Dual Inventive ZKL 3000 RC User manual

Manual for installing
ZKL 3000 Remote Control (RC) Line Blockage System
ZKL 3000 RC
May 2023

2
1. Introduction 3
2. Definitions & technical specifications 3
a. Application of ZKL 3000 RC 3
3. Conditions & safety instructions 4
a. Conditions of use 4
b. Instructions 4
4. Components 5
a. ZKL 3000 RC and Ancillaries 5
b. The ZKL 3000 RC Unit 6
c. Batteries and Chargers 6
5. Charging the batteries 7
a. Instructions prior to use 7
b. Charging a backup battery 7
c. Charging an external battery 7
6. Testing the ZKL 3000 RC 8
a. Preparations 8
b. The override key switch 8
c. Function test for installation 9
7. Installing the ZKL 3000 RC 10
a. Installing the ZKL 3000 RC in the track 10
b. Functional test in the track 11
c. LED Indications 13
d. Replacing external battery 13
e. Removing the ZKL 3000 RC from the track 14
8. Alerts 15
a. Status screen alerts 15
b. Error and alerts 16
c. Error and alerts - reminders 19
9. Transport & storage 20
a. Transport 20
b. Storage 20
10. Maintenance & service 20
a. Maintenance 20
b. Service 21
11. Environment & recycling 21
In conclusion 21
CONTENTS
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1. INTRODUCTION
This manual details the correct method for installing the ZKL 3000 Remote Control (RC) Line
Blockage System safely. The ZKL 3000 RC system protects a section of track efficiently and effectively
by producing and monitoring a short circuit in the track, simulating a train in the section. This causes
the track circuit to be ‘OCCUPIED’, thus placing the protecting signals danger. This section is
immediately closed to rail traffic, enabling rail workers to perform work on the infrastructure safely.
The ZKL 3000 RC can be operated using either the MTInfo 3000 app or through the web interface MTinfo 3000.
This manual describes how to operate the ZKL 3000 RC using the MTinfo 3000 version 5 webplatform
and MTinfo 3000 app. The Remote Switch (RS) 3000 cannot be used on MTinfo 3000 version 5 to
switch a ZKL 3000 RC.
This manual is part of a set that details the entire ZKL 3000 RC system: The web interface
(MTinfo 3000), the Line Blockage System (ZKL 3000 RC), and the MTinfo 3000 app.
2. DEFINITIONS & TECHNICAL SPECIFICATIONS
a. Application of ZKL 3000 RC
The ZKL 3000 RC can be applied in track types with a width of 1,435mm, such as:
• NP46 • 85 lb RBS
• UIC54 • 109 lb
• UIC60 • 110 lb
• 95 lb RBS • 113 lb
Additionally, the ZKL 3000 RC can be used for mains voltage of both 1500 V and 25kV.
The ZKL 3000 RC can be used with the following track circuit systems:
You must NOT use a ZKL 3000 RC in locations with any of the following:
• Level crossings and/or service roads (or alongside)
• Axle counters
• Switches and Points
• Within 3m of the Tuning Zone
• In track circuits which have a frequency of 16.kHz or above
To connect to the ZKL 3000 RC the MTinfo 3000 app uses Dual Inventive’s wireless 3G network.
ZKL 3000 RC
• Jeumont-Schneider Peak Voltage
track circuit section
• Classic track circuit: 12V alternating
voltage 75 Hz
• Siemens electronic ripple control track
circuits FTGS46 & FTGS917
• GRS Overlay Track Circuit (OTC)
• Alstom Jade system
• Bi-rail type CV50B3P
• High power pulses type CVTHBG
• EBI track 400 OL (open line)
• Aster SF 15 type track circuit
• FS2600,
• Reed,
• HVI
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4ZKL 3000 RC
3. CONDITIONS & SAFETY INSTRUCTIONS
WARNING!
Please read all safety instructions carefully before using the ZKL 3000 RC, ensuring you
fully understand the system and how it works. When precautionary measures and safety
instructions are not followed properly there is a risk of electric shock, entrapment, fire
or even death.
a. Conditions of use
You are only allowed to install the ZKL 3000 RC if:
• you hold the ZKL 3000 RC competencies, and they are in date
• you have been assigned the appropriate user rights on MTinfo 3000
• you have been authorised to install the ZKL 3000 RC
As a competent user you are responsible for:
• any relevant paperwork, user names and passwords (and any authorisation codes via text
message or PIN that you have been assigned)
• managing your password and your PIN. You must never share this
information with others
b. Instructions
Other important instructions
• There are certain situations where it is not possible to switch the ZKL 3000 RC.
Please see the “Troubleshooting” section for more information should you encounter any problems
• Never perform any repairs to a ZKL 3000 RC. Please contact Dual Inventive for maintenance
and repairs
• Override keys must only be handed out to those who hold the ZKL 3000 RC competency
• Please take good care of the ZKL 3000 RC override keys by organising proper key management
to ensure they are not lost, stolen or damaged
• If the track circuit has been tuned including ZKL 3000 RC, the track circuit must be
tuned again after removal of the ZKL 3000 RC.
The batteries of the ZKL 3000 RC, both back-up and main, are lithium batteries and therefore
considered ‘dangerous goods’. Please ensure you follow the local laws and regulations when
storing and transporting these batteries. In case of damaged batteries, please avoid exposure and
discharge the battery in its original package conform the local laws and regulations. When you
are no longer in the possession of the packaging, we can deliver new packaging if required.
Instructions for first use
• Check whether the ZKL 3000 RC has the correct certification. Please consult our website
for the required certificates: www.dualinventive.com
• Please check whether local restrictions, regulations or certification apply to the use of
the ZKL 3000 RC
• Always take care of your own safety within the railway environment using the most current
applicable legislation
• Always visually inspect the ZKL 3000 RC for damage and perform a function test
DO NOT USE any ZKL 3000 RC if any damage or defects are detected. Please apply a label,
quarantine and return to your stores to be sent to Dual Inventive
• Always use the installation procedure set out in this manual for the ZKL 3000 RC
• Always start the installation with two fully charged batteries
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5
ZKL 3000 RC
4. COMPONENTS
A complete ZKL 3000 RC set consists of the following:
• Case including ZKL 3000 RC and ancillaries
• Batteries for ZKL 3000 RC with chargers
a. ZKL 3000 RC and Ancillaries
A ZKL 3000 RC set contains:
1. The ZKL 3000 RC including bypass clamps and override keys
2. Transport case
3. Backup battery
4. Battery compartment key
5. Manual
6. Key ring
7. Carrying strap
8. Test-Tool
9. Backup battery charger
10. USB (contains manual)
11. ZKL Clamp
12. Padlock
13. External battery
14. Charger external battery
15. Connection cable external battery
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6ZKL 3000 RC
4. CONTINUATION COMPONENTS
b. The ZKL 3000 RC Unit
1. A hinged frame
2. SWITCH 3000
3. Electronics casing (LEDs, GPS and black box recorder)
4. Battery compartment
5. Contact points
6. Locking mechanism
c. Batteries and Chargers
1. Backup battery
2. Charger backup battery
3. External battery
4. Charger external battery
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ZKL 3000 RC
5. CHARGING THE BATTERIES
The ZKL 3000 RC uses two types of batteries and chargers, which are displayed below
a. Instructions prior to use
• The chargers only have an IP20 protection level, so always charge the batteries in a dry,
indoor environment
• ALWAYS place the chargers at least 50mm apart for adequate cooling
• Always check the charger and cables for visible damage before use. DO NOT USE the charger
if any damage is detected
• Do not charge the batteries in an environment which is below 6°C
• The charger of both the backup battery and the external battery may only be repaired and
maintained by Dual Inventive
• Always transport and store the chargers in a dry environment
• Only use the charger that was supplied for that particular model
b. Charging a backup battery
• Plug the charger into a power socket. The green LED will illuminate to indicate mains power
• Connect the battery to the charger. The red LED on the charger will illuminate to indicate the
backup battery is being charged
• When the red LED switches off, the battery is fully charged
• The backup battery can stay connected to the charger without causing damage, although
after a period of time the red LED may illuminate again
c. Charging an external battery
• Connect the power cable to the battery and then connect the charger to the mains.
The two red LEDs on the charger will illuminate
• The fan in the charger should start at this point
• Both LEDs on the charger will remain red when the external battery is being charged
• When charged, one LED will turn green indicating this
• The external battery can stay connected to the charger, however it will not trickle charge
ATTENTION:
If you are to re-use the charger on another battery, please remove the charger from the
power before connecting the new battery.
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8ZKL 3000 RC
6. TESTING THE ZKL 3000 RC
a. Preparations
Before you start, check whether the ZKL 3000 RC system’s calibration is still in date.
You can find the “Next calibration date” sticker on the measuring unit.
Before installation, the user should check the ZKL 3000 RC for defects and perform a function test.
Testing the ZKL 3000 RC should always be done in a position of safety.
• Before testing, clean the contact points with a wire brush to ensure the best possible connection
• Before use, place two fully charged batteries into the ZKL 3000 RC
• Open the battery cover with the compartment key
• ALWAYS place the power cable on the notched side of the battery compartment
• Insert the batteries and pull the rubber fastener over the battery ends to lock them in position
• Close the battery cover and lock it with the compartment key
• Wait at least 10 seconds after installing the batteries to allow the ZKL 3000 RC to switch on
• Using the override key switch, switch the ZKL 3000 RC on
b. The override key switch
The override key switch has three positions:
Key up (fully clockwise) = ON
The ZKL 3000 RC is now set in an overruled manner
and will not produce a short circuit. The unit cannot
be operated remotely.
Key horizontal = OPERATIONAL
The ZKL 3000 RC is now operational and can be operated
remotely by either the MTinfo 3000 app or MTinfo 3000.
Key down (fully counter-clockwise) = OFF
The ZKL 3000 RC is now set in an overruled manner and
will not produce a short circuit. The unit cannot be
operated remotely.
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ZKL 3000 RC
6. CONTINUATION TESTING THE ZKL 3000 RC
The override key switches the ZKL 3000 RC ON or OFF without using either the MTinfo 3000 app or
MTinfo 3000. Use of the override key will overrule commands sent by both the MTinfo 3000 app and
MTinfo 3000 as the key switch always takes priority. Usually, the key switch would only be used
as a last resort.
Attention! The OPERATIONAL position has two settings.
OPERATIONAL - ON: When switched from the ON to OPERATIONAL (one turn to the left),
the ZKL 3000 RC remains activated creating a short circuit. However, it will now be possible to
remotely operate the ZKL 3000 RC using either the MTinfo 3000 app or MTinfo 3000.
OPERATIONAL - OFF: When switched from OFF to OPERATIONAL (one turn to the right), the ZKL
3000 RC remains deactivated. Again, it will now be possible to remotely operate the ZKL 3000 RC
using either the MTinfo 3000 app or MTinfo 3000.
Attention! Please wait a few seconds after operating the override key. If the override key is
switched through multiple positions too rapidly (such as from ON immediately to OFF),
the ZKL 3000 RC might not properly register this switch action.
c. Function test for installation
• Ensure that the contact points and the Test-Tool are clean
• With the Test-Tool present (as shown below), press the contact points together and switch
the ZKL 3000 RC ‘ON’ using the override key
• The green LED should start flashing (twice per second), indicating that a short circuit has
been detected. Check this status for at least five seconds
• If all is OK and the green LED continues to flash, switch the ZKL 3000 RC ‘OFF’ using the
override key. The LED should stop flashing. Again, check this for at least five seconds
• If the LED remains off, remove the Test-Tool. The ZKL 3000 RC is ready to be deployed
ATTENTION: If the ZKL 3000 RC does not pass the functional test before installation,
do NOT use the unit. Apply a label to the ZKL 3000 RC, quarantine it and return to your
depot/warehouse to be returned to Dual Inventive for repair.
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10 ZKL 3000 RC
7. INSTALLING THE ZKL 3000 RC
a. Installing the ZKL 3000 RC in the track
CAUTION, Please check whether local restrictions, regulations or certification apply to the use of
the ZKL 3000 RC.
After successfully testing the ZKL 3000 RC in a position of safety, the ZKL 3000 RC is then ready to
be installed in the track. Before doing so, ensure the rails are cleaned as thoroughly as possible
(to remove rust build up). This helps to create a good connection between the ZKL 3000 RC and
the track. A wire brush, connected to a power tool, is one such solution to clean the rails, as seen
in the images below:”
• Ensure that the distance between the bottom of the ZKL 3000 RC and any ballast is at least 3cm
• Set the override key switch of the ZKL 3000 RC to ‘ON’
• Unfold the ZKL 3000 RC and place the contact points on the web of the rail
• Partially insert and remove the ZKL 3000 RC during installation several times (being careful
to keep it in the same location) before the final placement of the ZKL 3000 RC. The contact
points will scrape the rust away from the rail web ensuring a better contact
• Using your hand or foot (and being careful to avoid trapping in the hinge), push the
ZKL 3000 RC down until it locks
• The green LED should start flashing (twice per second), indicating that a short circuit has
been detected. Check this status for at least five seconds
• Place the locking clamp over the hinge of the ZKL 3000 RC
• Insert the two metal locking plates in the base of the locking clamp
• Next, place the clamp around the two pins and lock with a padlock (as shown below)
• Place the external battery outside of the track in a safe location and secure it.
No padlocks or chains have been supplied for this purpose
• Pass the cable under the rail (on the side of the battery cover where possible) to the ZKL 3000 RC
• Open the battery cover and connect the plug of the external battery with the ZKL 3000 RC using
the connection cable to battery slot 2. Otherwise, the ZKL 3000 RC will not function properly
ATTENTION! You should always place the power cable to the side of the notch in the
battery compartment.
before after
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