J - Ansaldo STS
Contents
1. COMPUTER ROOM ENE x CARSPACE 0 MTB ELECTRONICS CABINET GROUP SIGNAL CABLE PI eu P2 T oat man aman e J P O MIB GROUP 3 SIGNAL CABLE su p GROUP 4 SIGHAL CABLE P m sa sss FIELD EQUIPMENT 93 CARSPACE EQUIPMENT P O CS CASE GROUP CABLE SIGNALS 1 9 TW PR 14 as FROM C TRACKS EM SIGNALS p E 1 9 PR 14 bl E T c er E deme 5 EOUIPMENT 0 CS CASE GROUP 3 CABLE 1 9 TW PR 414 GROUP 4 CABLE 1 9 TW PR 14 TT ee gt FROM GP3 TRACKS SIGHALS FROM GPA TRACKS CAR SPACE LAYOUT DIRECT DIGITAL 4 GROUPS F COMPUTER 7 FIELD d ROOM EQUIPMENT CAR SPACE ELECTRONICS CABINET NUT ae ee el ae te Su ten ety SZ 1 CAR SPACE RTP RACK A in C E ANALOC 5 ae CPU ANALOG SIGNALS 8 CH lt DETECTOR MUX A A CONNECTOR PCB CASE DR2. OO1UF BL gt 1 OOPF MEG Lu B NE E v 7 GS XI TP 0 TP 15 9 415 J R24 OHM CHANNEL 4 OHM 39 R88 OHM 15 i CHANNEL B4 R92 3 32K 5 94 3 pore Y x lt o o 3 B B24 8 C63 i 2 cso cs v BJ 2 1 OOPF 001 UF E UF lt L o 15 IP me 1 n CHANNEL A6 ON RI2 3 32K TP pl omea Je a3 AB x x 15 BI A22 C10 CB C6 C4 C54 c52 c50 C48 A3 z z uas T ooiur isv BH 1 00PF L isv ooiur T iur 7 lt m M ab v e dia Se Je 0 TP 32 OHM 110 R73 od CHANNEL 87 RIS 3 32K 820 c9 4 65 cs _ c53 csi 1 C49 43 2 k MEE iooer P UF lt Nx lt 57 TP l NOTES 2 TO ALL CIRCUITS 15 I 1 PINS 1 5 8 8 NOT USED A22 2 1C REQUIRES PRESS ON HEAT SINK ei s 3 THIS PCB HAS 4 CONNECTORS z 1 N4005 I pore com 370 MALE CONNECTOR A TOP FRONT PSC TO ALL CIRCUITS PSC 37D MALE CONNECTOR B BOTTOM FRONT i S ANALOG COMMON OR t 44 PIN CONNECTOR A TOP REAR nee x POWER SUPPLY COMMON PIN EDGE CONNECTOR B BOTTOM REAR 0 2 15 I N
3. WHT mea BS 015910 0679 TAQ WHT B3 073510 TAG WHT CS N 8 wW HR Locw STL NUT BINDING _ CONNECTOR TERE CoHMH E cTo amp R TERMIN 01919 120343 o 1t00 Sca osso WSHR 1 4 PLATE PCH TRAMP 16 31x 10 Rp Yr Pr PLATE J 04 7793 10 OTL Leck 4514 PLATR 01644 ca 2 no anm J731443 TERMINAL INE FAETON 1050012 s Sc amp 4 10 x Vz Hex CAP TAG WHT MG 2A TAG WHT MKG GHD 1 TAG WHT MUG TAG WHT TAQ WHT MKO GA 0 02 TAG WHT TAG WHT MKG OZ MKG IB 3075510 bye TAS WHT 28 31075510 TAG WHT MKO 3D J 075510 TAG WHT 4B 2 S OT PIO piri O 250 SEM PN NS LER 3o J 70530 TAG OF TAG WHT hiv TAG WHT MKA 8B Figure 7 5 Wayside Transformer Assembly Component Layout and Parts Lis 2 7 12 cc EE FF 321 E 2 5 259 E E 125 E 2 317 T HEE EE TEE 333 J L 340 E 341 342 J 122 23 EN 124 E REGUESTED BY REQUESTED ETE H 1 2 ge TERMINAL PANEL WITH TWO BOARDS PER GROUP UN377777 P dum
4. 109 CONT eels 08 UIC la MICE tuz nl 178 Wats jS G a 88 IM furtim Posant 16 100 wis COLE NT OR 118 net 14 9 WUD Can do oved8 qutodifitst mio Tet Pilots 5683 mot 10 COP ito TO o deos OF ottu UQ PAJOR willin oon REFERENCES AUCUN OF vias PALUS CONUS FORT Un HIS ORATIE 10 ME tend SERVICE 0 Cost tin 1813 CIMT ET 18 t 26 fato 168 AMG pe 1431 185 BARVICE PORTMAN One MST coe rient onion Sican 31 38 39 40 41 42 13 44 45 46 41 48 49 50 51 52 53 4 BACK TOP CONN AQ ADDRESS A3 AC Al ADDRESS A2 ADDRESS 1 gt PHASE DETECTOR AB CARO ILE A2 ADDRESS WIRING Al AA A3 ADDRESS A5 GP ot AJ TP gt TP TP GP 5 rest Polis GP 6 gt PHASE DETECTOR TP gt Pu 1 CARDE ILLE ee WIRING GP 8 AP TEST SLOT t AR TI sy AS TP 15V A A22 AZ IP PSC x A COM A SUPPLY x AF 15906 OUT PHASE DETECTOR AD TUA CARDF ILE WIRING AX 6 ANALOG COMMON ZERO OHM A18 AV BACK BOTTOM CONN B 5 SB e 2 15V RIT
5. A 4 5 dav i E eem 0 41 sa Y AR 055 144053 PIN v V b 9 SUPPLY g 5777 1 COMMON b M anaoa 420 E 4001 F T Sie a Ea az O46 400 o 14400 I rc e POOR iu enema E lt Lond Hay 1 Figure 6 5 P 6 4 15 Phe Oatector P C R 8 3 oB 8 Re t ew 8 n men tit NOTE a H PIN 5 PIN ms i tr 8 HP Typical Phase Detector Channel with waveforms corresponding to a 60 lz signal input having a F S phase shift 67 lo J nd mh n iA 5Y source Ins J Ins 15 5V 0 T pope qi j 15 00V Figure 6 G Phase Detector Troubleshooting Gulde P 6 7 AA BB cc DD GG HH JJ KK TI NH PP oo N lt o gt tu TO DIGITAL 1 0 SYSTEM B TO DIGITAL 1 0 SYSTEM A N o 1 N N 1 AS INSTALLED 3 4 5 6 1 8 9 10 tt 12 13 14 15 16 BOTTOM pui rx iii M LE MA CEDE 8310 CONN 16 820 Igi 104 82418 lt e BI 4 82i 6 B2418 B 9 413 822 TI 82418 83 eE 1 3 823 H B2418 84 B24 B24 o CFE A BS Z e R26 e mag ZERO OHM TOP A370 CONN A
6. 70 O RA C TRACK I cd 30 1 uc a B oc Fac WAYSTDE ME E XFMR Rwysp Xpk f TK Lgth 2 TK X TK TK 9 TK Lgth E 20V RMS a60Hz p PHASE COMPARATOR VVOUUOO0DO peg e T OB Figure 3 4 Typical Wayside Circuit Diagram for a Single Track UM AE 7 a d M bs Ac Me t ONDE D u Moe n Cal aa ofi tell P q wr Sra s soms Tegu a O z a as d 6 MED p me SA Mei PDA LOU ne d nca ridi e e s Ade ae tB Dr Mas On the Vector diagram transferring vector EBC to Point B produces Figure 3 7 Vector Relationship Between Phase Angle and Car Spaces Available Added to Figure 3 6 Vector EOC is equal to the sum of EOB and EBC Angle two represents the phase shift between EOB and EOC which is the car space data sensed by the phase detector By considering the extremes of track length for a minimum and a maximum value note that angle two varies directly with angle one and EBA and inversely with EOB Hence phase angle and track length car spaces availabl e are directly related to each other 3
7. etu v 1016 Oring WE Dry vw 9 IE PON A I SODA WEA gt 5194383434 WSIS 6 LAS 3 wos c 101164 93 82d a oc os gt Z AD bo TO 22 e em T14861DR VER ATF 00 dd HN 71 9 S 5 E x x lt c 2 o x r x c o m 44 PIN 37 PIN D STYLE 44 PIN 37 PIN D STYLE EDGE CONNECTOR CONNECTOR A EDGE CONNECTOR CONNECTOR B J 2 V V R60 3 32K 5 R62 3 32K es 4 Pa 0 1 RI20 OMM 47 CHANNEL 80 RI24 3 32K 815 x B34 e a i 1 AB erp 15V sw T S n 7 CHANNEL M C39 c3 t OOPF oorve 15v OO1UF HUF T NE S m To Rao 7 CHANNEL A2 oe 19 RIO4 OHM j Es CHANNEL 82 R44 3 32K 6 4 All 4 es c24 C14 c2 Leo ces A6 i ES BM zT T oo1ur 5 iur S 4 D 57 7 M TP 15 J 17 2 OHM x 44 RIO OHM CHANNEL B3 A9 89 ac hee 828 s 9 i c25 z ces ce A5 c ooer
8. 5 MOST CPU AROF ILE t 288 WATTS CAPACITY ATP A D INTERFACE CABLES TO OTHER GROUPS CASES CONNECTOR PANEL CARSPACE POWCR SUPPLY SPACE 4 NOTE LINES INDICATE FUTURE CROVTH CAPABILITY 120v 288 WATTS CAPACITY WAYSIDE EQUIPMENT Figure 1 1 Simplified Equipment Diagram of Carspace System 3 31 o Ref Fig 1 6 amp tN 237 3 99644 545984 48 55959 650 5 005 505 55 5 8 4 OBO HT 8844 500 100000 ff T 217 25 UPP omy i Pac 1 co wq Vou RCF FRONT ec 10 of t LAMBDA POWER 1 5 e g j 888888 848 885688 85855 8888 895 585 555 BARS CONMOP 05555 555555558 ps 485 88 666888 8 85888 4 5 6 8p 55 v H24 Carspace System Rack Figure 1 2 1 3 1 Wayside Equipment cont d B Wayside Transformer US amp S P N N451492 0101 Figure 7 5 contains 8 Surge Suppressors and 8 Signal Transformers Electrical 500 W 120 V 60 HZ Physical Size 7 5 8 x 9 37 64 x 10 1 8 Hatio 2 1 1 3 2 Tower Equipment A Car Space Rack Figure 7 6 Equipto Challenger P N 192Y01A17 Electrical 200 W 120 V 60 Hz Physical S
9. 9 1611 i1c2 984 100K ew iv PUN RtF 0 P ALL RESISTORS 1 4 WATT 4 UAESS SHORN e 54 F m ALL CAPACITANCEB IN MICRO FARADS bau Ma UNLESS OTHERWISE 6 5 K4 avy ce 010 054 97 T 1 16 100 7 19 et ots ran Paw 2126 1 1 014 dnd 914 cs l t A 553 57 HIT 5 109K 1 20 100K rin lec IY 1 15 d 1 d 015 ic o 2 1 IT T 13K ot A ftw 100K doers i jev Jai 15 c 2 e ci cs 39 944 stet at i Ars n1 100K 1 20 199 TS m v nio ci oto ex aye p TSK 1 29 toon 9v c ot 944 INTO i 14 11 100K 1 20 100 on 01 056 190 4 1 _ 64 nye aye ll Sv V 9 011 SK 1 29 1098 A Cc Ct 49 Aes Ti 1908 1 20 100R A L 9 nn S s 54 1 t i 014 m m Ix 18400 pp 19K tw 100 bel 91 MEM 814 way c 029 cre 03 1j 05 944 ZX n AP A120 AI U ASG P16 P 10 1 94 24 ne me 4 ow 1 19 199 LU f 2 039 er on P96 men R00 jid amp 534 MU bes sii 3 i Ut RID B gt Dare er Tsounce
10. MAE UNION SWITCH amp SIGNAL A member of ANSALDO Group S800 Corporate Drive Pittsburgh PA 15237 o On urate tLe UOI IO ONU A AN RARE GRUB ASAS SERVICE MANUAL 6591 XQ OO Om mono QOO C OC momen onam QQ QQ QQ men ommo mmodo nonno m once QI QE C DO QOO OC par Qr Qr oO RR AE Ne ern ater e ertet e y y eate Pr ara x RO ORG OM OO Qu ate ate aP tote Pawa qa asap P OR D INSTALLATION OPERATION and MAINTENANCE DIRECT DIGITAL 2 k d JA CARSPACE SYSTEM SSC March 1994 1 A 3 94 3026 or ee QUE COPYRIGHT 1994 UNION SWITCH amp SIGNAL INC PRINTED IN U S A TABLE OF CONTENTS Section CAR SPACE SYSTEM 1 1 PURPOSE 1 2 GENERAL DESCRIPTION 1 2 1 Wayside Signal Input Circuitry 1 2 2 Tower Equipment 1 8 SPECIFICATIONS 1 3 1 Wayside Equipment 1 3 2 Tower Equipment 1 CONTROLS AND INDICATORS 2 1 CAR SPACE RACK 2 1 2 CSPI MODE OPERATION III THEORY OF OPERATION 3 1 GENERAL THEORY 3 1 1 Car Space Measurement 3 1 2 Car Space System 3 2 DETAILED THEORY 3 2 1 Wayside Circuitry 3 2 2 Car Space Rack 3 3 SUBSYSTEM DETAILED THEORY 3 3 1 Operation of the Phase Detector P C B 3 3 2 Operation of Address P C B 3 3 3 Operation of the Driver P C B
11. 3 5 Operation of Dual Power Supply Hefer to Lambda Service Manual 3 l SECTION IV INSTALLATION 41 INSTALLATION CHECKOUT PROCEDURES Upon completion of the wayside and tower equipment installation perform the following procedures for making the Car Space System operationally acceptable 1 Inspect and test the integrity of insulated joints far end shunts and rail bonds if used of each track Also at this time check that undesired track shunting paths do not exist 2 Verify that the proper track connections are made the circuitry for track 1 indeed connects to track 1 and not to track 2 or 8 etc 3 Verify that the proper track transformer polarity connections are made adjacent rails of adjacent tracks are in phase for similar track shunting conditions 4 Perform the calibration procedures of Section V Calibration of the Car Space System 6053 p 4 1 SECTION V CALIBRATION AND TEST PROCEDURES 51 GENERAL REFER TO FIGURE 5 1 Calibration of this system is determined by comparing observed output readings with respect to controlled input signals For proper calibration of this system the power supplies must be properly adjusted each of the Phase Detector PCB s must be properly zero and gain adjusted and then the total system checked and adjusted The carspace system performance will vary with changes in climate therefore seasonal re calibration of the system is suggested The following procedure sho
12. 680 Be 5 M LED 8F GREEN A COM A SVOC IN 4 FROM CAR SPACE LED do E POWER 5 CREEN 7 1000 RI3 680 BH CARUF ILE A FA 15 WIRING 1 54 58 A 5 B8 N241 n 8241 810 824 ELLE EARL AA i FROM APRI y 89 CAROF ILE 8241A WIRING _ 241 SCac e MONE 31 0 T UNION SWITCH 8 SIGNAL INC PITTSBURGH PA 15231 YAROS GTR 1110 03 JUN 1993 usrBo ats ots h w 11486 4B6n006 o4f ATF Ti 486 1486HO06 tzlaz a o REVISIONS E3 2 25 93 AS INSTALLED 157107 ab ened a Wane WMD TOR MOTOS Miia 14111 00 67104516 90 WS 9 673015316 ASM Dem 0 AEM 90142 DT 216541 v 6 1 PG 00 91 100912 Bie ji TOO BL Ow Linzi W 10 Dov Gee Wit 9100110 Pu pe UC S T9009 ut Gale a ETA 149 Dev 111 93 G1 POS PQ 30111449 Gh tem uo Rit D PCOOS HIMA t ttt M 34911 9 LIRE HOD 1102094 DU Jii ON nuce 0141 D boved Sint MINOJ 136 1102612 DIU OV
13. All replacement parts should be direct replacements unless it is known that a different component will not adversely affect system performance Special Parts In addition to the standard electronic components some special components may be used in this unit These components are manufactured or selected by US amp S to meet specific performance requirements or are manufactured for US amp S in accordance with our specifications These special components are indicated in the Electrical Parts List by an asterisk preceding the part number Most of the mechanical parts used in this instrument have been manufactured by US amp S Order all special parts directly from your local US amp S Field Office or Representative Ordering Parts When ordering replacement parts from US amp S include the following information 1 Unit nomenclature 2 Unit serial number 3 A description of the part 4 US amp S Part Number Uxxxxxx xxxx p 7 1 7 2 PARTS LIST ILLUSTRATIONS The following parts lists are provided in the order listed Figure Description Page 7 1 Phase Detector PCB Component Layout and Parts List 7 3 4 7 2 Driver PCB Component Layout and Parts List 7 5 6 7 3 Address P C B Assembly Component Layout and Parts List 7 7 8 7 4 Track Transformer Assembly Component Layout and Parts List 7 9 10 7 5 Wayside Transformer Assembly Component 7 11 12 Layout and Parts List 7 6 Car Space Rack Assembly Component Layout 7 13 14 and Parts List
14. COHTROL 5 Z NN FIG 3 3 CAR SPACE OVERVIEW DIRECT DIGITAL TYPICAL GROUP amp TRACKS 3 7 R 3 3 4 Operation of the Wayside Circuitry Refer to Figure 3 4 The operation of the wayside circuitry is best described by the use of vector diagrams By using vectors a true relationship between phase angle and track length can be determined The line voltage EOA is equal to the sum of the voltage drops across the track transformer EBA and the wayside resistor EOB EBA varies directly with the number of car spaces available As the car spaces increase the track impedance and EBA increase and as the car spaces decrease the track impedance and EBA decrease When EBA increases EOB decreases causing angle one to increase When EBA decreases EOB increases causing angle one to decrease The relationship of phase angle to the measurement of track length can be determined by observing the instantaneous polarity and turns ratio of the wayside transformer EBC is opposite in phase and equal to one half of EOA as shown by the vector diagram of Figure 3 6 Vectoriallly Figure 3 4 is described by NOTE Z is the reflected impedence felt through the 30 1 track transformer jw i h I WAYSIDE IR DROP TRACX IR LOSS figure 3 5 Vector Relationship of the Track Transormer Voltage Droo 2 4 the Wayside Resistor Voltage Drop 2 1 and the Line Voltage Zaa
15. SEE DRAWING F004 SH 5 FOR DETAILS 9 WAY 36 PIN CONNECTOR PANEL M451075 5701 M451075 57 doge ind SEE DWG 451075 SH 57 J703004 703004 US amp S 36 PIN CONNECTOR 24 SLOT CARDFILE WITH BUSS BARS m KA N451056 5501 N451956 5501 US amp S BALL ED QUIS EPARATEL LAMBDA POWER SUPPLY ASSEMBLY CR932Y04002 LAMBDA ommo DUAL 15V SUPPLY C NUMBER NEEDED SPECIAL ORDER WIEDMULLER TERMINAL BLOCK ASSEMBLY N451441 3101 US amp S PHASE DETECTOR PCBS ENGR dm n CARSPACE DRIVER PCB DEPT cz 2 R C em E N451441 8902 n S n r T V A 0793100 0019 CARSPACE ADDRESS PCD ENGR 1 51441 1101 USES DUAL EXTENDER PCB ENGR PENNE H s YW APPTAB CARSPACE SYSTEM futt BODAENT PRURIT OF OIRN 4 IC WEI ve RN UDA 10 64 DE ODIS Cd AO MOLE TO Pur Docent Ot 18 16 CUR OL WAI h Sunt ro WE 6 fon PR FS CONTATS 4 TO W UD OR EATER it AF UCM IETD RC Pu vital AV 101 10 W cermin umon tnit b rov pe bate REFERENCES ITALIAN STATE RAILWAY CERVI Q YARD CL
16. Z Evi POSSIBLE 1 7 WAYSIDE EGUIPMENT CHECK PER SECTION i 5 4 ANO 5 5 Figure 6 2 System Calibration Indicates Faulty Readings 6 4 6 3 1 Flow Chart Support Ref A It is possible that the RTP rack s may not be powered up or that one of the A D cards is not plugged in The gate card is located at word 91 and the A D card is located at word 88 Also make sure that host computer is up and running Ref B Use a DMM to read analog voltage at output of driver board This voltage should be between 1 and 4 volts depending on the distance to the last standing car on the track Refer to attached Driver board schematic N451441 89E for output pin assignment information SYMBOL TANDARD DEF MMENT Terminal Box Used For Starting and finishing a Flowchart Decision Box The next logical question in the troubleshooting procedure is asked here and in such a way that either a yes ora no is the only possible answer Process Box Describes the next logical process or operation to be perfromed Subroutine Box Tells the Maintenance Personnel to perform one of the referenced trouble shooting procedures ALL OF THE BLOCKS IN THE FLOW CHART ARE REFERENCED WITH LETTERED DESIGNATIONS WHICH ARE DEFINED IN THIS SECTION UNDER FLOW CHART SUPPORT Table 6 1 Flow Chart Symbol Functions 6 5 Ref C Use a DMM to read analog voltage at output the Phase detector board This voltage should be b
17. both sides of the opto coupler to prevent coupling of noise by a common power supply Each Phase Detector PCB has a multiplexer referred to as the track mux to channel the analog phase angle information to the driver PCB Each Phase Detector PCB has like channels addressed simultaneously by the 4 bit address PCB output The track mux selects the specific phase detector circuit on the Phase Detector PCB The output of the track Mux is forwarded to the driver board for amplification The resultant DC analog signal is then sent to the RTP A D converter for digital conversion This is a 12 bit binary equivalent n 1 2 LSB of the input analog phase angle information This parallel 12 bit binary phase angle information is routed to the Host CPU and is converted to a digital value of available car spaces for the corresponding addressed track The available car space data for each of the tracks is stored and then updated by the Host Computer once a second In this way any or all of the requesting stations can retrieve the most up to date track fullness information The Host Computer Completes a full scan of the yard once every second The scan begins with the selection of the address of the first phase detector circuit track number one The driver board output voltages One for each Phase Detector PCB are then sent to the RTP A D Converter The analog voltages are then converted to binary and stored to memory The Host CPU then goes back and repea
18. extensive troubleshooting The first few checks below assure proper connection operation and calibration If the trouble is not located by these checks the remaining Field Maintenance or Sub System Trouble Analysis procedures for locating the defective sub system or PCB can be used When the defective part is located it should be re placed following the replacement procedures given under Corrective Maintenance a Check Control Settings Incorrect control settings can indicate a trouble that does not exist Make sure that all of the system controls are set properly For example Is all of the power being supplied to the Car Space Rack wayside circuits displays b Check Associated Equipment Before proceeding with the troubleshooting of the Car Space Rack check that the equipment used in conjunction with this rack is operating correctly Check that the signal lines are properly connected and that the inter connecting cables are not defective c Visual Check Visually check all of the car space sub systems Many troubles can be located by visual indications such as unsoldered connections broken wires a damaged circuit board damaged components etc Make sure that all of the cable cards and connectors are coupled and fully seated 6 1 d Isolate the Trouble to a Circuit To isolate the trouble to a circuit note the trouble symptom The symptom often identifies the circuit in which the trouble is located e Check Power Sup
19. p 7 2 Levens 994811 OOM KA 00500171100 onu Wt YI WERE I x 1445 __ amp LN DORN POTENT SS 940719 mangul 4 MAHON d TUN 1 TOL V4 7 5 RER 100 00713 yaw dr 3 i Sw die i maios ISO NA NE TN 51 Ro te i 4 10 1 RAR GLO ES j lt z ame GN Me was RAS ATR aneo gt r TUN Ies Less REE 11 1614 19 rii s BAA nar Oe u i i i NM 1 19 ELA a a E ES HAE NN 154 m C ep N 545 61 3 ares Oirr is 34 1 UKE N 3 J e y N T 4 M l r 3 C hul ha C n J C J ut J D e n ist N Z D N j C 7 a RI C J cre 59 939 L rir 1 M M l CJ C 7 e an Pag 5 1541 r 7 c3 pu o n pae Oris Q n v J U jess ELI stes 1 445 Er vy m bs M pp LJ 111 uy ond ass E s e noo pepe qq ch rmi xe u M net
20. track For any given track at a given location a range of 0 to 3 069 feet of available distance to last standing car or shunt on the track has its own particular corresponding range of phase angle degrees 0 degrees to some particular value The phase angle pairs are terminated in the Car Space Rack Phase Detector processed by the external RTP A D Converter run through the pre programmed Host computer and used to calculate as track fullness data 3 1 FAILOVER LOGIC ADORESS BOARD m SLOT 11 TTL OUTPUT DRIVER DRIVER BOARD NPUT A D GATE MUX SLOT Q VAX 4888 CPU WATCHDOG TIMER PHASE DETECTOR BOARDS SLOTS 1 THROUGH 4 0 CONTROLLER 080 VT 420 Figure 3 1 General System Block Diagram 3 2 2 Carspace Rack The Car Space Rack is wired to accomodate a phase detector for each track with eight successive tracks defining a group Each group has its own Phase Detector PCB A maximum of nine groups can be wired into the rack Depending on the number of tracks used in the yard one rack could contain one Phase Detector PCB as a minimum to nine Phase Detector PCB s as a maximum In each phase detector circuit on this PCB the phase angle information is coupled between the phase comparator and the low pass filter by an optical coupler This optical isolation scheme eliminates any direct connection between the rack s filtered analog voltages and outside interference In addition separate power supplies are provided on
21. using one half of a 747 dual op amp operational amplifier for its active element Pulses from the optical coupler are fed into the filter and its narrow bandwidth removes everything except the DC component of the pulses The second half of the 747 is an amplifier with a gain potentiometer to adjust the full scale reading of the filter output An offset potentiometer connected to the non inverting input of the filter op amp is used to compensate for the saturation voltage of the optical isolator transistor and to null out the combined offset voltages of the filter and amplifier op amps The eight channels of phase detectors and filter amplifiers are fed into a Burr Brown MPC16S sixteen channel C MOS analog multiplexer The multiplexer has a four bit BCD digital input code which is used to select the desired channel Channels one through eight of the multiplexer are used for the phase detector signals channel nine is connected to the five volt reference source channel ten is connected through a two to one voltage divider to the five volt reference and channels eleven through sixteen are not used and are tied to ground 3 3 2 Operation Of The Address P C B The Carspace address board is an interface to isolate a four bit address of an output of the external main yard dual computer or dual digital subsystem from the Carspace system Isolation is accomplished using opto isolators and separate input and output power supplies The circuitry requir
22. wy to AMI No E Jesi ELI C J J uni 0 L3 NZ C3 v gh TRE e ww VU n E35 F s er Sa an E J f C J 215 C 3 CJ 4 Tarbes Orn t6CATIDM er N C J D 6 N 3 ul Jess g 5 Gul U A 3 Ju I T en 7 one sit L B 113 e ut e C 7 IC C J C ares er e b 8 2 gt cf AG oe m ees Hu nd We ML 1 ase e ase 544 C J one E 7 C J 5 8119 bu 4 N kn N Dent s r 3 o w r CJ zul An ut Cy N Zl 1 l nis 20 rds 853 191 ies CL lt e 3 Ed 7 Tuo 21 m o N 4 by 1 4 t 3 z av Ma C e18 b neg U an oe 858 C J C J r dau 7 7 lt NS C AJ t Ge n 5 X E 34 x cu 8 d pm cI L z m 33 COMPONENT SIDE Figure 7 1 Phase Detector PCB Component Layout and Parts List p 7 3 4 GLYPTAL THREADS M wRCHCH TIGHT N 0x67 ZAN a SY Sy TAN SE AV VSIISVNA d JAOgO JSN YAL Bore SIDE OF BRACE M VIEW B SHOWING E E PAICE PUNCH 3 MAX 2 DIA HOLES ACF 4 ID Dis
23. 00 V 0 02 V CAUTION STEP 6 INVOLVES WORKING WITH 120 V ANY CONNECTIONS SHOULD BE MADE WITH 120 V POWER TURNED OFF a Option 1 Unplug Wayside input connectors P1 P8 Connect Carspace Simulator output cable to input connector P1 P8 for channel under test Jumper input pin B to input Pin C with the common wire on Signal Pin Ref for channel under test See Table 5 2 Confirm two sine waves are in phase with a dual trace scope on Pin B21 Channel 1 scope probe and B22 Channel 2 scope probe with respect to B20 Disconnect scope probes and common lead Option 2 Remove 120 V power from case Disconnect the signal C Sig C wire at the case transformer N451492 0101 Terminal C C1 C8 for track under test Place this wire in parallel with Signal B Sig B at Terminal B B1 B8 Apply 120 V power to case Confirm two sine waves are in phase with a dual trace scope on Pin B21 Channel 1 scope probe and B22 Channel 2 scope probe with respect to B20 Disconnect scope probes and common lead when finished 1 2 3 4 5 6 7 8 Signal Pin Ref B20 B17 B14 B11 BX BU BR BM Signal Pin B B21 B18 Bi5 B12 BY BV BS BN Signal Pin C B22 B19 B16 B13 BZ BW BP TABLE 5 2 5 2 b Connect the Positive scope lead to the comparator output for the track under calibration See Table 5 1 Place the negative scope lead at TP17 Observe the 15 Volt approx pulse Adjust Zero Potentiometer bottom row of pots until the pulse width decreases t
24. 1 4 LOCK WASHER BULK TOTO 8 T 22 4490211 0108 dM 1 4 20 NUT BULK Me uses T 22 J475120 0112 1 4 PLATE WASHER BULK USS ae I CCC ur s 22 J500136 0112 1 4 20X1 2 IN SCREWS BULK RECEIVED GH K 7007 T1496 T1485 486K700Z ATF C
25. 20 R a OR VU NN D ZERO OHM R25 emeg ZERO OHM A24 R6 es Geet 45 ZERO OHM DENOTES COMON FOR A SUPPLY PLUS AND NOTES 1 L MINUS 15 VOLT AND FOR PLUS 5 VOLT SUPPLY e TIE POINT TURRET 4 RELAY 1 PIN 1 IS COIL PLUS PIN 16 15 COIL MINUS 5 ALL RESISTORS Aw 51 CARBON UNLESS OTHERWISE NOTED 2 EXTERNAL B241A RIS PENES IP 2 470K IC 4 4 55 2 7K teow N PT R21 1 IP Os IC 5 4N35 RIA T ene 2 7K al 2 R20 A a7 470K ic 8 741504 150 150 ArY we a 150 i RI6 e 4 pow 150 6 s gt o cw vc 1 14 I pf lt 4 IC IP 5V R23 T SOS v AMICI Coe 1 805 NEN et sv _ NEN EAE 9 ZERO OHM E M YELLOW N T ol i mer REN RE2 B241 AMP A B2418 AMP Le A et a nS gh ce ha el i qe ee iaa B241A tANP a b m M u DOCU NT 11 COCENTE AX Tu PROPERTY GF per YO PK utat 10 109 Qh
26. 20V rms E Line of the WaysideTransformer Primary b EBC 60v rms E Secondary of the Wayside Transformer is equal to one half of EOA If not the wayside transformer or its connections are faulty and should be repaired or replaced c Remove one secondary lead from the track connection of the track transformer 6 6 Esec EAB 30 The secondary voltage of the track transformer should be equal to 1 30 of the primary voltage If not the track transformer or its connections are faulty and should be repaired or replaced 3 Check the value of the 600 ohm resistor and verify circuit continuity between the main terminal board and the track transformer 4 If able to change the location of the last standing shunt on the track in question do so and check that the phase angle variation between EOC and EOB agrees approximately with the relation described by the graph of Figure 6 6 Make a quick check by making and breaking a shunt across the secondary of the track transformer and observing that the phase angle goes to zero when shunted PHASE ANGLE NOT DEFINED TIME IN MILLISECONDS LINEARLY BEYOND 1000 FT 833 417 500 1000 DISTANCE FEET From TrackXFMR to last standing shunt Figure 6 3 Phase Angle In Relation To Distance Graph 6 4 3 Phase Detector P C B The Phase Detector PCB consists of two main sections the Phase Detector Circuit and the Multiplexer Each section is checked out as follows a The Phas
27. 3 3 4 Operation of the Wayside Circuitry 3 3 5 Operation of Dual Power Supply IV INSTALLATION 4 1 INSTALLATION CHECKOUT PROCEDURES Page 3 11 4 1 4 1 VI VII TABLE OF CONTENTS continued Section V CALIBRATION AND TEST PROCEDURES 5 1 GENERAL 5 2 POWER SUPPLIES 5 2 1 Power Supply Adjustments 5 3 CARSPACE SYSTEM CALIBRATION 5 3 1 Data Terminal Set up Procedure 5 3 2 System Calibration Procedure MAINTENANCE 6 1 GENERAL 6 2 BASIC TROUBLESHOOTING TECHNIQUES 6 3 FIELD MAINTENANCE PROCEDURES 6 3 1 Flow Chart Support 6 4 SUB SYSTEM TROUBLE ANALYSIS 6 4 1 General 6 4 2 Wayside Circuitry 6 4 3 Phase Detector P C B 6 4 4 Address Board P C B 6 4 5 Driver Board P C B 6 5 DETAILED CIRCUIT AND COMPONENT TESTING 6 5 1 General 6 5 2 Soldering Techniques 6 5 3 Circuit Board Replacement 6 6 SCHEMATIC DIAGRAMS PARTS LIST 7 1 GENERAL 7 2 PARTS LIST ILLUSTRATIONS Page 6 8 6 8 6 10 6 11 6 12 7 1 SECTION I CAR SPACE SYSTEM 1 1 PURPOSE The Car Space System is intended for application in classification yards as a car space data logging and signal conversion device The Car Space System is a data acquisition system that supplies analog track fullness information to the remote I O RTP data interface for conversion to digital data to be interpreted by the Host CPU that is controlling the Hump Yard 1 2 GENERAL DESCRIPTION Refer to Figure 1 1 for the simplified equipment diagram The car space s
28. 88 MALY WP RT INT OCR PHEL NP BRACKET GASXACT PLATE COVER GRIP CARLO WITH CHALE NIPPLE MOMCHCLATURE ram OLD COMPOUND CASTING AGSY KM TEST GPEC Y Track Transformer Assembly Component Layout and Parts List p 1 3 o A Dio tolas qo lt 2 H a j unice Se ee Z ow ow 29 dH PAI CIR BD 2 Ser WIRING DIAGRAM CONNECTOR viu REQUIRED 11 h i l LR MI li JHI ye uni CEO TAG UN 451088 4701 Lc TOP EDGE PRI BOARDS GOLDER Fon WIRING AND CIRCUIT DIN omn Srw 4 651403 5 04 TEST INSPECT PER SPEC EU GIAB no p View C C EN IN PART Df5 f 69 5 02 d 9 x yc PRI CIR 1 see WINING DIAGRA el mnes s y TIT GROUP Ul Suivi IOEMTIFICATION DESCRIPTION Mu yel RUMIT nil pt te ogassoss covece 017841 BOARD TERMINAL TREAMINAL POST TERMINAL TAG WHT MKG DOLS T G WHT MG BZ TAG WHT Mee 0001 TAG WHT A 1046 TAG WHT TAQ WHT CB 1040 TAQ WHT CA 154 TAG WHT ree
29. A F2 oos 001UF 100UF TO ALL CIRCUITS 15 AtS x 50 5 AV a S s m Qm ms m eee ma a O F O s Qum wm mas s m m s n s gt emmu os dgn Natal hduN 41486 Ndeiver etf 20 JUL 19935 13519 YARDS GTR fi 21 bi 12 02 81 11 91 ly 9b SY e t zr tb Ob 6 8 lt 9 St ve 1 0f 82 1 32 G2 05 S SECTION VII PARTS LIST 7 1 GENERAL When it becomes necessary to replace components during unit maintenance the following procedures should be followed in obtaining replacement parts a Standard Parts ll electrical and mechanical part replacements for this unit can be obtained through your US amp S local Field Office or Representative However many of the standard electronic components can be obtained locally in less time than required to order them from US amp S Before purchasing or ordering replace ment parts check the parts lists for the value tolerance rating and description NOTE When selecting replacement parts it is important to remember that the physical size and shape of a component may affect its performance in the instrument particularly at high frequencies
30. ASSIFICATION YARD CIRCUITS Q UNION SVITCH SS amp SIGNAL INC PITISBURGH PA 15237 MIELES 8180 19 OF ENS OR SIPON OF DE PRIOR VAUTER UNE w PRIOR YO PLAC IM MT FOATA OR THES Ow INTO ERNE HE UN ETE OENAR OF eios IER 10 A PAT AT AG At CUCULY TOLUCTION Core ADO 4 8 WCE OPEM TUT lt lt s 15 16 17 18 19 22 23 24 25 20 27 Paty 23 38 31 32 33 34 359 36 37 38 33 40 41 42 43 44 46 47 48 43 PART VENDOR DESCRIPTION ORDERED a US amp S MANUFACTURER MANUFACTURER u PART E ul DISTRIBUTOR DISTRIBUTOR Hg d TERRIER CHALLENGER EQUIPMENT RACK SPECIAL ORDER EQUIPTO Sei EN _ 36 IN DEEP W PLEX DOOR N A US amp S RACK NAME TAG CUSTOMIZED PER RACK AS REQUIRED 9 CHARACTER 20 N A 800102 05 EQUIPTO MAR PROOF SCREW EQUIPTO 108X5 8 IN pese CGP 2 SPC TECH GROMMET L 23N3659 NEVARK CONTINUOUS GROMMET ROLL FOR 19 12 GUAGE 037 015 100 FT ROLL MIN PURCHASE 0565 CABLE SUPPORT TIE BAR ENGR FOR 19 RACK 18 25 HOLE CENTER HOLE CENTER 00 0401 03 EQUIPTO SPEED NUT 20 CR931Y012105 BULK EN USS i 22 J475121 01 11
31. CURRENT HIGH CURRENTS MAY DAMAGE THE DIODE DO NOT MEASURE SCHOTTKY DIODES WITH AN OHMMETER USE A SUBSTITUTE DIODE 3 Resistors Check the resistors with an ohmmeter Check the Electrical Parts List for the tolerance of the resistors used in this instrument Resistors normally do not need to be replaced unless the measured value varies widely from the specified value 4 Transformers Check for open transformers by checking continuity with an ohmmeter Shorted or partially shorted transformers can usually be found by checking the waveform responses when high frequency signals are passed through the circuit Partial shorting often reduces high frequency response roll off 5 Capacitors A leaky or shorted capacitor can best be detected by checking resistance with an ohmmeter on the highest scale Do not exceed the voltage rating of the capacitor The resistance reading should be high after the initial charge of the capacitor An open capacitor can best be detected with a capacitance meter or by checking whether the capacitor passes AC signals C Repair and Readjust the Circuit If any defective parts are located follow the replacement procedures given in this section Be sure to check the performance of any circuit that has been repaired or that has had any electrical components replaced 6 5 2 Soldering Techniques WARNING DISCONNECT THE UNIT FROM THE POWER SOURCE BEFORE SOLDERING Circuit Boards Use ordinary 60 40 ros
32. ICATED CABLE CONSISTING OF 9 TRISTED on r PAIR PREFERABLY 14 CONDUCTOR WITH BUT OVERALL SHIELD Se ge gt rs s E RT r3 fAUSO SUPPLIED BY CUSTOMER 1 VIA FIELD WIRING THE SEQUENCE OF TRACK NUMBERS IN THE YARD MUST BE MADE AGREE WITH THE NUVOERING SEQUENCE OF PHASE DETECTOR CIRCUITS WITHIN THE CAR SPACE RACK I E THE FIRST 6 SEQUENTIAL PHASE DETECTOR CHANNELS FUTURE GROWTH CAPABILITY ARE DEDICATED TO THE FIRST 8 YARD TRACK NUVBERS SIMILARLY FOR THE SECOND SHOW By DASHED LINE 8 ETC FURTHERMORE IF TRACKS 4 5 8 6 IN THIS FIRST GROUP DO NOT PHYSICALLY EXIST BECAUSE THEY ARE FUTURE TRACKS THEN PHASE DETECTOR CHANNELS 4 5 8 6 CANNOT BE USED AND THEN TRACK 7 INPUT CETS CONNECTED TO PHASE CHANNEL OF INPUT SIMILARLY FOR ETC 6 AFPLY 1 TRANSFORMER FER GROUP OF NO MORE THAN 8 TRACKS THIS XFAR TO BE SELECTED BY PROJECT ENG T APPLY TRANSFORMER PER CROUP OF LOPE THAN TRACKS 8 THIS CABLE TO BE SUPPLIED AND INSTALLED BY ENGINEERING SEE FIGURE 6 17 FOR SIGNAL PIN OUT INFORMATION CARSPACE SYSTEM PHYSICAL LAYOUT AND APPLICATION INFORMATION 3PQSOPMLSC F 168 12 NSR G 4 T 12 13 M n T2 n 267 1 udus d a lr 4 iK 9 19K 1 2 ate NOTES SOR ICI ice tM 111 C 1 HP 3008 4331
33. IVER INPUT f l S TRANSF ORMER PCB E na oU jute E eae Rite ae eee on qo PACKAGE RTP RACK B INPUT es s ATE CPU B ANALOG SIGNALS 8 CH lt 2 MUX B B CONNECTOR y E E EDGE ue La ENT ME P ADDRESSING f gt x TV 51 EN SSS RTP RACK B 7 NONEM I INPUT TRANSISTOR B CONNECTOR Y EDGE EDGE 5 1 OUTPUT CPU B BI B CONNECTOR E EDGE 154 TEPORE INPUT m 4 BITS Sle oe B B Z X qum Sa x B CONNECTOR A EDGE EDGE DDRESSING E POS nN 2 E T M IHPUT J m 1 8 CONNECTOR ps 1 i D i INPUT Ki Eg HER RIP RACK A CPU A AO A CONNECTOR at ama OUTPUT CPU A Al F A CONNECTOR SLOTS 1 TO 4 4 BITS CPU 2 x A CONNECTOR ADDRESSING CPU A A3 PER me A COHNECTOR QU M LC LM DN RE RT SLOT 11 mn I POWER SUPPI Y ASSEMBLY gt TIMER A m 15V CON ew Cee Apu Mud E pres ee Fee meas M dC UM CM LE WATCH DOG TIMER B CPU SELECTION I FAILOVER RTP DIG 1 0
34. Procedure This procedure is for calibration purposes only and is not intended as a troubleshooting guide It is therefore assumed that the carspace system has been working correctly and all wiring and components have been previously verified For total system calibration start with tracks 1 8 Phase Detector PCB and check from track 1 to track 32 sequentially Refer to Figure 6 7 Phase Detector Troubleshooting Guide The following stepwise procedure is written for calibrating any one channel on any one Phase detector PCB Specific pin number information is provided in Table 1 below 5 1 PCB Channel No 1 2 3 4 5 6 7 8 Zero Potentiometer R7 R13 R19 R25 R31 R37 R43 Offset Potentiometer R97 R98 R99 R100 R101 R102 R103 R104 Gain Potentiometer R105 R106 R107 R108 R109 R110 R111 R112 Comparator output test point 2 4 TP5 TP6 TP7 TP8 PCB board output test point 18 TP19 TP20 TP21 TP22 TP23 TP24 TP25 1 2 3 4 Table 5 1 Phase Detector PCB Output Test Points And Potentiometers for Channels 1 8 Power Off the instrumentation card file Remove the Phase Detector PCB to be adjusted insert Extender card and re insert the Phase Detector PCB into the extender card connector Power On the car space cases breakers on fuses in Power On the Instrumentation Card File Connect a DVM positive lead to pin A16 of PCB under test Connect negative lead to TP26 Adjust R147 until the meter reads 5
35. T m 1 1 I l t l l E 1 I I IS TUTTO I y _ Es 1 tm B i 4 J L J U m NGS h MIM 1 rita T 1 y i 2r ITEMS FOR REF OILY 1 CLAMP WASHERE 002106796 BOLT SH 210 G5 13 V0 HEX HD CTL BOLT Ur S609 CAD PL 1 HER STL UT 074 6013 CAD PL t STL LOCK WASHER 400 UT 47283 CAD PL ee UE x ME WS RP uuu XE CIE p 115 11612919 1392 TOP or START LUAD i s s am 41 O FINISH LEAD iQ WIRING DIAGRAM vents mor TENTI E luuays e4 estos tas a rss eds i NINO NOVEL oe CMBOSSCO NOMCHCLATUR REF LINT owe ul 4 1409 UM 441008 0101 UMAS 1005 Uy 316644 VI 616051 EE 0747191 xp 651166 0103 10461155 63505 UM 398798 89350318 07 712089 UF 51105 UDA NODC 843106 5 Figure 7 4 TRANSFORMER t FLAT SIL TP nut AE YP TERMINAL TA 10 5 BR MACH NP DESCRIPTION Tassy r COVER WASHED Lote St TP INSERT mst rt sc SC Vito vy AE LOR RO
36. TING s i SEE NOTE T SEE NOTE 6 ert es 3 TERMINAL n BOARD 1 f lt 2 1 lt y y eee 4 4 lt s 5 n T A l lt 7 Bk NOTE 5 a ee iz 8 8 M lc AT 9 9 SIGNALS lt FROM to 16 C GROUP 0 i gt lt Vout 9 TO 2 12 COOUR SYSTEM gt cC rs I F 14 14 is gt 16 16 18 8 TRACK COULPING IFAR NOTE 4 9 UH4 1154 0 0 N IFOR OF at TRACK XFMRS TO TRACK 3 TK SIGNALS FROU MIS r p s C CROUP I L 5 r L 2 TO MINIMIZE CROSS TALK EFFECT THE TRACK TRANSFORMERS SHOULD BE CONNECTED SHOWN SO THAT ADJACENT RAILS OF ADJACENT TRACES WILL BE IN PHASE FOR SIMILAR TRACK CONDITIONS r 3 A THESE POINTS APPLICATION OF LIGHTING PROTECTION SPECIFICALLY TO BACK UP T gt ra THE SURGE ARRESTORS USED IN THE SIGNAL PACKAGE 15 ADVISABLE C GROUP 3 l 4 LINE FEED RESISTOR RLF TO BE 600 OHM 60 14 IT 16 SUCCESTEO THAT ALL THESE RESISTORS BE MOUNTED ON 4 ALUMINUM HEAT SINK S A THIS WEATHER PROOF CABLE MUST BE A DED
37. chniques of this section CAUTION 120V 60HZ AC EXISTS ON THE INPUT PAIR TO THE FRONT END OF THE PHASE DETECTOR PCB S 6 2 BAO DATA NT TO DATA TERMINAL TURNED ON YES S CORRECT VOLTAGE PRESENT AT ORIVER SOARO OUTPUT POSSIBLE FAULTY RTP INTEFACE APPLY POWER TO ALL ASSEMBLIES S CORRECT VOLTAGE PRESENT AT PHASE DETECTOR PCB OUTPUT PIN A4 YES POSSIBLE FAULTY DRIVER BOARO NO ARE FIELO INPUT CABLES PROPERLY NG CONNECT CABLES CONNECTED TO RACK ERLY PROPERL YES CHECK ADORESS 8 ARE OTHER SEVEN CHANNEL FIELD OUTPUTS CONNECT IONS OPERAT1ON PER SEC 6 4 ANO 6 5 CORRECT REPAIR PER SECTICN 5 4 3N 43 OF CARSPACE MANUAL 15 ALL WAYSICE ECUIPMENT ANQ IRCUITRY WORKING PROPERLY Q o j i i i i t i in Figure 6 1 Bad Data Sent To Terminal Display S i ROUTINE CALIBRATION INDICATES FAULTY REA OING S SUPPLY SIGNAL OF KNOWN PHASE SHIFT TO PHASE DET INPUT CHANNEL 5 IS THIS PHASE SHIFT REFLECTED IN PHASE OET OUTPUT VOLTAGE REPLACE PHASE OETECTOR CALIBRATE NEW ONE OCES CORRECT VOLTAGE APPEAR AT CRIVER BOARD OUTPUT REPLACE DRIVER lt 5 RTP INTERFACE CONNECTED AND WORKING PROPERLY REPAIR RTP INTERFACE 1 i c
38. circuit s series resistor will be found to be very close to zero degrees of phase shift Similarly when the track is empty there is a relatively large amount of inductance in the circuit and the track current will lag the system voltage Circuits are provided which will measure the amount of phase shift occurring between the two input signals from the track and therefore phase shift is the variable used to measure track length 3 1 2 Car Space System The Car Space System is a data acquisition system designed to provide track fullness information as a derived function of externally developed track associated phase angle measurements for a maximum of 72 tracks to any or all three independent requesting stations The system utilizes separate and continuously energized phase detector circuits which are multiplexed in a cascaded fashion for identification of a given track in a given group The selected analog information from the phase detector is sent to an external A D converter The A D converter output is sent to the Yard system Host CPU The Host CPU controls the scanning of the phase detectors stores the digital data and outputs the data upon request to any of the the yard system stations 3 2 DETAILED THEORY Refer to Figure 3 2 and 3 3 for the Detailed System Block Diagrams 3 2 1 Wayside Circuitry By proper connection of the Wayside Circuitry the phase angle signals are made to be direct indications of the available car spaces on a
39. e Detector Circuit 1 Perform the Phase Detector Calibration Procedures of Section V to determine if the circuit is operating correctly Satisfactory completion of the calibration procedures indicates that the circuit is operating correctly Any error that develops during the calibration procedures indicates a circuit failure that can be corrected by performing the following trouble analysis steps 6 7 6 4 3 Phase Detector P C B cont d 2 Refer to Figure 6 4 and with an oscilloscope make a point to point comparison of the specified points 3 Determine which components are faulty and replace them Repair any loose or damaged connections b The Multiplexer If the Multiplexer is suspected of being the problem compare the output signal to the input signal of the multiplexer by addressing the proper channel and monitoring the output If the output does not correspond to the addressed input the multiplexer chip 1C25 or its connections are faulty 6 4 4 Address board P C B If the Address Board P C B is suspected of being faulty refer to US amp S Test Spec EU 7995 sheets 8 10 for detailed testing instructions 6 4 5 Driver Board P C B If the Driver Board P C B is suspected of being faulty refer to Section V of US amp S Test Spec EU 7782 for detailed testing instructions 6 5 DETAILED CIRCUIT AND COMPONENT TESTING 6 5 1 General A Check Voltage and Waveforms Often the defective component can be located by checkin
40. ed to switch the address data from CPU A to CPU B is included Control of the switching is via external input The secondary purpose of the Address PCB is to fuse and route the Carspace system clean Power A supply plus and minus 15 volt power feeds to the remainder of the Carspace cardfile 3 3 3 Operation Of The Driver P B C The driver board contains 16 independently connected LM 759 Op amp circuits Each one of these is designed to amplify the low level analog output current of the phase detector board Each Op_Amp is capable of producing as much as 325 ma of drive current to an externally connected load This non inverting follower configuration of the OP Amp circuit causes the output signal to remain very stable under a variety of loading conditions Because of the feedback design used for this configuration it is a unity voltage gain circuit There is one LM759 Op Amp circuit used for each Phase detector P C B 3 4 DATA FROM CARSPACE RACK ANALOG ADDRESS TO CARSPACE RACK ADDRESS SWITCHING CONTROL CPU A c s FAILOVER A B SELECT LOGIC BOX ADDRESS SWITCHING CONTROL CPU B r M a ADDRESS TO CARSPACE RACK DATA FROM CARSPACE RACK
41. etween 1 and 4 volts depending on the distance to the last standing car on the track Refer to attached Phase detectorboard schematic N451441 3101 for output pin assignment information and Section 6 4 3 of this manual for troubleshooting guidelines Ref D Does all of the wayside equipment and circuitry prove good By performing the steps included in the Wayside Circuitry Troubleshooting Guide of this section the equipment and circuitry for the wayside can be checked Ref E Calibrate the Phase Detector PCB Perform the procedures of Section V Phase Detector Calibration If board still does not work properly repair and test per US amp S spec EU 6346 6 4 SUB SYSTEM TROUBLE ANALYSIS NOTE The schematics for all of the sub systems and their interconnections are included at the end of this section 6 4 1 General Once the problem is traced to a particular sub system one of the following steps can be performed 1 Replace the defective sub system with a known good spare 2 Repair the defective sub system as per the following procedures WARNING MAKE SURE POWER IS OFF BEFORE REMOVING ANY SUB SYSTEM OR DAMAGED COMPONENTS MAY RESULT 6 4 2 Wayside Circuitry Refer to Section 11 Operation of the Wayside Circuitry 1 Determine that all of the lightning arrestors and surge suppressors leaky and the fuses are not blown 2 Make certain that the following voltages agree Refer to Figure 3 4 a EOA 1
42. for P1 9 16 for P2 etc followed by lt RTN gt For a single track number just enter number 4 You will be prompted to select repeat mode Type y followed by lt RTN gt 5 The Driver output voltage raw value binary A D output and converted value feet will be displayed until another key is hit 6 When verification of tracks 1 8 is complete hit lt ESC gt to return to menu SECTION THEORY OF OPERATION 3 1 GENERAL THEORY Refer to Figure 3 1 for the General System Block Diagram 3 1 1 Car Space Measurement The car space measurement equipment measures the distance on a storage track from a given reference point usually clearance point to the point of last standing shunt on that track as produced by the last car on the track The operation of the car space circuits utilizes the effect of electrical phase relationship reflected from the rails of a track An alternating current applied to the rails of a track will encounter an impedance composed of resistive and inductive components This current lags in time when compared to the voltage across a series resistor in the circuit The inductance of the track varies directly with its length so that the shunt produced by the last standing car determines how much inductance is offered by the track as a circuit component When the track is full the inductive effect will be almost non existent and a comparison of these circuit currents with the voltage drop across the
43. g for the correct voltage or waveform in the circuit Typical voltages and waveforms are presented through out this manual NOTE Voltages and waveforms given in this manual are not absolute and may vary slightly between units B Check Individual Components The following procedures describe methods of checking the individual components in the Car Space Sub System Components which are soldered in place are best checked by disconnecting one end This isolates the measurement from the effects of the surrounding circuitry 6 8 1 Transistors The best check of transistor operation is actual performance under operating conditions If a transistor is suspected of being defective it can best be checked by substituting a new component or one which has been checked previously However be sure that circuit conditions are not such that a replacement transistor might also be damaged If substitute transistors are not available use a dynamic tester such as Tektronix Type 575 Static type testers are not recommended since they do not check operation under simulated operating conditions 2 Diodes A diode can be checked for an open or shorted condition by measuring the resistance between terminals With an ohmmeter scale having an internal source of between 800 millivolts and 3 volts the resistance should be very high in one direction and very low when the leads are reversed CAUTION DO NOT USE AN OHMMETER SCALE THAT HAS A HIGH INTERNAL
44. in core solder and a 35 to 40 watt grounded pencil type soldering iron on the circuit boards The tip of the iron should be clean and properly tinned for best heat transfer to the solder joint A higher wattage soldering iron may separate the wiring from the base material The following techniques should be used to replace a component on a circuit board Most of the components can be replaced without removing the boards from the unit 1 Grip the component lead with long nose pliers Touch the soldering iron to the lead at the solder connection Do not lay the iron directly on the board When the solder begins to melt pull the lead out gently This should leave a clean hole in the board If not the hole can be cleaned by reheating the solder and placing a sharp object such as a toothpick into the hole to clean it out A vacuum type desoldering tool can also be used for this purpose Bend the leads of the new component to fit the holes in the board If the component is replaced while the board is mounted in the unit cut the leads so they will just protrude through the board Insert the leads into the holes in the board so the component is firmly seated against the board or as positioned originally If it does not seat properly heat the solder and gently press the component into place Touch the iron to the connection and apply a small amount of solder to make a firm solder joint Do not apply too much between the component body and the solde
45. isplay should read 600 feet 55 feet 1 standard car length Note The display will normally drift within 5 feet over time The carspace system accuracy is contingent upon the quality of cable cable connections rail rail shunts and especially rail bonds The carspace accuracy is relatively linear to to the calibration point of 900 feet then increasing in error to the end shunt This is normal c Remove test shunt from 600 ft point Verify that the data display reads the distance to go to the last car or if empty the end of track length to the double end shunts 11 Repeat steps 7 10 on the next channel of the Phase Detector PCB 12 Repeat steps 1 11 on the next Phase Detector Board 5 3 SECTION VI MAINTENANCE 6 1 GENERAL Trouble analysis of the equipment used in this system necessitates that maintenance personnel have a working back ground in electronics including theory and fundamental troubleshooting procedures The following test equipment or equivalent is recommended for equipment troubleshooting Multimeter Simpson 260 Digital Voltmeter Fluke 8000A Fairchild 7000 Oscilloscope Tektronix 465 with two 10 1 Divider Probes Two Extender Cards 545 UN451441 1101 Two Rail Shunts 7 ft long with heavy rail clamps 06 ohm or less 6 2 BASIC TROUBLESHOOTING TECHNIQUES The troubleshooting procedures for the total system are arranged in an order that checks the simple possibilities before proceeding with
46. ize 85 80 H x 21 06 W x 36 00 D B Lambda Power Supply Assembly Electrical Input Q 117 V RMS 41095 60 HZ Output 1 15V 0 3A 2 15V 0 3A Physical Size 5 3 16 Hx 21 Dx 19 W Weight 27 16 C Carspace Cardfile Assembly US amp S P N N451056 5501 Cardfile Contains Driver Board 1 US amp S P N N451441 8902 Address Board 1 US amp S P N UJ793100 0019 Phase Detector Boards US amp S P N N451441 3101 One per group of eight tracks 2 1 SECTION Il CONTROLS AND INDICATORS CAR SPACE RACK Refer to Figure 1 2 When operating from any of the system data terminals within the yard control system software operating system it is possible to monitor the activity of the carspace system by typing in various commands at the system prompt 2 1 1 CSPI MODE OPERATION CSPI is the name of the routine which reads and displays carspace track information on a continuous basis This routine is selected from within the DIO I O interface test program 1 To run DIO Log in on the system terminal and type DIO at the system prompt 2 A menu will appear on the screen with several utility program options Select menu option Car Space Input by typing CSPI next to the gt gt gt prompt followed by lt RTN gt This will access the carspace test program that allows the verification of all signal interfaces between the Carspace Rack and the Host Computer RTP 3 You will be prompted for a track range Type 1 8
47. o the point where it disappears C Return The Sig C wire back to its original position on the case transformer as required 8 a Adjust the gain potentiometer for this track top most row of pots 5 turns clockwise from its most counter clockwise setting b Connect a DVM positive lead to the PCB output Test pin for this track See Table 5 1 negative lead should be connected to TP 26 for all measurements c Place a good shunt across the rails at the connections to the track transformer for the track under calibration Make sure connections are clean and tight d Adjust offset pot for this track middle row of pots so that the DVM reads 0 000 VDC Make sure data terminal display reads 0 Feet Adjust as necessary to zero display e Disconnect the shunt from the track 9 a Measure the rail and permanently mark it with paint at 900 feet from the track transformer leads Place the shunt tightly at this point b Adjust the gain potentiometer for the track under test top most row of pots such that the data terminal display reads 900 feet Note Normal drift about this number is typically within 5 feet The measured pulse width at the comparator output for this track See table 5 1 is typically between 9 and 1 millisecond Typical voltage is 1 5 volts 10 a Measure the rail and permantly mark it with paint at 600 feet from the track transformer leads Place the shunt tightly at this point b The data termina d
48. plies If all of the circuits are operating incorrectly the trouble may be in the power supply However a defective component elsewhere in the unit can appear as a power supply failure and may also affect the operation of other circuits The Lambda Service Manual lists the tolerances of the LND W 152 power supplies in this system If the power supply voltage is within the listed tolerance the supply is considered working correctly If the power supply voltage is outside the listed tolerance the supply is either misadjusted or operating incorrectly 6 3 FIELD MAINTENANCE PROCEDURES The possible trouble symptoms can be generalized into two categories I A failure in the front end of the system which would be indicated by faulty data to an entire group s 2 One of the tracks displays the wrong car space data as compared to the actual known car space availability reported by the others Using this generality the commort failure symptoms of the Car Space System can be identified as follows 1 Bad Data being sent to Terminal Display Refer to Figure 6 1 2 Routine Calibration Indicates Faulty Readings Refer to Figure 6 2 Troubleshooting flow charts for locating and correcting a problem have been developed for each of the symptoms listed above The symbol functions used in the flow charts are standard and are defined in Table 6 1 NOTE Before applying the flow charts for trouble analysis check the basic troubleshooting te
49. r joint with a pair of long nose pliers or other heat sink Clip the excess leads that protrude through the board Clean the area around the solder connection with a flux remover solvent Be careful not to remove information printed on the board 6 10 6 5 3 Circuit Board Replacement If the circuit board is damaged beyond repair the entire assembly including all soldered on components can be replaced Part numbers are given In the Mechanical Parts List for the completely wired board Observe the soldering precautions given in the soldering techniques of this section If the bottom side of the board must be reached or if the board must be moved to gain access to other areas of the unit only the mounting screws need to be removed The inter connecting wires on the PCB can quickly be disconnected to allow the board to be removed WARNING MAKE SURE THAT THE POWER IS TURNED OFF BEFORE REMOVING OR INSERTING A PCB THIS PROCEDURE WILL PREVENT FURTHER CIRCUIT DAMAGE 6 6 SCHEMATIC DIAGRAMS Application Drawings and PCB schematics for the Car Space System are provided to aid the maintenance personnel in system troubleshooting WAYSIDE CASE RELAY COVPUTER ROOM 8 120 nz SUPPLY 200w GROUP J CAPACITY WAYSIDE SIGNAL ISOLATION GND 9 0451492 0201 E XFLR E sein SYSTEM GROUND 5 UN451492 010 N 00w RA
50. ts the phase detector multiplexer and conversion routine for the next channel This repetition continues until all eight of the tracks on each board are read After all of the phase detector channels are read the Host CPU scans the two reference voltages full scale and half scale on each Phase Detector PCB to verify validity of data These references are compared to the programmed voltage references and if a discrepancy occurs the fail bit for that board is set After one second the scan is reinitiated and the sequence is repeated 3 3 SUBSYSTEM DETAILED THEORY 3 3 1 Operation of the Phase Detector P C B Refer to Section VI Figure 6 7 The Phase Detector PCB UN451441 3101 uses an LM319 dual highspeed comparator to compare the phase difference between the two incoming signals RC filtering and diode limiting are provided on the inputs of the comparator to provide for transient protection and noise reduction One of the RC filters contains a potentiometer for varying the phase of its input signal and hence provides a zero set for the comparator The comparator s open collector output drives the Hewlett Packard 5082 4351 highspeed optical coupler directly The output of the optical coupler is wired through a resistor to an LM309 5 volt referenced source The output of the optical coupler is a fixed pulse amplitude with a 60 Hz repetition rate which varies in width with a phase change The filter is a 1 Hz low pass two pole Butterworth type
51. uld be followed whenever attempting to calibrate the carspace system This procedure will cause a false distance to go reading to be sent to the yard computer It is suggested that the track be empty or at a minimum open to approximately 950 feet The track should be blocked and the switch ahead of the track transformer should be spiked Calibration and trouble analysis of the equipment used in this system necessitates that maintenance personnel have a working background in electronics including theory and fundamental troubleshooting procedures Failure to obtain the correct readings from previous steps will require troubleshooting not covered in this write up 5 2 POWER SUPPLIES 5 2 1 Power Supply Adjustments Apply power to Carspace Rack Turn Lambda Power Supply on Verify 15V 15V on the following extender card pins A22 AZ B1 BA Verify 15V 15V on A18 AV B5 and BE Verify Common on A6 AF B3 and BC Adjust Power Supply outputs as necessary per Lambda Product Manual Maintain per Lambda Product Manual 5 3 CARSPACE SYSTEM CALIBRATION NOTE Refer to Section VI General for the recommended test equipment needed to perform the following procedures 5 3 1 Data Terminal Set up Procedure following the procedure described in Section of this manual set up the data terminal to display carspace information on the screen This will be required while performing the system calibration procedure 5 3 2 System Calibration
52. ystem is subdivided into two sections the trackside signal input circuitry and the tower equipment 1 2 1 Trackside Signal Input Circuitry The Trackside Signal Input Circuitry consists of a 30 1 track transformer a 2 1 signal reference transformer a 600 ohm resistor and a surge suppressor per each track Eight signal transformers and eight surge suppressors are packaged in an assembly referred to as the wayside transformer Each wayside transformer can be used to service a maximum of eight tracks 1 2 2 Tower Equipment The Tower Equipment consists of the Car Space Rack Figure 1 2 This is the signal processing center for the total system and is interfaced with the wayside signal input circuitry and the RTP A D gate card The rack contains an analog electronics cardfile consisting of Phase Detector PCB s an address board a driver board In addition the rack contains a Lambda power supply assembly Track signal data is received from the wayside circuitry and translated to an appropriate analog signal level to be sent to the external RTP A D converter The digital output of the A D is then sent to the host computer for interpretation 1 3 SPECIFICATIONS A Track Coupling Transformer US amp S P N N451154 0101 Figure 7 4 Electrical 50 V A 60 Hz Physical Size 17 1 2 x 6 x 4 1 2 Hatio 30 1 LeeL pr TRACKS 1 8 CARSPACE RACK CASE MTO EQUIPMENT GROUP OVERALL ISOLATION SHIELD 2 XFMR 120v HZ
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