IP-230 - New York Air Brake
Contents
1. 1 YORK AIR BRAKE CORPORATION 748 Starbuck Avenue Watertown New York 13601 IP 230 OPERATOR INSTRUCTION AND MAINTENANCE GUIDE FOR TRAINLINE ENERGIZING DEVICE TED April 2009 Issue No 2 Copyright New York Air Brake All rights reserved THIS PAGE INCLUDED FOR DOUBLE SIDED COPYING APRIL 09 B IP 230 Copyright New York Air Brake All rights reserved Revision Level Section Change Date 01 ALL Original Release June 07 02 3 3 Add Section 3 3 Servicing the Fuse April 09 3 5 Add Reference No 5 Fuse IP 230 C APRIL 09 Copyright New York Air Brake All rights reserved THIS PAGE INCLUDED FOR DOUBLE SIDED COPYING APRIL 09 D IP 230 Copyright New York Air Brake All rights reserved TO TIDES EMP TQM a ua es one 1 2 SNS EM u Zula na 1 LA anced dase 1 1 1 2 Overview of Trainline Energizing Device 1 1 1 3 Overview of Car Control Device CCD Brake Pipe Limited Emulation 1 12e EDS 2 13 a uA 3 13 1 DRANG Interface 3 1 3 2 Line Voltage Interface RS 3 20 FUNCTIONAL INSTRUCTIONS nn 52. are connected 3 Verify all wagon brake pipe hoses are connected and brake pipe is zero 0 4 Verify the CCD IDM cable is connected 5 Check all CCDs NOT in emulation mode for the fault LED on 6 Verify all CCDs have batteries and batteries are charged 7 Re try energizing the trainline using the procedure in section 2 1 For additional information on CCDs and emulation mode refer to section 2 2 APRIL 09 14 IP 230 Copyright New York Air Brake All rights reserved THIS PAGE INCLUDED FOR DOUBLE SIDED COPYING IP 230 15 APRIL 09 Copyright New York Air Brake All rights reserved 5 0 RETURN MATERIAL AUTHORIZATION PROCESS All material returned from the field to New York Air Brake NYAB Knorr must have a Return Material Authorization RMA number A NYAB Knorr representative will provide the RMA number To receive a RMA number and to get additional information regarding the RMA process call Knorr Bremse SA Telephone 011 961 7800 Kempton Park South Africa KBL KNORR Telephone 613 389 4660 Ext 328 Kingston Ontario CANADA OR NYAB KNORR Telephone 315 786 5494 Watertown New York USA APRIL 09 16 IP 230 Copyright New York Air Brake All rights reserved THIS PAGE INCLUDED FOR DOUBLE SIDED COPYING IP 230 17 APRIL 09 Copyright New York Air Brake All rights reserved 6 0 LIST OF ABBREVIATIONS BC BP BPLE CCD ECP ER IDM TED APRIL 09 Brake Cylinder Bra
3. brake The emergency brake can subsequently be released using the CCD pneumatic back up by recharging the brake pipe 1 APRIL 09 Copyright New York Air Brake All rights reserved e ltis also expected that Railroad operation rules will require that a departure type brake test be performed prior to moving the train using emulation 1 2 LEDS The TED has three LED s on the top front panel which indicate the following GREEN YELLOW RED DESCRIPTION Off Off Off Disabled Off On Off Off Ready On On Off Ready but Low Battery Off Flashing Off Disabled Discharged Battery Off Off On Energizing Trainline Sending Emulation Message Flashing Off Off Trainline Energized Emulation Message Sent Off Off Flashing Error Energizing Trainline Error Sending Message READY indicator flashes TED turns off automatically NEW YORK AIR BRAKE CORPORATION TRAINLINE ENERGIZING DEVICE TED Ready when lit eLo Batt when lit 9140 ON when lit eCommunicating eCritically low eFault Condition when flashing when flashing when flashing Figure 1 LEDs on Top Cover APRIL 09 2 Copyright New York Air Brake All rights reserved IP 230 1 3 1 3 1 1 3 2 IP 230 INTERFACES The TED has two main interfaces Trainline Interface Connects via the Inter Car Connector to an ECP wagon with a short train of up to twenty five wagons to have their CCDs activated and set
4. respond to its pneumatic back up e f brake pipe is above approximately 50 psi brake cylinder will be 0 e f brake pipe is below approximately 40 psi brake cylinder will be applied If brake pipe pressure is vented to zero 0 the Car Control Devices CCDs will exit brake pipe limited emulation mode If it is desired to continue operation in brake pipe limited emulation mode the Trainline Energizing Device would need to be reconnected and operated as described in section 2 1 There are other conditions when the Car Control Devices CCDs will exit brake pipe limited emulation mode including ECP Head End Unit HEU beacons and trainline power are received If the CCD battery becomes insufficient or upon detection of internal faults If brake pipe does not exceed 45 PSI 310 KPa after entering BP emulation after one 1 hour PWR Power LED COM Communication LED Should be steady during emulation mode BRK Brake application LED FLT Fault LED Figure 5 CCDs 7 APRIL 09 Copyright New York Air Brake All rights reserved THIS PAGE INCLUDED FOR DOUBLE SIDED COPYING APRIL 09 8 IP 230 Copyright New York Air Brake All rights reserved 3 0 MAINTENANCE 3 1 CHARGING THE BATTERY It is suggested that the TED s battery charger line input port be connected to 100 240 VAC when not in use The built in battery charger contains circuitry to inhibit charging if the battery is damaged The charger also will appl
5. to brake pipe emulation mode CAUTION DONOT apply any voltage into the TED through this port substantial damage will occur Figure 2 Trainline Interface Inter Car Cable Line Voltage Interface Connect a standard line cord to the IEC 320 C14 AC inlet for charging the TED s battery The charger is automatic and may be left energized for extended periods of time It is recommended that the battery charging port be connected and energized when not in use The charger will accept 100 240 VAC Figure 3 Line Voltage Interface 3 APRIL 09 Copyright New York Air Brake All rights reserved THIS PAGE INCLUDED FOR DOUBLE SIDED COPYING APRIL 09 4 IP 230 Copyright New York Air Brake All rights reserved 2 0 FUNCTIONAL INSTRUCTIONS 2 1 SETTING A ECP TRAIN INTO BRAKE PIPE LIMITED EMULATION BPLE MODE 1 With zero 0 brake pipe pressure with all brake pipe hoses connected connect the inter car connectors on up to twenty five wagons together CAUTION NEVER connect the TED when another power source such as an ECP equipped locomotive is connected to the trainline Substantial damage to the TED will occur CAUTION NEVER use more than one TED to attempt to energize a consist of wagons 2 Press and hold the left hand momentary switch After a period of two seconds the green TED Ready indicator will light If the green indicator does not light see troubleshooting section 4 0 3 Once the green indica
6. 2 1 SETTING A ECP TRAIN INTO BRAKE PIPE LIMITED EMULATION BPLE MODE 5 2 2 ENDING BRAKE PIPE LIMITED EMULATION BPLE MODE 7 30 25 ee 9 3 1 CHARGING THE BATTERY sss 9 32 SERVICING THE BAT TERY uu uu 9 3 3 SERVICING THE FUSE suu nie cede ec el 10 3 4 CONNECTING THE BATTERY 1 aasan esti 11 2 5 REPA CEA BI E PARTS a Nr er 12 3 6 13 40 TROUBLE SHOOTING tae 14 AD T Sm 14 4 2 CCDREMULATION MODE 14 5 0 RETURN MATERIAL AUTHORIZATION PROCESS 16 60 LIST OF ABBREVIATIONS a Se a ns 18 IP 230 E APRIL 09 TABLE OF CONTENTS Copyright New York Air Brake All rights reserved THIS PAGE INCLUDED FOR DOUBLE SIDED COPYING APRIL 09 F IP 230 Copyright New York Air Brake All rights reserved 1 0 1 1 IP 230 DESCRIPTION WARNING HAZARDOUS VOLTAGE 140V CONTACT WITH PINS WHEN ENERGIZE INDICATOR IS LIT MAY CAUSE ELECTRICAL SHOCK AND INJURY SYSTEM Purpos
7. O PROPERTY DAMAGE PERSONAL INJURY OR DEATH APRIL 09 10 IP 230 Copyright New York Air Brake All rights reserved 3 4 CONNECTING THE BATTERY When the TED is shipped from New York Air Brake the battery is left disconnected It must be reconnected before its first use Complete instructions are in section 3 3 The positive wire needs to be connected to the positive terminal on the battery and the negative wire to the negative terminal on the battery Cross connecting the terminals could result in serious injury and damage to the TED The positive terminal on the battery is marked red The positive wire has a strip of red casing on the wire a strip of white casing on the wire with markings as well as a 90 degree connector The negative terminal on the battery is marked black The negative wire has a strip of white casing on the wire with markings as well as a straight connector Red Positive Casing on wire White casing with markings 90 degree connector Straight Connector Br White casing with markings Positive battery terminal Negative battery terminal Figure 9 Detailed Battery Connections IP 230 11 APRIL 09 Copyright New York Air Brake All rights reserved 3 5 REPLACEABLE PARTS KEY a SUC Saa DESCRIPTION NYAB PART NUMBER 1 Cover Screw 784056 2 Battery Cover 783958 3 Battery 774481 4 Complete TED 782936 5 Fuse 1A 761660 APRIL 09 C
8. e The intent of this User Manual IP 230 is to familiarize an end user with the basic operation and need for the Trainline Energizing Device TED for operation of ECP equipped rail wagons in brake pipe limited emulation mode This manual instructs a user in the steps to connect operate and remove the device from a train and to maintain and replace the battery This manual does not include heavy repair maintenance testing requirements or detailed functional descriptions Overview of Trainline Energizing Device The Trainline Energizing Device TED is to allow short term distance haulage of ECP equipped train wagons without an ECP equipped locomotive This is accomplished through setting a short train Less than 25 wagons up into Limited Brake Pipe Emulation mode The TED is a portable device plugged into the trainline connector at either end of a consist of ECP equipped wagons to be moved The purpose of the TED is as follows e Provide enough trainline power to wake up the ECP car equipment e Send the ECP wagon equipment a network message setting them for Emulation Mode e estimated that TED with a fully charged battery be operated 25 times before recharging is required Section 3 1 Overview of Car Control Device CCD Brake Pipe Limited Emulation Brake pipe limited emulation is a mode that an ECP train is setup for that allows each CCD to respond to changes in brake pipe to apply or release brake cyl
9. ht hand switch is released the 140VDC output will be terminated NOTE Ifthe TED detects an overload or low output voltage the output will also be 10 terminated A departure type brake test is to be performed prior to moving the train using brake pipe limited emulation This test should include charging brake pipe and inspecting the train to verify that the brakes release on all wagons and it should also include making a service reduction in brake pipe pressure and inspecting the train to verify that the brakes apply on all wagons It is expected that the locomotive set ER BP to 620 KPa for release pressure Setting at a lower release pressure will result in lower BC pressures and resulting brake ratio levels Once the Car Control Devices CCDs have entered brake pipe limited emulation they will use brake pipe pressure in order to determine the brake command of application or release Service or emergency rates of brake pipe pressure reduction will result in brake applications based on loaded weight condition Brake pipe pressure increases will result in a direct release of brake cylinder pressure to zero 0 emulating a DB 60 Brake pipe reductions from release will result in brake cylinder applied proportional to brake pipe reduction 6 IP 230 Copyright New York Air Brake All rights reserved 2 2 ENDING BRAKE PIPE LIMITED EMULATION BPLE MODE 1 IP 230 When exiting BPLE mode the CCDs shut down power off and will
10. inder The CCD brake pipe limited emulation is expected to be used in trains of approximately 10 to no more than 25 wagons for haulage at low speeds by non ECP equipped locomotives It is expected that it will be used at a mine or to switch small cuts of wagons from the mainline track into shops or loading sites Another possible use of emulation would be in order to move wagons off the mainline into sidings etc in the event that certain train wide ECP failures have occurred It is expected that Railroad operation rules will limit the use of brake pipe limited emulation so that is not used in long trains or in excess of a speed limit that should be specified by Railroad operation rules The reason for this is based on the following e The use of this brake pipe emulation function relies on the CCD staying powered up using its battery back up When the CCD s battery becomes low it will electrically cut out and BC will stay released or any BC pressure applied will be released if BP is not in emergency This will not be detectable by the train operator particularly if the brake pipe is in release If several or all cars have cut out the train operator will not know it until a service brake request is made at which time insufficient braking may be available to stop the train At this time the train operator would need to initiate an emergency brake pipe reduction The CCDs including any that have cut out will then apply BC using its pneumatic back up
11. ke Pipe Brake Pipe Limited Emulation Car Control Device Electrically Controlled Pneumatic Brake Control System Emergency Reservoir Identification Module Trainline Energizing Device 18 Copyright New York Air Brake All rights reserved IP 230
12. opyright New York Air Brake All rights reserved Figure 10 Assembly of TED 12 IP 230 3 6 INTER CAR CABLE In the event that the trainline interface of the TED becomes damaged and needs to be replaced refer to section 5 0 to contact a NYAB representative Figure 11 Inter Car Cable IP 230 13 APRIL 09 Copyright New York Air Brake All rights reserved 4 0 TROUBLE SHOOTING 4 1 TED LED S GREEN YELLOW RED DESCRIPTION CORRECTIVE ACTION 1 Replace battery If it doesn t work Off Off Off Will not power up 2 Refer to section 5 0 to contact NYAB representative On On Off Low Battery Charge the battery ASAP Battery is dead and will Off Flashing Off not charge the trainline Immediately charge the battery 1 Make sure you don t release either switch until the trainline is energized 2 Try again If it does not work 3 Make sure there are 25 or less 22 ee wagons Off Off Flashing Error energizing trainline If ok and sending message 4 Make sure the all trainline wiring is connected If ok 5 Replace the battery If it still does not work refer to section 5 0 to contact a NYAB representative 4 2 CCD EMULATION MODE If the CCDs are in emulation mode the COMM LED will be solid If all CCDs are not in emulation mode follow these steps 1 Power down the TED by releasing either or both switches 2 Walk train to verify all ECP inter car connectors
13. rtment w battery IP 230 9 APRIL 09 Copyright New York Air Brake All rights reserved 3 3 SERVICING THE FUSE The TED has a fuse inline with the power coming into the unit for battery charging This fuse is intended to protect the transformer and battery charging circuit In the event that the TED will no longer charge a battery both the battery and fuse may be inspected together The fuse is located within the battery compartment Refer to the previous section 3 2 regarding battery service In order to inspect the fuse the battery compartment cover must be removed using a Phillips screwdriver The fuse holder is attached to the battery wires and is typically located near the lower right hand corner of the compartment between the battery cradle and outside cavity walls The battery must be set aside before the fuse holder can be fished out Figure 8 Fuse Holder WARNING THE TED MUST BE DISCONNECTED FROM THE POWER CORD WHEN REMOVING OR INSTALLING A FUSE LINE VOLTAGE 110VAC 240VAC IS PRESENT INSIDE THE FUSE HOLDER FAILURE TO DISCONNECT MAY RESULTS IN PROPERTY DAMAGE PERSONAL INJURY OR DEATH The fuse holder is opened by holding the body and then pressing down and twisting counter clockwise the cap If the fuse element is blown away replace the fuse with a 1 Amp 250V Fast Acting 3AG type fuse NYAB P N 761660 WARNING DO NOT SUBSTITUE ANY FUSE THAT DOES NOT CONFORM TO THE ABOVE SPECIFICATIONS DOING SO MAY LEAD T
14. tor has illuminated continue to hold the left hand switch active Press and hold the right hand switch The green indicator will extinguish and the red Energize indicator will illuminate warning that 140VDC is present on the trainline If the LED s do not perform this way see troubleshooting section 4 0 Left Hand Switch Right Hand Switch Figure 4 TED Switches 4 After the red LED comes on there will be approximately 10 seconds under normal operation before the red LED goes out and the green LED flashes signaling the sequence is complete NOTE If either the left or right hand switch is released the 140VDC output will be terminated and the train may not be in BPLE mode NOTE Ifthe TED detects an overload or low output voltage the output will also be terminated The red LED goes off immediately 5 Remove the TED from the ECP trainline IP 230 5 APRIL 09 Copyright New York Air Brake All rights reserved APRIL 09 6 The NYAB KNORR Car Control Devices CCDs have an LED that provides an indication that it has entered brake pipe limited emulation this is indicated by the COM LED on the CCD being lit solid See figure 5 Wabtec wagons DO NOT indicate they have entered BPLE mode Walk the train to verify CCDs have entered emulation mode by observing the COMM LED is solid ON If all or some CCDs are not in emulation mode see troubleshooting section 4 0 NOTE If either the left or rig
15. y a fast charge initially but will switch to a float trickle charge when fast charging has been completed 3 2 SERVICING THE BATTERY The TED requires a 12V 5A hr sealed lead acid battery NYAB P N 774481 There is no necessity for a pre defined battery replacement schedule as battery life is dramatically influenced by how the TED is used However when the TED no longer has the ability to consistently energize the trainline as indicated by the yellow Low Battery or red Fault Condition LEDs the battery will need to be replaced This is accomplished by 1 Remove the battery compartment cover lower section of the top front of the TED This only requires a Phillips screwdriver Lift out the old battery and disconnect the two wires They are connected with 14 quick disconnects DO NOT reverse the battery leads this will damage the TED Connect the red positive lead from the TED to the new battery s positive terminal This connector is also at a 90 degree angle See section 3 3 Connect the black negative lead from the TED to the new battery s negative terminal This connector is straight See section 3 3 Install the new battery it will fit in only one orientation Slide the wires fully inside of the battery compartment Replace the compartments cover and torque the screws to 21 23 in lbs Dispose of the old battery properly Figure 6 Battery Compartment w o battery Figure 7 Battery Compa
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