MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 1 of 20 MODIFIED & UPGRADED TSR MAGNET SERIES 2 OPERATION AND MAINTENANCE MANUAL Customer: NETWORK RAIL Contract: Modified & Upgraded TSR Magnet Purpose: To Operate and Maintain System Document No: YEL200190 - 1 - D - 2 TITLE NAME JOB TITLE SIGNATURE DATE Author Finetech Engineering Ltd Design Consultant Andrew Carruthers Aug 2023 Checked C. Smith Technical Consultant C Smith May 20 24 Approved J S Olley Director John S Olley May 20 24 Rev Date Description of Revision By Chkd Appd A 17/03/03 Original J.C. R.A. R.A. B 27/03/03 Magnet storage, test and assembly maintenance updated. J.C. R.A. R.A. C 06/05/03 Section 2. Rail track type suitability added. 3 rd rail electrified lines safety precaution note added. Section 5.2. magnet test sign - off sheets updated. J.C. R.A. R.A. D 07/05/08 Security modifications added. J.C. R.A. R.A. MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 2 of 20 E 31/05/24 Modified & upgraded locking mechanism CS JSO JSO Table of Contents 1. GENERAL ................................ ................................ ................................ ............................ 3 1.1 Introduction ................................ ................................ ................................ ............................ 3 1.2 Overview of Manual ................................ ................................ ................................ ................ 4 1.3 Safety Clothing ................................ ................................ ................................ ........................ 6 2. Track Fitting ................................ ................................ ................................ ....................... 6 2.1 Suitable types of tracks ................................ ................................ ................................ ............ 6 2.2 Installation to Rail ................................ ................................ ................................ ................... 7 2.3 Security System ................................ ................................ ................................ ....................... 8 2.3 Removal from Rail ................................ ................................ ................................ ................... 8 3 HANDLING ................................ ................................ ................................ .......................... 8 3.1 Storage ................................ ................................ ................................ ................................ ... 8 3.2 Transportation ................................ ................................ ................................ ......................... 9 4. MAINTENANCE OF INSTALLATION ................................ ................................ .................... 9 4.1 Fault Finding Guide ................................ ................................ ................................ ................ 10 4.2 Magnet Testing ................................ ................................ ................................ ...................... 10 4.4 Spares Parts List ................................ ................................ ................................ .................... 11 5.0 ATTACHMENTS ................................ ................................ ................................ .............. 13 5.1 TYPICAL MAINTENANCE RECORD SHEET. ................................ ................................ ................ 13 5.2 12 MONTHLY TEST, CALIBRATION RECORD SHEET ................................ ................................ .... 14 5.3 General Arrangement Drawing of TSR ................................ ................................ .......................... 18 5.4 QR Code and Link for Access to the Training Video ................................ ................................ ....... 18 5.5 TSR Magnet Pictorial Fitting Instructions ................................ ................................ ..................... 19 MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 3 of 20 1. GENERAL 1.1 Introduction Yardene Engineering has been manufacturing track magnets for Temporary Speed Restriction (TSR) for the past 20 years and are constantly developing and improving our product range. As the portable track magnet design had not changed since 1988, we carried out a market survey where we listened to the needs of the staff on the ground. This survey highlighted a need for a safely installed lightweight portable magnet for use on DC lines and standard tracks. There are two types of magnet assemblies covered by this manual: - Yellow Magnet (standard strength) - PADS No . 062/006787 Green Magnet (extra strength) - PADS No . 062/006788 Due to the design of the magnet clamp assembly, it allows the installation of the unit to the track by only one person. This therefore minimises the exposure to personnel in the danger area. NOTE: All Staff having access to this video MUST BE officially trained by a Network Rail Supervisor or an Official Yardene Engineering Trainer and be signed off and approved to use the TSR. Green TSR Single Arm Magnet – Extra Strength Yellow TSR Single Arm Magnet – Standard Strength MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 4 of 20 1.2 Overview of Manual This operations manual provides an overview and technical description to a level that makes it a suitable reference for the operation, storage, maintenance, fault finding, and testing of the magnet assembly. NOTE: Although this manual identifies certain safeguards that need to be taken when fitting the magnet assembly, it does not define general personal and system safety measures that shall be implemented in order to fit these magnets. Before Fitting or using the TSR Single Arm Magnet the technician or engineer MUST be Trained in its use and be fully signed off by Yardene or by Network Rail against an approved Training Programme and the TSR MUST have valid in - date Calibration Certificate It is also expected that all staff before fitment MUST: MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 5 of 20 MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 6 of 20 1.3 Safety Clothing Safety Clothing Trackside That MUST BE Worn to fit the TSR Single Arm Magnet as a minimum must include: 2. DESCRIPTION OF INSTALLATION / REMOVAL NOTE: The suitability of the magnet assembly to clamp to various rail types is stated below: - 2. Track Fitting 2.1 Suitable types of tracks On conventional sleeper tracks (concrete, timber or steel sleepers). Suitable types of rail section; Flat bottom, 109 FB, 110A FB, 113A FB, UIC 54 and UIC 60. Unsuitable types of tracks and rail; Slab track, Way beam track e.g. some bridge decks. Rails fitted with check rails (although maybe used on opposite rail) and 95lb bull - head rail. MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 7 of 20 2.2 Installation to Rail Always inspect the clamp assembly for damage before installation. NOTE: DO NOT UNDER ANY CIRCUMSTANCES FIT MAGNET TO 3 rd RAIL When used on third - rail electrified lines , only use the Green coloured TSR with the stronger magnet. T he clamp assembly must be fitted to the rail furthest from the conductor rail. In the exceptional situation where the presence of a check rail only allows the clamp assembly to be fitted to the rail adjacent to the conductor rail, additional safety precautions must be taken, e.g., wearing electrical gauntlets and using conductor rail shielding. Clear away sufficient ballast to allow the clamp end to pass under the rail freely The clamp assembly consists of two clamps : one fixed and the other moving (sprung - loaded). For fitting instructions, refer to the magnet mould. Stand between the 4 - foot rail, holding the magnet assembly by the handlebar and locking clamp. Position the clamp end under the rail, locating the fixed clamp on the foot of the rail. The clamp end weight is now on the rail, so you can release your hand from the handle Operation: 1 Fit clamp to the foot of rail 2 Using the lever pull back to open 3 Locate the magnet to the rail and release the locking bar 4 Turn the locking mechanism clockwise to secure 5 Fit security ‘C’ washer and tighten To ensure no unauthorised removal or tampering of the assembly , use the Security System as stated in section 2.3. TSR Overview MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 8 of 20 2. 3 Security System When the Magnet has been installed and secured onto the track in the normal way, release this M12 Star Knob enough for the new Chain Attached Security “C” Washer to slide between the Bolt Head and Magnet Metal Work, then tighten This will ensure prolonged horizontal forces cannot loosen the Moving End of the Magnet. 2.3 Removal from Rail 1 Remove the security ‘C’ washer 2 Turn the locking mechanism anti - clockwise to unfasten 3 Remove the magnet away from the rail 3 HANDLING NOTE: Personnel fitted with ICDs , particularly Magnets, can activate a switch that prevents the ICD from delivering vital signals such as lifesaving shocks. If you have an ICD or pacemaker, avoid close or prolonged contact with magnets or their magnetic fields When handling the magnet assembly, any personal items that could be affected by a strong magnetic field , e.g., swipe cards, credit cards, watches, etc., should be removed and stored safely away. As a guide, any items that could be affected by magnetic fields should be kept 0.6m (2ft) from the Yellow M agnets and 1.25m (4ft) from the Green M agnets. 3.1 Storage IMPORTANT: Different types of magnets must not be stacked together. Incorrect storage can result in magnets becoming de - magnetized. Always store in the tube provided. Ensure the storage area is dry. When magnet assemblies are being stored, they must be orientated either side by side, lengthways, or on top of each other, bottom on top. Stacked on top of each other. Clamp end over Magnet end. Stacked side by side. Clamp end beside Magnet end. Length ways on to each other. Clamp end facing Magnet end. MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 9 of 20 NOTE: On no account must the magnets be stacked on top of each with like – poles closest i.e. top face to top face or bottom face to bottom face. This equally applies in transportation. 3.2 Transportation All storage instructions apply when in transportation. The magnet assembly is supplied with a transportation case, which allows the assembly to be stored and transported without damage. Care must be taken when transporting the assembly. Although the case has been designed and manufactured to give maximum rigidity and magnet assembly protection, situations may occur where the tube becomes damaged. To ensure the assembly remains in good condition , the damaged tube must be replaced. Transportation Case 4. MAINTENANCE OF INSTALLATION Preventative maintenance is essential to ensure the assembly operates correctly and maximises its working life. To do so, the magnet assembly must be serviced and maintained in accordance with Yardene Engineering Ltd requirements. Return the magnet assembly to Yardene Engineering Ltd in the transportation tube for magnet testing and calibration to the manufacturer’s specifications. Once this has been completed , the final calibration certification will be issued. NOTE: Ensure the calibration certification is completed before the expiry date. Yardene Engineering Ltd provides a combined test, calibration and maintenance service if required . The complete maintenance will be carried out together with the magnet testing. Ref to section 4.2 Magnet Testing. MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 10 of 20 4.1 Fault Finding Guide FAULT POSSIBLE CAUSE POSSIBLE REMEDY Assembly will not come free of rail after the fixing clamp has been unscrewed and released. Security ‘C’ washer still attached Moving clamp seized Remove ‘C’ Washer Check locking mechanism is unscrewed Unable to clamp on foot of rail correctly, leaving the magnet face too high (not in horizontal position). Clamp bar is not fully tightened Tighten locking mechanism. Inspect the clamping jaws for damage. If damage is apparent, or the moving clamp still is not moving correctly, call Yardene Engineering for advice. Magnet failure Not attached to rail correctly Refer to manual 4.2 Magnet Testing It is essential for the correct operation of the magnet assembly that the magnet is tested every 12 months. To ensure the magnet is correctly tested and calibrated to manufacture’s specifications, the assembly must be returned in the transportation case to Yardene Engineering Ltd. NOTE: Every magnet assembly has a record data sheet held at Yardene Engineering Ltd indicating all test, calibration and maintenance data. This information can be obtained on request 4.3 ACCESS TO FITTING INSTRUCTIONS VIA A QR CODE Note: Each TSR also has a QR Code label attached. When this label is scanned by a mobile device such as a phone or tablet, the technician or engineer will be taken directly to a simple video explaining the TSR fitting and removal sequence This does not replace your training, but it is available should there be any confusion or uncertainty during the fitting process. If you are ever unsure about the TSR's fitting or whether it has been fitted correctly, you MUST refer to your supervisor. MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 11 of 20 If this QR Code has been damaged, this MUST BE reported immediately to Yardene so that a replacement can be supplied. 4. 4 Spares Parts List Description Yardene Part No. Yellow Magnet 6082YELL Green Magnet 6081GRN Yellow Magnet Mould 2240YELL Green Magnet Mould 2240GRN Main Body 6098 Fixed Clamp 6100 Moving Clamp - Bolted 6099 Clamping Bar 6101NEW Spring Retainer 200175 Internal Compression Spring LC - 120L - 7 Ball & Socket Joint 689 - 423 Black Nylon Sleeve YAR01NEW 10mm Studding YAR02NEW 10mm Rod YAR03NEW Roll Pin 5 x 35 YAR04NEW M12 Star Knob GN5334 - 60 Handle - Bar 200178 End Cap 200179 Magnet Bonding Adhesive PLEXUS MA822 Magnet/Moulding Encapsulation PROSET Security ‘C’ Washer YEL200999 Security Chain 6108NEW Terry Clip A001 Magnet Instruction Label PP01 MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 12 of 20 YEL Label PP02 Calibration Label PP03 Transport Tube 6107 M16 x 50 Csk Screw High Tensile S/S 3231 10mm Cap Screw S/S 2041550 M8 x 20 Hex Bolt S/S 6087NEW M8 ‘C’ Washer S/S 6088NEW M8 Spring Washer S/S 6089NEW M12 Plain A Washer S/S 6097NEW M12 Spring Washer S/S 6095NEW M12 x 35 Hex Bolt S/S 6097NEW M16 x 50 Csk Skt Hd Screw S/S 6102NEW Roll Pin 5 x 20 S/S 2472 14G x ¾ Self Tapping Hex S/S 2536 M12 Nordlock Spring Washer S/S 6112NEW M12 x 45 Skt Hd Cap Screw S/S 6111NEW M8 x 100 Skt Hd Cap Screw S/S 6110NEW M8 Nyloc Nut S/S 6091 35mm Rod S/S YAR05NEW Hex Bit S/S YAR06NEW 12mm Rod S/S YAR07NEW 8mm Rod S/S YAR08NEW MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 13 of 20 5.0 ATTACHMENTS 5.1 TYPICAL MAINTENANCE RECORD SHEET. Customer: ................................. Date: ............................. Name of Engineer: ...................... Serial No.: ...................... 1.0 MAGNET ACTION TAKEN 1.1 Testing To ensure the magnet is correctly tested and calibrated to manufacture’s specifications, the assembly must be returned in the transportation case to Yardene Engineering Ltd. The Pass Approval Certification cannot be issued until the magnet has been calibrated. Every magnet assembly has a record data sheet held at Yardene Engineering Ltd indicating all test, calibration and maintenance data. This information can be obtained on request. 2.0 MOULDING 2.1 Inspect the condition of the GRP moulding. Look for any cracks or structural damage. If evident, replace immediately. 3.0 CLAMPING ASSEMBLY 3.1 Inspect condition of all moving parts. 3. 2 Ensure the locking mechanism operates freely and locks the fixed clamp down correctly. 3. 3 Clean and lubricate the moving clamp shaft. To do this, apply enough inward pressure to the spring retainer (located in end of moving clamp) to allow the ease of removal of the M8 locking nut and bolt. Remove the spring retainer and spring. Lightly grease the moving clamp shaft inner and outer surfaces and spring. Slide spring back into the shaft and replace the spring retainer ensuring the whole lines up with the M8 bolt. Slide M8 bolt through assembly. Refit washer and locking nut. Ensure nut is fully tightened. MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 14 of 20 5. 2 12 MONTHLY TEST, CALIBRATION RECORD SHEET 12 Monthly Test Calibration & Maintenance Record PASS AND APPROVAL SIGN - OFF SHEET. STANDARD STRENGTH MAGNET ( YELLOW ASSEMBLY ) PADS No. 062/006787 Customer : Order No. Yardene S.O.P. No: Name of Test Engineer: Magnet Serial No.: TSR Magnet Assembly Serial No.: South Pole Uppermost Check: Yes No Diagram shows magnet reading positions. Position Flux Density Max/Min Limits Actual mT readings Pass Fail S1 S4 S3 S2 S5 MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 15 of 20 Height above rail level (mm) Min mT Max mT S1 115 2.5 18 S2 115 2.5 18 S3 115 2.5 18 S4 115 2.5 18 S5 115 2.5 18 COMMENTS AND RECOMMENDATIONS FROM WORK CARRIED OUT: Pass Approved By: ...................................... (YARDENE ENGINEER) Date Pass Issued: ......................... NEXT INSPECTION / CALIBRATION DATE: ......................... MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 16 of 20 12 Monthly Test Calibration & Maintenance Record PASS AND APPROVAL SIGN - OFF SHEET. EXTRA STRENGTH MAGNET ( GREEN ASSEMBLY ) Customer : Order No: Yardene S.O.P. No: Name of Test Engineer: Magnet Serial No .: ESR ESR Magnet Assembly No.: South Pole Uppermost Check: Yes No Diagram shows magnet - reading positions. Position Flux Density Max/Min Limits Actual mT readings Pass Fail E1 E3 E6 E8 E5 E2 E4 E7 E9 MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 17 of 20 Height above rail level (mm) Min mT Max mT E1 193 5.0 20 E2 193 5.0 20 E3 193 5.0 20 E4 193 5.0 20 E5 193 5.0 20 E6 193 5.0 20 E7 193 5.0 20 E8 193 5.0 20 E9 193 5.0 20 COMMENTS AND RECOMMENDATIONS FROM WORK CARRIED OUT: Pass Approved By: ...................................... (YARDENE ENGINEER) Date Pass Issued: ........................................ NEXT INSPECTION / CALIBRATION DATE : .................... MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 18 of 20 5.3 General Arrangement Drawing of TSR 5.4 QR Code and Link for Access to the Training Video The Training Video Link is: https://vimeo.com/manage/videos/962172311 The QR Code to Access the Video is: Scan the code with your mobile device, and it will take you directly to the TSR Training Video. MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 19 of 20 5. 5 TSR Magnet Pictorial Fitting Instructions MODIFIED & UPGRADED TSR MAGNET SERIES 2 O&M MANUAL – No. YE L200190 - 1 - D - 2 Page 20 of 20 Yardene Engineering 2000 Limited, Daux Road, Billingshurst Sussex, RH14 9SJ. Tel: (01403) 783558 Email: Sales@yardene.co.uk Website: www.yardene.co.uk