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Digitair Model 6695-CC End-of-Train Sense & Brake Unit (SBU

1. Figure A 2 Continued Composite SBU Lead Acid Battery PNs N26301601 N26301602 N26301603 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS m el 1 ue I E Yer 7 VAN 99636 4 PLACES 4 n Hb AT wa a 71 eae n ITEM 355 REMOVED MEASURE THE DISTANCE NGS WITH NUT THIS IS THE ps BETWEEN THE SHOULDERS OF THE TWO FITTI ITEM 350 ADD 174 TO THE MEASURMENT LENGTH TO CUT THE TUBE ITEM 340 INSTALL COTTER PIN ITEM 330 SO THAT IT MOVES FREELY N APPLY LOCTITE 242 ITEM 375 TO THREADS
2. fr EE L 27 s A Q 2 I 1 D IN TA WE HI s o LE JS Wy CC NS Figure A 5 Main Housing With Door Yellow PN N26301201 Gray PN N26301202 Blue Yellow PN N26301203 Main Housing with Door PN N26301204 Main Housing PN N26301205 SM 7066 12 98 APPENDIX A PARTS LISTS amp DRAWINGS SECTION SHOWING ASSEMBLY OF BATTERY DOOR IT 10 AND LATCH 17 15 TO C 1T 5 17 15 WITH DOOR OPEN A CLAMP FRAME IS NOT INSTALLED ON N26301206 ASSY DWG NO R263012 A 51 52 APPENDIX PARTS LISTS amp DRAWINGS A 20 CRANK HANDLE ASSEMBLY PN N24607401 Description Part Number Quantity per Assembly Spindle Claw M24602501 Bushing Coupler Mnt M24602401 15 Bearing Thrust Oilite 548 0001 00 2 20 Spring Take Up Digitair 410 0003 00 1 SM 7066 12 98 A 53 APPENDIX PARTS LISTS amp DRAWINGS CSE 11 3sv349 31971918907 aivo Tum 127 11 112 3111907 ONISN S LI 310 145 OLNO
3. f 9 Ut DIGIT AIR CHEST EE ad A VIEW gt A Z R 6369 500 96 50 SECTION B B L r N FOR CUSTOMERS THAT REQUIRE AMTECH TAGS IT 205 INSTALL TAG INTO SLOT AND SECURE IT WITH
4. BOG f T d mr N SYN doe J EI cl 1 140 25 N ed Hi ly I y F 3 50 REF ELI An ELA d ELA 1 i 6909 eu 5 dm 1 1 lt SECTION
5. p 2 dx ME LOGIC INPUTS us 2 _ E s na i B 3 3 HIE zla E CE 5 z 5 D T STR 2 1116 aa t en 8 DIAG ROPT Ages 8 H s guint g Dus ve ng a 501 04 HUXIN 2117 2222 17 1786 2 8K 17 1284 2 8K 12 1780 2 8K 13 0 2 OEL 1 mum 14 02 QE 58 x 538 74606 n e FLER 3 25038 OM FLASKE 1 1784 x We cM EW Gam h 5 74H04 4 Roa 8 2 RXHUDIQ 5 z ag xS 5 a 8 us HE 1 d 3 zS 7410577 d x EST M 1 iL lt i 8 Td Lara 149 OUTPUTS x 1 SET 2 5 8 1 ijo ANLG PUA 57 228 te 8415 3 1 at HE TRAN PUA i 51 0 Hx 2 ausi pm 52 03 17 x 1 LT SHITOH Di d 1 1 i 3 16 18 FLASH gt D ERN 24804 5 24 REG D 1 s vx 5 4g n dai 5 0 US 1 lt SET BT gt i
6. A TORQUE PINS 175 20 8 25 TO 86 IN LBS F 2 50 SECTION A A MAKE ALL ELECTRICAL CONNECTIONS TO CONTROLLER OF ELECTRONICS CAGE IT A J STAMP APPROPRIATE PART NUMBER AND SERIAL NUMBER ON NAMEPLATE IT 85 BEFORE ASSEMBLING TO CASE AT PROXIMATE L Nc 90 OG AN FOR ADDIT IONA 26501801 SEE Figure A 3 Composite SBU NiCAD Battery Gray Dual Pressure Quick Exhaust Small Hose PN N26301801 DWG NO R263018 SM 7066 12 98 A 27 28 APPENDIX PARTS LISTS amp DRAWINGS EE D s EP 1 us eA em AAN N Rett w
7. I 2 127 2 SW N E 1 1 30 HAN lt 1 r 9 soma f Feist i 2 S Q m GR 1 14 N 3 E SECTION A A s DO 270 275 280 4 PLACES A INSTALL COTTER PIN SO THAT IT MOVES FREELY 2 CRIMP CLOSED OPEN END OF S HOOK 1 115 AFTER ASSEMBLY APPLY LOCTITE PIPE SEALANT 17 150 TO THREADS ON BOTH ENDS FOR ADDITIONAL INFORMATION AND ASSEMBLY VIEWS SEE DRAWING R263 SH 015 DWG NO F263015A Figure A 1 Continued Composite SBU NiCAD Battery PNs N26301501 N26301502 N26301503 N26301504 N26301505 SM 7066 12 98 A 9 10 7 ji lt 4 L x 1 1 NS 1 2751210 OC 4 PLACES 50Y 255260 BYES 2 PLACES UA n k 5
8. Figure 4 Main Housing Assembly Yellow PN N26301401 Gray PN N26301402 Blue Yellow PN N26301403 Main Housing PN N26301404 Main Housing Assembly PN N26301405 APPENDIX PARTS LISTS amp DRAWINGS 2 5 7 53 lt lt gt lt 1 13 vi vi M yr VIEW LOOKING AT INSIDE OF HOUSING TO APAPTER 17 35 P sz SECTION A A SHOWING MOUNTING OF MANIFOLD ASSY E 15 TO INSIDE OF HOUSING 17 5 Gs TIT ER H VS SECTION B B SHOWING MOUNTING OF ADAPTER 17 35 TO INSIDE OF HOUSING IT 5 APPLY SMALL BEAD OF RTV AROUND EDGE OF MARKER LIGHT LENS ITEM 151 APPLY SMALL DOT OF RTV TO CORNERS OF GASKET ITEM 210 TO SECURE IN PLACE AN TORQUE SCREWS IT 260 TO 12 IN LBS N APPLY RTV TO GROOVE ON BASE OF ANTENNA ITEM O PRIOR TO SE
9. 26301902 J8IS 6 A 16 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS AN L GA 65 im SECTION C C 5 ee MN DIGIT AIR AING r END OF TRAIN TELEMETRY SYSTEM 2 LU NI a d j IL pl XXX 543 T 1 k YS 55 6 Lo 3 AS 5 J l NZ 10 c 1 4
10. APPENDIX PARTS LISTS amp DRAWINGS d 5 T Ll Ex G il SECTION JA INSTALL COTTER PIN SO THAT IT MOVES FREELY A CRIMP CLOSED OPEN END OF S HOOK 1 115 AFTER ASSEMBLY APPLY LOCTITE PIPE SEALANT IT 150 TO THREADS 2 ON BOTH ENDS AN FOR ADDITIONAL INF VIEWS SEE DRAWING R263 S ORMATION AND ASSEMBLY 015 F263 SH O0I5B Figure A 1 Continued Composite SBU NiCAD Battery PNs N26301501 N26301502 N26301503 N26301504 N26301505 SM 7066 12 98 A 11 12 APPENDIX PARTS LISTS amp DRAWINGS A 6 COMPOSITE SBU LEAD ACID BATTERY GRAY SMALL HOSE QUICK EXHAUST PN N26301601 Description Part Number Quantity per Assembly 10 _ Electronics Cage Assy 4605 1 15 PB NS Interface 50 1 20 Screw NyonOT2828H037 260727005 4 25 Washer Nylonirwosooe M7S1820000 4 30 Pulse Batey M26300 1 35 Scew 632x7l6PanHead 4507298017 7 45 Scew440xi4PanSS J5072970004 6 55 Stmdof 440xi2Mi 2592009 4 60
11. 4 3 4 1 14 Voltage 5 4 4 4 1 15 Diagnostics Port Power Supply 4 4 ANALOG GRE UNS aS 4 4 4 2 1 Detection of Transmission From Cab Unit 4 4 4 2 2 Receiving de atit EEE EEE NER 4 4 4 2 3 Transmitting Data rater Ee 4 4 4 2 4 Brake Pressure Circuit s ooo eR eaa tue 4 5 4 2 5 Temperature Dope Sene Dee 4 4 4 2 6 Baltery Circi KR Et 4 5 SM 7066 12 98 iii TABLE OF CONTENTS 4 3 MARKER LIGHT CONTROL MTEST AND 4 5 44 EMERGENCY BRAKE VALVE 5 4 5 4 4 1 Solenoid ACUVANOMN suser 4 5 4 4 2 Solenoid Activation Confirmation 4 6 4 4 3 TESTING m c Cx 4 6 4 4 4 Testing the Sinking MOSFET 16 4 6 4 4 5 Testing the Sourcing MOSFET 14 4 6 4 4 6 Interface Board 4 7 4 4 7 6 4 7 4 5 MARKER LIGHT BOARD u uuu ala 4 7 4 5 1 Optical and Mechanical 5 4 7 4 5 2 Marker Light 4 7 4 5 3 Ele
12. ACTUATOR 24 INCH POUNDS ey 22 SEE H DETAIL A MANIFOLD BODY P BRE we MES ER EE ATQ TM GENT A 7 Cast Manifold Assembly PN N24604101 SM 7066 12 98 A 57 58 APPENDIX PARTS LISTS amp DRAWINGS 22 EOT ADAPTER ASSEMBLY N24609901 Description Part Number Quantity per Assembly PCB Connector Assy N24700701 PCB RF Barrier N24701001 Cable Ribbon 13 In J0458510053 SM 7066 12 98 A 59 APPENDIX PARTS LISTS amp DRAWINGS a E a cc i e LJ d co LL C246099 Figure A 8 EOT Adapter Assembly PN N24609901 A 60 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 23 ELECTRONICS CAGE ASSEMBLY STANDARD NICAD BATTERY TYPE PN N24600204 Description Part Number Quantity per Assembly 15 Unit MotionSensor _______ 1 20 Synthszd Radio Prgmd N Amer N24600007 L 1 30 RubberExrudedChan A07508 1 4 10 001 i fio 115 PCB EOT Display Extender E 50 55 65 70 75 85 95 Washer SST Plate No 6 J4751200108 UNE 5 6 6 pm EN 9 9 a 105 cr si L 142 SM 7066 12 98 A 61 APPENDIX PARTS LISTS amp DRAWINGS A 24 ELECTRONICS CAGE ASSEMBLY STANDARD LEAD ACID BAT
13. MADE IN 1 USB TERRAS ER 1 UIEH R DISPLAY 045851 APPLICATION SHOWING DISPLAY BD STANDOFF CONNECTOR INSTALLATION 1 MATTE PS N FOR COMPONENT PART NUMBER REFS SEE COMPUTER BM 5 FOR SCHEMATIC DIAGRAM SEE 8451923 SH 4QE 2 3 TEST PER SPEC EU 8044 4 AFTER ALL COMPONENTS ARE MOUNTED TREAT PER PT 9368 1 SPRAYCOAT ALL OVER USING THE FOLLOWING PRECAUTIONS A MASK PHOTOCELL PHI DISPLAY AND CONNECTORS DSP1 amp DSP2 USING MASKING MATERIAL THAT LEAVES NO RESIDUE A CONNECTORS DSP1 amp DSPZ TO BE MOUNTED ON SOLDER SIDE OF PCB PER VIEW A MOUNT STRNDOFFS IT 25 ON SOLDER SIDE OF PCB PER VIEW USING HARDWARE AS CALLED FOR ON 4519234901 ASSEMBLY ONLY ITEMS 25 30 35 k 40 ARE NOT INSTALLED ON 4519234802 ASSEMBLY Figure 15 Display PCB 4519234002 SM 7066 12 98 85 APPENDIX PARTS LISTS amp DRAWINGS al 5 8 e fa fa l 2 8 Im a 8 ja 10 e e Wy Z E DISPLAY 11 DO 3 AO D1 1 02 14 D3 17 D4 1 15 06 2 WR 4 CUE 18 BL 5 3 9 von 19 HG2416S LO e
14. APPENDIX A PARTS LISTS amp DRAWINGS 25 SECTION C C SECTION 8 8 DETAIL A N STAMP NAMEPLATE ITEM 85 USING APPROPRIATE FCC 8 IC4 305 INFORMATION AS SHOWN IN TABLE BELOW A INSTALL REFLECTIVE DECAL ITEM 140 OVER MARKER LIGHT LENS ON N26301506 ONLY FLAT WASHER ITEM 305 TO BE INSTALLED BETWEEN PCB AND TOP OF BOSS TORQUE SCREWS 117 100 TO 12 INALBS A 00 NOT OVERTIGHTEN CABLE CABLE ASSEMBLY SHOULD MOVE FREELY A TORQUE SCREWS AND STANDDFFS ITS 45 8 55 TO 4 IN LBS CUSTOMERS THAT REQUIRE AMTECH TAGS 17 205 INSTALL TAG INTO SLOT AND SECURE IT WITH CENTER IT 200 IN UPPER HALF OF TAG WINDOW AS SHOWN DO NOT COVER NUMBERS ON NUMBER TAG IT 80 SECURE TAG IT 80 WITH MAKE ALL ELECTRICAL CONNECTIONS TO CONTROLLER PCB OF ELECTRONICS E IT 10 AND INTERFACE PCB 11 18 STAMP APPROPRIATE PART NUMBER AND SERLAL NUMBER ON EMBL I AT NAMEPLATE 17 85 BEFORE ASSEMBLING TO CASE APPROX IMATF SHOWN A TORQUE PINS 175 20 8 25 TO 46 IN LBS MARE ICs DESCRIPTION LA CRYSTAL FOR ADDI TI ONAI INFORMATION AND ASSEMBI Y VIEWS FOR PC NO f AZ489FT
15. SECTION CRIMP CLOSED OPEN END OF S HOOK 1 115 AFTER ASSEMBLY AA APPLY LOCTITE PIPE SEALANT IT 150 TO THREADS ON BOTH ENDS FOR ADDITIONAL INFORMATION AND ASSEMBLY VIEWS SEE DRAWING R263 SH 018 DWG NO R263018A Figure A 3 Continued Composite SBU NiCAD Battery PN N26301801 SM 7066 12 98 A 29 30 APPENDIX PARTS LISTS amp DRAWINGS A 10 MAIN HOUSING ASSEMBLY YELLOW PN N26301401 Description Part Number Quantity per Assembly 10 Antenna ConeShaped 7930730013 1 tens eter Gasket 4 20 Lens Marker Gasket M24601102 30 Pin Dowel3 46x1 1 4SS 70487220005 2 35 EOT AdapterAssy 24609901 1 80 Screw 10 32x5 8 SOC 45001240004 1 Decal Tape Reflective M24600804 Enclosur 1 1 4 Washer SST Lock No 10 J4751210109 Adhesive Loctite 454 40416080005 Grease Lubriplate Mag 1 438 0003 00 Jaw Fixed Stu Mount Raw 442 0050 00 Moveable 24602601 Crank Handle Assy N24607401 Wedged Foot Digitair Stu 440 0039 00 Screw Self Tap No 6 0 750 376 1523 00 Button Plug 5 8 Black 441 0064 00 Ring C Size 125 External 408 0423 00 Retainer Shaft M24603001 Screw 8 32 x 1 2 Hex Skt J5001240032 HdSS M24607 101 Washer Flat 1 2 1 250 O D 390 0214 00 SM 7066 12 98 A 31 APPENDIX PARTS LISTS amp DRAWINGS A 10 MAIN HOUSING ASSEMBLY YELLOW PN N
16. 8 T gt STORAGE OF CAL IERATION VALUES ere AND OPERATING VANLEGE a 2 ANN Hif 324K 1 84 12 aui sZ Sav R E x Tia H TENABLE He DBRT TEST TANPA a gt 1 1984 182K 7 an asu Pwan a gt i UP Xm I e we 18 96 1764 12 12 x 14 18 80 6K 5 74 1 vba B UFEF 2 er a 2 2 A 3 MODE TELIK BAT TEST gt MOSI 9 49 5 401 OPG 3 s 1 19 4764 40 2K D IDEM 4 E 5 BATTERY mn wu 2 i lt 14 msa 091628 COMPONENT AR lt NOT INSTALLED 18 0K 11 Pear at 18 8 BUS SETUP gt i122 1 2 p 124 5 57 91828 178412 p 5 pe amp mm RESET VERT 24MC32 6 THES l 8 86132485 x a 51843504 55 CE TR 3 VERT si 1621 Ex Ess m 9 5 6 255 E E Gib E ER Emneio 6 00105 2 5 x 5 2 E2 RES 841 9338 wee 5 ENE 741004 ge base 5 5 3 1 5 S SOLNOIO 5 lI 1 29 e 14 P x 3 D 57 8 8 a LB IZ E S 3 5 UAE X x R182x E 23 3 i gt
17. TNT OG 5 amp 7 JA SECTION B B A ae r 1 OOO GY 1 E e S A ite T Ti H 0211 2 4 39 SECTION A A kn Mmi FOR CUSTOMERS THAT REQUIRE AMTECH TAGS IT 205 INSTALL TU TAG INTO SLOT AND SECURE IT WITH RTV ees CENTER NAMETAG 17 200 IN UPPER HALF OF TAG WINDOW 33 4 AS SHOWN DO NOT Feen E RS on NUMBER TAG IT 80 SECURE TAG IT 80 WI ma on M U N roue Luc c IED WITH CASE ASSEMBLE BRACKE 8 CONFIGURE 580 PER EU 8338 30 TA TN MAKE ALL ELEC TRICAL _ CONNEI CTIONS TO CONTROLLER PCB OF Lo SI ANE NAMEPLATE MERC sing APPROPRIATE FCC amp ELECTRONICS CAGE 10 AND INTERFACE IT 15 A STAMP APPROPRIATE PART NUMBER AND SERIAL HERDET ON NAMEPLATE 17 85 BEFORE ASSEMBLING CASE Eafe APPROXIMATE LOCATION SHOWN SN M MEM mecs 0 LARA 109195243 LAC 7 22 PPS NP2422341 4 001 29841 953460 SYNTHESIZED TORQUE SCREWS ITEM 100 TO 12 IN LBS IN FOR ADDITIONAL INFORMATION AND ASSEMBLY VIEWS FOR PC NO N2630160 SEE DRAWING 263 5 016 AND FOR PC NOS INSTALL CONNECTOR ASSEMBLY ITEM 110 0 THAT KEY WAY N26301602 AND N26301603 SEE DRAWING F263 SH 0l 6B IS IN POSITION SHOWN ORQUE SC
18. o 38 E 2 b SEKE 38 E PAL 2 8 ANALOG POWER SWITCH 2 2731 PS 205 x PSL a E 06 UREF I 18 3 VBAT 1 52 E t 9 AUKIN G le 8 53 tuat RUXQUT HS 252853 EIER 7 8 UOLTS m Sx s 5 VERT NC x EA NC n E SADR AN SND Hen 2 8 NC NC ud M gt 5 15 7 are 3 i7 VERT VERT S TEST a Six S 2 a 14 3 MARKER I 18 og BL 1 8 MATE 3 IHE 1 ask x 1 101 088 5 823 2 4 5 C Y V 558 TRANSDUCER AUX 7 5 7 8 E ANLG PUR l 2 8 De estate SH 57 BATTERY STATUS x 3 9 40614 a z Ate 5 E BATTERY LATCH CIRCUIT TO SHEET 1 I 22 MAIN BORD Ug 84 f vert ix o aL HUM BATE 824 p ums 5 NFLASH lt E MEST M 5 aa gt VERT 3 UQUT 822 52 8 8 8 2 1 SET BAT lt 1 d 2 140K 1 84 12 T s t s DD gi La 16 NL M VERT SU lt s 5 825 8 zs gt ANALOG m ANLE PHA TRAN PHA pg PTD PUh UREF I 2 _ gt 2 DECOUPLING CAPACITORS 18 ONE EACH IC POWER PIN BAT TEST lt BATTERY
19. 28 018 MG ring r788 MATING SIDE nsi 09 p dp ges 02 04 Ds RESISTOR RESISTOR RESISTOR SUFFIX VALUE VALUE URLUE 843 OHMS 858 OHMS Rol OHMS 1601 1735552 0379 8 BGK J735552 9498 14 K 1735552 0563 655K 1682 J735552 1333 2 67K J 35552 8466 64 9K 4735552 0571 896 NOTES 4 CONFORMAL COAT FINAL ASSEMBLY PER PT 9368 1 SPRRYCUORT USING THE FOLLOWING PRECAUTIONS A MASK CONNECTOR CONTACTS FOR J1 AND J2 USING MASKING MATERIAL THAT LEAVES NO RESIDUE B PROTECT LED S AND POTENTIOMETER C MASK GROUNDING PAD LOCATED NEAR R37 6 POLARIZED PART OUTLINE SHOWN BELOW 21 CHAMFERED EDGE DENOTES POSITIVE END OF CAPACIITORS AND CATHODE END CF DIODES 451923 Sh 16 Figure A 16 EOT Marker Light NiCAD Type SBU PCB PN N4519231601 Lead Acid Type SBU PN N4519231602 SM 7066 12 98 A 91 APPENDIX PARTS LISTS amp DRAWINGS This page is intentionally blank A 92 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS SM 7066 12 98 MLATCH UBRT2 ASS 332K 1 80 1X CD40328 wnesasT S
20. 1 1 80 17 12 VBAT1 VBAT1 54 5194350 5 B1iuF 504 10 5 100K 17 84 2 2 6048938 R z amp X a E hen E x VNGGGST S Z 23 gt 58 gt g 5 un 858 lt Tur _ 342K 1284 17 a A m 8 4 a PRLL4981 6049938 3 ua sta kj ig 5 3 M a 3 VBRT1 SH UBAT2 SU x NORMALLY TILT TO CLOSE 1 SIS435DY 43 UBATI SW 4g UBATL SH A Zoo 3 3 cas og 5 P CELL amp 1 9 1 8k 1 REG 322K 1784 17 VERTA SW 4801 ABS 5 SIS43SDY 018 Fes Continued on Next Page _______ VERTS SH luf 50 1 71 5K 1480 12 4227 768K 1 84 14 8 4 VF RE DI TR TH W 1 107555 PRLL 48 DESIG DEVICE GND PUR uz 6049938 GND 4 2 NOTES 1 ALL RESISTORS ARE 1 1 8W UNLESS OTHERWISE NOTED 2 ALL CAPACITORS ARE 102 UNLESS OTHERWISE NOTED VEATA SU Fats iuf 17 4 140379210 7 VBRT3 SH 451923 Sh 16G 1 of 2 Figure A 17 EOT
21. 6 3 12 t M E VN 160 8 x 5 00 04 x cce x 5 amp x H SL RISB ser 3 325 f 8 aot gd s 8 7 85 1858 H x 52 1 EM 5158 x x xz 5 Ac x x 2 PRLL1961 ua E di 2 1886 149 1 1 Ji ILC3704 x 4 a O ai 1 9 x 8 BUF e MET 200 198 014 2 ET ety M OUR m da 5 x ase Um 3i 12 a 8 x 3 UBAT 13 5 4 E R 5 TFL ESET AT S SX ELY z x NC 145880 13 332K 1284 1 x M NOTES n m AME 3 BS Sl 1 ALL FESISTORS ARE 12 UNLESS OTHERMISE NOTED 4 55 SSE 2 CAPACITORS ARE 197 UNLESS OTHERHISE NOTED m ETT x i2 v 2 R 4 FIXED RESISTOR OPTION BE INSTALLED ONLY WEN T R43 k A44 ARE INSTALLED CHED M 8 2 pas 12 255 7 55 ZA FIXED FESIGTOR OPTION BE INSTALLED ONLY UFEN AN 5 4001 amp ASE ARE NOT INSTALLED G a BATOPTZ PUR CN A X JUMPERS JP THRU JPG AND CONNECTOR 114 FOR DEVELOPMENT LEE ONLY o yaar 5 8 82 2 58 5 m 5 y Drawing 247009 2 of 2 7 H Figure A 11 SBU Controller
22. 5 4 SM 7066 12 98 SECTION PERIODIC MAINTENANCE Operation _ Value Tolerance Comments en 5 nitials Brake dump test Pressurize 12 gallon tank Remove the input voltage return it to gt 12 to 50 psig Remove air VDC and reapply it Exhaust valve should supply and connect the tank close within 3 seconds to the End Unit glad hand Use Ear and Eye Protection Step 2 Trip Cab Unit Emergency Exhaust valve should open and vent the Brake Switch tank to lt 10 psig within 5 seconds Use Ear and Eye Protection Step 3 Wait for the End Unit Pressure in tank should be lt 4psig solenoid to close 25 to 45 seconds Step 4 Press Comm Test button Cab Unit should display 0 psig on Cab Unit Marker Light Press and hold test button The Marker Light should flash when the Sensor Test until the word PHOTOCELL ambient light is below the threshold and appears then release stop flashing when the ambient light is above the threshold Motion Detector Apply air pressure of 50 psig Verify that the Cab Unit indicates Test Press and hold test button STOPPED Step 1 until the word PRESSURE appears then release Leave the End Unit motionless for 2 minutes Step 2 Lean the End Unit towards Verify that the Cab Unit indicates the Marker Light FORWARD The Marker Light should flash 5 times and then stop Step 3 Within 5 seconds lean the Verify that the Cab Unit indicates unit away from the Marker REVERSE
23. o a lal jal 51 2 8 ja 0 o 0 DI 10 Q a a io a Figure 15 Continued EOT Display PCB PN N4519234002 86 5 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 31 PCB EOT MARKER LIGHT NICAD TYPE SBU PN N4519231601 Reference Description Part Number Quantity Designator per Assembly 0 sm rosmieormarerlgm 3776614002 1 R56 R54 Res Smd 1 8 W 100 0K Ohm J7355520484 11 R44 R39 R43 R62 R38 R45 R64 R40 R52 Res Smd 1 8 W 16 2K Ohm NI Ojo 951125 ke 25 40 45 R60 Res Smd 1 8 W 33 2K Ohm J7355520438 55 R55 R57 Res Smd 1 8 W 332K Ohm J07355520534 R48 R59 C1 C3 C6 Capac 01 MFD Smt J7091530011 C8 C9 C10 C12 C17 C18 100 C13 C7 C189 Capac 1 MFD Smt J7091530012 7 C15 105 Capac 2 MFD 50 VDC J7091450902 1 110 Capac 2 2 MFD 20V Smt J7091530017 1 115 C14 Capac 6 8 MFD 20V Smt J7091530019 2 5 1 70 75 85 40 45 957 60 70 75 80 85 90 125 1 02 08 Diode Smt 4001 7261020003 D4 05 D6 07 010 011 U1 135 DS1 thru Diode LED Red HLMP8103 J7261500293 144 DS144 Ul Int Ckt LT1178IN J7150290734 1 145 Int Ckt Smt 4093 J7150340049 1 SM 7066 12 98 A 87 APPENDIX PARTS LISTS amp DRAWINGS A 31 PCB EOT MARKER LIGHT NICAD TYPE SBU PN N4519231601
24. COMPONENT SIDE OF BOARD e RIVET AND SDLDER red 9 ISS A MADE IN USA VIEW 1J2 SHOWING APPLICATION OF CONNECTOR JRCKS TO PCB BRTTERY BD QUS amp SI 1 FOR COMPONENT PRRT NUMBER REFS SEE COMPUTER BM 3 INSTALL CONNECTOR JACKS IT S PER VIER 451923 Sh 35 Figure A 20 EOT Battery PCB PN N4519233501 SM 7066 12 98 A 103
25. Accepted One bit Errors Errors Three bit Errors Four bit Errors Rejected Failed Bit Sync Failed Frame Sync E go back 1 repeat 4 quit program To return to the Main Diagnostics Menu press lt gt SM 7066 12 98 3 5 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 5 5 Transmit a Continuous Unmodulated Carrier To transmit a steady unmodulated carrier return to the Main Diagnostics Menu and select 5 for Transmit Carrier and press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 8 Copyright 1995 Union Switch amp Signal Inc Show Model And Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 12008 Hz Transmit 1800 Hz Transmit Preamble Transmit 198 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking 1 2 3 4 5 6 8 9 Transmit Garrier INITIATED duration 5 seconds Enter menu item number Esc After 50 seconds the carrier will turn off automatically Press lt Esc gt to select another function or return to the Main Diagnostics Menu 3 5 6 Transmit a Continuous 1200 Hz Modulated Carrier To transmit a steady 1200 Hz modulated carrier return to the Main Diagnostics Menu and select 6 f
26. removing the battery and install the Radio TX Inhibit Adapter as shown in Figure 2 10 between the radio cable connector 15 pin D type and J6 on the SBU Processor PCB This inhibits all transmissions initiated by the SBU to prevent possible damage to the communication monitor Re apply power to the SBU by reinstalling the battery SOLDER PINS 1 13 15 CLIP PIN 14 OM 2 J1 17D A15P Ja AMPHENOL 17D A153 U Figure 2 10 Radio TX Inhibit Adapter Connector Connect the radio to the antenna input of the communications monitor and set the center frequency of the monitor as specified in Table 2 4 for local oscillator frequency Measure receive frequency error The error measured must be within 4 53KHz Once complete remove power re connect the radio antenna cable to the BNC connector of the transceiver and then remove the adapter from J6 and the radio cable Re connect the radio cable to J6 insuring that both screws are seated Re apply power to the SBU SM 7066 12 98 2 27 SECTION II SHOP MAINTENANCE 2 6 4 7 TX Center Freq for Johnson Data Telemetry JDT Transceiver 1 The Johnson Data Telemetry JDT transceiver is synthesized UHF type radio The transmitter center frequency is controlled by a Temperature Compensated Crystal Oscillator TCXO which has a frequency stability of 1 5 parts per million over its operating temperature range The Transmit Center Frequency
27. R29 R31 R32 R34 R42 R48 R53 R54 R57 R63 R68 R72 R74 77 R78 R79 R93 0 R2 R7 R9 Res Smd 1 8 W 10K Ohm J7355520388 11 R10 R13 R58 R87 R89 R90 R100 50 R30 R49 Res Smd 1 8 W 140K Ohm J7355520498 Res Smd 1 8 W 3 57K Ohm J7355520345 Res Smd 1 8 W 162K Ohm J7355520504 Res Smt 10 Meg 1 8 W J7355522002 R20 R88 Res Smd 1 8 W 1000 Ohm J7355520292 R38 R45 R46 Res Smd 1 8 W 2 80K Ohm J7355520335 80 R83 Res Smd 1 8 W 20 0 Ohm J7355520417 95 R5 R6 R25 Res Smd 1 8 W 332K Ohm J7355520534 a masa R3 R3 Res Smd 8W453KOhm 7355520355 RIS Res Smd 18 W44 2K Ohm 7355520450 815 Res 1 8 86 6 Ohm J7355520478 Res Smd 1 8 17332 Ohm J7355520438 R67 Res Sm 1 8 W 523K Ohm R62 Smt 500 Ohm 25W 96208500134 1 SM 7066 12 98 A 67 APPENDIX PARTS LISTS amp DRAWINGS A 27 SBU Controller PN N24700901 Continued Reference Description Part Number Quantity Designator per Assembly 180 C13 C14 C20 Capac 1 UF 50V J7091530003 C26 C30 C66 C67 185 C3 C12 C6 Capac 1 Smt 47091530012 C48 C51 C54 C57 C60 C63 C44 C45 C17 C42 C68 C69 Capac 22 PF Smt J7091530015 Capac 2 2 MFD 20V Smt J7091530017 210 C46 Capac 3 3 MFD 20V Smt J7091530018 215 C8 C9 C23 Capac 6 8 MFD 20V Smt 47091530019 C24 220 01 02 D3 07 Diode Smt 4001 J72610
28. 011 Mon Aug 18 16 41 11 1997 Enter menu item number You may select another function or press lt Esc gt to return to the Main Diagnostics Menu 3 5 2 System Information If the item selected needs several lines to display its result it will clear the screen and display the result in place of the menu For example if you wish to examine the state of the SBU press lt 2 gt for Show System Information and then lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 8 Copyright 1995 Union Switch amp Signal Inc Show System Information Brake Pressure 125 psig Secondary Pressure 168 psig Temperature 25 Celsius Moving FALSE Forward FALSE Brake Solenoid OFF Marker Light State OFF Current 721 mA 132 counts Replace Battery FALSE Telemetry Battery Timed level 997 Condition OD Voltage 13 0 volts 217 counts Battery Jumpers SHARED 2 4AH m Esc back Fi repeat F4 quit program This screen permits the user to examine the brake and secondary air pressures temperature motion detector output brake solenoid and Marker Light state battery condition and strapping options To update this screen press lt F1 gt To return to the Main Diagnostics Menu press lt Esc gt 3 4 SM 7066 12 98 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 5 3 Clear and Show Received Message Statistics The SBU is constantly gathering stati
29. 200 APPLY DROP OF LOCTITE 454 TO SPRING IT 200 TO TT 7 HOLD IN PLACE 205 H 1 280 5 A APPLY _ LOCTITE 425 TO THREADS ON PLUNGER EE NEU 17 230 AND NUTS 17 235 PRIOR TO ASSEMBLY A INSTALL SPRING 205 SO THAT LOOP END IS WRAPPED 2 AROUND ROLL PIN IT 200 AND END WITH 90 BEND IS Leet INSTALLED INTO HOLE ON LATCH IT 195 590 224 GIN 220 210 ars A 3 WHEN CRANK HANDLE ASSEMBLY IT 155 IS FULLY INSTALLED 17 175 6 TEES EAT RETAINING RING 175 INTO GROOVE ON FEET 17 160 FACES OUTWARDS WHEN INSTALLED FEET ARE SECURED IN POSITION WITH SCREWS IT 170 AS SHOWN PAST WITH LUBRIPLATE GREASE IT 245 FOR ALL ADDITIONAL NOTES VIEWS AND PART NUMBERS SEE DWG R263 SH 014 Figure A 4 Main Housing Assembly Continued PNs N26301401 N26301402 N26301403 N26301404 N26301405 DWG NO E263014A SM 7066 12 98 A 43 44 APPENDIX PARTS LISTS amp DRAWINGS A 15 MAIN HOUSING WITH DOOR YELLOW PN N26301201 Description Part Number Quantity per Assembly Main Housing Yellow N26300401 Door Battery Yellow M26300101 15 Latch EOT M26302301 2 20 Pin Hinge SS EOT BCHO 16 J5611290008 2 Pin Latch SS EOT BCLP 15 J5611310016 SM 7066 12 98 A 45 APPENDIX PARTS LISTS amp DRAWINGS A 16 MAIN HOUSING WITH DOOR GRAY PN N26301202 Description Part Number Quantity per Assembly Main Housing Gra
30. CONTINUED per Assembly 155 Us ImCH ICM7SSSMJA 71500979 1 17150340053 8 2 200 C23 10 025 37091530020 1 205 Res 1840 10K Ohm 735552088 1 A 88 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 32 PCB EOT MARKER LIGHT LEAD ACID TYPE SBU PN N4519231602 Reference Description Part Number Quantity Designator per Assembly sa 7760140000 1 R66 Pot 100KOhm1 aw 6208500088 1 R56 R54 R44 Res Smd 1 8 W 100 0K Ohm J7355520484 11 R39 R43 R62 R38 R45 R64 R40 R52 Varis 22 VDC Sind 35 Reo Res Smdi BW332K Ohm 7365520438 R59 R61 Res Smd 1 8 W 681K Ohm J7355520564 C1 C6 C8 01 Smt J7091530011 C9 C10 C12 C17 C18 100 C13 C7 C19 Capac 1 MFD Smt J7091530012 C15 C21 Capac 2 MFD 50 VDC 47091450902 118 125 D1 D2 D8 DA Diode Smt 4001 J7261020003 05 06 010 011 130 D3 Diode Smt Zener 5 1V J7261020001 135 DS1 thru 05144 Diode LED Red HLMP8103 J7261500293 70 35 60 Em 90 95 7 1 1 2 D 140 Int Ckt LT1178IN J7150290734 145 Int Ckt Smt 4093 J7150340049 3 1 150 Int Ckt Smt 3702 CMOS J7150340051 155 5 Int Ckt ICM7555 MJA J7150290737 160 Int Ckt Smt MAX8211ESA J7150340053 O 01 SM 7066 12 98 A 89 APPENDIX
31. GOOD or BAD is relatively instantaneous Press lt Esc gt to select another function or return to the Main Diagnostics Menu 3 5 12 Test ROM To initiate a test of the SBU EPROM memory return to the Main Diagnostics Menu and type 12 for Test ROM and press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Switch amp Signal Inc Show Model And Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1288 Hz Transmit 1866 Hz Transmit Preamble Transmit 188 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Gircuit Initiate Emergency Braking oco JA CA OO N m m MM ae Test Rom GOOD Enter a menu item number The response GOOD or is relatively instantaneous Press Esc to select another function or return to the Main Diagnostics Menu SM 7066 12 98 3 9 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 5 13 Test Brake Valve Circuit To initiate a test of the emergency brake solenoid return to the Main Diagnostics Menu and type 13 for Test Emergency Brake Circuit and press lt Enter gt The following screen showing the state of the solenoid and drive transistors will appear US amp S End of Train System Diagnostic Unit Software 1 80 Copyright 1995 Union Switch amp Sig
32. Wait 5 minutes for the SBU to power down as a result of having zero air pressure Set the output of the air source to 0 psig Connect the air source to the glad hand Apply 10 psig to the SBU air line The SBU should power up the Marker Light should flash for a configured number of seconds default 5 the telemetry system will run a self test and the standard test information will be displayed on the SBU The pressure should indicate 10 psig on the SBU display and also on the CDU Apply known air pressures to cover the rest of the desired measurement range e g 20 45 and 85 psig In each case verify that the CDU displays correct air pressure to within 2 psig SM 7066 12 98 2 7 SECTION II SHOP MAINTENANCE 2 3 11 Zero Pressure Shutdown Set the output of the air source to 0 psig The SBU should power down after approximately five 5 minutes as result of having zero air pressure 2 3 12 Motion Detector Set the pressure to approximately 50 psig the exact value is not critical Leave the SBU motionless for a minute to ensure that the motion detector is fully at rest Ensure that the Cab Unit indicates no motion or stopped High ambient vibration shaking floors etc will give poor results in the following motion tests If necessary steps should be taken to isolate the SBU from the vibration 2 3 13 Check Forward Motion 1 Move the SBU sharply forward i e in the direction it would move on a forward moving
33. m 2 864 REF J 00 REF SHOWING DISPLAY BOARD ITEM 25 SCALE 2 1 1 90 dale ER B EN 35 m S E I F3 HAM Fj Fa Sy V o FA E P 9 pe TN NE JE 1 0 2 FOR N24600204 THRU N24600206 8 N24600208 THRU lt 24600210 SEE VIEW MARKER LIGHT 17 40 WILL BE UNPOPULATED gt FOR N24600202 ASSEMBLY ONLY nan A PLUG EPROM IT 105 INTO SOCKET 022 8 SECURE IN PLACE USING ITEM 125 4 Y 299 4 606 REF gt 100 Figure 9 Electronics Cage Assembly Standard NiCAD Battery Type PN N24600204 Standard Lead Acid Battery Type PN N24600205 NiCAD Australia Frequency Radio PN N24600206 NiCAD Orange Composite Type PN N24600208 DWG NO F246002 SM 7066 12 98 A 65 66 APPENDIX PARTS LISTS amp DRAWINGS A 27 SBU CONTROLLER PN N24700901 Reference Description Part Number Quantity Designator per Assembly 20 R60 Res Sma 1 8 W442 Ohm J7355520258 35 R36 R94 R95 Jumper Smt 0 Ohm Res J7355522004 R96 R97 R99 40 R4 R1 R11 Res 1 8 W 100 0K Ohm J7355520484 3 R12 R16 R17 R18 R21 R22 R23 R24 R28
34. 52311 310 ITENISSV 885 009 Q39V9N3 38 15 9 11 310 145 ATENISSV JHL 30 1538 N334138 NMOHS SV dVO 80 OL S2 11 310 isnrav 323405 0798 HO HLIM HSNI SI NId 40 1 OS 08 11 Nid 18354 087113 Nid ONDHaS 803 TIIYG vid 0217 NI De aioin 97 AAA 1 OS Wall OLNI ONIT 4 SQVSYHL M3YIS OLNO 09 1 ALIWVIO 404 NMOHS M3IA 030014 3 RR C246 Sh 074 Figure A 6 Crank Handle Assembly PN N24607401 SM 7066 12 98 A 54 APPENDIX PARTS LISTS amp DRAWINGS A 21 Cast Manifold Assembly PN N24604101 Description Part Number Quantity per Assembly 10 Solenoid Vans Asy 1 Switch Pressure Brk Pressure Switch Cable Assy N246022 01 Screw SST 6 32 x 5 16 Pan J507298 0105 Washer SST Plate No 6 J475120 0108 Cable Tie Self Lkg J703310 M24604201 Adhesive Loctite 454 SM 7066 12 98 A 55 APPENDIX PARTS LISTS amp DRAWINGS This page is intentionally blank A 56 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS TORQUE TO NUT BRAKE 24 INCH POUNDS S LENOID 3 SPECIFICATION PLATE PRESSURE ENTIRE SURFACE ET a SWITCH THIS SIDE SOLENOID BODY PRESSURE TRANSDUCER i BOTTOM PLATE ALL AROUND TIRE SURFACE IS SIDE T
35. Apply air pressure of 0 psig Press Enter tion is outdated proceed with the libration If calibra rest of the ca Read the brake pressure on the LED display If out of spec abort the remainder of the test and check transducer Step 3 Apply air pressure of 100 If successful select Enter Date of Brake psig Pressure Calibration and enter date If Press Enter unsuccessful abort the remainder of the test Brake Pressure Apply air pressure of 0 psig 0 psig 0 3 psig Calibration Press and hold test button Verification until the word PRESSURE Step 1 appears then release display If out of spec abort the remainder of the test and check transducer psig display If out of spec abort the remainder of the test and check transducer Low Battery Test Apply input voltage gt 12 VDC Cab Unit should have no indication of low Press and hold test button battery until the word PRESSURE J1 jumper in shared position appears then release Step 2 Slowly reduce battery voltage Supply 1v until the Cab Unit indicates voltage 11 8 Weak Battery Step 3 Slowly reduce battery voltage Supply 1v until the Cab Unit indicates voltage 10 8 Replace Battery Step 4 Reduce battery voltage to 1 0 v End Unit indicated battery condition is 9 3V Press and hold test ABORT End Unit will power down button until the word TEST appears then release Table 5 4 Operational Tests All Units
36. PARTS LISTS amp DRAWINGS A 32 PCB EOT MARKER LIGHT LEAD ACID TYPE SBU PN N4519231602 CONTINUED 2 4 Designator Assembly Q2 A 90 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS D451923 16 m gt m m 9 D x a g E c d zn 59 a C 9C 9C 9C oC 9C 9C 9C 9C 9C 909 oC 9C oC 9C oC 9C C C 9C 9C 9C 9C eC 9C 9C 9C 9 9g C 9C 9C 9C C 9C 9C C 9 CC 9C 9C eC C 9C 9C 9C 9C 9C 9s 9 eC oC 9C oC 9C C 9C CC 9C 9C 9C 9C 9C 9C 90 9s XC 9C 2C 9C 9C 9C oC 9C C 9C 9C 98 CC 9C C 9C 0C 9g SC 9C 9C 9C 2C 9C 9C 9C 9C 9C 9C 98 s D 834 H3S R36 A33 Aal 28 B2Z R25 B23 R21 819 Ri Als RIS All AS 8 Re 111 zu LL IL IL ILILI LI 23211 2 28 825 824 R22 R20 R18 RIS 5143 05142 05141 05140 05139 05138 05137 05136 05135 05134 a nnnnrnr HRTING SIDE a MARKER LIGHT BD 1 OQ 06851 SEE NOTE 4C g RGB MADE IN USA
37. PNs N26301601 N26301602 N26301603 SM 7066 12 98 A 19 20 APPENDIX PARTS LISTS amp DRAWINGS a lt E AN CRIMP CLOSED OPEN END OF S HOOK IT 115 AFTER ASSEMBLY zs APPLY LOCTITE PIPE SEALANT 150 TO THREADS ON BOTH ENDS FOR ADDITIONAL INFORMATION AND ASSEMBLY VIEWS SEE DRAWING R263 SH 016 DWG NO F263016B Figure A 2 Continued Composite SBU Lead Acid Battery PNs N26301601 N26301602 N26301603 SM 7066 12 98 A 21 22
38. Ps INSTALL O RING SUPPLIED WITH VALVE 6 CUT OUT IN MANIFOLD ITEM 310 DISCARD NUT SUPPLIED WITH ITEM 350 AND REPLACE WITH NUT ITEM 355 ITEM 165 INTO A CRIMP CLOSED OPEN END OF S HOOK 1 115 AFTER 3 ASSEMBLY APPLY LOCTITE PIPE SEALANT IT 150 TO THREADS Z ON BOTH ENDS FOR ADDITIONAL INFORMATION AND ASSEMBLY VIEWS SEE DRAWING R263 SH 016 DWG NO F263016C A 23 24 APPENDIX PARTS LISTS amp DRAWINGS A 9 COMPOSITE SBU NICAD BATTERY GRAY DUAL PRESSURE QUICK EXHAUST SMALL HOSE PN N26301801 Description Part Number Quantity per Assembly 10 Electronics Cage Assy 4600 1 15 Assy BatterylinierfaceEOT 1 2 60 Cover Fuse M24604601 80 Numberfag O M24606 90 RearlidAssy DM amp IR 26301701 110 Nut 6 32 SS Elastic J048102 115 S Hook 2 875 Galv 408 0737 00 5 7066 12 98 25 APPENDIX PARTS LISTS amp DRAWINGS This page is intentionally blank A 26 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS 5 Latus N reu XE HHT Uy SECTION
39. RE2 uss2 x 18 580 57 _ 151 woo 20 PRESS Hc e Em 18 ar 1 OSCL CLKIN 804 lt C4 x x Fey OSCZ CLKO HE 8 8 9 r 1 PCB ACE IX A V 18 RCS Hix 8 ser 1 8K 1 84 1 mere 2 23 GND EX ACS ADS HEX 52 ADS RD2 Ex x unasesT 5 7 SZ N RE a 2 a Nu 2 i 7 PIC16C74JU e 1784 1X 2783 7 ANN 138 96 8 RDXL SAH 301K 1 84 1 ER ba eg lt 9 H ur C6 x gt SUDC x 7 T 9 9 GND x sx x SHIELD 188K 1 8M 1 d 3 922 2 i 55 LJ x lt lt 6 5 815 S K EEE 1 44 7 8 SND 27 A KE 5 JP2 3 ox GND Q x FOR JUMPER JACK S UNDS ST S UNDG ST x I g 2 47 208 e bs lt Tras lt E 7 7 lt x c ES SND GND x T 38 GND GND GND GND GND e 247005F Figure A 14 Motion Sensor PCB Schematic PN N24700501 SM 7066 12 98 A 83 84 APPENDIX PARTS LISTS amp DRAWINGS A 30 PCB EOT DISPLAY PN N4519234002 Reference Description Designator per Assembly 0 10 1 Res Light Dependent J792585016 1 DSP1 Conn 11 Pos Term Strip J7091460857 2 COMPONENT SIDE OF PCB Ll ee G6 CGU esa Of om
40. Transmit 1800 Hz Transmit Preamble Transmit 166 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking Transmit 1866 Hz Transmitting duration 48 seconds After 48 seconds the carrier will turn off automatically Press lt Esc gt to select another function or return to the Main Diagnostics Menu 3 5 8 Transmits Continuous Message Preamble To transmit a alternating 101010 1200 Hz 1800 Hz modulated message preamble return to the Main Diagnostics Menu and select 8 for Transmit Preamble and press lt Enter gt The following screen will appear Qoo CON US amp S End of Train System Diagnostic Unit Software 1 8 Copyright 1995 Union Switch amp Signal Inc Show Model find Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1266 Hz Transmit 1866 Hz Transmit Preamble Transmit 166 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking Transmit Preamble Transmitting duration 48 seconds Enter a menu item number hack Fi After 48 seconds the carrier will turn off automatically Press lt Esc gt to select another function or return to the Main Diagnostics Menu SM 7066 12 98 3 7 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 5 9 Transmi
41. ensure that the average current is measured Both open and shorted LEDs can be detected by measuring the total current flow and comparing it to preset limits 4 8 SM 7066 12 98 SECTION PERIODIC MAINTENANCE 5 0 PERIODIC MAINTENANCE CHECKS AND SERVICES The following schedule 1 guideline for periodic maintenance on the SBU Model 6695 The following recommended checks should be performed as indicated SERVICE MANUAL TYPE OF TEST RECOMMENDED SCHEDULE REFERENCE External As required for performance SM 7066 Section 2 3 verification after repair or any time External Every 3 months SM 7066 Section 2 3 Pressure measurement circuitry Every 6 months SM 7066 Section 3 6 calibration Radio power and center Every 6 months or at least once SM 7066 Section 2 6 4 frequency calibration per year per FRA requirements Emergency Valve Inspection and Every 6 months SM 7066 Section 2 6 3 Test Radio alignment SBU and Cab Once per year per FRA SM 7066 Section 2 6 4 Unit SBU measurement circuitry requirements calibration Table 5 1 Periodic Maintenance Checks and Services 5 1 BATTERY REPLACEMENT Depending on the configuration ordered the SBU Model 6695 CC can use up to two NiCad rechargeable batteries or a single Lead Acid type battery The SBU consumes a minimum of DC power thus maximizing battery replacement cycles 5 1 1 NiCad Battery Replacement To replace the NiCad style battery follow these
42. ensuring that the card guides line up with the ends of the processor board Do not force it into place If the SBU is dual pressure type unit first plug the auxiliary pressure transducer connector onto J9 on the processor board 2 Replace the six 6 hexhead capscrews in the rear panel Using a 5 32 Allen wrench tighten them uniformly alternating back and forth from top to bottom and side to side Do NOT apply threadlocker LOCTITE to the screws when securing the rear panel This will case the composite material to become brittle and prone to breakage Torque the six screws to 12 in Ibs 1 36 nm MAXIMUM Over torquing these screws can cause the inserts to pull out 2 5 12 Retesting After reassembly test the SBU as stated in Section 2 3 Quick External Tests 2 6 CHECKS AND TESTS OF THE MAJOR SBU ASSEMBLIES For the following checks and tests disassemble reassemble the SBU as required per the procedures described above in Section 2 5 Also refer to the parts lists and drawings in Appendix A 2 6 1 Testing the Air Manifold Assembly for Leaks Inspect the Air Manifold Assembly for the following e External damage Particles obstructing the exhaust hole The nut on top of the solenoid valve is secure e The seal around the Pressure Switch and Transducer 1 Remove and clean the screen or replace if clogged 2 Apply 85 psig air pressure to the Air Manifold Assembly via the air line connection and then close the air suppl
43. last car on start e SBU battery status weak or replace e Warnings about the brake pipe pressure threshold e f a Highly Visible Marker HVM Light is fitted on the SBU its on off flashing status is displayed e Radio communications status 1 4 SM 7066 12 98 SECTION I INTRODUCTION 1 6 SBU FUNCTIONAL DESCRIPTION The SBU mounts on the coupler of the last car of the train and is powered by 1 up to two Nickel Cadmium NiCad type batteries or 2 a single Lead Acid type battery The SBU connects to the train s air brake system via an AAR standard Glad hand The SBU transmits data to the Cab Unit using a nominal 2 Watt radio transceiver typically transmitting at 457 9375 MHz and receives commands from the Cab Unit at 452 9375 MHz These frequencies are standard for North American railroad operations however the SBU is available for operation at other UHF frequencies The SBU air sensing system incorporates a pressure transducer designed to be accurate to 1 psig 6 895 kpa To conserve battery life the SBU automatically powers itself down when the brake line pressure is 5 psig 34 kpa or less for 5 minutes Power is automatically restored when the pressure rises above approximately 10 psig 69 kpa The Dual Pressure type SBU is fitted with an additional pressure transducer and air hose glad hand This provides for monitoring of an additional air pressure source other than the main brake pipe Each SBU is factory coded with a
44. 1 5 SECTION I INTRODUCTION e PRESSURE Displays the current brake pressure for 30 seconds default time setting e ARM Although displayed the Arming Process can be initiated at any time TEST Displays the customer identification string the software version number the battery condition the results of self test the brake line pressure causes a Marker Light self test and sends a status report to the Cab Unit e PHOTOCELL Blanks the LED display to permit an operator test of the Marker Light 1 7 CAB UNIT GENERAL DESCRIPTION AND CONSIDERATIONS The SBU may be used with any AAR compatible Cab Unit to display the status at the rear of the train to the locomotive crew All of the various Cab Units are similar in that they mount in the locomotive cab connect to an antenna mounted on the roof derive DC power from the locomotive receive and transmit data to from the SBU via UHF radio For information on the various US amp S DIGITAIR Cab Units compatible with the Model 6695 CC SBU consult the following manuals SM 7042 Models 6652 CLU Model 6653 IDU Operator s Guide SM 7050 Models 6656 6656A CDU Installation and Operator s Guide SM 7050A Models 6656 6656A CDU Shop Maintenance SM 7063 Model 6696 CDU Installation and Operation SM 7064 Model 6696 CDU Shop Maintenance 1 8 ORDERING INFORMATION Refer to Service Manual SM 7065 Section 1 5 for ordering information regarding the various features options and mechanical configur
45. 10 Reinstalling the Electronics Cage 1 Ease the electronics cage into position tucking the top end behind the base of the antenna 2 Secure the electronics cage with seven 7 6 32 machine screws two near the base of the antenna one in the upper left hand corner of the Marker Light PC board one in the upper right hand corner of the Marker Light PC board one above and slightly to the left of the radio two along the bottom edge of the Marker Light PC board Be certain to use washer and lockwasher with each screw e If the SBU is equipped with slotted type screws to secure the electronics use leaf spring type locking screwdriver e g ChanneLock model 77H to ease the installation of the screw washer lockwasher combination e In Dual pressure 5805 pay particular attention to the placement of connectors J9 and J10 These two connectors are not keyed and could be interchanged 3 Replace the push on connectors located along the back edge of the microcontroller PC board When properly installed the wires on all connectors should extend towards the opening of the SBU From bottom to top the connectors are 2 14 The emergency brake valve solenoid J12 The pressure switch J11 The pressure transducer J10 The secondary pressure transducer if present J9 The test button J8 SM 7066 12 98 SECTION II SHOP MAINTENANCE 2 5 11 Reinstalling the Rear Panel 1 Carefully reinstall the rear panel
46. 2 6 4 Transceiver Module Alignment and Calibration The following procedure describes how to align and calibrate the SBU Transceiver Module The procedure applies to both the Motorola and Johnson Data Telemetry JDT type transceivers This is followed by specific information for performing adjustments for each type of radio During the course of the procedure refer to Section 3 0 which describes how to use the Diagnostic Software to perform radio adjustments 2 6 4 1 Removal of SBU Rear Panel 1 Using a 5 32 Allen wrench remove the 6 hexhead capscrews securing the rear panel Carefully lift off the rear panel 2 Inspect the rear panel and gasket for damage If damage is noted replace the panel and or gasket before re installing the rear panel In SBUs equipped for secondary air pressure measurement an additional air hose is fitted to the rear panel When removing the panel unplug the auxiliary pressure transducer connector from the SBU processor board SM 7066 12 98 2 21 SECTION II SHOP MAINTENANCE 2 6 4 2 Equipment Setup 1 Disconnect the SBU antenna BNC connector from the transciever and connect a watt meter in series with the transceiver and antenna as shown in Figure 2 5 To SBU Antenna To SBU Transceiver Figure 2 5 Use of Watt Meter 2 Connect a Radio Test Cable to J7 on the SBU Processor Board Note that Pin 1 on J7 is at the bottom The Radio Test Cable is constructed as shown in Figure 2 6 Note See F
47. 6 and 10 0 volts ABORT Battery is non usable Voltage is less than approximately 9 9 volts 4 The results of self test e g Self Test GOOD or Self Test 5 The brake pipe pressure the display will read PH where is the brake pressure in psig To further conserve battery capacity leading zeros are suppressed in the display for example 85 6 When the TEST button is released status report is transmitted to the Cab Unit 7 communications monitor is available connect small whip antenna to the antenna input of the monitor and set the monitor to check the transmitter frequency 457 9375 477 700 MHz The transmitter frequency error should be 2 29 KHz 2 4 SM 7066 12 98 SECTION II SHOP MAINTENANCE 2 3 4 Communications 1 4 Insert a charged battery into the SBU For bench testing it is recommended that a 50 ohm dummy load be connected to the Cab Unit antenna connector RF leakage is sufficient at this range for good two way communication if the equipment is working properly Power up the Cab Unit To ensure that it is not armed enter an ID of 00000 or use the Disarm function Then enter the ID of the SBU under test The Cab Unit should indicate a Not Armed condition 2 3 5 Communications Test Press and hold SBU TEST button until the display reads and then release it as in the previous section Since no pressure is applied
48. Checks and Services Mechanical and Electrical Drawings with associated Parts Lists Procedure for Making SINAD Measurements to Verify the Receiver Sensitivity SM 7066 12 98 SECTION I INTRODUCTION 1 5 SBU MODEL 6696 CC HARDWARE FEATURES The photo below highlights the SBU Model 6695 CC typical external components The Exhaust Valve and Air Hose are available in other configurations to accommodate specific requirements Antenna Unit Housing LED Marker Light Pocket for AEI Tag Reflective Decals ID Code Tag Test Button i LED Display Wind Locking Lever isplay Window Carrying Handle Crank Handle Battery Door Latch 2 Exhaust Valve and Coupler Clamp Glad Hand Figure 1 2 SBU Model 6695 CC 1 5 4 SBU Composite Case The SBU Model 6695 CC features a molded case manufactured using the latest composite materials This provides the strength and durability required to protect the internal electronics and related components from the severe environment encountered in the field such as temperature vibration impact and handling abuse The latest technology in RF shielded gasket material gives the SBU a high degree of water resistance and RF shielding A water resistant conformal coating is applied to all Printed Circuit Boards PCBs along with gold plated connectors for additional protection The Model 6695 CC SBU is designed to be lightweight with enhanced balance and a large handle for ease of hand carrying The
49. J0675840012 O Ring EOT Conductive 39 75 40675840011 Bracket EOT Clamp Retainer M26302401 Gasket RF M24610201 SBU Antenna Gasket M24306101 A 36 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 13 MAIN HOUSING PN N26301404 Description Part Number Quantity per Assembly 10 Antenna Cone Shaped 793073003 1 15 Lens Marker M24601101 20 ens Mater Gasket 1 30 Pin Dowe3H6x1 4SS 048722005 2 35 EOT AdapterAsy 4609 1 40 Washer SSTPiateNo6 4751200008 8 45 _Washer SSTLockNo6 3475121017 8 50 Display Lens M46030 1 55 ORIgAS 568BANo 130 40675840 1 60 Nut 4 1 2 12Retaining M24602 1 gt Acrylic Foam 2 W J0773730024 Washer SST Lock No 10 J4751210109 Jaw Moveable M24602601 Crank Handle Assy N24607401 Grease Lubriplate Mag 1 438 0003 00 Wedged Foot Digitair Stu 440 0039 00 Washer Flat 1 2 1 250 O D 390 0214 00 Screw Self Tap No 6 0 750 376 1523 00 Ring C Size 125 External 408 0423 00 Button Plug 5 8 Black 441 0064 00 Retainer Shaft M24603001 Screw 8 32 x 1 2 Hex Skt HdSS 45001240032 Screw SST 3 8 16 x 3 Nut 3 8 16 Elas Stop Jaw Fixed Stu Mount Raw 442 0050 00 Adhesive Loctite 454 40416080005 SM 7066 12 98 A 37 APPENDIX PARTS LISTS amp DRAWINGS A 13 MAIN HOUSING PN N26301404 CONTINUED Description Part Number Quantity
50. Light Step 4 Rock the End Unit gently Verify that the Cab Unit indicates back and forth for 20 MOVING seconds BEN motionless for 30 seconds STOPPED Step 6 Lean the End Unit away the Verify that the Cab Unit indicates Marker Light REVERSE The Marker Light should flash 5 times and then stop Step 7 Within 5 seconds lean the Verify that the Cab Unit indicates unit towards from the Marker FORWARD Light Step 8 Rock the End Unit gently Verify that the Cab Unit indicates back and forth for 20 MOVING seconds en muc motionless for 15 seconds STOPPED Table 5 4 Continued Operational Tests All Units SM 7066 12 98 5 5 SECTION V PERIODIC MAINTENANCE WARNING Ensure that the Transceiver s antenna output is connected to an antenna RF Monitor or 50 ohm dummy load when initiating transmissions Lack of an RF load can cause overheating of the transmitter and eventual failure 2 Technician s Operation Stimulus _ Value Tolerance Comments Transmit Use Diagnostic PC to 2 watts O w 25 w Use R62 on main board to adjust RF transmit un modulated if adjustment is made re lock Power carrier R62 with Glyptol or equivalent Transmitter Use Diagnostic PC to 457 9375 If out of spec correct by Center transmit un modulated adjusting coil L101 in the radio Frequency carrier This adjustment should be set for 200 Hz at room ambient temperature see Note 1 below Receive
51. MAINTENANCE Leave the SBU motionless until the motion detector resets Move the SBU so it tilts over a couple of inches This should trigger the impulse detector the waveform on pin 6 should go to 5V or 0V Rock the SBU back and forth at about 3 Hz Check the vibration output pin 8 on the scope the vibration level should drop towards 0V with increasing amplitude 2 6 2 2 Functional Check of New Style Solid State Motion Detector Preparation 1 Prepare a small level work area and use the circular bubble level to assure that the surface is actually level Preset the power supply output voltage to 5 0 Vdc 0 1V Turn off the power supply Remove the JP2 jumper plug from its dummy terminal posts located just outside and to the left of the RF shield box Install this shorting jumper plug onto the JP1 terminal posts inside the RF shield box Using a short lead with very small Pomona clips short pins 4 and 6 of terminal strip J2 For test and measurement purposes any circuit common connections can be made to pin 6 of J2 or to the shield fence which is electrically the same point and more convenient 2 5 Volt Bias Adjustment 1 Connect the positive terminal of the 5V power supply to pin 1 of terminal strip J2 using very small Pomona clips Connect the common terminal of the 5V power supply to pin 6 of terminal strip J2 or to the shield fence Using very small Pomona clips connect the Digital Multimeter DMM to pi
52. PCB Schematic PN N24700901 SM 7066 12 98 A 75 76 APPENDIX PARTS LISTS amp DRAWINGS TO D VOLTAGE REFERENCE MICROPROCESSOR POWER 11815 RESISTOR OPTION RADIO YIATURL GROUND S Tis m analog VERT SW 9 x h p Q CURRENT varT S4 5 TN 111121 5 F x 4 E ua i Ton ran P SU 1 2 pen don AE 4 1418 D TR 12 1784 1 0M 31 71205 4 3 x smi VREF 5 z0 ER 3 n nen 5 me 1 20 8 NC ag wtlys 1 55 nr 02 8 Su Sns g 12 i EDS 71 3 E 3286 2 E DE mu 18 B 24 23428 z 5 as 16 Hs oe DM 8 5514 5 3 57 6 2 3 Hi 5 11 07 TRANSDUCER PSI 57 88 22 21 23 lt gt SE e I Tree ES Wd s PST ATN SND 1
53. SBU LED display should display the standard self test messages The CDU should indicate 0 psig 5 After the SBU display goes dark begin slowly reducing the supply voltage 6 When the supply voltage reaches approximately 11 40 VDC the CDU should indicate a WEAK Battery condition Continue reducing the supply voltage slowly 7 When the supply voltage reaches approximately 10 50 VDC the CDU should indicate a REPLACE Battery condition 2 4 SBU MECHANICAL INSPECTION Prior to performing shop maintenance on the SBU visually inspect the unit for mechanical damage Refer to Section 2 3 1 for details 2 4 1 Torque Requirements for Composite Case Fasteners The composite case utilizes special threaded inserts for fastening the rear cover to the main housing and to mount the various electronic and mechanical assemblies comprising the unit When tightening the associated fasteners observe and adhere to the following torque requirements HVM Light Lens 6 32 Slotted Head Screws Telemetry Compartment 6 32 Slotted Head Screws Coupler Jaw Shaft Retainer Bar 41 in lbs 8 32 Allen Head Screws Table 2 2 Torque Requirements for Composite Case SBU SM 7066 12 98 2 9 SECTION II SHOP MAINTENANCE 8 in Ibs 0 90 nm 7 screws 6 in Ibs 0 68n 4 screws 12 in Ibs 1 36 nm 8 in Ibs 0 90 nm 6 mounting screws 4 screws 12 in Ibs 241 46 in Ibs 1 36 on BOE BE 46 in Ibs 5 20 I gt d
54. SBUs equipped with secondary air hose can be calibrated in the same fashion 3 14 SM 7066 12 98 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 7 SET PASSWORD PROTECTION SCREEN This screen is displayed when Password Protected Items is selected from the Main Menu 0565 End of Train System Diagnostic Unit Software 1 Copyright 1995 Union Switch amp Signal Inc Enter Password Set Customer String to 31 characters Change Password Cup to 9 characters Enter menu item number Esc go back This menu changes the Customer String or enters a new password The default password is set to US amp S unless otherwise specified by the customer Once the password is changed it is the responsibility of the railroad to remember the new password setting If the password is forgotten the Customer String cannot be changed and the SBU or its Processor Board must be sent to US amp S to default the password back to US amp S The first item in the Password Protected Items menu is Enter Password This password must be correctly entered before the other two menu items can be accessed The default password is US amp S unless otherwise specified by the customer Once the correct password has been entered the user can perform the following two functions 1 Enter or change the Customer String using the Set Customer String up to 31 characters menu 2 Change the existing password using the Chan
55. SM 7066 12 98 SECTION II SHOP MAINTENANCE 2 6 6 Receive Audio Level 1 The following procedures apply to all of the the JDT radio module versions except for the Australian version radio N24600009 which is described separately in Step 3 2 Setup the communication monitor to generate signal specified in Table 2 5 for Receive Frequency 60dbm frequency modulated at 3 0KHz deviation and 1200Hz audio tone Adjust the RX GAIN pot R43 for an output of 4 volts peak to peak at the RX OUTPUT of the Radio Test Cable The communication monitor should be used to both generate the RF output being fed into the radio and also to monitor the audio output from the SBU s filter RX OUTPUT If the communication monitor can not be used to set the RX OUTPUT use an oscilloscope R43 is adjusted re lock with Glyptol or equivalent 3 Setup the communication monitor for 1800Hz audio tone Measure the peak to peak amplitude of the RX OUTPUT The signal should be between 3 7 and 4 5 volts peak to peak Australian JDT Radio 4 Setup the communication monitor to generate signal specified in Table 2 5 for Receive Frequency 90dbm frequency modulated at 2 0KHz deviation and 1500Hz audio tone Adjust the RX GAIN pot R43 for an output of 300 mVp p to 1200 mVp p at the RX OUTPUT of the Radio Test Cable The communication monitor should be used to both generate the RF output being fed into the radio and also to monitor the audio ou
56. a DIAG lt Bets V CMOS 23 02 3 VTRANS 2 3 UTRANS x 74HC 2 2516 8 8 CHAK x 5 5 a alt 3 a 3 a x da 5 RESET TRAN PA TRAN PA 10791 x 8 03 05 580109 5 m x v V Figure 11 SBU Controller PCB Schematic PN N24700901 SM 7066 12 98 A 73 74 APPENDIX PARTS LISTS amp DRAWINGS
57. chart provides step by step rapid operational check of the SBU including adjustment information on the trimpots located on the Processor Board The chart may be used by a radio shop technician as a test check off sheet Operation Value Tolerance Comments sius 5 nitials Power up test Press and hold test button The display should indicate Customer until the word TEST User String US amp S by default Software appears then release Rev Battery Condition and Brake Pressure Marker should flash several times and then stop The LED display will 90 dark after displaying the brake pressure for 30 seconds default configurable Pressure Initiated Apply brake pressure gt 10 The display should indicate Customer Power up User String US amp S by default Software Rev Battery Condition and Brake Pressure Marker should flash several times and then stop The LED display will go dark after displaying the brake pressure for 30 seconds default configurable If ambient light levels are below the threshold Marker will begin flashing again when display goes dark Pressure Initiated Remove brake pressure The unit should continue to operate for 5 Shutdown minutes before powering down Power consumption should be 3 ma after power down Brake Pressure Use Diagnostic PC to select i Calibration Enter Date of Brake Step 1 Pressure Calibration Use Diagnostic PC to select Step 2 Calibrate Brake Pressure Sensor
58. gt 0105 100K 1784 17 PSI _ gt 9 I 5 x E x gt Etat gu gat B 378 8 epi 28 3298 0525 9 A39 A 845 gt ty 8 8 8 3 T3 3 8 8 8 8223 S 5 e 8 E x 9 lt 9 a a 8 lt yt 357 VANIL OG 8 3 Es a l E E s gt 8 amp 8 3 B 3 8 5 8 37 gg 032 EET B 8 B B 8 8 8 8 8 4 NOTES 1 pi L u 1 RLL RESISTORS 1H UNLESS OTHERMISE NOTED 57 2 9 CAPACITORS ARE 10 UNLESS OTHERLIGE NOTED D247009L Figure A 11 SBU Controller PCB Schematic PN N24700901 SM 7066 12 98 A 77 78 APPENDIX PARTS LISTS amp DRAWINGS A 28 UNIT MOTION SENSOR PN N24610101 Description Part Number Quantity per Assembly Motion Sensor Mtg Bracket 24609602 1 PCB Motion Sensor 24700501 1 15 Screw 6 32 x 3 8 Pan J5072980106 25 Washer SSTLockNo6 4751210107 4 30 Cable Ribbon N2461001 1 SM 7066 12 98 79 APPENDIX PARTS LISTS amp DRAWINGS M3IA 09 Z uV Vu C246 Sh 101 Figure A 12 Motion Sensor Unit PN N24610101 A 80 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 29 PCB MOTION SENSOR PN 2 Assembly Brd EOT Motion Sensor
59. key the radio for short time e g 5 seconds for each check It is NORMAL for a good radio to drift slightly e g 1000 Hz If the radio continues to drift outside the Tolerance value listed in the chart above it should NOT be put into operating service SM 7066 12 98 5 7 SECTION V PERIODIC MAINTENANCE i Technician Operation Stimulus Value Tolerance Comments Transmit Use Diagnostic PC to transmit unmodulated carrier 457 937 5MHz Transmitter Center Frequency Use Diagnostic PC to transmit unmodulated carrier See Table 2 5 for other frequencies Use Diagnostic PC to transmit preamble Transmitter Deviation For all transceivers except Australian version P N N24600009 Australian version P N 2 0 KHz N24600009 Input 452 9375 MHz 60 dBm FM Modulated 1200 Hz tone 3 0 KHz Deviation Use Diagnostic PC to select any non transmit mode See Table 2 5 for other Setting Receive Audio Levels Except Australian version p n N24600009 Setting Receive Audio Levels Australian version p n N24600009 Input 472 500 90 10 3 Vp p dBm FM Modulated 1500 Hz tone 2 0 KHz Deviation Use Diagnostic PC to select any non transmit mode 2 watts 0 w 25 w Use R62 on main board to adjust if adjustment is made re lock R62 with Glyptol or equivalent 675 Hz Ifthe reading is out of tolerance return the tran
60. of the LEDs during manufacturing or repair A special lens with individual pillows is placed in close proximity to the LEDs to disperse the inherently circular pattern primarily in the horizontal direction to meet the requirements set forth by the Federal Railroad Administration for a minimum light intensity of 100 candela on center and 50 candela at 5 vertically and at 15 horizontally from center 4 5 2 Marker Light Operation The operation of the Marker Light is enabled by the activation of a pressure switch connected to the brakeline of the train Once the brakeline pressure has been applied the Marker Light will continue to operate after brakeline pressure has been removed until such time as the battery is removed The Marker Light is designed to work with a photocell PH1 that is mounted on the elevated Display Board The photocell and its associated circuitry enable the flashing of the Marker Light when the ambient light drops below the ambient light level set forth by the Federal Railroad Administration A tilt switch SW1 has been incorporated onto the Marker Light board so that once the Marker Light has been removed from the train and tilted the Marker Light will automatically turn OFF Brakeline pressure must be removed before the tilt switch is enabled to turn off the Marker Light This ensures that the Marker Light will not be effected by vibration 4 5 3 Electrical Description The Marker Light Board includes th
61. steps 1 Release the retaining latches on the battery compartment door and open it 2 Remove the retaining nut s holding the battery in place Remove the used battery from the compartment Recharge each used NiCad battery as required 3 Align the hole of the replacement battery with the post in the battery compartment 4 Place the replacement battery onto the post and tighten the retaining nut all the way until the battery is secure Do not overtighten 5 Close and secure the battery door with the retaining latches 5 1 2 Lead Acid Battery Replacement The SBU version supporting the Lead Acid type battery contains a battery compartment that holds one Lead Acid rechargeable battery To remove the battery grip the battery enclosure and pull it out of the compartment To install the battery slide it into the compartment so that it mates with the internal power connector SM 7066 12 98 5 1 SECTION V PERIODIC MAINTENANCE 5 2 FUSE REPLACEMENT If the system processor radio or marker light fails remove the fuse cover to gain access to the fuse panel Check the following fuses and replace with 2 Amps as required Processor Power Marker Light Power Table 5 2 Fuse Functions 5 3 CLOSED CASE PRESSURE SENSOR CALIBRATION The Closed Case Calibration function eliminates the need of opening the case for recalibration of the pressure transducer s and associated circuitry usually every 90 days During the regular 90 d
62. two 2 4 40 machine screws retaining the 15 connector and remove the connector 3 Remove the four 4 2 56 machine screws securing the radio and make sure to locate remove and save all washers and lockwashers Lift out the radio 2 5 4 Removing the Motion Detector 1 Remove the Electronics Cage Assembly as described Section 2 4 3 2 Unplug the 10 pin Motion Detector ribbon cable connector from the processor board 3 Remove the 6 32 machine screws and washers securing the Motion Detector and lift it out 2 5 5 Removing the Air Manifold Assembly 1 Unplug the push on connectors associated with the components on the Air Manifold Assembly These connectors are associated with e The pressure switch e The pressure transducer e The emergency brake valve solenoid 2 Remove the SBU air hose or In Line Exhaust Valve located at the bottom underside of the SBU Note that the hose has a swivel fitting Be sure to grip the end most hex portion of the fitting 3 Using a 5 32 Allen wrench loosen and remove the four hexhead capscrews and washers securing retaining the Air Manifold Assembly Now the Air Manifold and its gasket can be removed 2 5 6 SBU Reassembly When tightening the various screws used for each assembly follow the torque requirements for each as stated Section 2 4 1 Over torquing the screws can cause the inserts to pull out 2 12 SM 7066 12 98 SECTION II SHOP MAINTENANCE DO NOT APPLY THREADLOC
63. unique five digit identification number contained in non volatile electrically erasable PROM EEPROM This ID number is included in each transmitted report so that the Cab Unit can disregard reports from SBUs on nearby trains Similarly the Cab Unit includes the ID code in its transmissions so that only the matching SBU will respond The SBU measures the pressure and status inputs once per second It transmits a report approximately once per minute when the pressure and status inputs are steady and more frequently when any of the following parameters change Each report is approximately 0 25 seconds in duration The conditions monitored by the SBU include e HVM light on off state e Battery condition e Motion detector state e Emergency valve circuit state No air state no air pressure for more than the default value of 5 minutes In addition to measuring and transmitting pressure and status information the SBU listens for commands from the Cab Unit 3 times per second If it receives an emergency brake application command the SBU vents the brake line by activating its emergency brake exhaust valve Various test modes are incorporated into the SBU Of major importance is the external TEST button and the associated four character LED display When the test button is pressed and held the display shows the following functions The operation selected is determined by the function displayed when the button is released SM 7066 12 98
64. unit features highly reflective 3MTM Diamond Grade reflective tape on the trailing side to increase night visibility for approaching train crews SM 7066 12 98 1 3 SECTION I INTRODUCTION The unit also features conveniently located battery compartment door on its reflector side Within the battery compartment is an RS 232 serial diagnostics port that connects to a PC This allows technicians to configure diagnose and calibrate the unit without opening its main electronics case Key XMTR Diagnostics and Calibration Lap top Information i i Internal for Diagnostics Transceiver Sleep Carrier Detect LED 8888 Display Internal RAM Transmit Signal Conditioning Circuitry Marker Light Marker Light Enable Internal Pressure D Light Acknowledge AID Signal Converter Conditioning Pressure Circuitry Switch Ambient Tilt Regulator Light Sensor Switch System E Brake Actuate E Brake EPROM Battery e 12VDC Solenoid Circuitry Parameter velocity EEPROM Motion Sensor vibration Figure 1 3 DIGITAIR SBU Typical Block Diagram 1 5 2 SBU Operating Features and Functions The SBU when operating in conjunction with a Cab Unit provides the locomotive operator with A digital display of the brake pipe pressure at the rear of the train e The ability to apply an emergency brake from the rear of the train An indication of motion of the last car moving stopped and the initial direction of motion of the
65. 1 to be installed oriented as shown OF BOARD Position component with notched edge toward designation XTAL1 left side of board 3 Install Connector J6 per View C DWG NO 247009 71 72 APPENDIX PARTS LISTS amp DRAWINGS 991 43 COMPONENT dE INSTALLED qm Drawing 247009K 1 of 2 COMPONENT KRIS INSTALLED CHANNEL SELECT OPTION COMPONENT xng7 INSTALLED m COMPONENT 3 INSTALLED i ADIT Ec Q2 28 COMPONENT NOT INSTALLED mx pata p BX AUDI OPTION RXRUDIO B Oe COMPONENT INSTALLED 57 TXAUDIO 4 24 IN TRANS PALLAGaL 17198517 x 8 mL LS 52 8 a 442 L BU 1 x s gt nura 23 tr e a 8 5 50 95 FORWARD 1 2 4 3 pa REVERSE 5 MILET a NOTION oan UBAT SU QG 2 89 232 INTERFACE P nr 18 88232 TX ER GAR a T2IN x 43 REIN v Ed R20UT 2 50 2 9 x L BAS z 238 LT 128815 S E E 8
66. 1 en a BHH SEDTGHH SE TBHH 9550 6850 6859 4854 7 4 Nj 5 4 99 SEBT HH SL TBHH SEBTEHH ZE 880 gesa 2681 1589 ta 2 Di Dt gt peu SL TBHH Xr Mel zat 1859 EBSO 1251 2 59 gt A b a gt A D Teu SEPIBHH SEOTBHH SEOTBHH XT 8259 2450 9251 5259 pi Pi PZ SE TBHH 5 50 SEQTBHH SEBISHH 2954 pee pe b SEQ T8HH 1980 2 Be SE ESHH XT cop 9550 SE TBHH SEBLBHH 5950 950 6959 WN bi yid ZT 6650 p pr SEQTEHH SCETEHH 5950 2 4 ST TEKHH 4 Aa D gt 77 gt 18 SEWTSHH SEOTEHH ccm XI CST 8951 635 9150 A SIE GEOTUHH SEPIOHH SCOTUHH Xl 550 8354 7339 AAA A P 43 SEBIGHH 58018 SEBIGHH 19 8550 2554 9550 5554 4 b an gt 2 D b r SCBIOHM SE TBHK SCUTGHH Xp 291 BISU 3250 A NNN gt t z N z P N ZIU SEOTBHH 291 Erat msa 054 EESQ 7 LA SE
67. 185 7 7 2 N 2 2 plass 5 Ji 04 N C Ra t JI 145822 aiia G Ji LIGHT F3 N F R SUFFIX 3402 ONLY a 2 ON SUFFIX 3402 23 04 amp JPL NOT INSTALLED 20 451923 Sh 34E Figure A 19 EOT Interface NiCAD Type SBU PCB PN N4519233401 Lead Acid Battery SBU PN N4519233402 A 100 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS INSTALL JUMPER WIRE IT 15 AT LOCATION JP1 BETWEEN PINS 2 amp 3 2 3 4 LA 7776615 779 N451923 34XX a m Lu LL 2 pent ca MADE IN USA ASSEMBLY DWG 451923 5 34 TOP SILKSCREEN PCB PART NO ASSEMBLY NO CONNECTOR 17 70 BE INSTALLED AT LOCATIONS 1 amp BATI ORIENTRTED AS SHOWN 67 DIA HOLES SHOWING ASSEMBLY DF 3481 VIEW SHOWING ASSEMBLY DF 3482 A 3402 TO BE ASSEMBLED PER VIEW A A QN 3402 COMPONENTS JP1 D3 amp D4 NOT INSTALLED 7 INSTALL JUMPER BLOCKS JPZ ON PINS 2 AND 3 INSTALL JUMPER BLOCKS JP3 AND JP4 DN PINS 1 AND 2 451923 Sh 34 Figure A 19 Continued EOT Interface NiCAD Type SBU PCB PN N4519233401 Lead Acid Battery SBU PN N4519233402 SM 7066 12 98 A 101 102 APPENDIX PARTS LISTS amp DRAWINGS A 36 PCB EOT BATTERY PN N4519233501 Reference Description Part Number Quantity per Assembly Brd PC EOT Battery J776616780 1 TJ1 TJ2 Jack For Stu Battery 6621 306 0036 00 2
68. 1981403 SUOI23NNOO 8 MOT104 3 1 3104 8 530831 SNISN HINO TIB 1800AbbdS 1 8966 14 834 5143404409 178 43149 72 ral 50831 N38 01 LON 71043882 9NI38 Su3I d 3S0N 41433N SNISN S Nid 110 1104 181 11 9 NOISN3IX3 17 MAIN TA 49808 01 91 40 3015 1913 6 213 519 x bli ET d Lobb L7 ae s 8431 2431 1931 Ga In sf Y SSI 708 5 NOLLON 103 lt 79 N 247 Sh 005 Figure A 13 Motion Sensor PCB PN N24700501 SM 7066 12 98 A 82 APPENDIX PARTS LISTS amp DRAWINGS SUDC 500 2 9 Li m luF vz 580 5 if e 9 l bag 2 UB CHOKE Ba e T amp 9 2 HBS 4 2 x 38 2 RB4 5 E 3 paz Lx T RB2 HEX 45 FAA RBI 154 RAs 2 8 E 4 vbo2 2 GND i x
69. 2 32 SM 7066 12 98 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 0 SBU DIAGNOSTICS AND CALIBRATION The SBU Model 6695 CC does not rely on dedicated external device for unit diagnostics All of the unit diagnostic tests and calibration functions are included on the DIGITAIR Diagnostics Software Disk This runs on standard DOS compatible personal computer PC which plugs into the SBU s diagnostic port located in the battery compartment via standard off the shelf straight through male to female DB 9 type serial communications cable The cable is available in most computer and office supply stores 3 1 DIAGNOSTIC SOFTWARE DISK The Diagnostic Software Disk contains a single program named diagunit exe The software can be ordered under US amp S part number N451232 1264 3 5 disk or N451232 1265 5 25 disk The software incorporates a full set of diagnostic functions for maintenance purposes and supports the capability to fully configure the SBU s operating features This manual provides examples of the configuration functions and provides detailed information on SBU diagnostics Refer to Service Manual 7065 Installation amp Operation for detailed configuration information and procedures 3 2 CONNECTING THE DIAGNOSTICS COMPUTER 1 Open the battery compartment 2 Plug the serial communications cable between the diagnostics computer and the DB 9 Diagnostic Connector located in the battery compartment This port is
70. 20003 D6 D8 D9 285 U5 Int LT10131N8 47150290745 68 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 27 SBU CONTROLLER PN N24700901 CONTINUED Reference Description Part Number Quantity Designator per Assembly 315 Ui itCk SmiLTI08 1 320 gt InCK Sm MC145388 37150340050 1 325 023 ImtCK Smtar4 J034052 1 330 Uii ItCk LTi0BsT 07450280733 1 Xsir 510435 PWR MOSFET 350 Q1 Q5 Q6 Xstr VN VNO605T MOSFET J7313760007 Q7 Q15 Q9 Q10 Q11 Q13 360 L1 L2 Inductor 10 UH Smt J7034850010 RVI RV2 480 C10 C11 Capac 01 MFD Smt 47091530011 17 C15 C16 C33 C35 C36 C39 C40 C65 C70 C71 C72 C73 SM 7066 12 98 69 APPENDIX PARTS LISTS amp DRAWINGS This page is intentionally blank A 70 SM 7066 12 98 R74 72 JL JL ores Ll Gl S SC mO ores F IM R78 C EL _ C3 8 a Goa SOL PRES SW CLIP PIN AS CALLED FOR OG VIEW SHOWING PIN REMGVAL CONNECTORS VIEW B VIEW SHOWING MOUNTING 111885 WITH HEATSINK VIEW SM 7066 12 98 J18 COMPONENT SIDE 11 E RS i le 49 8104 1 8 4 7 re 2 E 4 3 0 8 J 7 AUX PRES ARN
71. 26301401 CONTINUED iol Boca per Assembly 250 S Hook 2 875 Galv 408 0737 00 2 10 32 5 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 11 MAIN HOUSING ASSEMBLY GRAY PN N26301402 Description Part Number Quantity per Assembly 40 Antenna ConeShaped 79307003 1 _ 15 Lens Marker M24601 101 1 30 Pin Dowel36x11488 048722005 2 35 EOT AdaperAsy N24609001 1 40 Washer SSTPlateNo6 44751200108 8 45 Washer SSTlokNo6 24751210107 8 50 Dipaylen M2460330 1 55 O kRigAS 568ANo130 067584004 1 60 1 12 72 Retaining M24032 1 Switch Push Button SPST 65 Swich PushButonSPST 80 Screw i0 32x5 8SOC J5001240004 90 Scew SST 32xi 2Pan 25072080108 100 C Gasket Manifold 24604303 D D S S Assy Cable EOT N26301001 Washer 10 Plate SST J4751200110 W Assy Cable EOT Manifold N26300901 Tape Acrylic Foam 2 W J0773730024 M ecal Tape Reflective Bat Dor M24600805 100 ecal Tape Reflective Enclosure M24600804 M N 160 Wedged Foot Digitair Stu 440 0039 00 185 Retainer Shaft M24603001 Washer 3 8 Fiat SS 215 Scew SST3B 6x3 350734908 1 Plunger 172 13 Thread SM 7066 12 98 A 33 APPENDIX PARTS LISTS amp DRAWINGS A 11 MAIN HOUSING ASSEMBLY GRAY PN N26301402 CONTINUED Descripti
72. 4774 1098128 25KHZ N26301501 SEE DRAWING F263 5H 015A AND FOR PC NO MOTORO K44GNS1001 A 25301502 8 N26301504 SEE DRAWING F263 SH 015B MOTOROL A 081852 SYNTHESIZED KANNE A ESOSSBRE4TI 109195243 TRES JOHNSON 4 SYNTHES1 ZED DL 34i4 NP42423414 001 29841953464 2202 DWG NO R263015 Figure A 1 Composite SBU NiCAD Battery Gray Small Hose Quick Exhaust Valve PN N26301501 Composite SBU NiCAD Battery Gray In Line Exhaust Valve PN N26301502 Composite SBU NiCAD Battery Yellow Small Hose Quick Exhaust PN N26301503 Composite SBU NiCAD Battery Blue Yellow In Line Valve PN N26301504 Composite SBU NiCAD Battery Orange Small Hose Quick Exhaust PN N26301505 SM 7066 12 98 7 8 APPENDIX PARTS LISTS amp DRAWINGS
73. 5 CC SBU and a Cab Display Unit e g CDU Model 6696 If a fault occurs in the system try to isolate the problem to either the SBU or CDU To do this exchange each unit in turn with a known good unit Also use the built in Test Modes described in Section 2 6 Once the problem has been determined to be a fault in the SBU it will be one of two types 1 SBU does not work at all 2 SBU works incorrectly intermittently or partially For the first type of fault verify that the SBU is receiving power by examining the fuses and protection diodes located under the black plastic cover in the battery compartment Also verify that the TEST push button is making contact when pressed For the second type of fault troubleshoot the unit to identify the faulty PCB or electrical component for each of the SBU major assemblies listed below Refer to the assembly drawings schematic diagrams and associated parts lists provided in Appendix A 1 Back Cover Assembly Dual Pressure Type SBU e Pressure Transducer Air Hose Glad Hand Assembly 2 Battery Compartment e EOT Battery PCBs e EOT Interface PCB includes fuses 3 Electronics Cage Assembly e Radio Transceiver Module e EOT Processor PCB e EOT Marker Light PCB e EOT Display PCB Motion Detector Module EPROM 4 Air Manifold Assembly Solenoid Valve Assembly e Pressure Switch e Pressure Transducer SM 7066 12 98 2 31 SECTION II SHOP MAINTENANCE This page is intentionally blank
74. 5 psig and close the line to the air supply The Cab Unit should indicate this pressure within 2 psig Activate the Emergency Switch on the CDU The solenoid valve exhaust valve in the SBU should open within approximately one 1 second A loud blast of air should be heard and the air tank should empty within five 5 seconds The Cab Unit should display O psig After a configurable period of time default 45 seconds the valve should close with an audible click In the case where the SBU is configured for Set Brake Valve Open Duration a equal to zero seconds the solenoid valve will remain open indefinitely until the TEST push button is pressed 2 3 8 Marker Light HVM 1 2 6 Press and hold the TEST button on the SBU until the display reads PHOTOCELL the SBU will display PRESSURE and TEST before indicating PHOTOCELL then release the button The display will become dark for the operator to check the photocell light sensor for proper operation SM 7066 12 98 2 SECTION II SHOP MAINTENANCE If the ambient light level is relatively high due to bright lights or sunlight cover the light sensor located inside the display window to ensure that the Marker Light begins to flash The CDU should indicate HVM On or MARKER On Uncovering the sensor again should cause the Marker Light to stop flashing The CDU should indicate that the Marker Light has turned off If
75. ATING O RING CUT TAPE ITEM 120 TO A LENGTH OF 6 AND APPLY TO BACK OF RIBBON CABLE ON ADAPTER PCB IT 35 APPROX AWAY ROM BOARD BEFORE ASSEMBLING THE PCB ASSEMBLY TO HOUSING SCREWS IT 40 TO 10 IN LBS A APPLY SMALL BEAD OF RTV AROUND OF TEST SWITCH CIT 65 MOUNTING HOLES IN GASKET 17 20 MERE ren THAN SCREWS 17 90 FOR OPTIMAL SEALI __ APPLY PRESSURE ON GASKET TO INSURE IT Nor P Miele D WHEN INSTALLING SCREWS SN APPLY ADHESIVE 1 1351 TO END OF PIN 17 30 INSERT PIN INTO HOLE IN HOUSING 5 AND WIPE OFF EXCESSIVE ADHESIVE BEFORE IT DRIES EXCESSIVE ADHESIVE COULD INTERFERE WITH GASKET 11 20 AND RESULT IN IMPROPER SEALING COAT O RING 17 55 3 RI SUPPLIED WITH SWITCH IT 65 WITH GREASE LUBRIPL 140 BEFORE ASSEMBLY PLUG TWO FAST ON TYPE CONNEC TORS OF CABLE TO TERMINALS OF SWITCH IT 65 IGNORE COLOR DIFFERENCE OF CABLE WIRES FOR ADDITIONAL INFORMATION AND ASSEMBLY VIEWS SEE DRAWING E263 SH 014 DWG NO R263014 A 41 42 APPENDIX PARTS LISTS amp DRAWINGS 2 DA ZN N THIS SHEET IS NOT REQUIRED ASSY OF N26301406 5 VAA
76. Cover Fuse M24606 1 70 WeashrNo4STLlok 10890 4 80 M22466 1 85 1 90 Rear Lid Gray M26030 1 95 StpFoam M2460808 1 S Hook 2 875 Galv 408 0737 00 Support Chain Hose 408 0735 00 ed SSG 5 815 x Washer SST Lock No 8 SM 7066 12 98 A 13 APPENDIX PARTS LISTS amp DRAWINGS A 7 COMPOSITE SBU LEAD ACID BATTERY YELLOW RESETTABLE IN LINE VALVE PN N26301602 Description Part Number Quantity per Assembly 10 Electronics Cage Assy 4605 1 15 PB 50 1 20 Screw NyonO12828H037 260727005 4 25 Washer Nylonirwosooe M7S1820000 4 30 Pulse Batey M26300 1 35 Scew 632x7l6PanHead 4507298017 7 45 Scew440xi4PanSS J5072970004 6 55 Stmdof 440xi2Mi 2592009 4 60 Cover Fuse M24606 1 70 WeashrNo4STLLlok 0440 4 80 NumerTag M24606 1 85 M24609 4 90 Read Yellow M26030 1 95 SpFoam M46030 1 S Hook 2 875 Galv 408 0737 00 Washer 5 8 PIn Flat SST J4751200118 4 4 4 4 ed SSG 5 815 Sealant Pipe 40153 4 Valve In Line Resettable QKEx 792426000 ArrHoseAssy Eor 092760000 1 Scew SSTG 32x2 Pa
77. HOUSING PN N26301405 CONTINUED Description Part Number Quantity per Assembly 270 O Ring EOT Conductive 36 J0675840012 1 Gasket RF M24610201 SBU Antenna Gasket M24306101 A 40 SM 7066 12 98 255 OR CABLE MANIFOLD ASSY IT 30 DOGG 119 AN SM 7066 12 98 F 2 1 C
78. IGITAIR Model 6695 CC Shop Maintenance this manual 1 1 DEFINITION OF TERMS The following terms and abbreviations are used throughout this manual EOT End of Train Refers to an End of Train telemetry system comprised of a Cab Unit mounted in the locomotive and an End Unit mounted on the coupler of the last train car SBU Sense and Brake Unit A two way End of Train End Unit capable of remote Emergency Brake Application such as the SBU Model 6695 CC CDU Communication Display Unit Any generic two way End of Train Cab Unit HVM Highly Visible Marker Device The Marker Light portion of the SBU an FRA approved flashing light used as a warning device to mark the end of the train 1 2 SBU MESSAGE PROTOCOL COMPATIBILITY The SBU Model 6695 CC is compatible with all EOT equipment employing existing protocols such as the American Association of Railroads AAR End of Train message protocol It meets or exceeds the guidelines of the AAR along with the Federal Railroad Administration FRA the Federal Communications Commission FCC and Industry Canada IC regulations 1 3 TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link R A I L Team is comprised of experienced product and application engineers ready to assist and resolve any technical issues concerning DIGITAIR End of Train equipment or any US amp S product Any questions regarding the contents of this Service Manual should be directed to the R A I L
79. IRE 46 in Ibs 5 20 4 screws in Ibs 0 45 nm Figure 2 2 Torque Requirements for Back Panel and Electronic Mechanical Assemblies 2 5 SBU DISASSEMBLY AND REASSEMBLY PROCEDURES While performing the following procedures please refer to the parts lists and drawings provided in Appendix A CAUTION The SBU contains static sensitive components Always work at a grounded workstation and observe proper ESD handling practices Uninstalled circuit boards must always be contained in static free bags If these procedures are not followed equipment damage may result When tightening the various screws used for each assembly follow the torque requirements for each as stated Section 2 4 1 Over torquing the Screws can cause the inserts to pull out 2 10 SM 7066 12 98 SECTION II SHOP MAINTENANCE DO NOT APPLY THREADLOCKER LOCTITE TO ANY OF THE SCREWS WHEN TIGHTENING THEM THE CHEMISTRY OF THE THREADLOCKER CAN CAUSE OUTGASSING AND WILL ATTACK THE COMPOSITE MATERIAL MAKING IT BRITTLE THREADLOCKER IS NOT REQUIRED AS ALL SCREWS EITHER HAVE LOCKWASHER OR ARE SECURED BY TENSION 2 5 1 Removing the Rear Panel 1 Remove the battery or batteries from the SBU 2 Using a 5 32 Allen wrench remove the six 6 hexhead capscrews in the rear panel Carefully lift off the rear panel 3 Carefully inspect the rear panel gasket for damage If damage is noted replace the gasket before re installing the rear panel In SBUs equ
80. KER LOCTITE TO ANY OF THE SCREWS WHEN TIGHTENING THEM THE CHEMISTRY OF THE THREADLOCKER CAN CAUSE OUTGASSING AND WILL ATTACK THE COMPOSITE MATERIAL MAKING IT BRITTLE THREADLOCKER IS NOT REQUIRED AS ALL SCREWS EITHER HAVE LOCKWASHER OR ARE SECURED BY TENSION 2 5 7 Reinstalling the Pressure Manifold 1 Place the gasket and manifold the bottom of the battery compartment with the solenoid facing towards the open end Replace the four 4 hexhead capscrews and lockwashers Tighten with 5 32 Allen wrench Install the air hose or the in line exhaust valve using pipe sealant US amp S J041753 Loctite 56747 or equivalent Be sure to grip the end most hex portion of the fitting when tightening 2 5 8 Reinstalling the Radio 1 2 Place the radio into the mounting slot in the electronics cage Secure the radio with the four 4 2 56 machine screws Use a washer and lockwasher with each screw Replace the 15 pin connector and secure it with the two 2 4 40 screws 2 5 9 Reinstalling the Motion Detector 1 SM 7066 12 98 Place the Motion Detector in the electronics cage making sure that the ribbon cable is facing toward the open end of the enclosure Secure the Motion Detector with 6 32 machine screws Use a washer and lockwasher with each screw Reconnect the 10 pin Motion Detector ribbon cable connector to J4 on the processor board 2 13 SECTION II SHOP MAINTENANCE 2 5
81. Marker Light Schematic NiCad Type SBU PCB PN N4519231601 Lead Acid Type SBU PN N4519231602 A 93 94 APPENDIX PARTS LISTS amp DRAWINGS Xp ng cop 190 EFTSQ 5154 4 NAN SE TSHH n t SEUTEHH 46 b SEPTEHH 17159 Er ISO SE TEHH 18159 SEPTSHH 66150 SCUTSHH 66150 si SE TEHH 70139 GEN SELG 80154 pr 55018 SEBISHK 32150 2150 p SEQTOHH A ANN pi 2 291 TEN SCULEHH Xt 02150 etu pr SEG T HH SCOTOHH SEBISHH 1159 518 SE T SHH xr mer cgi 5850 SEBISHH KT CS pi SEQTBHH 1859 SE TSHH SCOTBHH SEPIOHH XT 51154 21154 11159 7 7 7 b 7 b b A bey SE TBHH SEPIOHH XI nk ge ee 5 Sg AAA pp P BEH SEBT8HH Xi ml 8050 28159 524 asa A AW DEZ PE DE SE TBHH ur meer d GJEL GJE emo Nvv P pb 8 SEWISHH SCOIGHH 98750 5 154 XL 281 ELEN D pL SCUISHM SEUTSHH 9650 5654 9850 5850 ME 9
82. Menu 3 10 SM 7066 12 98 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 6 PRESSURE SENSOR CALIBRATION To initiate the Pressure Sensor Calibration function return to the Main Menu type 3 and then press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Switch amp Signal Inc Choose The Calibration Pressure Calibrate Brake Pressure Sensor Enter Date of Brake Pressure Calibration lt 9 characters Calibrate Secondary Pressure Sensor Enter Date of Secondary Pressure Calibration lt characters Enter menu item number To calibrate the primary and optional secondary pressure transducers perform the procedures described in the follow sections 3 6 1 Choosing the Upper Pressure Setpoint The brake pressure calibration technique performs Zero and span correction to ensure correct readings The default upper limit for the span adjustment is 100 psig 690 kpa However some railroads have established calibration procedures that while they still use 0 psig kpa for the zero adjustment use a different upper limit To define an upper brake pressure limit other than 100 psig 690 kpa type 1 for Choose the Calibration Pressure and press lt Enter gt The following screen will appear Choose The Calibration Pressure Current value is 100 psig 0 back F4 quit program Enter a new value for the brake pressure cal
83. OL ON OVER C Current flowing through solenoid i gt 1 4 gt shorted coil 14 A gt 1900 ma gt normal on i lt 300 ma gt normal off SOL ON is located at U23 pin 13 OVER C is located at U23 pin 14 Table 4 1 Solenoid Activated Bit Status 4 4 3 Testing To test the health status of a solenoid and proper operation of the switching circuit biasing resistor R75 is used in conjunction with the two voltage dividers that will apply one half to the emergency brake solenoid This voltage allows the brake solenoid circuit to be tested without actually activating the solenoid by turning on the sinking and sourcing MOSFETs one at a time and checking the voltage present on both sides of the solenoid 4 4 4 Testing the Sinking MOSFET Q16 1 016 pin 18 is set low and EBRAKE2 016 pin 18 is set high SBRAKE2 U23 pin 2 bit must produce a logic high 2 The EBRAKE2 bit is then set low The voltage present on the positive side of the solenoid will be pulled to ground SBRAKE2 must produce a logic low indicating that the voltage dropped below approximately 5 1 volts If the two conditions above are met then the Sinking MOSFET Q16 and the solenoid are good 4 4 5 Testing the Sourcing MOSFET Q14 1 U16 pin 18 is set low and the EBRAKE2 U16 pin 18 is set high SBRAKE1 U23 pin 1 must produce a logic high 2 The EBRAKE 1 bit is then set high The volt
84. ON rnnt 3 1 DIAGNOSTIC SOFTWARE DISK eeii 3 1 CONNECTING THE DIAGNOSTICS COMPUTER 3 1 RUNNING THE DIAGNOSTIC SOFTWARE ON THE 3 1 MAIN MEN u oo cre dei e o E Ge 3 3 DIAGNOSTICS MENU gur 3 3 3 5 1 Software Version Number 0 4 3 4 3 5 2 System Information messer arnested 3 4 3 5 3 Clear and Show Received Message Statistics 3 5 3 5 4 Show Received Message 3 5 SM 7066 12 98 3 6 3 7 IV 4 0 4 1 4 2 TABLE OF CONTENTS 3 5 5 Transmit a Continuous Unmodulated 3 6 3 5 6 Transmit a Continuous 1200 Hz Modulated 3 6 3 5 7 Transmit a Continuous 1800 Hz Modulated Carrier 3 7 3 5 8 Transmits Continuous Message Preamble 3 7 3 5 9 Transmit 100 Messages doe ont dus 3 8 3 10 Test Marker 3 8 3 94 Test RAM See 3 9 9 9 TERM 3 9 3 513 T st Brake Valve Circuits de 3 10 3 5 14 Initiate Emergency Braking I eir 3 10
85. PRESSURE SENSOR CALIBRATION nennen 3 11 3 6 1 Choosing the Upper Pressure 3 11 3 6 2 Calibrating the Brake Pressure 3 12 3 6 3 Recording the Brake Pressure Sensor Calibration Date 3 14 3 6 4 Calibrating the Secondary Air Pressure 3 14 SET PASSWORD PROTECTION 3 15 CIRCUIT DESCRIPTION 2 4 Ce faic Vade 4 1 CIRCUIT 4 1 PROCESSOR BOARD EP E EH 4 1 4 1 1 EPROM MEMORY 4 1 4 1 2 EEPROM Memnon a a R Ta N Da Na ha has 4 1 4 1 3 4 1 4 1 4 Reset 4 1 4 1 5 System 4 2 4 1 6 Battery Latch 4 2 4 1 7 Expansion POL iP E 4 2 4 1 8 Microcontroller Power Supply 4 3 419 Analog Power Supply VANALOG ean 4 3 4 1 10 Pressure Transducer Power Supply Vprp 4 3 4 1 11 Pressure Transducer Power Switch Q10 4 3 4 1 12 Modem Power Supply 8 4 3 4 1 13 Radio Power Switch
86. PTION 4 1 7 Expansion Port The microcontroller PC Board is equipped with an expansion port J13 that will permit future hardware expansion Additionally it provides access to the Address and Data buses for debugging Voltage Regulation and Power Management Circuits There are a number of voltage regulators and switched power sources within the SBU as described in the following paragraphs 4 1 8 Microcontroller Power Supply This regulator U10 supplies the 5 volts for the digital circuits 4 1 9 Analog Power Supply VANALOG This regulator U4 is controlled by the microcontroller output bit ANLG PWR U16 pin 13 When the bit is set high seven 7 volts are applied to the analog circuits Some of these analog circuits are switched off when not in use by microcontroller output bits to further reduce power consumption 4 1 10 Pressure Transducer Power Supply VPTD second voltage regulator U9 is also controlled by the ANLG PWR bit It provides the voltage source for the VREF 1 generator U3 and the Pressure Transducer 4 1 11 Pressure Transducer Power Switch Q10 Power is applied to the Pressure Transducer when the ANLG PWR bit is set as described in Section 4 1 9 However the transducer is not enabled until the PTD PWR U16 pin 12 bit is set providing a ground path for the transducer Once the PTD PWR bit is set and the appropriate stabilization approximately 15 msec time has passed the output of the Pressu
87. REWS 8 STANDOFFS ITEMS 45 8 55 TO 4 1 85 DWG NO R263016 Figure A 2 Composite SBU Lead Acid Battery Gray Small Hose Quick Exhaust PN N26301601 Composite SBU Lead Acid Battery Yellow Resettable In Line Valve PN N26301602 Composite SBU Lead Acid Battery Gray In Line Valve PN N26301603 SM 7066 12 98 A 17 18 APPENDIX PARTS LISTS amp DRAWINGS x L J Ge B L lt EXE A 7 1 AT ee L y NOM E a DWG NO F263016A A CRIMP CLOSED OPEN END OF S HOOK 17 115 AFTER ASSEMBLY APPLY LOCTITE PIPE SEALANT 1 150 TO THREADS ON BOTH ENDS FOR ADDITIONAL INFORMATION AND ASSEMBLY VIEWS SEE DRAWING R263 SH 016 Figure A 2 Continued Composite SBU Lead Acid Battery
88. RF shield box 10 Carefully position the lid of the RF shield box onto the shield fence and softly press the lid to a full seated position 2 20 SM 7066 12 98 SECTION II SHOP MAINTENANCE 2 6 3 Emergency Valve Inspection 1 Inspect the emergency brake exhaust valve brakeline air filter screen visible from the inlet port of the valve Remove any particles being careful not to force them inside the valve 2 Check the emergency brake exhaust valve piston movement by pressing on it When fully depressed the piston should completely clear the emergency brake valve exhaust hole 3 Apply greater than 30 psig 207 kpa to the SBU and close the supply valve Depress the pressure relief valve on the emergency brake exhaust valve and check that all air is exhausted 4 Apply 85 psig 586 kpa air pressure to the SBU then close the air supply valve Listen for air leaks at the emergency brake exhaust valve and at both ends of the air hose The pressure should not drop by more than 8 psig 55 kpa in 1 minute If an air leak is suspected at a certain component apply soapy water to the area in question and watch for bubbles Correct if necessary Perform Emergency tests as stated in section 2 3 7 If the emergency brake exhaust valve is found to be faulty it should be returned to US amp S for inspection Attempting to service the emergency brake exhaust valve is not recommended The valve requires no lubrication and has no user repairable parts
89. SECTION II SHOP MAINTENANCE being filtering by a narrow low loss bandstop 1 KHz filter The filtered signal stripped of the audio tone contains only the internally and externally generated noise and distortion Allowing for the filter insertion loss the ratio of these two levels signal plus noise plus distortion to noise plus distortion is the SINAD and is typically computed and displayed automatically The ratio is expressed in decibels with the standard value being 12 dB 2 6 7 1 Measuring the SINAD To enhance the signal and suppress the noise the SBU is equipped with an audio bandpass filter that was optimized for the modem frequencies of 1200 and 1800 Hz To correctly measure the SBU receiver s sensitivity using the SINAD technique it is necessary to treat the receiver and audio filter as a system Measure the SINAD as follows 1 Remove the SBU s Rear Panel 2 Connect the SBU Radio Test Cable See Figure 2 56 from the output of the audio output filter at J7 located beside the 15 pin D connector on the Processor Board to the audio input of the SINADDER Be sure to insert the connector in the proper orientation This is a relatively noisy place on the PC board so for best results use a shielded cable keeping the center conductor length near the pins to an absolute minimum 3 Disconnect the SBU antenna at the BNC connector on the top of the radio 4 Set an FM modulated RF Generator as follows and connect to the rad
90. SW RF GAIN RADIO ane eoe VIEW SHOWING 0815 CONNECTOR MOUNTING TO BOARD VIEW C SOLDER SIDE OF PCB 24 2123 st 912 9 825 R31 ms J 446 esL _ GAC 5 R22 gt 08 R33 TP12 TS 2 Jen L 4 EY d 2 88 uu esu RX GAIN MOTION DET For Component Part Number Refs See Parts List After all components are mounted treat per PY 9368 1 Spraycoat all over using the following precautions A Mask off connectors through 713 DSP1 amp DSP2 potentiometers R43 R50 R62 and all IC sockets On connector J8 clip off top of pin 1 flush with connector as shown in View B On connector J12 clip off top of pin 2 flush with connector as shown in View B Connectors J5 J14 Jumpers JP1 JP2 JP3 andU21 not used at this time Mask 5 during wave soldering and reflow Polarized part outline shown below n Chamfered edge denotes positive end of LJ capacitors and cathode end of diodes Figure A 10 SBU Controller PCB Assembly PN N24700901 cis asl id R2 JC J ar _ col dcs APPENDIX PARTS LISTS amp DRAWINGS 48808 YITTOHINOJ NES BSN NI 3084 D R9 d ar We pt C 48 1 LC BOAC De Ta Crystal XTAL
91. Smt 77661684 1 a _ 15 J1 Term Str 10 Pin TSW 105 25 J7091461093 20 Res SmdiiBW267KOhm 735552049 1 Eus one __ Res Smd 1 8 W 511 Ohm J7355520264 E R2 R5 Res Smd 1 8 W 100 0K Ohm J7355520484 R12 R13 R14 ner C5 C6 KE NM Smt 1UF 50V C9 il Smt 022 MFD 50V J7091530033 55 C3 10 100 7095305 1O 60 15 1007 7091530034 1 80 u ImCK PICICTLO4 P ___7160290707 1 90 3709213008 1 2 126 Ui _IntCkt Acoeler ADXLOSAH 715029078 1 130 Ui Ped ICMnigi0Lead 135 Endesure Shelded 7051890008 1 SM 7066 12 98 A 81 APPENDIX PARTS LISTS amp DRAWINGS aga MAIN Yad 93408 OL 391 1914 91H 11815 1 LI 084 SNISN 08408 01 4311815 1 38 OL 18 MAIN 834 11815 1 53504804 8 1 33 804 YOLIINNOJ 831104 38 01 S Nid 9 1802 TYWHOSNOJ 83138 413 9414309105 804 SAIOH UIG 088 2 74518 HS O 901934405 NO e 46 13 2445 Ydd 1531 913195 TIYLSNI 18 34943 913115 26 QT31HS 802 34883 2 SNId u3dunf 5138005 5031 VW 419 431340 3nd1S3d ON JUIH3lUM ONDISUM 9NIS ANG if 804 5
92. TERY TYPE PN N24600205 Description Part Number Quantity per Assembly 55 Rubber Chan 4 35 Cabe Transmiter 1 60 Weasher SpingLockNo2 47521003 4 80 Adhesve Lodite454 041608005 001 85 BusigSmRf 300W 705074 1 90 Scew 440x38PanHd 450729706 4 95 Weashe No4FlSS 07506 4 100 Weashe SSTlockNo4 17521005 4 105 Prom EOT Puse SBU 84515527 110 Standoff 4 40 x 4 250 47927750041 Cable Tie Self Lkg 70330 1 A 62 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 25 ELECTRONICS CAGE ASSEMBLY NICAD AUSTRALIA FREQUENCY RADIO PN N24600206 Description Part Number Quantity per Assembly 35 RebberExruded 4 35 Cabe Transmiter 1 60 Weasher SpingLockNo2 47521003 4 80 Adhesve Lodite454 041608005 001 85 BusigSmRf 300W 705074 1 90 Scew 440x38PanHd 450729706 4 95 Washe No4FlSS 75120096 4 100 Wesher SSTlockNo4 07521015 4 105 EOTReaUnt 550 1 110 Standoff 4 40 x 4 250 47927750041 Cable Tie Self Lkg 70330 1 SM 7066 12 98 A 63 APPENDIX PARTS LISTS amp DRAWINGS A 26 ELECTRONICS CAGE ASSEMBLY NICAD ORANGE COMPOSITE TYPE PN N24600208 Description Part Number Quantity per Assembly 35 Rubb
93. Team via telephone at 1 800 652 7276 or via Internet e mail at railteam switch com SM 7066 12 98 1 1 SECTION I INTRODUCTION 1 4 INTRODUCTION AND GENERAL OVERVIEW The DIGITAIR End of Train Telemetry System consists of a Sense and Brake Unit SBU mounted on the coupler of the last train car that communicates via UHF radio with a Cab Unit such as the DIGITAIR Model 6696 Communication Display Unit CDU mounted in the locomotive cab The SBU when operating in conjunction with a Cab Unit provides the locomotive operator with information about the conditions at the rear of the train that are important to the operation of the train as depicted in Figure 1 1 below LOCOMOTIVE LASTCAR p m EE seamen RF LINK pec i 6695 BRAKE PRESS BATTERY STATUS VEHICLE STATUS ODOMETER CAB UNIT BRAKE GAR MOTION INPUT OPT Oo LINK TEST EMERGENCY ACTIVATION Figure 1 1 Two Way End of Train Telemetry Functions This Service Manual provides information on the SBU Model 6695 CC as follows Functional Description and Specifications Ordering Information and Service Equipment Options Test Equipment Requirements and Built in Test Modes for Troubleshooting amp Repair Mechanical Inspection and Disassembly Reassembly Instructions Operation of the Diagnostic Unit Software Detailed Circuit Description Periodic Maintenance
94. Trimpot R66 located on the Marker Light PCB Assembly is used to adjust the ambient light threshold This trimpot is accessible by removing the SBU s back cover and is located at the bottom of the Marker Light Board below the Motion Detector Module Trimpot R66 is factory calibrated for specific light threshold and sealed It should typically NOT require adjustment In the event that maintenance on the SBU involves the replacement of components on the Marker Light Board the replacement of the four character LED display board or the photocell on the LED display board trimpot R66 can be used to readjust the ambient light sensitivity To perform this adjustment select the PHOTOCELL function using the SBU s TEST button as described in the Unit Testing Section in Service Manual 6496 SM 6496 Simulate dusk or dawn ambient light conditions by placing an appropriate light source e g a flashlight with diffused lens directly against the display window Since the SBU s back cover is removed ensure that other light sources i e bench lamp sunlight etc do not interfere with the adjustment Turn trimpot R66 in the clockwise direction to reduce the sensitivity turn trimpot R66 in the counter clockwise direction to increase the sensitivity The HVM Light will flash or not flash accordingly When the adjustment is complete reseal trimpot R66 SM 7066 12 98 5 3 SECTION V PERIODIC MAINTENANCE 5 6 OPERATIONAL TEST CHART The following
95. UISHH SCOTBHH Xt M t 9950 5 50 US A A nits Nive RU 1 SEBISHH SC TSHH ur 8650 azsa 5190 A 58 Par gt SEBISHH W 2230 SEBISHH SE TSHH SE TBHH XP TOT bad 50 2 2 ND E pe 3 SEDTEHH SEGTSHH SE TBHH 18 291 HEST FESI tex 1680 MAY h b SE TSHH SC TSHH SE TBHH SXOTEHH ur cp 3080 e ra SEOTSHH SE TBHH SE TSHH SEV TBHH Mery 8150 2150 5158 SE TSHH SE TSHH 7250 0252 Ag gt Aa gt 5 9159 an td SEBTEHH Continued from previous ay SEBTOHH SEQTBHH SEQTSHH Xr 2150 1154 254 A p p 18 SE LGHH SE 1 BHH SEPLOHH 297 554 SE TBHH 550 SEOTBHH SEELSHH Page An SE TBHH 6159 an S Q7GHH SE TBHH 4001 TELENETAY 05 PRUL 4981 HUN POLER MLATCH PRESSURE SHITCH 1694 Tid VERRIDE LIGHT SENSOR X MTEST ENABLE POWEA MANUALLY MARKER LIGHT CURRENT AIRG FOR LIGHT ON INSTALLED 1 NARKEA P CELL PHOTOCELL LT1178 47 MARKER I AT MT 6587 1 0K 1 94 OG 18 2K 128813 S
96. UNION SWITCH amp SIGNAL 645 Russell Street Batesburg SC 29006 SERVICE MANUAL 7066 Digitair Model 6695 CC End of Train Sense amp Brake Unit SBU Composite Case Shop Maintenance amp Diagnostics Circuit Description Alignment Troubleshooting amp Repair Parts Lists amp Drawings December 1998 An Ansaldo Signal Company O 1998 Union Switch amp Signal Inc Printed in USA SM 7066 DOCUMENT HISTORY Original December 1998 1 0 2 0 2 1 2 2 2 3 2 4 2 5 TABLE OF CONTENTS INTRODUCTION vs 1 1 FAMILY OF MANUAL S are 1 1 1 1 DEFINITION OF TERMS vaere 1 1 1 2 SBU MESSAGE PROTOCOL 1 1 1 3 TEAM AND TECHNICAL SUPPORT 1 1 1 4 INTRODUCTION AND GENERAL 02 2 2 1 2 1 5 SBU MODEL 6696 HARDWARE FEATURES 1 3 1 5 1 SBU Composite Case 1 3 1 5 2 SBU Operating Features 1 4 1 6 SBU FUNCTIONAL DESCRIPTION asset 1 5 1 7 CAB UNIT GENERAL DESCRIPTION AND CONSIDERATIONS 1 6 1 8 ORDERING INFORMATION esses enne nnne nennen nnns 1 6 1 9 DIAGNOSTIC SOFTWARE DISKETTE i
97. age present on the negative side of the solenoid will be pulled to VBAT SW SBRAKE1 must produce a logic low indicating that the voltage rose above approximately 9 9 volts If the two conditions above are met then the Sourcing MOSFET Q14 and the solenoid are good A divider network R7 R68 R69 R70 and R71 is used to provide the reference voltages to the comparators used for both verification and testing of the emergency brake solenoid 4 6 SM 7066 12 98 SECTION IV CIRCUIT DESCRIPTION 4 4 6 Interface Board The Interface Board mounted inside of the battery compartment plugs into the Microcontroller Board to carry the battery battery configuration jumper and diagnostic port leads through the intercompartmental wall into the telemetry compartment The shared unshared battery jumper the fuses and isolation diodes also reside on this board 4 4 7 Display Board The Display Board is small PC board that is mounted on standoffs to place it closer to the LED display window on the side of the SBU near the handle It contains the LED Display and the photocell PH1 for monitoring the ambient light level for Marker Light control 4 5 MARKER LIGHT BOARD 4 5 1 Optical and Mechanical Details The SBU Marker Light uses an array of 144 red or amber super bright LEDs arranged in a square matrix pattern as its light source The LEDs are placed vertically on the printed circuit board to eliminate the need for aligning adjusting or directing
98. ations available for the SBU Model 6695 CC 1 9 DIAGNOSTIC SOFTWARE DISKETTE The SBU does not rely on a dedicated external device for system diagnostics and configuration All of the unit diagnostic tests and configuration functions are included on diskette that runs on a standard DOS compatible personal computer PC The PC plugs into the SBU s Diagnostic Port located in the battery compartment via a standard serial cable The Diagnostic Software has been designed to permit easy customization of the operation of the SBU Most of the variable default values and functions are user selectable set by the factory at purchase time or by railway technicians via a PC computer The Diagnostic Software program on the disk is named diagunit exe and its use is described in Section 3 0 1 6 SM 7066 12 98 SECTION I INTRODUCTION The Diagnostic Software Diskette can be ordered under the following part numbers Part Number 3 5 Diskette N451232 1264 5 25 Diskette N451232 1265 Table 1 1 Diagnostic Software Diskette 1 10 SBU SPECIFICATIONS PARAMETER TYPICAL UNITS NOTE Environmental Storage fonpertire Ranges Va Storage Temperature Range 40 70 Humidity 50 non condensing 95 J Altitude 12000 3 660 feet meters Vibration Vertical amp Lateral Peak pp MN em SS ON
99. ay check the calibration technician connects a personal computer loaded with diagnostic software to the RS 232 diagnostic port within the battery compartment and applies known air pressure to the SBU If the error between the applied pressures and the measured values exceed the maximum permitted error the technician may elect to do a software recalibration for the SBU In this process the PC compares the known and meas ured values and uploads corrected calibration information to the parameter storage EEPROM in the SBU If during the Closed Case Calibration check the calibration is determined to be outside of preset boundaries this may indicate a problem with the electronics for the pressure transducer The technician will be informed and recalibration will not be allowed For full instructions on how to perform Closed Case Calibration refer to Section 3 6 Signal Analog to Digital Conditioni Converter Figure 5 1 Closed Case Calibration of the SBU 5 2 SM 7066 12 98 SECTION PERIODIC MAINTENANCE 5 4 MOTOROLA TRANSCEIVER MODULE DIP SWITCH SETTINGS When making adjustments or installing a new Transceiver Module of the Motorola type into the SBU verify that its internal DIP switch settings are as follows Incorrect DIP Switch settings will cause the Transceiver to operate intermittently Table 5 3 Motorola Transceiver Module DIP Switch Settings 5 5 ADJUSTING MARKER LIGHT AMBIENT LIGHT SENSING CIRCUIT
100. ck Panel and Electronic Mechanical Assemblies 2 10 2 3 Indication of Forward and Reverse Motion 2 19 2 4 Waveform on Pin of Meee AR 2 19 2 5 USE Or Watt MEET eee ei MOI t 2 22 2 5 SBU adio Test Cable SARS 2 23 2 7 Component Locations on SBU Processor 2 24 2 8 Connection to Communications Monitor 2 25 SM 7066 12 98 2 9 2 10 2 11 5 1 1 1 1 2 1 3 1 5 2 1 2 2 2 3 2 4 2 5 4 1 5 1 5 2 5 9 5 4 5 5 5 6 TABLE OF CONTENTS Radio TX Inhibit Adapter Connector 2 27 Motorola Transceiver Coil L101 Location Cover Removed 2 27 JDT Transceiver Frequency Adjust Access Hole Location Cover Removed 2 28 Closed Case Calibration of the SBU 5 2 LIST OF TABLES Diagnostic Software Diskette nidi RP 1 7 SBU Model 6695 CC Specifications 1 7 Transceiver Specifications SBU Equipped With Motorola RNET 450 Transceiver 1 8 Transceiver Specifications SBU Equipped With Johnson Data Telemetry Transceiver 1 9 NiCad Battery Specifications isan ce eee ee 1 9 Maintenance Equipment Requirements 2 1 Torqu
101. ctrical DESENPION Vare 4 7 45 31 Power ON OFF Grutas 4 8 4 5 3 2 Ambient Light Sensing 4 8 45 33 Flashing eterne 4 8 4 5 3 4 Fault Detection Circuit 4 8 V PERIODIC MAINTENANCE 5 1 5 0 PERIODIC MAINTENANCE CHECKS AND SERVICES 5 1 S BATTERY REPLACEMENT ad 5 1 5 121 NiCad Battery 5 1 5 1 2 Lead Acid Battery Replacement 222452 524552 24 8 5 1 5 24 FUSE REPLESGEMEN oni i b oq uq eium SSS 5 2 5 3 CLOSED CASE PRESSURE SENSOR 5 2 54 MOTOROLA TRANSCEIVER MODULE DIP SWITCH SETTINGS 5 3 55 ADJUSTING MARKER LIGHT AMBIENT LIGHT SENSING CIRCUIT 5 3 5 6 OPERATIONAL CHECK 5 4 APPENDIX A PARTS LISTS AND 2 2 2 A 1 LIST OF FIGURES amp ILLUSTRATIONS 1 1 Two Way End of Train Telemetry Functions 1 2 1 2 SBU Model un ea ah ca 1 3 1 3 DIGITAIR SBU Typical Block 1 4 2 1 Emergency Brake Test Equipment niam bese 2 6 2 2 Torque Requirements for Ba
102. e Requirements for Composite Case SBU 2 9 Solid State Motion Detector Direction State 2 18 Radio Transmit and Receive Frequencies 2 25 Johnson Data Telemetry Radio Transmit and Receive Frequencies 2 26 Solenoid Activated Bit States Lar 4 6 Periodic Maintenance Checks and Services 5 1 5 2 Motorola Transceiver Module DIP Switch Settings 5 3 Operational Tests Al UNS ass SSN ENN 5 4 Quick Radio Calibration Chart for SBUs Equipped With Motorola RNET 450 MT or EP 5 6 Quick Radio Calibration Chart for SBUs Equipped With Johnson Data Telemetry 5 8 5 7066 12 98 V vi This page is intentionally blank TABLE OF CONTENTS SM 7066 12 98 SECTION I INTRODUCTION 1 0 FAMILY OF MANUALS This is one of two Service Manuals for the DIGITAIR End of Train Model 6695 CC Sense and Brake Unit SBU To differentiate the Composite Case CC style SBU from US amp S similar aluminum style unit this manual refers to the SBU as the Model 6695 CC The complete family of manuals includes SM 7065 DIGITAIR Model 6695 CC Installation amp Operation SM 7066 D
103. e circuits described in detail in the following paragraphs SM 7066 12 98 4 7 SECTION IV CIRCUIT DESCRIPTION 4 5 3 1 Power ON OFF Circuit The Power ON OFF Circuit consists of two NAND gates U2 configured as set reset flip flop In normal operation the MLATCH signal from the Microcontroller Board forces pin 11 of U2 to latch high applying power VBAT1 SW to the Ambient Light Sensing Circuit via Q1 and Q2 Once latched the flip flop can only be reset by either tilting the Marker Light or by removing power MLATCH although partially derived from the pressure switch is used instead of a direct pressure switch input to permit the user to force the Marker Light on for marking railcars set out on sidings at night without air pressure For test purposes the MTEST signal from the Microcontroller Board will also turn on VBAT1 SW for the period of time that it is asserted high To flash the Marker Light for test purposes MFLASH must also be asserted high to simulate low ambient light level If the battery voltage drops below preset value approximately 9 5 volts at the battery terminals or approximately 9 0 volts at the board allowing for isolation diode drops the low battery shutdown sensor U3 resets the Power ON OFF flip flop turning the Marker Light power off to prevent damage due to battery cell reversal 4 5 3 2 Ambient Light Sensing Circuit The Ambient Light Sensing Circuit is a comparator circuit U4 that applies power t
104. ealidBue 3 26300304 24751200118 155 WashenSSTLokNo6 75121017 7 160 Cable Gal Steel 26 Long 40702050880 1 165 In Line Quick Exhaust 792426007 470 Niple i4NPTSS 7924260015 1 175 ArHoseAsy 0327600050 1 200 NameTagCSX 24603417 1 305 Washer M334674 240 coe aa Serer 4 24606303 1 J8IS 4 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 5 COMPOSITE SBU NICAD BATTERY ORANGE SMALL HOSE QUICK EXHAUST PN N26301505 Description Part Number Quantity per Assembly 10 Electronics Cage Assy 4608 I 15 Assy BatterylinierfaceEOT N26301301 1 60 Cover Fuse 24604601 90 RearLid Orangs M26300305 S Hook 2 875 Galv 408 0737 00 Screw 8 32 x 5 8 Pan Head 45072950110 SM 7066 12 98 A 5 APPENDIX PARTS LISTS amp DRAWINGS This page is intentionally blank A 6 SM 7066 12 98 a DIGIT AIR END OF TRALN TELEMETRY SYSTEM URIGN SWITCH amp SIGNAL VIEW
105. ed is installed in the unit Whenever a new telemetry battery is installed a CMOS Latching circuit U7 and its associated circuitry senses its presence and sets its output bit TBAT NW low U13 pin 8 This bit is read by the microcontroller each time it runs its power up initialization routine If TBAT NW is low during initialization the microprocessor sets the battery state of charge to 100 and the SET BAT U18 pin 12 output bit high briefly to reset the battery latch The battery latch will not change state again until the battery is removed and replaced If an old battery is installed by mistake the state of charge calculation will be incorrect However since the battery voltage measurement takes precedence over the battery status counter the dropping battery voltage will be detected and transmitted to the Cab Unit If TBAT NW is high during initialization it is assumed the same battery is in the unit and the micro controller will resume the battery charge calculations based on the most recently saved battery state Three battery configuration jumpers named through BATOPT2 located on the interface board in the battery compartment are read by the microcontroller during initialization so that the proper discharge rate can be applied to the calculation See the SBU Model 6695 CC Installation and Operation Manual SM 7065 for information on the positions of the 3 jumpers 4 2 SM 7066 12 98 SECTION IV CIRCUIT DESCRI
106. er 35 Cabe Transmiter 1 60 Weasher SpingLockNo2 47521003 4 80 Adhesve Lodite454 041608005 001 85 BusigSmRf 300W 705074 1 90 Scew 440x38PanHd 450729706 4 95 Washe No4FlSS 75120096 4 100 Wesher SSTlockNo4 07521015 4 105 EOTReaUnt 550 1 110 Standoff 4 40 x 4 250 47927750041 Cable Tie Self Lkg 70330 1 A 64 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS 2 reo VIEW A A SHOWING ORIENTATION OF RADIO IT 20 2 ay G qe BOTTOM VIEW SHOWING APPLICATION 17 50 OF GASKET GJ mc m ud RE IN DIRECTION OF ARR OW U22 U2 25YN amp Gn 9 5 QU 1 H ie VIEW
107. ev 10 45 RESISTOR RESISTOR RESISTOR 71601 4735552 4373 8 1735552 4488 1735552 568 188 1 84 12 Al s 97525 Eg 4735652 1571 tn 1 10 8 9735552 1334 451923 Sh 16G 2 of 2 N4519231602 d Type SBU PN N4519231601 Lead Ac Figure A 17 Continued EOT Marker Light Schematic NiCad Type SBU PCB PN A 95 96 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 33 ASSEMBLY BATTERY INTERFACE EOT PN N26301301 Description Part Number Quantity per Assembly PCB EOT Battery N4519233501 15 W 18 Awg Tefzel Red A0458520006 1 20 W 18 Awg Tefzel Black A0458520000 1 Jumper Assy 156 SM 7066 12 98 A 97 APPENDIX PARTS LISTS amp DRAWINGS 8 Z SNId NO id 52018 u3dAnnr 8 9340909 335 5439 ON LYYd LN3NOdA09 4417 S39V1d 8 4 1 2311394 NIVHIS H19N37 OL Lf Hi9N31 66 01 13 HLONIT 8676 1 01 19 ayog 01 830105 QNY 4001 S HLONIT 9 01 109 IL Ove m o ge 9 70 263013 Figure A 18 Battery Interface EOT Assembly PN N26301301 SM 7066 12 98 A 98 APPENDIX PARTS LISTS amp DRAWINGS A 34 PCB EOT INTERFACE NICAD TYPE SBU PN N4519233401 Reference Description Part Number Quantity peee per Assembly Brd PC EOT Interface J776616779 1 Conn DB9 Fema
108. for Composite Case Fasteners 2 9 SBU DISASSEMBLY AND REASSEMBLY PROCEDURES 2 10 2 5 1 Removing the Rear Panel DIU 2 11 2 5 2 Removing the Electronics Cage Assembly 2 11 2 5 3 Removing the Radio Transceiver Module 2 12 SM 7066 12 98 i 2 6 2 7 3 0 3 1 3 2 3 3 3 4 3 5 TABLE OF CONTENTS 2 5 4 Removing the Motion Detector um i 2 12 2 5 5 Removing the Air Manifold 2 12 2 5 6 SPU RES eee 2 12 2 5 7 Reinstalling the Pressure 2 13 2 5 8 Reinstalling Ne 2 13 2 5 9 Reinstalling the Motion Detector 2 13 2 5 10 Reinstalling the Electronics 2 14 2 5 11 Reinstalling the Rear Panel 2 15 EROR m 2 15 CHECKS AND TESTS OF THE MAJOR SBU ASSEMBLIES 2 15 2 6 1 Testing the Air Manifold Assembly for Leaks 2 15 2 6 2 Functional Check of the Motion Detector 2 16 2 6 2 1 Functional C
109. fy that the SWR is less than 1 5 1 Use the Diagnostic Software to re transmit a carrier 3 Disconnect the Watt Meter from the SBU and connect the SBU to the Communications Monitor RF IN OUT port as shown in Figure 2 8 2 24 SM 7066 12 98 SECTION II SHOP MAINTENANCE Communications Monitor To SBU Transceiver RX OUTPUT TX OUTPUT To J7 on SBU Processor PCB Radio Test Cable Figure 2 8 Connection to Communications Monitor 2 6 4 4 Transmitter Center Frequency For all transmitter tests ensure that the Transceiver s antenna output is connected to an antenna RF Monitor or 50 ohm dummy load when initiating transmissions Lack of an RF load can cause overheating of the transmitter and eventual failure 1 Check the transmit center frequency for the Motorola or Johnson Data Telemetry transceiver module as follows a Use the PC Diagnostic Software to transmit an unmodulated carrier b Using the communication monitor verify that the TX center frequency is as listed in Table 2 4 Motorola RNET 450 Radio or Table 2 5 Johnson Radio Country Part Transmit Frequency Receive Frequency RX Local Oscillator Number Frequency North America 457 9375 Mhz 452 9375 Mhz 407 9375 Mhz PIN N24600004 Australia 450 250 Mhz 450 250 Mhz 405 250 Mhz PIN N24600005 Table 2 4 Motorola RNET 450 Radio Transmit and Receive Frequencies SM 7066 12 98 2 25 SECTION II SHOP MAINTENANCE Country Part Tran
110. g through the divider network 4 3 MARKER LIGHT CONTROL MTEST AND MFLASH There are two control bits that allow the programmer to operate the Marker Light manually When the MTEST U17 pin 17 bit is set high battery voltage is applied to VBAT1 SW This applies power to the Marker Light circuits regardless of brake pressure and tilt switch positions When the MFLASH U17 pin 18 bit is then set high the Marker Light will flash regardless of ambient light conditions These control lines make it possible for the microcontroller to perform a Marker Light test when the test push button is pressed or when the train starts to move 4 4 EMERGENCY BRAKE VALVE CONTROL 4 4 1 Solenoid Activation There are two MOSFET switches Q14 and Q16 that must be set in order to activate the emergency brake solenoid To activate the solenoid EBRAKE1 U16 pin 18 is set high and EBRAKE2 016 pin 19 is set low The two opposite states are used to prevent the brake solenoid from inadvertently activating during power up or power down due to both bits achieving the same state or in the event of a failure in one of the MOSFETs SM 7066 12 98 4 5 SECTION IV CIRCUIT DESCRIPTION 4 4 2 Solenoid Activation Confirmation To confirm that the solenoid coil has been activated there are two comparators that provide the necessary status bits that must be checked by the microcontroller The following describes the state of each bit while the solenoid is activated S
111. ge Assy 4600 1 15 Assy BatterylinierfaceEOT 1 60 24604601 80 NumbrTag 24601601 90 RearLid Gray M26300302 115 S Hook 2 875 Galv 408 0737 00 Washer 5 8 PIn Flat SST 2 5 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 3 COMPOSITE SBU NICAD BATTERY YELLOW SMALL HOSE QUICK EXHAUST PN N26301503 Description Part Number Quantity per Assembly 10 Electronics Cage Assy 4606 1 45 Assy BatterylinierfaceEOT 1 2 60 Cover Fuse M24604601 Strip Foam M24603703 Screw 10 32 x 5 8 SOC J5001240004 Label SBU M24604801 Nut 6 32 SS Elastic J048102 S Hook 2 875 Galv 408 0737 00 SM 7066 12 98 A 3 APPENDIX PARTS LISTS amp DRAWINGS 4 COMPOSITE SBU NICAD BATTERY BLUE YELLOW IN LINE VALVE PN N26301504 Description Part Number Quantity per Assembly 10 Electronics Cage Assy 4600 1 15 Assy Battery Interface EOT N26301301 25 BatenLocaigPin6621 442007401 2 30 NutAssembyDigtrStu 148017600 2 35 Scew 632x7 6PanHead 3507298017 9 40 Washer SSTPlateNoG 34751200008 9 45 Scew440xi4PanSS 4507297014 6 55 Stedof 440x 12 25920069 4 60 Cover Fuse M46061 1 2047940 80 NumbrTag 4601601 90 R
112. ge Password up to 9 characters menu To return to the Main Menu press lt gt SM 7066 12 98 3 15 SECTION SBU DIAGNOSTICS AND CALIBRATION This page is intentionally blank 3 16 SM 7066 12 98 SECTION IV CIRCUIT DESCRIPTION 4 0 CIRCUIT DESCRIPTION This section provides detailed circuit description of the various boards used in the SBU 4 1 PROCESSOR BOARD The Motorola 68HC16 microcontroller U20 is a high speed 16 bit control unit with built in Analog to Digital Converter ADC and 1 Kbytes of internal RAM It was selected for use in the SBU Model 6695 CC because of its flexibility and low power consumption The SBU is designed for maximum battery life and minimum unit weight Since power con sumption is a prime consideration a large percentage of the internal circuitry of the 68HC16 is turned off sleep mode when not needed It is turned on briefly only three 3 times per second for making measurements and for checking for incoming signals from the Cab Unit Only the system clock and the internal timers keep running during these sleep periods 4 1 1 EPROM Memory The firmware for the SBU is stored in a 32 Kbyte EPROM 022 Even though the power consumption for EPROM memory is lower than for example FLASH EPROM memory ina low power application such as this additional steps must be taken to reduce power consumption wherever possible Since the vast majority of the power consumed by an EPROM occur
113. he Brakeline Pressure Switch or the Test push button Power is temporarily applied to VBAT SW Q2 which powers the microcontroller through a low power voltage regulator for about 1 2 second Once the microcontroller is up and running the PWR ON bit is set high to maintain power to the system through VBAT SW This allows the microcontroller to turn itself off when either brake pressure is removed for more then 5 minutes or battery voltage is drops below the cutoff threshold as determined by the ADC 4 1 6 Battery Latch Circuit For trouble free operation ensure that the batteries placed in the SBU are as fully charged as possible Depending on the configuration ordered the SBU Model 6695 CC can use either Nickel Cadmium NiCad or Lead Acid type batteries Units using NiCad batteries are different from those using lead acid style batteries in that in deep discharge service they exhibit an output voltage that remains flat for a much longer time The voltage drops off very rapidly however when the battery is exhausted With Lead Acid type batteries the output voltage measurement under load provides a reasonably good indication of remaining charge On NiCad type units to determine the state of charge the microcontroller maintains a running calculation based on running time and ambient temperature to determine the state of the battery To do this it must be able to determine when a new battery which it is assumes to be freshly charg
114. heck of Old Style Crystal Pendulum Motion v AE 2 16 2 6 2 2 Functional Check of New Style Solid State Motion Detector 2 17 2 6 3 Emergency Valve InspecllOr 2 21 2 6 4 Transceiver Module Alignment and 2 21 2 6 4 1 Removal SBU Rear Panel 2 21 2642 Equipment Setup vassere seres 2 22 2 6 4 3 RF Transmit POWGE eai eot eoe eo on nev 2 24 2 6 4 4 Transmitter Center 2 25 2 6 4 5 TX Center Freq for Motorola RNET 450 Transceiver 2 26 2 6 4 6 Receiver Center Frequency for Motorola RNET 450 2 27 2 6 4 7 TX Center Freq for Johnson Data Telemetry JDT TRAMSCCIVOR EE 2 28 2 6 5 Transmit Center Frequency Adjustment 2 28 2 6 6 Iecelve A dio is e d 2 29 2 6 7 Measuring Receiver Sensitivity Using SINAD 2 29 2 7 6 1 Measuring the SINAD e n PP ua 2 29 TROUBLESHOOTING 2 31 2 7 1 System Level 2 31 SBU DIAGNOSTICS AND 3 1 SBU DIAGNOSTICS AND CALIBRATI
115. hould be lit and LED3 should be dark If this is not the case you may have bumped or moved the unit Wait 20 25 seconds to see if the LED status changes The DMM reading should be between 2 4 and 2 6Vdc 4 With the unit in the stopped condition tap the rear of the unit as shown in Figure 2 2 The LED status should indicate the forward condition in Table 2 3 That is all the LEDs should be dark The DMM reading should be between 4 8 and 5 1 5 After the unit has returned to the stopped condition tap the front of the unit as shown in Figure 2 3 The LED status should indicate the reverse condition in Table 2 3 That is only LED3 should be lit The DMM reading should be between 0 0 and 0 1Vdc Tap from Rear Indication of Forward Motion Tap from Front Indication of Reverse Motion Figure 2 3 Indication of Forward and Reverse Motion Motion to No Motion Time out Verification This next step will verify the time it takes to register a stopped condition once motion has actually ceased 1 Tap the unit from either the front or the rear and note that the green LED LED1 has gone dark The green LED should light between 8 and 22 seconds 2 Turn off the power supply SM 7066 12 98 2 19 SECTION II SHOP MAINTENANCE Power Cycle Timing Verification 1 Connect the oscilloscope probe ground clip to the shield fence and the probe tip to pin 3 of terminal strip J2 On Time Mea
116. i de OU Pg GN Vibration Longitudinal Peak ME ET EE 9 4 1 1 EE 2222 22 21 o 0 2288 11 88 1027 Shock any axis peak half sine wave 1115 10 g duration Physical Housing Dimension including coupler mount J Depth A J 50127 Height including antenna 1 37593 Wilh 14056 inm 23 04 Mg si Power Requirements NiCad or Lead Acid Battery Operating Voltage Range Within Specification 105 Degraded Specification 140 142 NoDamage Range 142 Vd Battery Protection reverse polarity fuse 1 14 0 Vdc SBU Telemetry with HVM 2 batteries Range NoDamage 2001380 psigkpa Range Operaing 125 60 Jpsgka Error pm 1 320 psigkpa MeasurementInterval 960 mec Power On Threshold 6 7 960 psigkpa Power Off Threshold NO AIR 5 35 psig kpa 1 NiCad rechargeable continuous operation Note Reported Weak and Replace times will be less 2 Values given assume that HVM Light is off 50 of the time i e during the day Table 1 2 SBU Model 6695 CC Specifications SM 7066 12 98 1 7 SECTION I INTRODUCTION PARAMETER TYPICAL MAX UNITS NOTE HVM Strobe Light FRA a
117. ibration limit For optimum calibration accuracy itis recommended that if a value other than 100 psig 690 kpa is used that the upper limit be set to 5 or 10 psi 35 or 69 kpa above the highest expected value of brake pressure To return to the Main Calibration Menu press lt Esc gt SM 7066 12 98 3 11 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 6 2 Calibrating the Brake Pressure Sensor The SBU Model 6695 CC is designed to permit software calibration of the brake pressure sensor and its associated circuitry To initiate brake pressure calibration connect the glad hand to a source of known air pressure Return to the Main Calibration Menu and type 2 for Calibrate Brake Pressure Sensor and press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 8 Copyright 1995 Union Switch amp Signal Inc Set the brake pressure to psi Press enter when complete Set the air pressure attached to the glad hand to zero press lt Enter gt when this is done The following screen will appear Now set the brake pressure to 100 psig Press enter when complete Esc go back F4 quit program 3 12 SM 7066 12 98 SECTION SBU DIAGNOSTICS AND CALIBRATION Set the air pressure to 100 psig 690 kpa or to the indicated upper limit as was defined in Choosing the Upper Brake Pressure Setpoint and press lt Enter gt If the software calibration was successful the f
118. igure 2 7 for location of J7 and adjustment trimpots on the SBU Processor Board 3 Open the battery compartment and connect the Diagnostic PC via the serial communications cable to the DB 9 Diagnostic Connector located in the battery compartment 4 Apply power to the SBU 5 Execute the PC Diagnostic Software from the floppy disk or hard drive as instructed in Section 3 0 Press the SBU TEST button to initiate communications between the SBU and the PC 2 22 SM 7066 12 98 SECTION II SHOP MAINTENANCE Keep these leads as short as possible Molex 50 57 9005 or equiv RX Output Pin 5 Gnd Pin 4 RX Audio Pin 2 TX Audio TX Output Molex 16 02 0096 or equiv 3 pcs Shielded Audio Cable 3 to 4 feet long Figure 2 6 SBU Radio Test Cable SM 7066 12 98 2 23 SECTION II SHOP MAINTENANCE Figure 2 7 Component Locations on SBU Processor Board 2 6 4 3 RF Transmit Power 1 Using the PC and Diagnostic Software transmit continuous unmodulated carrier Adjust the RF GAIN pot R62 for a transmitter output of 2 watts to the antenna The test software will key the radio transmitter for 50 seconds If the transmitter times out before the adjustment has been made use the PC to repeat the transmission of the carrier If R62 is adjusted re lock with Glyptol or equivalent To stop the transmission at any time or once complete press lt Esc gt 2 Check the reflected power to veri
119. io antenna input with a short BNC Cable RF Output Frequency See Tables 2 4 and 2 5 for RF Frequency RF Output Level 50 dBm Modulation 1 KHz Sinewave Deviation 3 0 KHz deviation 2 0 Khz for Australia JDT Radio 5 In Normal operation the receiver is turned on three 3 times per second to listen for the Cab Unit signal If nothing is heard the receiver is turned off again to minimize the power consumption It is impossible to correctly measure the SINAD under these conditions However when the SBU is placed in PC diagnostics mode the receiver is turned on continuously 6 Insert a battery into the SBU or connect a 12 VDC bench power supply to the battery pins Be sure to observe proper polarity 7 Run the Diagnostic Software as described in Section 3 0 It is not necessary to make selection at this time The receiver will be on continuously for any non transmit mode 8 Setup a SINADDER to measure SINAD and begin reducing the RF signal level until the SINAD is 12 dB The output level of the RF generator in uV or dBm is the reference sensitivity of the receiver The sensitivity should be 0 4uV 115 dBm or less If the measured sensitivity exceeds 0 4uV 115 dBm the Transceiver Module should be replaced 9 Disconnect the test equipment and reinstall the Rear Panel 2 30 SM 7066 12 98 SECTION II SHOP MAINTENANCE 2 7 TROUBLESHOOTING GUIDE 2 7 1 System Level The DIGITAIR system consists of the Model 669
120. ipped for secondary air pressure measurement an additional air hose is fitted to the rear panel When removing the panel unplug the auxiliary pressure transducer connector from the SBU processor board 2 5 2 Removing the Electronics Cage Assembly 1 Disconnect the Antenna coaxial cable BNC connector from the radio transceiver module 2 Disconnect the ribbon cable connector from the processor board and bend it out of the way 3 Remove the four 4 five 5 for the Dual Pressure type SBU push on connectors located along the back edge of the processor PC board These connectors are associated with e The pressure switch e The pressure transducer s e The emergency brake valve solenoid e The test button Locate the 7 electronics cage mounting screws e two 2 near the base of the antenna one 1 in the upper left hand corner of the Marker Light PC board one 1 in the upper right hand corner of the Marker Light PC board one e 1 above and slightly to the left of the radio e two 2 along the bottom edge of the Marker Light PC board Remove the seven 7 machine screws making sure to locate remove and save all washers and lockwashers SM 7066 12 98 2 11 SECTION II SHOP MAINTENANCE 2 5 3 Removing the Radio Transceiver Module Depending on the length of the screwdriver blade it may be easier to first remove the Motion Detector 1 Remove the Electronics Cage Assembly as described Section 2 5 2 2 Remove the
121. le J7091460847 1 04 Conn Hdr 3 Pos JP4 5 30 JP2 JP3 Jack Shorting J713343 JP4 eee 45 FLFLES Cie PC Tipe SA c mem 35 32 W 2 60 J2 Washer SST Lock No 4 J4751210105 SM 7066 12 98 A 99 APPENDIX PARTS LISTS amp DRAWINGS A 35 PCB EOT INTERFACE LEAD ACID BATTERY SBU PN N4519233402 Reference Description Part Number Quantity per Assembly Brd PC EOT Interface J776616779 TG Eu Conn DB9 Female 2709146087 1 10 D1 D2 Diode IN5822 Rect J7261500173 4 15 JP1 W 22 Bare Tinned Cop A043183 083 Conn Header 12 Pos 2709146088 1 2 Strip Cont Post 36 J7259120001 1 JP2 JP3 JP4 Jack Shorting J713343 Brd PC EOT Interface J776616779 C C 1 f F1 F2 F3 Fuse 2 Amp 250 V J710021 3 F1 F2 F3 Clip Fuse PC Type 3AG J576794 6 Screw 4 40 x 3 8 Pan Hd J5072970106 u 2 Washer No 4 Flat SS 475120016 2 60 52 Washer SST Look No4 475121015 2 Fuse 3 Amp 250 V 710090 N Header PC Brd Mnt 350539 2 J7091460947 u 4 75 Lael 1 0 4075962 80 _ Label Datab 2075955004 1 BATI A b 9 n P BAT1 12 J1 m PROCESSOR PONER 145822 28 15822 4 P i gt 5 o D 0
122. lected configuration feature or function the Diagnostic Mode must be terminated in the SBU This is done by unplugging the communications cable and then either pressing the SBU TEST button or powering down the unit by removing the batteries US amp S End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Switch amp Signal Inc To initiate diagnostics power up the Unit in normal operation connect a straight through cable from the PC to the Unit press the button on the Unit to start diagnostics mode Currently using COM port 1 To initiate communications between the SBU and the diagnostic computer briefly press the SBU TEST button The Main Menu screen will appear 3 2 SM 7066 12 98 SECTION SBU DIAGNOSTICS AND CALIBRATION At this point the user may select Diagnostics Configuration Calibration or Password items 3 4 MAIN MENU To proceed select one of the sub menus shown and press lt Enter gt US amp S End of Train System Diagnostic Unit Software 1 Copyright 1995 Union Switch amp Signal Inc Diagnostic Items Configuration Items Pressure Sensor Calibration Password Protected Items Enter a menu item number 3 5 DIAGNOSTICS MENU The Diagnostic Items Menu displays selections that may display information about or perform a diagnostic test on the SBU US amp S End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Switch amp Signal Inc Sh
123. m mee j Cycling Life Capacity After 1000 Cycles 50 Miscellaneous Mon Yr of Manufacture is marked on each battery One cycle 5 hours discharge at 800 ma to 10 00 Volts after slow or quick charge Table 1 5 NiCad Battery Specifications SM 7066 12 98 1 9 SECTION I INTRODUCTION 1 11 LEAD ACID BATTERY SPECIFICATIONS For specifications on the Lead Acid type battery please consult the battery vendor s documentation 1 10 SM 7066 12 98 SECTION II SHOP MAINTENANCE 2 0 INTRODUCTION This section provides description of the built in SBU Test Modes and shop troubleshooting guide to help isolate system faults to the assembly and board level Information is also included that may enable diagnosis of a number of faults down to the component level 2 1 TEST EQUIPMENT REQUIREMENTS To perform detailed troubleshooting and maintenance of the SBU the following equipment is recommended and or required Power Supply 0 15 volts 3A fine adjustment Xantrex 6020D or equiv Air supply See Figure 2 1 0 85 psig 0 600 kpa Quick opening valve Glad hand fitting Volume At least 1 liter upstream of glad hand downstream of regulator Pressure regulator Adjustable 0 85 psig 0 600 kpa setable to 1 psig 6 895 kpa stable to 0 1 psig 0 690 kpa at no flow Air tank 8 to 20 gallon 34 to 340 liter capacity with See Figure 2 1 Glad hand coupling attached directly to inspection port Air pressu
124. n 5072980108 4 Nametag M46045 1 x Tag Batt Shadow 340789780081 1 Screw 832x518 Pan Head J507295010 4 Washer SSTPleieNo8 4751200009 4 Washer SSTLockNo8 44751210108 4 Clamp 4 Assy Bracket 26302003 1 M63002 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 A 14 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 7 COMPOSITE SBU LEAD ACID BATTERY YELLOW RESETTABLE IN LINE VALVE PN N26301602 CONTINUED Description Part Number Quantity per Assembly Tubing Thermoplastic 1 4 OD A7742140013 Fitting 90 Degree Elbow 40327600076 1 Fitting Flareless Tube J0327600077 1 J0327600078 Threadlocker 242 SM 7066 12 98 A 15 APPENDIX PARTS LISTS amp DRAWINGS A 8 COMPOSITE SBU LEAD ACID BATTERY GRAY IN LINE VALVE PN N26301603 Description Part Number Quantity per Assembly 10 Electronics Cage Assy 2460005 1 15 PCB NS Interface N4519233402 1 25 Washer Nyion 17005009 54751820020 4 30 Brkt Pulse Battery 1 45 Screw 440 55 55072970 6 55 Stendof 440x 12 125920009 4 60 Fuse 1 80 NumbrTag O M24601600 90 RealidGry 26300302 20702050630 180 Screw SST 6 32 1 2 Pan 5072980108 265
125. n 5 of terminal strip J2 and circuit common The positive meter lead will connect to pin 5 and the negative meter lead will connect to circuit common at pin 6 of J2 or the shield fence Hold the motion detector assembly against the flat surface by applying pressure to the bottom rear of the bracket using your finger or a small weight The motion detector assembly must remain level and completely motionless during this adjustment Turn on the 5V power supply Adjust the R15 potentiometer until the DMM reads 2 5Vdc 0 05V Turn off the power supply but leave it connected to the assembly Place a drop of Glyptol or fingernail polish onto the side of the adjuster screw of R15 to prevent it from turning SM 7066 12 98 2 17 SECTION II SHOP MAINTENANCE Testing the Integrity of the Board Connector J1 and Its Associated Board Traces 1 Move the positive lead of the DMM to pin 2 of J1 and the negative lead to pin 3 of J1 2 Turn on the power supply The voltage indicated on the DMM should be 5 1Vdc Move the negative lead of the DMM to pin 4 of J1 The voltage indicated on the DMM should be 5 1Vdc 205 ge Move the positive lead of the DMM to pin 8 of J1 With the unit completely motionless LED 1 amp 2 are lit the voltage should be between 4 5 and 5 0Vdc N Turn off the power supply but leave it connected to the assembly 8 Setup the DMM to read Ohms 9 Connect one lead of the DMM to pin 1
126. nal Inc Test Brake Valve Circuit Status GOOD Solenoid GOOD Source transistor GOOD Sink transistor GOOD To return to the Main Diagnostics Menu press lt Esc gt 3 5 14 Initiate Emergency Braking To initiate a test of the emergency braking function return to the Main Diagnostics Menu and type 14 for Initiate Emergency Braking and press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 Copyright 1995 Union Switch amp Signal Inc Show Model And Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1288 Hz Transmit 1866 Hz Transmit Preamble Transmit 100 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking Initiate Emergency Braking INITI TED duration 45 seconds Enter a menu item number Esc The solenoid will open with an audible click WARNING If air pressure is connected to the glad hand it will be released to the atmosphere when the solenoid valve is opened Use safety glasses and ear plugs when performing this step if air pressure is applied otherwise personal injury may result After 45 seconds the solenoid will close again with an audible click Press lt Esc gt to select another function or return to the Main Diagnostics
127. ng is intended as a quick shop test to check out an SBU without removing its rear panel It is to be performed with the equipment stabilized at a room temperature If any problems are encountered the SBU will have to be opened and tested more thoroughly Refer to Section 2 4 2 2 SM 7066 12 98 SECTION II SHOP MAINTENANCE 2 3 1 Mechanical Check The entire SBU should be visually inspected for mechanical damage In particular the following items should be checked Unit housing Antenna External TEST button LED display window Battery door hinges gasket and latches Battery holding and locating pins and retaining nuts Mounting clamp Frame Coupler mounting jaws Spindle and spindle handle Shaft and shaft retainer Rubber feet Security Locking Latch Emergency brake exhaust valve glad hand and hose 2 3 2 Initial Jumper Settings for Test For SBUs equipped with NiCad type batteries if the jumper was originally in the lower position example between pins 1 and 2 unshared batteries make note to return it to that position before returning the SBU to service To simplify the test procedures for SBUs equipped with NiCad type batteries ensure that the large jumper J1 on the Interface Fuse board inside the battery compartment is in the upper position such as between pins 2 and 3 shared batteries This places the two batteries in parallel so that single battery may be placed in either position to powe
128. o the flash oscillator and LED driver circuits once ambient light drops below given level The circuit has hysteresis built in to prevent output jitter when light levels approach the Marker Light s ambient light set point The MFLASH signal from the Microcontroller Board will simulate low ambient light level for test purposes by turning on VBAT3 SW for the period of time that it is asserted high MTEST must also be asserted high 4 5 3 3 Flashing Circuit The flasher circuit utilizes 555 style timer chip U5 to establish the frequency and duty cycle of the Marker Light 100 msecs on and 900 msecs off The output of the timer drives the LED driver to turn Marker Light LEDs on and off When the LEDs are supposed to be on MOSFETs Q7 and Q8 produce low true signal HVM ON This signal is used in conjunction with the Fault Detection Circuit described below to verify that the LEDs are actually on The HVM ON signal causes an interrupt request IRQ1 each time the light is turned on The interrupt service routine reads the Marker Light current and based on pre defined limits determines the status of the Marker Light LEDs 4 5 3 4 Fault Detection Circuit The total current for all the LEDs is determined by measuring the voltage drop across R37 This voltage is expanded by U1 to improve the ADC accuracy R47 and D38 are used to limit the maximum output voltage to protect the ADC C6 is used to dampen the output signal to
129. of J1 Touch the other lead to pin 2 of J1 and then to pin 3 of J1 The DMM should indicate an open circuit condition for both 10 Connect one lead of the DMM to pin 10 of J1 Touch the other lead to pin 8 of J1 The DMM should indicate an open circuit 11 Reconfigure the DMM to read DC Volts Pins 5 7 and 9 are not tested because they are not used on the Motion Detector Assembly or the End of Train unit motherboard Pin 6 will be tested in the following section Motion and Direction Verification In the following steps the on board 3 LED array will be used along with the DMM as a motion and direction state indicator The truth table for the three LEDs is shown in Table 2 3 below A 1 means the LED is lit a O means it is dark LED Status LE LED2 Red Epa Red DMM Reading Stopped 2 4 2 6 VDC EEE 4 8 5 1 VDC 0 1 Reverse 0 0 0 3 VDC Table 2 3 Solid State Motion Detector Direction State 1 Move the positive lead of the DMM to pin 6 of connector J1 and the negative lead to the shield fence 2 Remove the shorting jumper between pins 4 and 6 of terminal strip J2 2 18 SM 7066 12 98 SECTION II SHOP MAINTENANCE 3 With the unit completely motionless turn on the power supply and observe the LED array consisting of LED 1 2 and 3 At power on and with motionless unit the LED status should indicate the stopped condition of Table 2 3 That is LED1 Green should be lit LED2 Red s
130. ollowing screen will appear The brake pressure transducer is now calibrated Esc go back F4 quit program If the software calibration was unsuccessful this screen will appear US amp S End of Train System Diagnostic Unit Software 1 8 Copyright 1995 Union Switch amp Signal Inc Reading out of range for psig calibration cannot calibrate Check the brake pressure transducer If this screen appears the sensor or its associated circuitry is too far out of range for software calibration correction In either case to return to the Main Calibration Menu press lt Esc gt SM 7066 12 98 3 13 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 6 3 Recording the Brake Pressure Sensor Calibration Date To record the brake pressure calibration date return to the Main Calibration Menu and type 3 for Enter Date of Brake Pressure Calibration and press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 Copyright 1995 Union Switch amp Signal Inc Enter Date of Brake Pressure Calibration lt 9 characters Current value is 3 19 98 Enter new value SC Enter the date in the form MM DD YY where MM month DD day of month and YY year To store the date press lt Enter gt to return to the Main Calibration Menu press lt Esc gt 3 6 4 Calibrating the Secondary Air Pressure Sensor Like the brake pressure calibration above
131. on Part Number Quantity per Assembly Nut 1 2 13 Jm SS J4803170110 Lubricant 14 oz Cartridge 438 0002 00 250 S Hook 2 875 Galv 408 0737 00 2 255 Clamp Cable HP 6NG1 J6902340022 2 A 34 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 12 MAIN HOUSING ASSEMBLY BLUE YELLOW PN N26301403 Description Part Number Quantity per Assembly 10 Antenna GoneShaped 793073008 1 15 Lens Marker M24601 101 20 30 16 11485 2048722005 2 35 EOT AdaperAssy ____________ 1 40 Washer SSTPiateNo6 475120018 8 45 Washr SSTLokNo6 5475121017 8 50 Dipaylen M46030 1 55 ORingAS 568ANo 130 206758400 60 Nut 1 1 2 12 Retaining M24032 1 gt D ecal Tape Reflective Enclosur M24600804 Wedged Foot Digitair Stu 440 0039 00 Washer Flat 1 2 1 250 O D Button Plug 5 8 Black 441 0064 00 Retainer Shaft M24603001 Screw 8 32 x 1 2 Hex Skt HdSS J5001240032 lach Nut 3 8 16 Elas Stop SM 7066 12 98 A 35 APPENDIX PARTS LISTS amp DRAWINGS A 12 MAIN HOUSING ASSEMBLY BLUE YELLOW PN N26301403 CONTINUED Description Part Number Quantity per Assembly 235 Nut 1 2 13 Hvy Jm SS 44803170110 Clamp Cable HP 6NG1 J6902340022 Screw 10 32 x 1 2 Pan SS J5072960108 QN O Ring EOT Conductive 36
132. ones The synthesized audio is scaled and filtered U5 and U6 to smooth out the waveform The output bits are set low when not in use to minimize the inactive currents flowing through the resistor network 4 4 SM 7066 12 98 SECTION IV CIRCUIT DESCRIPTION 4 2 4 Brake Pressure Circuit There is no analog circuitry required to scale the pressure transducer The output of the transducer is 0 5 to 4 5 volts corresponding to 0 to 150 psig range Any values outside this range will indicate a faulty pressure transducer The output yields 5 46 ADC counts per psi To minimize power consumption the pressure transducer has an FET Switch controlled by PTD PWR 016 pin 12 About 15 milliseconds are required for stabilization between when the transducer is turned on and when readings can be taken 4 2 5 Temperature Circuit The ambient temperature is measured by a Dallas Semiconductor DS1620 IC U12 and transferred by way of a two wire synchronous serial bus to the microcontroller 4 2 6 Battery Circuit Since the actual battery voltage is well above the maximum input range of the ADC the battery circuit provides an output proportional to exactly one third of the battery voltage To take a battery voltage measurement the BAT TEST bit U17 pin 16 must be set high This activates the low impedance divider network to load the battery After the battery measurement is complete the BAT TEST bit is returned low to minimize the inactive current flowin
133. or Transmit 1200 Hz and press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 Copyright 1995 Union Switch amp Signal Inc Show Model And Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1266 Hz Transmit 1866 Hz Transmit Preamble Transmit 100 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking JA GT QO s Transmit 12008 Hz Transmitting duration 48 seconds Enter a menu item number Esc go hack Fi After 48 seconds the carrier will turn off automatically Press lt Esc gt to select another function or return to the Main Diagnostics Menu 3 6 SM 7066 12 98 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 5 7 Transmit a Continuous 1800 Hz Modulated Carrier To transmit a steady 1800 Hz modulated carrier return to the Main Diagnostics Menu and select 7 for Transmit 1800 Hz then press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 8 1 2 3 4 5 6 8 9 Copyright 1995 Union Switch amp Signal Inc Show Model And Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1288 Hz
134. ow Model find Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1200 Hz Transmit 18008 Hz Transmit Preamble Transmit 100 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking Owe Tn Aone Enter a menu item number Esc go back Fi repeat selection Select a diagnostic test from this menu by entering an item number and press lt Enter gt To return to the Main Menu press lt Esc gt If the item selected needs only a single line to display its result the text will appear directly above the prompt box SM 7066 12 98 3 3 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 5 1 Software Version Number If you wish to check the version number of the software residing in the SBU press lt 1 gt for Show Model And Version and then press lt Enter gt The following screen will appear 1585 End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Switch amp Signal Inc Show Model And Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1200 Hz Transmit 1800 Hz Transmit Preamble Transmit 166 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking 1 2 3 4 5 6 8 9 Show Model And Version
135. per Assembly 235 Nut 1 2 13 Hvy Jm SS J4803170110 2 250 Sok 2875 Gav 4003 2 Screw 10 32 x 1 2 Pan SS J5072960108 O Ring EOT Conductive 36 J0675840012 2 5 2 i 1 A 38 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 14 ASSEMBLY MAIN HOUSING PN N26301405 Description Part Number Quantity per Assembly 40 Antenna ConeShaped 19307303 1 15 Lens Marker M24601101 es ener 1 30 Pin Dowel36x11488 3048722005 2 35 EOT AdaperAsy N24609001 1 40 Washer SSTPlateNo6 44751200108 8 45 Washer SSTlokNo6 24751210107 8 50 Dipaylen M2460330 1 55 O kRigAS 568ANo130 067584004 1 60 1 12 72 Retaining M24032 1 Switch Push Button SPST 65 Swich PushButonSPST 80 Screw i0 32x5 8SOC J5001240004 90 Scew SST 32xi 2Pan 25072080108 100 C Gasket Manifold 24604303 D D S S Assy Cable EOT N26301001 Washer 10 Plate SST J4751200110 W Assy Cable EOT Manifold N26300901 Tape Acrylic Foam 2 W J0773730024 M ecal Tape Reflective Bat Dor M24600805 100 ecal Tape Reflective Enclosur M24600804 M N 160 Wedged Foot Digitair Stu 440 0039 00 185 Retainer Shaft M24603001 Washer 3 8 Fiat SS 215 Scew SST3B 6x3 350734908 1 Plunger 172 13 Thread SM 7066 12 98 A 39 APPENDIX PARTS LISTS amp DRAWINGS A 14 ASSEMBLY MAIN
136. pproved ETT co cuo no VEE Effective Intensity centerline 100 30 Candela Effective Intensity pp PP L ePisvhotodd 1 1 1 590 67 428088 22201 pee Fl ashPerod o 1 j sc Em 20000001 8 1 Motion Detector Indications Provided Stop Forward Reverse Moving Reporting Rate Pressure change lt 2 psig pp gh ee e s Pressure change 5 psig or more Reports are also made if NO AIR external status change motion change or external TEST button pushed Table 1 2 SBU Model 6695 CC Specifications continued PARAMETER MIN TYPICAL MAX UNITS NOTE Radio Transmitter Section Frequency Range UHF North America P N N24600004 457 9375 Australia P N N24600005 EE GEM 250 Power Output Watts Frequency Stability 40 C to 60 C Emission fm __ 16 20 m s Radio Receiver Section Frequency Range UHF North America P N N24600004 452 9375 Australia P N N24600005 450 250 Sensitivity Input req d for 12 dB SINAD __ 025 04 w Frequency Stability 409 to 600 C E EE ONE HMM Selectivity 25 KHz ME Eee Intermoduation Immunity dB Spurious Rejection 55 dB Image Rejection 50 dB Table 1 3 Transceiver Specifications SBU Equipped With Motorola RNET 450 T
137. r Use Diagnostic PC to Center select any non using a Communications Monitor Frequency transmit mode 452 9375 MHz 45 MHz IF Frequency Use TX Inhibit Adapter to protect Monitor If the reading is out of tolerance return the transceiver to US amp S Use R50 on main board to adjust if adjustment is made re lock R50 with Glyptol or equivalent Table 5 5 Quick Radio Calibration Chart For SBUs Equipped with Motorola RNET 450 Transceiver 5 6 SM 7066 12 98 SECTION PERIODIC MAINTENANCE Operation Stimulus Value Tolerance Comments Setting Input 452 9375 MHz Measured at J7 using the Radio Receive 60 dBm FM Test Cable Use R43 on main Audio Modulated 1200 Hz board to adjust if adjustment is Levels made re lock R43 with Glyptol step 1 iation or equivalent See Table 2 4 for other frequencies See Table 2 4 for other frequencies Measure Modulated RF If sensitivity is greater than Receive Generator set to RF 0 4 replace transceiver Sensitivity Output Freq SINAD 452 9375 MHz RF Output Level 50 dbm Modulation 1 KHz Sinewave Deviation 3 0 KHz See Table 2 4 for other frequencies Table 5 5 Continued Quick Radio Calibration Chart For SBUs Equipped with Motorola RNET 450 Transceiver T When adjusting the transmitter center frequency check for frequency drift over a period of several minutes Check this by using the Diagnostics PC to
138. r both the telemetry and the HVM For the Lead Acid battery type SBU leave the jumpers in their default positions SM 7066 12 98 2 3 SECTION II SHOP MAINTENANCE 2 3 3 External Functional Tests Remove the batteries from the SBU Insert charged battery in the telemetry battery compartment Press and hold the SBU test button until the display reads TEST and then release it The Marker Light will flash for configured number of seconds default 5 The telemetry system will run self test and the following information will be displayed on the SBU four character LED display 1 The Customer Identification String or US amp S by default 2 The software version number e g REV11 3 The battery condition depending on the type of battery as follows A For the NiCad Battery type SBU one of the following displays Battery is Good More than 39 of timed charge remaining where indicates the estimated percentage of battery life remaining Low 12 to 39 timed charge remaining WEAK Weak Less than 12 of timed charge remaining REPLACE Replace 0 of timed charge remaining B For the Lead Acid Battery type SBU one of the following displays GOOD Battery is good Voltage is approximately greater than 11 9 volts WEAK Battery is weak Voltage is approximately between 11 9 and 10 7 volts REPLACE Battery needs replacement Voltage is approximately between 10
139. ransceiver 1 8 SM 7066 12 98 SECTION I INTRODUCTION PARAMETER TYPICAL UNITS NOTE Radio Transmitter Section Frequency Range UHF 450 480 MHz North America P N N24600007 457 9375 Australia P N N24600009 477 700 Finland P N N24600010 457 650 Argentina P N N24600011 458 075 PowerOutput T wes Frequency Stability 409C to 609C 1 7 216 1 1 Spurious andHarmonicFM U 7 Deviation transmitting preamble KHz North America Australia i 5 Finland Radio Receiver Section Frequency Range UHF 480 MHz North America 452 9375 Australia 472 500 Finland 467 650 Argentina 458 075 Sensitivity Inputreqdfor 2dBSINAD 025 04 w Frequency Stability 409C to 600 C sip Selectivity 25 KHz VS intermoduiationimmunity 7 dB SpuiousandimageRejedion 1 70 Table 1 4 Transceiver Specifications SBU Equipped With Johnson Data Telemetry Transceiver PARAMETER TYPICAL MAX UNITS NOTE Physical Dimensions Heg 1 _ 262665 Length 658168 ji mmm Width 1 0 0 0 27570 in mm Weight 360163 Ibs kg Capacity f20madischargerate pp 39 A
140. re Transducer is measured by the ADC and then turned off until it is needed again 4 1 12 Modem Power Supply VMODEM This regulator U8 is controlled by the microcontroller output bit TRAN PWR U16 pin 15 When this bit is high seven 7 volts are applied to the modem op amps U5 and U6 4 1 13 Radio Power Switch VTRANS Supply Power MOSFETs Q8 and Q9 are also controlled by the TRAN PWR U16 pin 15 microcontroller output bit When TRAN PWR is set high power is applied to the transceiver via voltage regulator U11 SM 7066 12 98 4 3 SECTION IV CIRCUIT DESCRIPTION 4 1 14 Voltage References VREF 1 produced by U3 is a 5 0 volt level used to scale the microcontroller s internal 10 bit converter VREF 2 produced by is a 2 5 volt level used as the virtual ground for the modem receiver circuit It is set at one half the full scale value of the ADC so that only a single sided supply is required These references are related so that if VREF 1 drifts the analog signals used to generate VREF 2 will drift with respect to VREF 1 thus reducing the conversion errors 4 1 15 Diagnostics Port Power Supply While there is no external regulator or switch for the diagnostics port RS 232 driver chip U1 power to this circuit is controlled by the microcontroller When the RS 232 port is not in use the receive line is pulled high with a pull up resistor causing the DIAG bit U13 pin 6 to be pulled low When a host computer i
141. re gauge 0 200 psig 0 1380 kpa Setra Model 360 Digital Pressure Gauge 0 5 psig 3 45 kpa Temperature probe 0 5 C resolution of 0 1 C Fluke 2175A Thermocouple J K T or E room ambient temperature range RF Thruline Wattmeter 500 MHz 5 and 25W Bird 43 or equiv elements with BNC style connectors Communications monitor Motorola R 2600 or equiv Carrier accuracy Better than 1 PPM Deviation meter Scope display Receive transmit capability Sinadder Type N RF input output connector preferred Table 2 1 Maintenance Equipment Requirements SM 7066 12 98 2 1 SECTION II SHOP MAINTENANCE 2 2 GOVERNMENT LICENSES Only personnel who have the proper government FCC issued licenses may perform adjustments to the radio portion of the equipment COMPRESSED AIR WHEN WORKING WITH COMPRESSED AIR MAKE SURE THE AIR SUPPLY IS CLEAN THE TEST EQUIPMENT IS IN GOOD ORDER AND THE GLAD HAND IS FULLY ENGAGED BEFORE APPLYING AIR PRESSURE ALWAYS PRESS THE PRESSURE RELIEF BUTTON ON THE EMERGENCY VALVE BEFORE DISCONNECTING IT FROM THE GLAD HAND WHEN PERFORMING EMERGENCY BRAKE EXHAUST VALVE TESTS BEWARE OF THE BLAST FROM THE BOTTOM OF THE VALVE IF THESE ACTIONS ARE NOT TAKEN PERSONAL INJURY COULD RESULT HIGH VOLTAGE AVOID PERSONAL CONTACT WHEN UNIT IS POWERED UP 72V DC POWER INPUT TO CDU IS BEING USED TO SYSTEM TEST THE SBU THIS LEVEL OF DIRECT CURRENT IS DANGEROUS IF CONTACTED 2 3 SBU QUICK EXTERNAL TEST The followi
142. reamble Transmit 100 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking WK Test Marker Light INITIATED duration 6 seconds Enter a menu item number The Marker Light will flash ON for 100 msec OFF for 900 msec for the defined Marker Light Test duration regardless of ambient light conditions When the indicated period has expired the Marker Light will stop flashing To modify the test period see Setting the Marker Light Test Duration under the Configuration section Press lt Esc gt to select another function or return to the Main Diagnostics Menu 3 8 SM 7066 12 98 SECTION SBU DIAGNOSTICS AND CALIBRATION 3 5 11 Test RAM To initiate a test of the SBU RAM memory return to the Main Diagnostics Menu select 11 for Test RAM and press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 Gopyright 1995 Union Switch amp Signal Inc Show Model And Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Garrier Transmit 12 Hz Transmit 1866 Hz Transmit Preamble Transmit 166 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking 1 2 3 4 5 6 8 9 8 2 3 4 1 1 1 1 1 Test Ram GOOD Enter menu item number The response
143. s connected to the Controller PCB the receive line sees a steady mark condition approximately 12 volts This forces the DIAG bit high to indicate the presence of the diagnostics PC The DIAG bit is polled whenever the test push button is pressed If the DIAG bit is high the DIAG PWR U17 pin 13 bit is set applying power to the RS232 interface chip The DIAG PWR bit will be cleared by removing the host computer from the diagnostics port To get out of test mode it is necessary to again press the test push button 42 ANALOG CIRCUITS 4 2 1 Detection Of Transmission From Cab Unit On 330 millisecond intervals the SBU checks to see if a Front to Rear transmission is present Power is applied to the transceiver by setting the TRAN PWR bit high and testing the RADIO CD U14 pin 5 bit to determine if a carrier is present 4 2 2 Receiving Data Power is applied to the required circuits for the receive operation The radio squelch is disabled by setting the SQ DIS U16 pin 17 bit low Note that radio squelch can be disabled if desired See Service Manual SM 7065 4 2 3 Transmitting Data Five microcontroller output bits U20 pins 72 through 76 and a resistor network R51 R82 R83 R84 R85 R86 R50 form a rudimentary five bit digital to analog converter to generate the modem audio output tones Predetermined values from a lookup table are written sequentially to the five bit output bits on fixed time intervals to synthesize the modem t
144. s when it is accessed placing the microcontroller into sleep mode also dramatically reduces the power consumed by the EPROM A second 32 Kbyte EPROM U21 has been included on the PC board for future expansion 4 1 2 EEPROM Memory The SBU ID code all configuration perimeters and calibration constants for pressure and temperature are permanently stored in a Serial EEPROM U25 The SPI serial bus on the microcontroller is used for data transfers into and out of the EEPROM During the initialization operation when the SBU is powered up these constants are loaded into RAM for quick access 4 1 3 Expanded I O Although the 68HC16 microcontroller has a number of direct digital input and output pins the SBU requirements exceed the total available Five additional ICs two 2 octal input buffers U14 and U15 and three 3 octal output latches U16 U17 and U18 satisfy the I O requirements 4 1 4 Reset Function The reset function is handled internally for the microcontroller During the reset operation the microcontroller checks the state of the data bus DO through D7 to determine configuration parameters While reset is low DO is pulled low through Q11 to configure the controller for an eight bit external data bus SM 7066 12 98 4 1 SECTION IV CIRCUIT DESCRIPTION 4 1 5 System Power On Circuit The power on circuit utilizes low power CMOS one shot U2 and its associated circuitry that is triggered by either activation of t
145. sceiver to US amp S Use R50 on main board to adjust if adjustment is made re lock R50 with Glyptol or equivalent 100 Hz Measured at J7 using the Radio Test Use R43 on main board to adjust if adjustment is made re lock R43 with Glyptol or equivalent FM Modulated RF Generator set to RF Output Freq 452 9375 MHz RF Output Level 50 dbm Modulation 1 KHz Sinewave Deviation 3 0 KHz 2 0 KHz for Australian radio Measure Receive Sensitivity SINAD Measured at J7 using the Radio Test Use R43 on main board to adjust if adjustment is made re lock R43 with Glyptol or equivalent If sensitivity is greater than 0 4 uV replace transceiver Table 5 6 Quick Radio Calibration Chart For SBUs Equipped with Johnson Data Telemetry Transceiver 58 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 1 COMPOSITE SBU NICAD BATTERY GRAY SMALL HOSE QUICK EXHAUST VALVE PN N26301501 Description Part Number Quantity per Assembly 10 Electronics Cage Assy 4600 1 15 Assy BatterylinierfaceEOT 1 60 Cover Fuse 24604601 90 Rear Lid Gray m26300302 S Hook 2 875 Galv 408 0737 00 SM 7066 12 98 A 1 APPENDIX PARTS LISTS amp DRAWINGS A 2 COMPOSITE SBU NICAD BATTERY GRAY IN LINE EXHAUST VALVE PN N26301502 Description Part Number Quantity per Assembly 10 Electronics Ca
146. set up for 9600 baud 8 data bits 1 stop bit no parity 3 3 RUNNING THE DIAGNOSTIC SOFTWARE ON THE PC To run the Diagnostics Software perform the following 1 Power up the SBU and the PC 2 Connect the 9 pin serial communications cable between the PC and the SBU s Diagnostic Port connector NOTE The SBU s Diagnostics Port is permanently set up for 9600 baud 8 data bits 1 stop bit and no parity 3 On the PC execute the PC Diagnostic Software from the floppy disk or from the hard disk if it has been copied there by typing diagunit followed by lt Enter gt 4 The Communications Set Up Screen will appear as shown on the next page The program name and version appear at the top of the screen The box at the bottom of the screen displays any prompts for user input The last line shows applicable PC function keys SM 7066 12 98 3 1 SECTION SBU DIAGNOSTICS AND CALIBRATION 5 The software defaults to PC serial port COM1 If use of COM2 is required press lt F2 gt to use COM2 Press lt F1 gt to return to COM1 6 To quit the program at any time press lt F4 gt The program will prompt with Really quit Y N If is selected the program will terminate If is selected the program continues 7 To completely terminate the diagnostic mode in the SBU unplug the communications cable and then either pressing the SBU TEST button or power down the unit by removing the battery To activate the se
147. should be measured and be within 675 Hz The Receive Center Frequency does not need to be checked It will be correct if Transmit Center Frequency is correct If the center frequency measurement is ouside the 675 Hz range the TCXO must be adjusted This is done by removing the JDT module s cover and locating the FREQ ADJ ACCESS HOLE on the bottom side of the Loader Board as shown in Figure 2 11 Use a small screwdriver to adjust the TCXO for the desired frequency J204 User Interface FUSE BOTTOM SIDE PC BOARD R317 DEV LIMIT ADJ D R432 AUDIO ADJ FREQ ADJ ACCESS HOLE MOD SENSITIVITY ADJ Figure 2 11 JDT Transceiver Frequency Adjust Access Hole Location Cover Removed 2 6 5 Transmitter Deviation 1 The following procedures apply to all of the the JDT radio module versions except for the Australian version radio p n N24600009 which is described separately in Step 3 Using the PC transmit a Continuous Message Preamble Adjust the TX GAIN pot R50 for 3 0KHz 1KHz deviation The communications monitor should be set as specified in Table 2 5 for the applicable TX frequency The test software will key the radio transmitter for 50 seconds If R50 is adjusted re lock with Glyptol or equivalent Australian JDT Radio 3 For the Australian version JDT radio p n N24600009 repeat Step 2 above but adjust the TX GAIN pot R50 for 2 0KHz 1KHz deviation 2 28
148. smit Frequency Receive Frequency RX Local Oscillator Number Frequency North America 457 9375 MHz 452 9375 MHz N A PIN N24600007 Australia 477 700 MHz 472 500 MHz N A PIN N24600009 Finland 457 650 MHz 467 650 MHz N A PIN N24600010 Argentina 458 075 MHz 458 075 MHz N A PIN N24600011 Table 2 5 Johnson Data Telemetry Radio Transmit and Receive Frequencies 2 6 4 5 TX Center Freq for Motorola RNET 450 Transceiver 1 This procedure only applies to SBUs equipped with the Motorola Transceiver 2 The center frequency should be within 2 29 KHz If the reading is out of tolerance correct by adjusting Coil L101 in the Motorola radio Coil L101 is located inside the module as shown in Figure 2 9 This adjustment should be set for 200 Hz at room ambient temperature When adjusting the transmitter center frequency check for frequency drift over a period of several minutes Perform this by using the Diagnostics PC to key the radio for a short time e g 5 seconds for each check It is NORMAL for a good radio to drift slightly e g 1000 Hz If the radio continues to drift outside the tolerance value of 2 29 KHz it should NOT be put into service 2 26 SM 7066 12 98 SECTION II SHOP MAINTENANCE 11 TX chl L101 TX ch L104 Figure 2 9 Motorola Transceiver Coil L101 Location 2 6 4 6 Receiver Center Frequency for Motorola RNET 450 1 Remove power from the SBU
149. so it remains motionless High ambient vibration shaking floors etc will give poor results in the following motion tests If this becomes a problem steps should be taken to isolate the SBU from the vibration 2 Observe pins 6 and 8 of J4 on the Microcontroller board with an oscilloscope sweep speed of 0 5 seconds per division 3 Observe the waveform on pin 6 velocity or motion It should be a constant value between 2 4 and 2 7 volts After ten 10 seconds the motion detector s internal reset relay will be released Observe that the waveform has a momentary increase about once per second after release of the relay and that it remains at about the same level 4 Check the waveform on pin 8 vibration It should also have the periodic increase and should be greater than 4 4 volts during the increase while the motion detector is motionless 5 Now gently tilt the SBU Check the waveform on pin 6 Its trace on the scope should smoothly change to a new value the once per second momentary increase should still be observed If the waveform jumps to 5V or OV the motion was too rough and the impulse sensor in the motion detector was triggered try again after waiting until the motion detector relay activates on Stop and releases 2 seconds later 6 If the waveform on pin 6 is jagged the motion detector crystal is fractured in this case return the motion detector to US amp S for repair 2 16 SM 7066 12 98 7 SECTION II SHOP
150. stical information about the received message failures and bit errors whenever it is operational To measure the communication effectiveness of an SBU CDU combination it is necessary to first clear these totals Select 4 from the Main Diagnostics Menu and press lt Enter gt The following screen will appear to indicate that the statistics counters have all been zeroed US amp S End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Switch amp Signal Inc Show Model find Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 12 Hz Transmit 18 Hz Transmit Preamble Transmit 166 Messages Test Marker Light Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking 1 2 3 4 5 6 8 9 Clear Received Message Statistics DONE Enter menu item number Esc go hack Fi repeat selection 3 5 4 Show Received Message Statistics Place the CDU into the Continuous Transmit Mode At any point you may select 3 and press lt Enter gt to display a snapshot of the statistics indicating the number of messages accepted and rejected and the types of bit errors encountered if any up to that point To update the display press lt F1 gt US amp S End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Switch amp Signal Inc Show Received Message Statistics
151. surement Reference Figure 2 4 2 Set the scope vertical attenuator to 1V div and the sweep speed to 10msec div Set the trigger to Normal positive slope detection and the trigger level to about 2 volts Turn on the power supply 4 With the unit completely motionless the scope trace should indicate a steady state level greater than 4 8 volts 5 Bump the Motion Detector to indicate motion When this is done the scope should trigger on the rising edge of the turn on pulse The pulse duration should be between 80 and 86 msec Adjust the trigger and horizontal position controls to fit the trace on the screen for easy measurement If the scope has cursors they may be helpful in making a quick and accurate measurement Refer to Figure 2 4 and verify the given timing parameters Duty Cycle 980 990 msec 80 86 msec lt Figure 2 4 Waveform on Pin 3 of J2 Off Time Measurement Reference Figure 2 4 6 Change the scope sweep speed to 250 7 Bump the Motion Detector to indicate motion When this is done the scope should trigger and display at least two 2 cycles of the pulse train Use the screen cursors to measure the duty cycle time The duty cycle should be between 980 and 990msec Refer to Figure 2 4 and verify the given timing parameters 8 Turn off the power supply and disconnect all test equipment and jumper leads 9 Remove the jumper plug from JP1 and install it onto the JP2 dummy pins outside the
152. t 100 Messages To transmit a series of 100 messages for statistical or test purposes return to the Main Diagnostics Menu select 9 for Transmit 100 Messages and press lt Enter gt The following screen will appear 1585 End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Suitch amp Signal Inc Show Model find Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1288 Hz Transmit 18880 Hz Transmit Preamble Transmit 100 Messages Test Marker Light 1 Test Ram Test Rom Test Brake Valve Circuit Initiate Emergency Braking 1 2 3 4 5 6 9 8 9 Transmit 166 Messages INITIATED duration 108 seconds Enter a menu item number Esc After 100 messages the carrier will turn off automatically Press lt Esc gt to select another function or return to the Main Diagnostics Menu 3 5 10 Test Marker Light To initiate a test of the Marker Light return to the Main Diagnostics Menu select 10 for Test Marker Light and press lt Enter gt The following screen will appear US amp S End of Train System Diagnostic Unit Software 1 0 Copyright 1995 Union Switch amp Signal Inc Show Model And Version Show System Information Show Received Message Statistics Clear Received Message Statistics Transmit Carrier Transmit 1266 Hz Transmit 1800 Hz Transmit P
153. the ambient light level is low the Marker Light should already be flashing To test a sensor in this condition shine a light on the display window The Marker Light should stop flashing and the CDU should indicate that the Marker Light is off When the light is removed the Marker Light should begin flashing again Press and hold the TEST button on the SBU until the display reads TEST then release the button The Marker Light should flash for the configured number of times and the SBU should run through the self test 2 3 9 Tilt Switch Operation The Marker Light is equipped with a tilt switch to ensure that the Marker Light does not continue to run after the SBU is removed from the train and laid down If pressure is present the tilt switch will not turn off the Marker Light 15 2 Apply at least 10 psig to the SBU Press and hold the SBU test button until the display reads TEST and then release it The Marker Light should flash briefly Immediately after the SBU display goes dark cover the photocell located behind the display window The Marker Light should begin flashing Tip the SBU over at least 50 The Marker Light should continue to flash Return the SBU to the vertical position Reduce the pressure to 0 psig Tip the SBU over at least 50 The Marker Light should stop flashing Returning the SBU to the vertical position should not cause the Marker Light to begin flashing 2 3 10 Pressure Power Up 1
154. to the SBU the Cab Unit should indicate 0 psig kpa Press the Comm Arm button on the Cab Unit The SBU should respond with a status update in approximately one 1 second Confirm that the Cab Unit indicates a successful Comm Test 2 3 6 Arming Check 1 2 Press the SBU TEST button Request to Arm signal is sent by the SBU When the Cab Unit receives the Request to Arm message it will indicate Arm Now Within five 5 seconds press the COMMUNICATIONS TEST button to initiate a Command to Arm message If the SBU receives the Command to Arm message within six 6 seconds of its initial arming message it responds with an Arming Confirmation message a normal status report complete with pressure reading with the confirmation bit set When the Cab Unit receives the Arming Confirmation message the arming process 1 SUCCESS 3 Observe that the Cab Unit indicates a successful arming sequence SM 7066 12 98 2 5 SECTION II SHOP MAINTENANCE 2 3 7 Emergency Brake Application 1 House Air Quick USE SAFETY GLASSES AND EAR PLUGS WHEN PERFORMING THIS PROCEDURE OTHERWISE PERSONAL INJURY MAY RESULT Refer to Figure 2 1 below for Test Equipment Setup Pressure Gauge 200 psi 1 Outlet Air Valve Tank Inlet Valve Pressure Regulator Filter Connect Figure 2 1 Emergency Brake Test Equipment Setup Connect the air tank to the SBU glad hand Pressurize the tank to 8
155. tput from the SBU s filter RX OUTPUT If the communication monitor can not be used to set the RX OUTPUT use an oscilloscope R43 is adjusted re lock with Glyptol or equivalent 5 Once complete disconnect the Radio Test Cable from the SBU 2 6 7 Measuring Receiver Sensitivity Using SINAD The sensitivity of a receiver is defined as the minimum level of an appropriately modulated input signal that will produce a desired intelligible output signal that is a specified level above the normal background noise SINAD is the gauge by which a 5 capability of separating the desired signal from the noise can be measured The SINAD measurement technique used in the Land Mobile Radio Service involves injecting an RF signal that is FM modulated with a one 1 KHz tone with a deviation equivalent to that seen in normal service into the receiver RF input and measuring the resulting audio output signal The device used to measure SINAD is often called a SINADDER but most Communication Analyzers such as the Motorola R 2600 also have this capability The term SINADDER is used hereafter as a generic term for all such devices The signal at the audio output of the receiver which is composed of the demodulated 1 KHz tone all internally and externally generated noise plus any receiver induced distortion is simultaneously measured two different ways by the SINADDER as a raw signal and after SM 7066 12 98 2 29
156. train and then gently rock the unit to simulate continued train movement 2 The Cab Unit display should indicate Forward After about 20 seconds the Cab Unit display should indicate Moving 3 Hold the SBU motionless After a few seconds the CDU display should indicate Stopped 2 3 14 Check Reverse Motion 1 Move the SBU sharply backwards i e in the direction it would move on a backward moving train and then gently rock the unit to simulate continued train movement 2 The CDU display should indicate Reverse After about 20 seconds the CDU display should indicate Moving 3 Hold the SBU Unit motionless After a few seconds the CDU display should indicate Stopped If the display indications were not correct repeat to verify the failed indication It could be that the train s movements were not simulated correctly or that transmissions were corrupted by transmissions from other SBUs 2 3 15 Battery Sensing 1 Preset the variable voltage power supply to 12 5 volts and turn it off 2 Remove the battery or batteries from the SBU Using clip leads connect the variable voltage power supply to the SBU s battery contacts Be careful to observe the polarity when connecting the leads 2 8 SM 7066 12 98 SECTION II SHOP MAINTENANCE 3 Turn on the power supply 4 Press and hold the SBU TEST button until the display reads TEST and then release it The Marker Light should flash and the
157. tt rti 1 6 1 10 SBUSPECIFIGATIONS GRENER 1 7 1 11 LEAD ACID BATTERY 1 10 SHOP tn cuna en x uar er o napa Rx 2 1 INTRODUCTION dct ban eni n aedi c ues 2 1 TEST EQUIPMENT RE OUREMENIS aa 2 1 GOVERNMENT LICENSES ene 2 2 SBULQUICK EXTERNAL TEST 2 2 2 3 1 Mechanical Check ete rhe oon qr gre en 2 3 2 3 2 Initial Jumper Settings for so SSR 2 3 2 3 3 External Functional DRIN E NRI 2 4 2 3 4 IS eric tt 2 5 2 3 5 Communications Test 2 5 2300 Arming Gheck Ge 2 5 2 3 7 Emergency Brake Applicatiof u uu pepe carece ee cope ge 2 5 2 3 8 Marker Light HVM NS 2 6 2 3 9 Tilt SwitGh Operation a e an Aw 2 7 23 107 Pressure Power Ups oru e ood 2 7 2 3 11 Zero Pressure Shutdown eta a roll eies 2 8 2 3 12 Motion BOelGlOF nies rect aene th enm nac 2 8 2 3 13 Check Forward MOLIOF noe 2 8 2 3 14 Check Reverse 2 8 23 15 B ter SENSING Eco ae eee 2 8 SBU MECHANICAL INSPECTION 2 9 2 4 1 Torque Requirements
158. y N26300402 Door Battery Gray M26300102 15 Latch EOT M26302301 2 20 Pin Hinge SS EOT BCHO 16 J5611290008 2 Pin Latch SS EOT BCLP 15 J5611310016 A 46 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 17 MAIN HOUSING WITH DOOR BLUE YELLOW PN N26301203 Description Part Number Quantity per Assembly Main Housing Blue Yellow N26300403 Door Battery Blue Yellow M26300103 15 Latch EOT M26302301 2 20 Pin Hinge SS EOT BCHO 16 J5611290008 2 Pin Latch SS EOT BCLP 15 J5611310016 SM 7066 12 98 A 47 APPENDIX PARTS LISTS amp DRAWINGS A 18 MAIN HOUSING WITH DOOR PN N26301204 Description Part Number Quantity per Assembly N26300404 Door Battery Yellow M26300101 15 Latch EOT M26302301 2 20 Pin Hinge SS EOT BCHO 16 J5611290008 2 Pin Latch SS EOT BCLP 15 J5611310016 A 48 SM 7066 12 98 APPENDIX PARTS LISTS amp DRAWINGS A 19 MAIN HOUSING PN N26301205 Description Part Number Quantity per Assembly Main Housing Orange N26300405 Door Battery M26300104 15 Latch EOT M26302301 2 20 Pin Hinge SS EOT BCHO 16 J5611290008 2 Pin Latch SS EOT BCLP 15 J5611310016 SM 7066 12 98 A 49 APPENDIX PARTS LISTS amp DRAWINGS This page is intentionally blank A 50 SM 7066 12 98
159. y valve 3 Listen for air leaks If an air leak is suspected at a certain component apply soapy water to the area in question and watch for bubbles If leaks are found release the air pressure Tighten and or reseal around the suspected component and retest SM 7066 12 98 2 15 SECTION II SHOP MAINTENANCE 2 6 2 Functional Check of the Motion Detector The SBU will be equipped with one of two types of Motion Detectors as follows Old Style Crystal Pendulum Motion Detector P N N451873 8001 e New Style Solid State Motion Detector P N N24610101 2 6 2 1 Functional Check of Old Style Crystal Pendulum Motion Detector The motion detector is an accelerometer that detects the various forces acting on the SBU It has two outputs vibration and velocity The latter is a composite of two signal processing functions in the hardware of the Motion Detector an integrator and an impulse detector The vibration output is a DC level that decreases with increasing vibration The motion status is interpreted from the two signals by the microcontroller To perform a functional test of the motion detector the SBU must be held vertically The following steps examine the raw output of the motion detector and are given to provide confirmation and a diagnosis of problems seen in the External Test described in Section 2 3 12 1 Place the SBU in a vertical position so that the motion detector is in its normal operating orientation and hold the enclosure

Digitair Model 6695-CC End-of-Train Sense & Brake Unit (SBU

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Digitair Model 6695-CC End-of-Train Sense &amp; Brake Unit (SBU

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Digitair Model 6695-CC End-of-Train Sense & Brake Unit (SBU