variant
Nominal Operating Current 300 mA @ 110Vac
Relay Based Interlocking BR941A
Solid State Interlocking (SSI) Current Path 1 or 4
110V Low Power Consumption (5 Watt CLS) Variant with Voltage Free
Contacts
Nominal Operating Current 45 mA @ 110Vac
Relay Based Interlocking BR941A
Solid State Interlocking (SSI) Current Path 1 or 4
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Storage
The standard CLS LITE signals are supplied complete two to a pallet and ALT
variants one to a pallet with protective packaging which should not be removed prior
to delivery to site. The signal heads can be stored outdoors if required.
The signal should be retained on the pallet until ready for installation and
when removed should not be laid in such a way as the lenses are at risk of damage.
The time it is laid down should be kept to a minimum
The two warning labels, protec tive strip and Lower Backboard Extension can b e left
in position until the head is mo unted on the base but should be moved prior to
aligning the signal as shown in the Backboard Arrangement sections of this manual.
Safety
Before commencing assembly, any local safety requirements affecting the continued
safe working environment of the signalling installation and/or the working railway,
either directly or indirectly should be carried out. It is the user’s responsibility to
ensure all necessary risk assessments, permissions to work and preparatory safety
activities are correctly completed and adhered to throughout the installation and
subsequent life of the signal.
The gross weight of the signal is clearly marked on the top of the signal as shown
and installers should ensure that they have sufficient measures in place to ensure a
safe lift.
All activity on the CLS LITE, both mechanical and electrical, must only be carried out
by staff deemed competent in these fields by their employer. It is the user’s sole
responsibility to ensure that the CLS LITE is installed and/or maintained by
certificated and competent staff.
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Pre Installation Checks
It is assumed that the mounting/foundation for the particular signal has been
installed and has been accepted by the person responsible for structures prior to
commencement of the installation.
The signal should be checked for damage and any remaining transit packing
materials should be removed and correctly disposed of.
The signal modules each weigh 5.5 Kg and can be removed to lighten the signal for
lifting during installat ion. This is covered in the Module Replacement sectio n of this
document.
BEFORE THE COMMEN C EMENT OF ANY ACTIVITY, ARRANGEMENTS
SHALL BE APPLIED TO PROTECT THE WORKING RAILWAY.
CLS LITE Variants
There are two types of CLS LITE head and they are defined by the way they ar e
mounted. The installation instructions are different and it is important that you
identify which variant you are installing.
CLS LITE was originally designed to be used on ‘conventional’ non-folding structures
such as gantries and standard signal posts and also the Collis Folding Post.
It is supplied with the standard baseplate mandated in NR/SP/SIG10062.
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The other type can only be used with the Unipart Dorman GRP Post and Assisted Lift
Trunnion and will be delivered wi th the Spigot Bracket attached. Where t h i s method
is employed, this document should be rea d in conjunction with the ALT Operations
and Maintenance Manual C64.65976 whi c h is available on the Unipart Dorman
website.
Detachable Alignment Scope
The Unipart Dorman Detachable Alignment Scope is an optical device that allows
accurate signal alignment and is c ommon to both variants of the CLS LITE. It is
stored in a bespoke carrying box and should be returned to Unipart Dorman annually
for an alignment verificati on check.
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There is an adaptor bracket available that enable a suitable camera to be fitte d to
the scope. The camera and mount are sub ject to their own separate instruct ion
sheets available on the Unip art Dorman website.
If the Scope lenses require any cleaning to be carried out, the only mediums
approved are water and proprietary detergents.
Do not use any solvent based or ab rasive cleaning material, as this may
irreparably damage the lenses.
Ensure there is no grit etc on the lens and then using a lint free cloth moistened with
the water detergent solution, car efully wipe the lens clean before using a dry second
cloth to remove any water spotting etc and give a final buffing.
When the scope is moved from a cold to hot environment or vice versa there may
occasionally be some temporar y fogging of the internal lenses which will c lear when
the temperatur es i n side and outside the scope equalise.
Do not attempt to disassemble the scope to gain access to the i n ternal lenses
as this will disturb the optical alignment and the scope will need to be returned to
Unipart Dorman for adjustment on the sp eci al to type jig
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INSTALLATION AND ALIGNMENT OF CLS LITE HEADS
ON ALL STRUCTURES EXCEPT THE UNIPART DORMAN
ASSISTED LIFT TRUNNION
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Preparing and Mounting the Signa l Head
The signal will arrive from the factory on a standard pallet where it should remain
until ready to commence the installation onto the prepared base.
Remove all packaging materials and dispose of in accordance with current
procedures and retain any paperwork etc as required.
The mounting nuts and bolts which att ached the head to the pallet are transit
fixings only and shall not be used to mount the signal onto the base
Having taken into account the gross weight marked on the signal head and where
necessary removed the module(s) to reduce this weight, an onsite risk assessment
should be undertaken and a method of lifting the head into place shall be
determined. Two removable lifting rings are fit ted to assist in mechanical lifting.
Once in the required position, the CLS LITE is secured to the base platform using
suitable mounting hardware. E nsure the Lower Backboard extension is fitted in its
operational position as detailed below.
Backboard Arrangement
The signals are required to display a uniform backboard of at least 300mm from the
centre of the lit aspect and the following procedure is applicable to bot h m ounting
arrangements. To prevent damage to the lower portion of backboard during transit a
removable section is fitted in a stow ed position to enable the signal head to be
bolted securely to its pallet. A s part of the installation, this extension piece must be
moved into its operational position below the aperture once it has been removed
from the pallet.
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The backboard must be moved to its in-service position before aligning the
signal as in the transit position; it obscures the holes in the backboard the scope
looks through and the signal will not meet the 300mm backboard criterion
Remove the Lower Backboard Extension from its stowage position above the
aperture by removing the two 3mm Al len scr ew s sho wn in blue below. Refit the two
screws and dispose of the 2 white plastic labels and the black plastic edge pr otector
properly.
Using the existing Allen screws shown in g r een below, mount the plate at the
bottom of the backboard.
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Correctly fitted backboard on a 3 aspect short h ousing signal head shown – 3 aspect tall and 4 aspect
signals have the same arrangement)
.
Signal Alignment
General Notes
GREAT CARE SHOU LD BE TAKEN TO AL IGN THE SIGNAL IN STRICT
ADHERENCE TO TH E SIGNAL SIGHTING FORM REQUIREMENT S
The Signal Sighting Form (SSF) w il l provide the definitive, signal specific alignment
details and should always be consulted prior to commencement of work.
Where the centre of the most restrict i v e aspect is greater than 2750mm above the
LH running rail, the signal is generall y aligned to a target board (PADS Number
086/011540) at a point detailed in the Signal Sighting Form.
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