Tactical EBMST User manual

LUL, Bakerloo Line
'72 Stock Refurbishment
Heating, Ventilating
& Air-conditioning
Multi-stage Thermostat for Cab
Instruction Manual
Contents
Introduction................................................................
...........................
2
Block diagram ................................................................
.......................
2
Description ................................................................
............................
2
Temperature measurement ................................................................
....
3
Output switching ................................................................
...................
3
Operator interface................................................................
..................
4
System layout diagram................................................................
..........
4
Power supply................................................................
.........................
5
Installation................................................................
.............................
5
System connection diagram................................................................
...
5
System wiring list................................................................
..................
5
Technical Specification................................................................
.........
6
Ordering information................................................................
.............
8
Supplier information................................................................
..............
8
Copyright (C) 1997 Tactical Controls Limited
This document contains proprietary information which is protected by copyright. All rights reserved. This document or parts thereof may not
be reproduced in any form without written permission of the publishers.
The information in this document is subject to change without notice and should not be construed as a commitment by Tactical Controls
Limited. Tactical Controls Limited shall not be liable for errors contained herein or for incidental or consequential damages in connection
with the furnishing, performance or use of this material.

Tactical Controls Limited Multi-Stage Thermostat
Instruction Manual
Introduction
This instruction manual describes a microprocessor-based Multi-Stage Thermostat (MST)
with application to the LUL, Bakerloo Line '72 Stock Refurbishment Heating, ventilating &
Air-conditioning for Cab.
The MST is designed to measure the cab temperature and switch the heating or air-
conditioning according to the selected setpoint.
Test and diagnostics are included for temperature simulation and system status indication.
Block diagram
All Rights Reserved.
C
Filename:
Size:
Drawing N o.:
Title:
Tactical Controls Limited
Rev. Description Iss. Ch . Auth. Date
A3
BLOCK
SYSTEM BLOCK DIAGRAM
SUPPLY
23-JUL-19971 EBMST/IM/BLOCK
MULTI-STAGE THERMOSTAT
-52VDC
OVERCOOL TRIP
OVERHEAT TRIP
FROST-STAT TRIP
LP TRIP
HP TRIP
CONVERTER ON
SYSTEM
WATCHDOG
DIGITAL INPUTS
OUTPUT
CONTROL
STAGE
MICROCONTROLLER
ANALOGUE INPUT
ANALOGUE
INPUT COM NO STAGE 1
COM NO STAGE 2
COM NO
COM NO
STAGE 3
STAGE 4
STAGE 1 LED
STAGE 2 LED
STAGE 3 LED
STAGE 4 LED
HARDWARE AND SOFTWARE FILTERS HARDWARE AND SOFTWARE FILTERS
SENSOR INPUT
NTC TEMPERATURESETPOINT
SELECTION INPUT
INDICATOR
INTERFACE
TRIP AND
DIAGNOSTIC INPUT
POWER SUPPLY
RFI
SUPPRESSOR
BATTERY VOLTAGE
Description
At the heart of the system is the microcontroller which reads the cab temperature from a
Negative Temperature Coefficient (NTC) device. This signal is transient protected, buffered,
hardware and software filtered before it is connected to the microprocessor input.
The 4 output stages are switched OFF and ON according to the sensor temperature and the
selected setpoint.
There are 4 setpoint selections: OFF, 19, 21 and 23°C.
Trip and diagnostic indicators are provided for Overcool, Overheat, Frost-stat, LP and HP
trip, and Converter ON indication.
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Tactical Controls Limited Multi-Stage Thermostat
Instruction Manual
The supply to the microprocessor is derived from the -52Vdc supply via a step-down switch
mode power supply. It is surge and transient protected.
The supply voltage is monitored for low supply voltage cutout. The 4 output stages are
switched off if the supply voltage is above -32Vdc and resumes when the supply voltage is
below -36Vdc.
Temperature measurement
The microcontroller works out the temperature by means of continuously measuring the
resistance across the NTC device and check it against a resistance/temperature look-up table.
°C
Rt
°C
Rt
14 3707.9 21 2689.6
15 3536.8 22 2571.5
16 3378.3 23 2459.8
17 3225.9 24 2353.3
18 3081.3 25 2252
19 2939.5 26 2155.6
20 2813.6 27 2063.9
The signal from the NTC device is transient protected, amplified and filtered before it reaches
the microcontroller input.
Output switching
The output switching is derived from Ebac Ref. No. RCM-BAK-06-02 Issue D, 14/04/97.
THERMOSTAT CONTROL LOGIC
OUTPUT STAGE 1 STAGE 2 STAGE 3 STAGE 4
HIGH HEAT 0 1 1 0
LOW HEAT 0 1 0 0
LOW COOL 1 0 0 1
HIGH COOL 1 0 0 0
SETPOINT LOGIC 19°C
OUTPUT STAGE 1 STAGE 2 STAGE 3 STAGE 4
TEMP. rising falling rising falling rising falling rising falling
HIGH HEAT off off on on 16-off 15-on off off
LOW HEAT off off 17-off 16-on off off off off
LOW COOL 19-on 18-off off off off off 19-on 18-off
HIGH COOL on on off off off off 21-off 20-on
SETPOINT LOGIC 21°C
OUTPUT STAGE 1 STAGE 2 STAGE 3 STAGE 4
TEMP. rising falling rising falling rising falling rising falling
HIGH HEAT off off on on 18-off 17-on off off
LOW HEAT off off 19-off 18-on off off off off
LOW COOL 21-on 20-off off off off off 21-on 20-off
HIGH COOL on on off off off off 23-off 22-on
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Tactical Controls Limited Multi-Stage Thermostat
Instruction Manual
SETPOINT LOGIC 23°C
OUTPUT STAGE 1 STAGE 2 STAGE 3 STAGE 4
TEMP. rising falling rising falling rising falling rising falling
HIGH HEAT off off on on 20-off 19-on off off
LOW HEAT off off 21-off 20-on off off off off
LOW COOL 23-on 22-off off off off off 23-on 22-off
HIGH COOL on on off off off off 25-off 24-on
Operator interface
The operator interface consists of 5 green LEDs for the multi-stage thermostat indication.
There are 3 yellow, 2 red and 1 green LEDs for trip and diagnostics indication.
MULTI-STAGE THERMOSTAT
TRIP & DIAGNOSTICS
LED
Description
LED
Description
Green POWER ON Yellow OVERCOOL TRIP
Green STAGE 1 Yellow OVERHEAT TRIP
Green STAGE 2 Yellow FROST-STAT TRIP
Green STAGE 3 Red LP TRIP
Green STAGE 4 Red HP TRIP
Green CONVERTER ON
System layout diagram
110.0 110.0
70.0
235.0250.0 220.0
122.5150.0
All Rights Reserved.
C
Filena me:
Size:
Drawing No .:
Rev. Description Iss. Ch . Auth. Date
A1
LAYOUT
Title:
Tactical Controls Limited
THERMOSTAT AND DIAGNOSTIC UNIT
LAYOUT DIAGRAM
ALL DIMENSIONS ARE IN MM. GENERAL TOLERANCE X = +/-0.5 X.X = +/-0.05
POWER ON
CONVERTER ON
HP TRIP
LP TRIP
1
2
3
225.0
105.0
MULTI-STAGE THERMOSTAT
STAGE 1
STAGE 2
STAGE 3
STAGE 4
KEY-SWITCH
EBMST\DWG\LAYOUT
NOTES:
1. CONNECTOR 1, 7-WAY REAR MOUNTING
(WITH SOCKET CONTACTS)
2. CONNECTOR 2, 5-WAY REAR MOUNTING
(WITH SOCKET CONTACTS)
3. CONNECTOR 3, 10-WAY REAR MOUNTING
(WITH PIN CONTACTS)
MATERIAL: SHEET STEEL 16SWG
FINISH: ZINC PLATED
WEIGHT: 4.0KG
Ø6.0
OVERCOOL TRIP
OVERHEAT TRIP
FROST-STAT TRIP
4-AUG-1997PRODUCTION ISSUE2
EBMST\IM Page 4 30 October1997
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Tactical Controls Limited Multi-Stage Thermostat
Instruction Manual
Power supply
The MST is powered by the Train's control supply which is nominally -52Vdc with the
positive pole earthed. The design can accommodate a ripple of up to 5V peak to peak, at a
nominal frequency of 850Hz and associated harmonics. The MST supply input is designed to
withstand the RIA12 Surge and Transient tests.
Installation
The MST is designed for back panel mounting through 4 M5 holes on a 70(W) x 235(H) mm
matrix. Please see System layout diagram for details.
System connection diagram
ALL DIMENSIONS ARE IN MM. GENERAL TOLERANCE X = +/-0.5 X.X = +/-0.05
DateAuth.Chk.Iss.DescriptionRev.
Tactical Controls Limited
Title:
Drawing No.: Size:
Filename: C
All Rights Reserved.
A2
CONNECT
WITH SOCKET CONTACTS
EXTERNAL
COMPONENTS
EBMST\IM\CONNECT
EBMST - EXTERNAL CONNECTION DIAGRAM
STAGE4
STAGE1
STAGE2
STAGE3
0V
0V
0V
0V
OFF
HIGH 23°C
MED 21°C
LOW 19°C
SUPPLY
0V -52V
CONNECTOR 1
H1
D1
B1
E1
STAGE1
STAGE2
STAGE3
STAGE4
-52V
CONNECTION
INTERNAL RELAY
VOLT-FREE
4. P1: SENSOR SIMULATION POT
5. CONNECTOR 3: 7 WAY PANEL MOUNTED CONNECTOR
3. K1: DERRICOTT SWITCH 22K5/R6S22
PART NO. CIR06F18-19S-F80-T12
PART NO. CIR06F16S-8P-F80-T12
WITH SOCKET CONTACTS
WITH PIN CONTACTS
1. CONNECTOR 1: 10 WAY FREE PLUG CONNECTOR
2. CONNECTOR 2: 5 WAY FREE PLUG CONNECTOR
NOTES:
-52V 0V
A
B
D
E
F
G
A3 B3 C3 D3 E3 G3F3
CONNECTOR 3
A3: HP TRIP
B3: LP TRIP
C3: LOW COOLANT
D3: COOLANT OVERHEAT
E3: COOLANT OVERCOOL
F3: 0V
G3: CONVERTER ON
P1
K1
1
2 6
1
2
CONNECTOR 2
C1 A1 G1 J1 K1 F1A3 B3 C3 D3 E3 F3 G3 B2
CONNECTOR 3
CONNECTOR 1
A1: SETPOINT LOW
C1: SETPOINT MEDIUM
G1: SETPOINT OFF
J1: 0V
K1: -52V
F1: EARTH
H1: STAGE 1 OUTPUT
D1: STAGE 2 OUTPUT
B1: STAGE 3 OUTPUT
E1: STAGE 4 OUTPUT
CONVERTER ON
C
K
D
EF
G
HJ
A
BC
D
BC A
E
NTC
A2
A2
B2
PCB-A
PCB-B
PCB-B
CONNECTOR 2
A2: SENSOR A
B2: SENSOR B
SCREEN
EARTH
EXTERNALLY
EARTH STUD
Immersion Heater Low
Immersion Heater High
Compressor & Cond Fan
Water Diverter Valve
28-OCT-1997
PART NO. CIR03R16S-1P-F80-T12
1.2 CONNECTOR 3 TO PIN CONTACT
System wiring list
Connections
Description
Connections
Description
A1 Setpoint Low A2 Sensor A
B1 Stage 3 output B2 Sensor B
C1 Setpoint Medium A3 HP Trip
D1 Stage 2 output B3 LP Trip
E1 Stage 4 output C3 Low coolant
F1 Earth D3 Coolant overheat
G1 Setpoint Off E3 Coolant overcool
H1 Stage 1 output F3 0V
J1 0V G3 Converter On
K1 -52V
EBMST\IM Page 5 30 October1997
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Tactical Controls Limited Multi-Stage Thermostat
Instruction Manual
Technical Specification
Supply
Voltage -32 to -63 Vdc; -52 Vdc nominal.
Ripple Unaffected by 5 volt peak to peak.
Input protection Reverse polarity protection. Surges and transients to BRB/RIA 12 and
RIA18 section 5, burst transient.
Current consumption 170mAdc maximum at -33Vdc (when 2 outputs are on)
70mAdc minimum at -33Vdc (when all outputs are off)
110mAdc maximum at -52Vdc (when 2 outputs are on)
45mAdc minimum at -52Vdc (when all outputs are off)
105mAdc maximum at -63Vdc (when 2 outputs are on)
40mAdc minimum at -63Vdc (when all outputs are off)
Low battery cut-out All outputs off when supply voltage is above -32Vdc. Output resumes
when supply voltage is below -36Vdc.
Sensor
Temperature One NTC sensor, 2-wire; resistance values between 14 to 27°C in
steps of 1°C are: 3707.9, 3536.8, 3378.3, 3225.9, 3081.3, 2939.5,
2813.6, 2689.6, 2571.5, 2459.8, 2353.3, 2252, 2155.6 and 2063.9
respectively. The sensor is not supplied.
Screened cable Sensor cable wires must be screened and connected to system earth
Indicators
Supply Green LED, illuminates when -52Vdc is connected to unit.
Stages 1 2 3 and 4 Four green Output LEDs, illuminates when output is energised.
Converter On Green LED illuminates when Converter in ON.
Cooling System Alarm Three Amber LEDs to indicate Cooling System Alarm.
Compressor Trips Two red LEDs to indicate High and Low Pressure Trip.
Setpoint input
Setpoint 19 Logic input; select 19°C when connected to -52Vdc.
Setpoint 21 Logic input; select 21°C when connected to -52Vdc.
Setpoint OFF Logic input; select off when connected to -52Vdc.
Setpoint 23 Select 23°C when none of the setpoint input is connected to -52Vdc.
Relay output
Relays The unit has four relay outputs, type: Schrack RP330024 with single
pole, normally open contacts. Common contacts of relays connected
to -52Vdc supply rail.
Contact rating The relays are rated at 250Vac, 16A.
Mechanical life Greater than 30 million operations.
Electrical life Greater than 1 million operations at 52Vdc, 0.5Adc.
Stability
Maximum drift Maximum of 0.3°C drift in switching temperature, over the
temperature range of 15 to 25°C and 1.5°C drift over -15 to 55°C.
EBMST\IM Page 6 30 October1997
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Tactical Controls Limited Multi-Stage Thermostat
Instruction Manual
Diagnostic and test
Key switch One change over contact, when key in non-removable position, input
is connected to the sensor simulation potentiometer. When the key-
switch is in removable position, the input is switched to the NTC
sensor input.
Potentiometer Panel mounted, 270°C turn, potentiometer, to simulate the NTC
sensor.
Connectors
Connector 1 Litton CIR030-18-19P-F80-T12, 10-ways rear panel mounted
connector with pin contacts.
The free-end of the connector being a socket type, CIR060F-18-19S-
F80-T12 plug.
Connector 2 (sensor) Litton CIR030-16S-8S-F80-T12, 5-ways, rear panel mounted
connector with socket contacts.
The free-end of the connector being a pin contact type, CIR06F-6S-
8P-F80-T12 plug.
Connector 3 Litton CIR030-16S-1P-F80-T12, 7-ways, rear panel mounted
connector with socket contacts.
The free-end of the connector being a pin contact type, CIR06F-6S-
1S-F80-T12 plug.
Environment
Operating temperature -15°C to +55°C.
Storage temperature -30° to +85°C.
Relative humidity 0 to 90%.
IP rating IP65
Mechanical
Dimensions 125mm(Width), 250mm(Height) and 110mm(Depth).
Refer to drawing number: EBAC\DWG\LAYOUT
Housing material: sheet steel 16SWG; zinc plated.
Weight 5Kg approx.
Mounting 4 M5 mounting slots 70mm x 235mm between centres.
Warranty 12 months return to base.
Standards
RSE/STD/031/PART 1: ISSUE B General requirements for electronic equipment
BRB/LUL/RIA No.13: 1990 General specification for electronic equipment used
on traction and rolling stock.
BRB/LUL/RIA NO.12:1984 General specification for protection of traction and
rolling stock electronic equipment from transient
and surges in DC control system
BRB/LUL/RIA NO.18:1990 General specification for interference testing for
electronic equipment used on traction and rolling
stock
BRB/LUL/RIA NO.20:1988 Equipment for vibration and shock testing of
equipment for railway vehicles
EBMST\IM Page 7 30 October1997
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Tactical Controls Limited Multi-Stage Thermostat
Instruction Manual
Ordering information
Ordering code: EBMST
You are welcome to order the unit by code or by description - EBMST Multi-Stage
Thermostat for LUL, Bakerloo Line '72 Stock Refurbishment Heating, Ventilating & Air-
conditioning for Cab.
Supplier information
Tactical Controls Limited
Unit 4 Marlborough Road
Lancing, West Sussex BN15 8TR
England
Tel: [phone]
Fax: [phone]
EBMST\IM Page 8 30 October1997
Issue 1.1