ATL Transformers ECO-RAIL T3067 User manual

O&M MANUAL
Class II Hybrid Isolating transformers.
Lightweight Cu & Al Range
English
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TRANSFORMERS
Copyright © ATL Transformers Ltd 2019 Doc Ref TECH145 Issue 7
650/110VAC 230/110VAC 400-415-440/110V 650/230VAC 230/230VAC

2Copyright © ATL Transformers Ltd 2019Doc Ref TECH145 Issue 72
CONTENTS
1.
2.
3.
4.
1.1 SAFETY NOTES...................................................................................................... 4
3.1 MOUNTING WITHIN APPARATUS HOUSING..................................................... 8
2.1 KEY ECO-RAIL® FEATURES............................................................................... 5-6
4.1 ROUTINE MAINTENANCE.................................................................................. 10
3.3 VOLTAGE ADJUSTMENT ...................................................................................... 9
4.3 MAINTENANCE AFTER FLOODING ................................................................... 11
1.2 PURPOSE............................................................................................................... 5
3.2 CABLE CONNECTION........................................................................................... 9
2.2 PRODUCT OPERATION........................................................................................ 7
4.2 TESTING IN SERVICE .......................................................................................... 10
4.4 SPARE PARTS ...................................................................................................... 11
INTRODUCTION
PRODUCT INSTALLATION
PRODUCT DESCRIPTION
PRODUCT MAINTENANCE
5.
TRAINING & COMPETENCE ..................................................................................... 11
TRAINING & COMPETENCE
6.
6.1 DATA SHEET REFERENCE .................................................................................. 10
6.3 DECLRATION OF CONFORMITY........................................................................ 12
6.2 NR COMPONENT APPROVALS.......................................................................... 11
PRODUCT MAINTENANCE
7.
MANUFACTURER CONTACTS.................................................................................. 12
MANUFACTURER CONTACTS
1.3 GUARANTEE.......................................................................................................... 5

Copyright © ATL Transformers Ltd 2019 Doc Ref TECH145 Issue 7 3
ECORAIL® TRANSFORMER RANGE .................................................................. 15-18
8.
REGULATORY REQUIREMENTS.............................................................................. 13
REGULATORY REQUIREMENTS
CONTENTS
9.
FREQUENTLY ASKED QUESTIONS .................................................................... 14-15
FREQUENTLY ASKED QUESTIONS
10.
PRODUCT WARRANTY ............................................................................................. 15
PRODUCT WARRANTY
11.
END OF LIFE DISPOSAL............................................................................................ 15
END OF LIFE DISPOSAL
12. ECORAIL® TRANSFORMER RANGE
APENDIX B: LABEL DETAILS .................................................................................... 20
APENDIX A: GA DRAWING ....................................................................................... 19
APENDIX C: WIRING DIAGRAMS ...................................................................... 21-31
APENDIX D: LEGACY MOUNTING BRACKETS ........................................................ 32
Version Implemented
By
Revision
Date
Approved
By
Approval
Date Reason
1 N.D.H. 24/03/15 B.M. 22/05/15 Product Approval
2 N.D.H. 01/06/15 B.M. 08/06/15 General document
review & Changes
3 N.D.H. 09/06/15 B.M. 10/06/15 Amended following NR
Review
4 N.D.H. 07/12/16 B.M. 07/12/16 Congurations added
5 C.J.W. 28/03/19 N.D.H. 12/04/19 Congurations added
6 C.J.W. 09/07/19 N.D.H. 09/07/19 Congurations added
7 C.J.W. 09/09/19 N.D.H. 09/09/19 10KVA GA Added
APENDIX E: DETAILED ASSEMBLY OF ECORAIL® TRANSFORMER...................... 33

4Copyright © ATL Transformers Ltd 2019Doc Ref TECH145 Issue 7
1. INTRODUCTION
SAFETY PRECAUTIONS
GENERAL
The need for Personal Protection Equipment (PPE) must be as-
sessed prior to undertaking installation or maintenance
operations.
HEAVY
EQUPMENT
All manual handling must be in accordance with the Manual
Handling Operations Regulation 1992
LETHAL VOLTAGES
Electrical power within this system/equipment is at a level
considered, by the low voltage directive 73/23/EEC, to be
sucient to kill.
Always assume conductors are live until proved dead.
Before attempting any maintenance task, ensure that equipment
is isolated from electrical supply.
When the electrical supply cannot be isolated,
testing/maintenance tasks are to be undertaken only by
personnel who are aware of the dangers involved and after all
necessary precautions have been taken.
WORKING PRACTICES
Unauthorized interruption of the system may endanger the safe
operation of the railway. Before attempting any maintenance on
the equipment, obtain the necessary permission from the rele-
vant authority. Ensure the consequence of any interruption has
been fully considered and understood.
If a component or equipment becomes overheated or burnt, a
toxic fume hazard may exist. Isolate the power to the
equipment, ventilate the area and allow the equipment time to
cool before carrying out repairs.
This equipment does not liberate any toxic or injurious gases
during normal operation.
When working on equipment, especially in the connes of a case,
do not wear metal rings, bracelets, watches, etc. These articles
can cause personal injury or damage to equipment by becoming
entangled in components or causing a short circuit.
1.1 SAFETY NOTES

Copyright © ATL Transformers Ltd 2019 Doc Ref TECH145 Issue 7 5
1.2 PURPOSE
This O&M Manual denes the operating & Installation guidelines for the ATL Transformers,
1 - 10KVA range of aluminium rail signalling transformers & 250VA - 4KVA range of copper rail
signalling transformers for use within a standard Network Rail approved Apparatus housing.
This transformer is Intended for use as a Class II Hybrid transformer for Class II based signalling
power distribution systems and Suitable for Class I Legacy system integration.
1.3 GUARANTEE
The function and safety of the equipment is only guaranteed if the warning and safety
instructions included in this manual are adhered to.
ATL Transformers Ltd is not liable for any personal injury or damage to property that occurs as a
result of the warning and manual being disregarded.
ATL Transformers Ltd does not accept any liability or warranty for damage due to the use of
non-approved spare parts and accessories.
2. PRODUCT DESCRIPTION
2.1 KEY eco-rail® FEATURES
The enclosed transformers t inside a standard Network Rail ApparatusHousing.The
transformers have an Ingress protection rating greater than IP32.
Primary Class II Terminals are housed within a separate double insulated enclosure and feature
a protective inspection cover which enables cables to be traced from the point of entry and
Inspection of Class II terminals under load.
Cable clamps are provided within the Class II compartment on 1KVA & above congurations to
secure incoming cables prior to termination.
Optional gland entry zones for both Class I Output & Class II Input cables are available on either
side of the enclosure. IP5X Blanking glands are provided to seal the unused gland holes once
cables have been terminated. This feature Limits the need for additional cabling/conduit and
reduces location restrictions commonly found within the FSP Apparatus Housing.
This range of eco-rail® transformers enables installation of multiple transformers within a single
FSP Apparatus Housing and reduces the power consumption of the overall system by way of
signicantly reduced losses.
The eco-rail® Aluminium range of transformers are specically designed to be Lightweight and
compact where space and weight are of a concern. Designed to support Network Rails Legacy
renewal work stream these transformers feature separate legacy brackets which enable the
installation of the transformer by a single operator reducing installation costs and resources by
half.

6Copyright © ATL Transformers Ltd 2019Doc Ref TECH145 Issue 7
Primary Class I Housing
Terminals Located on the front of the
enclosure in bottom window.
2. PRODUCT DESCRIPTION
2.1 KEY eco-rail® FEATURES
New innovative designs reduce installation and retrot time making tting eco-rail®
transformers a simple and ecient solution when downtime is critical. Our unique mechanical
design provides a sturdy and comfortable lifting facility as well as a footprint compatible with
standard BRS SM 440 accordance bar work.
Lifting Eye
Bolts
Enclosure
Body
Enclosure
Lid
Door
Secondary Class II Housing
Located on the front of the enclosure in
separate housing.
Enclosure
Base

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2.2 PRODUCT OPERATION
The Class II Hybrid transformer is designed to be fed from two wires 650VAC (±10%) Supply at a
nominal 50Hz (+4% to -6%).
The 650VAC Class II supply cables are to be connected within the double insulated compartment
through a straight or angled insulated coupling suitable for M32 exible conduit. Conduit should
meet the requirements of of NR/L2/SIGELP/27410 Issue 2 & NR/L2/SIGELP/27421 & 27422.
Cables are terminated to the transformers DIN rail terminal blocks provided within the
double insulated compartment which are designed to accept a cable size between 0.5-10mm².
The 110VAC Class I Output cables are connected to the transformer through an Insulated M20
Cable gland and terminated to the provided terminal blocks which are designed to accept a
cable size between 0.5-10mm².
Optional Cable entry points are provided at either side of the enclosure for both Class I & Class
II cables. Insulated Blanking glands are provided to cap the un-used cable entry points on the
enclosure and must always be tted.
The functional earth terminal is located with the Class I termination and is designed to accept a
cable size between 0.5-10mm².
Where a multi-Output eco-rail® transformer is selected any number of output windings can be
paralleled together to increase the transformers output. Care should be taken when making
parallel connections to ensure that polarity is maintained.
All cabling should meet the requirements of NR standards:
NR/L2/SIGELP/27410 Issue 2 and NR/L2/SIGELP/27421 & 27422

8Copyright © ATL Transformers Ltd 2019Doc Ref TECH145 Issue 7
DE DD
Dimensioning
The transformers shown in the general arrangement
drawings in Appendix A are designed to be securely xed
to substantial mounting rails or brackets such as BRS SM
440 bar work The bar work should be capable of bearing
the weight of the transformer using the 4 horizontal
footprint holes shown in Appendix A.
1.
Repercussions
Due diligence and care should be taken not to damage
any installed cable entry glands or couplings during the
installation process as this could compromise the safety
integrity of the unit. In the event that the paint nish
is damaged during installation a touch up pen is available
for aesthetics however paint is supplementary to the
base material and not critical to the units operational
integrity.
3.
Lifting
Safe lifting practices should be observed when handling
heavy transformers. Larger units 1KVA and above 30Kg
+ are tted with additional top mounted removable
Lifting eyes for crane assisted installation. Ensure that
the lifting eyes are secure and that the main door
is closed prior to lifting.
2.
3. PRODUCT INSTALLATION
3.1 MOUNTING WITHIN APPARATUS HOUSING
Additional mounting brackets are available for backplate legacy installations where required
reference Appendix D of this document.

Copyright © ATL Transformers Ltd 2019 Doc Ref TECH145 Issue 7 9
3.2 CABLE CONNECTION
Primary: Through glands provided into double insulated compartment, Cables to be secured
using cable clamps and terminated accordingly. Secondary: Through glands provided directly
onto secondary terminals. All cabling and conduit should meet the requirements of:
NR/L2/SIGELP/27410 Issue 2 & NR/L2/SIGELP/27421 & 27422.
3.3 VOLTAGE SELECTION
INPUT: Monitor the supply voltage with a calibrated DVM and take an average value over 3
minutes. Connect Supply to the nearest Input Voltage terminal provided i.e. If the monitored
voltage average RMS value over3 minutes is 648VAC then connect to input terminals T650 and
T0 respectively.
OUTPUT: The output terminals facilitate ne Voltage adjustment and the relevant terminal
should be used to achieve an Output voltage of 110V +/- 2% under load ensure that the output
voltage is achieved within the range of +/- 2%
NOTE: - If Ferrules are not being used cables should be stripped 10mm and secured
into the terminals. The recommended torque setting is between 2.0 – 4.0 Nm.
3.2.1 CONNECTING MULTI OUPUT TRANSFORMER WINDINGS IN
PARALLEL
Where a multi-Output eco-rail® transformer is selected any number of output windings can
be Paralleled together to increase the transformers Output. Eco-rail® transformers have been
designed to accommodate additional circulating currents generated when Paralleling the small
imbalanced winding impedances of our multi-output range. Care should be taken when making
Parallel connections to ensure that polarity is maintained across all windings. i.e to parallel two
500VA coils on a 1KVA dual output transformer. Connect the cables from the “to” terminals on
coil 1&2 together & the cables from the “t110” terminals on coils 1&2 together to supply a 1KVA
load.
WARNING
Antiphase connections are detrimental to a transformer and can
cause irreparable damage rendering the unit unsafe. Do not connect
dissimilar voltage groups together.

10 Copyright © ATL Transformers Ltd 2019Doc Ref TECH145 Issue 7
WARNING
The Inspection cover on the double insulated Class II compartment
MUST be tted and secured in the correct orientation following its
removal to access Class II terminals.The Inspection cover is notched so
as not to locate easily in an incorrect orientation, the tting of this part
correctly after any work within the Class II compartment is essential in
maintaining the Class II Integrity and safety of the transformer.
Disconnect incoming supply, and secondary connections.
Using a calibrated 500V d.c insulation resistance tester check insulation resistance. Primary to
body (Functional Earth) Secondary to body (Functional Earth) & Primary to Secondary.
All values should be greater than 100M ohms. Check Primary and Secondary winding resistances
with values on Data Sheet in Appendix C, and reconnect incoming supply to Primary terminals.
4.2 TESTING IN SERVICE
Check incoming supply voltage, adjusting Primary taps if necessary (using the method specied
in section 3.3).
Check Primary tap voltages. Terminal voltages should be within 10% of the nominal 650VAC
terminal voltage.
Reconnect secondary, and using a calibrated ammeter check the load current. The load current
should not exceed the value shown on the data sheet in Appendix C.
Check Secondary tap voltages. Voltages should be within 2% of the terminal voltage. Adjust
Secondary taps if necessary.
Relevant safety checks & testing should be conducted in addition to these checks & in line with
Network Rails controlled safety & inspection procedures prior to energizing the transformer.
These units are non serviceable and require observational maintenance only to their Class I &
Class II Terminals and protective covers which must be intact and installed as originally supplied.
This does not supersede any maintenance tasks or scheduling procedures network rail deem
necessary and set in accordance with. NR/SP/SIG/10661 Signalling Maintenance Task Intervals.
Each unit is provided with a serial number and part code reference. This Information is located
on the transformer rating plate and should be quoted at any Point where the unit is examined
and suspected to be compromised.
4. PRODUCT MAINTENANCE
4.1 ROUTINE MAINTENANCE