Unipart Dorman CLS LITE Manual

INTELLIGENT ENGINEERING UNIQUE PEOPLE WORKING TOGETHER
CLS LITE
Operation & Maintenance Manual
C64.65201
Issue 3
June 2019

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C64.65201 Issue 3 Jun 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 ASSISTED LIFT TRUNNION ..............................................8
Preparing and Mounting the Signal Head...............................................................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 Head.............................................................20
Backboard Arrangement.....................................................................................23
Alignment at the ALT .........................................................................................25
INSTRUCTIONS COMMON TO BOTH 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
Document Reference C64.65201 Issue 3 Apr 2019

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C64.65201 Issue 3 Jun 2019
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.
Issue Number
Dated
Reason
1
May 13
Initial Issue
2
Jan 19
Rewrite of Signal Alignment Section
3 Jun 19
Various Clarifications Based on Customer
Feedback
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 care are highlighted using the Caution Symbol
ACTIVITIES WHICH ARE OR HAVE THE POTENTIAL TO BE HAZARDOUS TO
PERSONNEL AND/OR EQUIPMENT ARE HIGHLIGHTED WITH THE
WARNING SYMBOL
Introduction
Following the introduction of the Unipart Dorman Integrated Lightweight Signal (iLS)
which is a versatile yet simple signalling solution for installation in a wide variety of
applications, a requirement for the enhanced optics and better maintenance
characteristics of the iLS module but housed in a classic Unipart Dorman Colour Light

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C64.65201 Issue 3 Jun 2019
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-cleaning. This allows maintenance cost reductions 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 is used, a less power hungry signal drawing just
45mA is available giving a consumption of just 5 Watts. A low current 24Vdc signal
head may also be specified, please contact Unipart Dorman for more information on
these energy saving options.
The CLS LITE can be installed anywhere a Classic CLS or Filament Head is currently
fitted or by using the Unipart Dorman Assisted 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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C64.65201 Issue 3 Jun 2019
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, protective strip and Lower Backboard Extension can be left
in position until the head is mounted 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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C64.65201 Issue 3 Jun 2019
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 installation. This is covered in the Module Replacement section of this
document.
BEFORE THE COMMENCEMENT 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 are
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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C64.65201 Issue 3 Jun 2019
The other type can only be used with the Unipart Dorman GRP Post and Assisted Lift
Trunnion and will be delivered with the Spigot Bracket attached. Where this method
is employed, this document should be read in conjunction with the ALT Operations
and Maintenance Manual C64.65976 which 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 common 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 verification check.

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C64.65201 Issue 3 Jun 2019
There is an adaptor bracket available that enable a suitable camera to be fitted to
the scope. The camera and mount are subject to their own separate instruction
sheets available on the Unipart 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 abrasive 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, carefully 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 temporary fogging of the internal lenses which will clear when
the temperatures inside and outside the scope equalise.
Do not attempt to disassemble the scope to gain access to the internal lenses
as this will disturb the optical alignment and the scope will need to be returned to
Unipart Dorman for adjustment on the special to type jig

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C64.65201 Issue 3 Jun 2019
INSTALLATION AND ALIGNMENT OF CLS LITE HEADS
ON ALL STRUCTURES EXCEPT THE UNIPART DORMAN
ASSISTED LIFT TRUNNION

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C64.65201 Issue 3 Jun 2019
Preparing and Mounting the Signal 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 attached 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 fitted to assist in mechanical lifting.
Once in the required position, the CLS LITE is secured to the base platform using
suitable mounting hardware. Ensure 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 both mounting
arrangements. To prevent damage to the lower portion of backboard during transit a
removable section is fitted in a stowed position to enable the signal head to be
bolted securely to its pallet. As 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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C64.65201 Issue 3 Jun 2019
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 Allen screws shown in blue below. Refit the two
screws and dispose of the 2 white plastic labels and the black plastic edge protector
properly.
Using the existing Allen screws shown in green below, mount the plate at the
bottom of the backboard.

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C64.65201 Issue 3 Jun 2019
Correctly fitted backboard on a 3 aspect short housing signal head shown – 3 aspect tall and 4 aspect
signals have the same arrangement).
Signal Alignment
General Notes
GREAT CARE SHOULD BE TAKEN TO ALIGN THE SIGNAL IN STRICT
ADHERENCE TO THE SIGNAL SIGHTING FORM REQUIREMENTS
The Signal Sighting Form (SSF) will provide the definitive, signal specific alignment
details and should always be consulted prior to commencement of work.
Where the centre of the most restrictive aspect is greater than 2750mm above the
LH running rail, the signal is generally aligned to a target board (PADS Number
086/011540) at a point detailed in the Signal Sighting Form.

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C64.65201 Issue 3 Jun 2019
These instructions refer to standard climbable structures such as posts/gantries and
the Collis Fold Down Post system only. The Collis Post is easily identified by the use
of a single, separate spring pot on the unit.
This Method is not to be used for signal heads mounted on the Unipart
Dorman Spigot Mount fitted into the GRP Post and installed in the ALT.
Instructions for this mounting method are contained in their own section of this
document
The removable Alignment scope should be fitted securely to the two mounting points
by screwing the two knurled screws into the threaded holes in the positions shown
for each signal configuration as shown:

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4 Aspect and 3 Aspect tall Housings
Use the threaded inserts in the inside of the frame in the positions shown below
which correspond with the door stay mounting on the opposite side of the frame.

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Scope fitted in a 4 aspect head – 3 aspect tall housing scopes are fitted in the same position
These two variants require the removal and retention of the plastic module spacer
fitted to the pivot bar to give enough clearance for the scope to be fitted.
Alternatively, unlock the module and lift off the pivot bar then slide the spacers into
the centre of the bar.
The alignment scope will not locate and fit properly unless the spacer is
moved from its normal operating position
Once the alignment procedure is complete, refit the module spacer to the pivot bar
with the flange end closest to the module. They are a ‘snap fit’ and will rotate freely
on the bar when fitted correctly or where the spacers were moved to a different
position on the bar return them to their original position.
The spacers centralise the module in its aperture and prevent the visor fretting
on the backboard, so must be returned to their operational positions when the scope
is removed
3 Aspect Short Housing
This signal uses an adaptor block to align the scope with the hole in the backboard
as shown:

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C64.65201 Issue 3 Jun 2019
The block needs to be repositioned on the opposite side of the frame where the door
opening side is changed. Detailed instructions on swapping the door are in a later
section of this document.
Vertical adjustment of the head’s tilt angle is carried out by loosening the bolt on
either side of the baseplate highlighted and tilting it about the pivot shaft. Once the
vertical alignment has been set and verified, tighten the bolts to 40Nm.

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C64.65201 Issue 3 Jun 2019
Horizontal adjustment is achieved by swivelling the head in the kidney slots on the
fixed mounting as shown.
Once the horizontal adjustment is complete tighten the mounting bolts to the torque
value specific to the size and material of the fasteners used.

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C64.65201 Issue 3 Jun 2019
The Collis Post System requires the use of a remote viewing device which attaches
to the signal head by using the Unipart Dorman scope mount or another suitable
method. The signal is raised, the alignment checked and then lowered for
adjustment as required. It is then raised and the alignment is verified before the
signal is lowered finally to retrieve the camera and Alignment scope.
Unipart Dorman does not recommend any particular camera or App. It is the user’s
responsibility that any camera and App is used in accordance with the
manufacturer’s terms and conditions of use and instructions.
Unipart Dorman cannot accept any responsibility for the performance of third
party equipment, applications or software systems.
Users of these devices and their supporting operating systems should satisfy
themselves that their usage will not compromise the device through the introduction
of malicious software, bugs and viruses etc.
The end user is also solely responsible for ensuring any images captured and
retained do not conflict with the Information Commissioner’s Office Codes of Practice
on privacy and the use of cameras, or the General Data Protection Regulations.
When the signal is aligned correctly to the point on the signal sighting form, ensure
all the mounting nuts are correctly torque loaded and the alignment scope is
removed and stored in its protective case.

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C64.65201 Issue 3 Jun 2019
INSTALLATION AND ALIGNMENT OF CLS LITE HEADS
USING THE UNIPART DORMAN ASSISTED LIFT
TRUNNION

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C64.65201 Issue 3 Jun 2019
The following instructions are unique to the Unipart Dorman Assisted Lift
Trunnion which is easily identified by the use of a single connection cover
and a circular baseplate. Installation of the ALT is covered in its own O&M
Document.