ip-246 tilt · personal eye protection must be worn to protect the eyes from possible injury. when...

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R a i l V e h i c l e S y s t e m s

I P - 2 4 6Rev. 02 (1/6/10) -en

Trainline Integrity and Locomotive Test Device (TILT)

Operator Instruction and Maintenance Guide

Trainline Integrity and Locomotive Test Device (TILT)Operator Instruction and Maintenance Guide Doc. No. IP-246

Revision: 02 1/6/10-en

This document was originally written in English.

Knorr-Bremse Group / 21

Copyright 2008© NYAB. All rights reserved, including industrial property rights applications.NYAB retains any power of disposal, such as copying and transferring.

Contact addressNew York Air Brake Corporation748 Starbuck AvenueWatertown, NY 13601USAPhone: +1 315 786 5200Fax: +1 315 786 5676www.nyab.com





Revision History

Rev. Date Name Para Description of Change

01 Nov/09 M. Parisian ALL Original Release

02 Jan/10 M. Parisian 5.2.1 KPa was psi





Table of contents

1 General Information 51.1 Technical changes 51.2 Target group for this document 51.3 Notes and warning messages 6

2 Safety 72.1 General Safety Awareness 7

3 System Description 103.1 Purpose 103.2 Features 103.3 Overview of the Trainline Integrity and Locomotive Test Device (TILT) 113.4 Interfaces 123.5 Trainline Interface 12

4 TILT Installation Instructions 14

5 Functional Instructions 155.1 Using the TILT for ECP Trainline Continuity Testing 155.2 Using the TILT for Switch Mode Termination 16

6 Maintenance 176.1 Replaceable Parts 176.2 Inter-Car Cable 17

7 Troubleshooting 197.1 TILT LED Troubleshooting Matrix 19

8 Return Material Authorization Process 20

9 Appendix 21





1.1 Technical changesNYAB reserves the right to change the equipment or this document at any time without giving special notice.

1.2 Target group for this documentThis document is intended for use by NYAB trained service technicians who

have the skill, experience, safety awareness and professional ability:

• to remove and install the equipment,

• to inspect, maintain and debug the equipment,

have read and understood this document from start to finish, and

are familiar with the safety codes and accident prevention regulations for these activities.

1 General information

Please read this document carefully from start to finish to ensure safety of operation. Failure to follow the safety alerts will result in death or serious injury.

This document will be useful to other target groups as well, e.g. project engineers. However, it does not claim to provide complete information for such target groups.





1.3 Notes and warning messages

The symbols indicate that important personal safety information follows. Carefully read and understand each safety related text message and apply the message to the operation and maintenance of the system as defined in the safety alert message. The fol-lowing are definitions associated with the different safety alert message categories.

Indicates an imminently hazardous situation, which if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

Indicates a potentially hazardous situation, which if not avoided, may result in death or serious injury.

Indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury. It may be used to alert against unsafe practices.

Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property





2.1 General Safety AwarenessTo prevent physical injury or death, all personnel directly or indirectly involved with the ope-ration of the equipment described in this manual must conform to the following:

2.1.1 Observe all rules and regulations of the railroad where the equipment is being used. Whenever there is a conflict between the instructions in this manual and the instructions of the user railroad, the rules and regulations of the user railroad will govern.

2.1.2 When performing any operation of the equipment while it is on the vehicle (on vehicle test, etc.) special precautions must be taken to ensure that vehicle movement will not occur which could result in injury to personnel and/or damage to equipment. Make sure the handbrake is applied and that the wheels are chocked to prevent vehicle from moving.

2.1.3 Shut off power and open airbrake breaker whenever continuity is to be checked or when handling equipment connections. When shutting off power by means of knife or switch.

2.1.3.1 Attach an approved WARNING tag to the open breaker

2.1.4 De-pressurize air system before loosening connections or components. Before removing any component from its mountings, the train must be safely parked. To prevent personal injury, all main reservoir, brake supply reservoir, and brake cylinder on the affected vehicle must be vented.

2.1.5 "Bottled" up air under pressure (even though air supply is cut off) may cause gaskets and/or particles of dirt to become airborne and an increase in sound level when any component part

2 Safety

High Voltages (AC and/or DC) are present. Always exercise extreme care when working in close proximity to electrically energized appa-ratus or when making current measurments. To prevent receiving electrical shock when performing electrical tests, hands must be clear of electrical components, contacts, and housing. There must be no bodily contact with the work area.

Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences.

Ensure that power and/or switches are turned off prior to making any electrical connections/disconnections.

Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences.





is removed from the equipment arrangement. Personal eye and ear protection must be worn and care taken to avoid possible injury when performing any work on these component parts.

2.1.6 The use of an air jet, which must be less than 30 PSIG, to blow parts clean or to blow them dry after being cleaned with a solvent will cause particles of dirt and/or droplets of the cleaning solvent to be airborne. These particles and droplets may cause skin and /or eye irritation. Personal eye protection must be worn to protect the eyes from possible injury. When using an air jet do not direct it toward another person.

2.1.7 If degreasing fluids are used for cleaning purposes, the current local safety regulations plus the safety precautionary statements of the manufacturer of the cleaning agent must be adhered to. Otherwise, physical harm could result from the inhalation of toxic fumes. Make sure the area is well ventilated when working with materials that produce harmful fumes.

2.1.8 Personal eye protection must be worn when doing any work to protect eyes from possible injury.

2.1.9 Where fasteners removed from the equipment are not satisfactory for reuse, care must be taken to select replacements that match the originals. Mismatched or incorrect fasteners can result in equipment damage or malfunction, or possible personal injury.

2.1.10 To ensure the correct functioning of each component, use only the manufacturers genuine spare parts as replacements.

Cleaning using compressed air can cause particles to become air-borne, be sure to:• Wear eye protection• Do not exceed 30 PSIFailure to observe these safety precautions can lead to serious injury.

Solvents and solvent fumes can be harmful to health, when using solvents, be sure to:• Wear eye, skin, and respiratory protection• Work in a well-ventilated area• Avoid repeated or prolonged contact• Keep solvent container closed• Keep solvent away from sparks, flames, and heatFailure to observe these safety precauitons can lead to serious injury or intoxication.





2.1.11 Appropriate tool selection is required when performing all maintenance operations to avoid personal injury.

2.1.12 Person(s) having the appropriate job skill level, as governed by the user railroad, are required when performing maintenance and/or operational tasks with the brake system and system components.

2.1.13 Whenever a valve or system component is removed from a vehicle for any reason, and it is reinstalled or replaced with a new or repaired and tested component, a stationary vehicle air brake test and an equipment test must be performed to ensure that the component functions properly within the system.

2.1.14 When air pressure measurements are to be made for the purpose of pressure level verification and/or adjustment, an air brake test gauge having an accuracy of ± 1 PSI is required.





3.1 PurposeThe intent of this Operator Instruction and Maintenance Guide, IP-246, is to familiarize an end-user with the basic operation and general use for the Trainline Integrity and Locomotive Test Device (TILT). This manual instructs a user in the steps to connect, operate, and remove the device from a train to perform the following functions in which it was designed for:

• ECP Trainline Integrity Troubleshooting Device

• ECP Termination Device For Locomotive Validation Testing

• Trainline Termination For Switch Mode Operation

3.2 Features• Interoperable With AAR S-4200 ECP Operating Systems

• Real Time Messaging Input To The Locomotive Display

• Self Contained Diagnostic LED's

• AAR Approved Inter-car Connector Trainline Interface

• No Brake Pipe Interface Required

• Automated Operation With Presence Of T/L Voltage

• Provides Termination To Allow Activation OF T/L Power During Switch Mode Operation

• Batteries Not Required

• No Calibration Required

• Lightweight Solution For Troubleshooting Line Of Road ECP Trainline Issues

• Lightweight Solution For Locomotive Validation Testing

• Lightweight, Compact, Rugged Duty Plastic Construction

• Approximate Net Weight Of 5-3/4 lbs..

3 System Description

During use of this device there are times when hazardous voltage (230VDC) may be present on the trainline. Contact with the pins when the ’Power Indicator LED’ is lit may cause electrical shock or serious injury.





3.3 Overview of the Trainline Integrity and Locomotive Test Device (TILT)

The Trainline Integrity and Locomotive Test Device (TILT) was created to assist the railroad industry in performing three functions as identified in Section 3.1, with its primary function to troubleshoot Trainline (T/L) Integrity and Conductivity issues on an assembled ECP train. The following areas identify the purpose of the TILT in detail:

3.3.1 Trainline Integrity Test Device:

The TILT's primary function was designed to be used as a T/L integrity and conductivity test device for an assembled ECP train. Weighing 5.75 pounds, this light weight and portable test unit was designed to terminate an ECP T/L circuit to help determine continuity across the T/L similar to an ECP EOT, but with safety considerations taken into account. Because the TILT does not incorporate a self contained power supply (battery), it relies on T/L voltage from the Head End Unit (HEU) used as an indication for the integrity of an ECP T/L.

A section of ECP T/L can be tested by connecting the TILT device to the Inter-car connector at the trailing section of the train being tested. Once connected, T/L continuity is validated from the lead locomotive by activation of T/L power, using diagnostics on the locomotive display, and with LED's located on the TILT itself. If the section of train tested is found to be acceptable, testing continues away from the lead locomotive, until the problem is identified. At that time the car or cars can be tagged for repair, and either removed from the train, or by-passed electronically through the use of an ECP T/L wrap around cable.

3.3.2 Locomotive Test Device:

The TILT is also designed to be used, if needed in place of an ECP EOT, as a locomotive validation test termination device.

The TILT can be placed on a single locomotive to be used to perform locomotive validation type testing. With the use of a TILT, locomotive validation testing can be performed in two parts:

• S/W Version Control and Initialization Testing

• Locomotive Functional Testing in ECP Switch Mode

3.3.3 ECP Switch Mode T/L Termination Device:

The TILT can also be used as a termination device allowing activation of T/L Power during Switch Mode Operation only. As outlined within this document, this is achieved by setting the TILT AAR EOT Beacon Parameters specific to enable Switch Mode Operation, while at the same time restricting use in Run Mode Operation under any circumstance.





With the TILT installed at the end of a section of train to be moved, and the locomotive Head End Termination (HET) complete, Switch Mode Operation can be performed with activation of T/L Power. This is a desired feature for the end user to be able to operate under ECP Switch Mode without depleting the CCD batteries due to the lack of T/L Power.

3.4 Interfaces

The TILT has one interface.

3.5 Trainline InterfaceConnects, via the Inter-Car Connector, to an ECP freight car or locomotive.

Figure 1 Trainline Interface (Inter-Car Cable)





3.5.1 LEDS

The TILT has three LEDs on the top front panel identified below, which can be used in the troubleshooting of an ECP T/L.

Figure 2 LEDs on Top Cover

• "T/L VOLTAGE PRESENT WHEN LIT" LED: Activates solid red when T/L voltage is recei-ved over 30 VDC from the lead locomotive. Depending on train length, T/L voltage at the end of an ECP train is typically above 200 VDC. If the TILT is connected to a section of train with T/L power applied, this LED should be lit under normal conditions.

• "COMM TRANSMISSION SENT WHEN FLASHING" LED: Activates flashing green when voltage to the TILT exceeds 70 VDC from the lead locomotive. When this LED flashes green, the TILT Transmission Communication is activated enabling EOT Beacon transmis-sion to the lead locomotive. This messaging can be observed within the EOT BPP display reported as "***". If the TILT is connected to a section of train and T/L power is applied, this LED should be flashing green under normal operating conditions.

• "COMM TRANSMISSION RECEIVED WHEN FLASHING" LED: Activates flashing green when voltage to the TILT exceeds 70VDC from the lead locomotive. When this LED flashes green, the TILT is receiving messaging from the lead locomotive. If the TILT is connected to a section of train with T/L power applied, and communication messages are being sent from the HEU, this LED should be flashing green under normal operating conditions.





The TILT is installed by connecting the Trainline Interface Inter-car Connector to the desired vehicle's Inter-car Connector. This is accomplished by pressing the spring tabs of the mating Inter-car Connectors and pushing them together. Depending on the mode of use, such as Switch Mode, the TILT must be secured to the vehicle with use of ties, straps, cords, or any other means.

Figure 3 Intercar Connectors

To activate and operate the TILT it must receive an input voltage from the Lead Locomotive. T/L Power can be supplied to the TILT from the Lead Locomotive by selecting the POWER and EXECUTE keys located within the ECP MAIN MENU. With T/L Power activated, various testing and troubleshooting can be performed as outlined in Section 5.0 of this manual.

With T/L Power OFF, the TILT can be removed from a vehicle through disconnecting the mating Trainline Interface Inter-car Connectors by pressing the spring tabs and pulling them apart.

4 TILT Installation Instructions

During use of this device there are times when hazardous voltage (230VDC) may be present on the trainline. Contact with the pins when the ’Power Indicator LED’ is lit may cause electrical shock or serious injury.





5.1 Using the TILT for ECP Trainline Continuity TestingTrainline integrity issues are normally defined, but are not limited to the following criteria:

• T/L Short - Loss Of T/L Power• Low T/L Power - % Operable Brake• No ECP EOT - HEU Can Not Find or Lost The ECP EOT Beacon

The following instructions help in determining if a TILT tested T/L is considered acceptable for use in an ECP train.

With one of the conditions identified above existing on an ECP train as displayed on the Lead Locomotive, in which the problem cannot be resolved through local diagnostics on that Lead Locomotive, it is recommended to begin searching for T/L integrity issues starting from the front to the rear of an ECP train using the TILT.

Before beginning to troubleshoot an ECP train for T/L integrity issues, it is recommended to disconnect all secondary/trailing unit ECP Power Supplies (TPSs) by disconnecting the TPS Output Connector on all trailing ECP locomotives equipped with a TPS (if accessible). If the problem goes away, indication is that one or more of the locomotive ECP Power supplies is faulty. Leave the trailing locomotive ECP Power Supplies disconnected and resume train operation until further evaluation can be performed. If the problem persists, proceed to troubleshoot the train per the following procedure using the TILT.

5.1.1 To confirm that the T/L problem is not within the lead locomotive consists, it is recommended to install the TILT between the trailing end of the last locomotive in the lead consist, and the 1st car of the train. With the train secured, and T/L POWER OFF, install the TILT Inter-car Connector by pressing the two lock tabs simultaneously and pressing together.

From the Lead Locomotive activate T/L POWER by selecting the POWER and EXECUTE keys located under the ECP MAIN MENU. If there are no T/L integrity issues within the locomotive consist, T/L POWER will activate and stay activated at the Lead Locomotive, and the TILT LED's will illuminate as follows:

• "T/L VOLTAGE PRESENT WHEN LIT" LED: Solid red • "COMM TRANSMISSION SENT WHEN FLASHING" LED: Flashing green • "COMM TRANSMISSION RECEIVED WHEN FLASHING" LED: Flashing green

If T/L POWER comes up, then deactivates after approximately 8 seconds, and the TILT LEDs do not stay illuminated, there is indication that the T/L issue is within the lead locomo-tive consists. To disable the TILT, deactivate T/L POWER by selecting the POWER and EXECUTE keys located under the ECP MAIN MENU. Verify that T/L POWER is OFF as indicated on the ECP display before disconnecting the TILT.

5 Functional Instructions





Typically if there is a T/L integrity issue upon power up, the following "may" be displayed under the following areas within the ECP Operating Screens:

• Locomotive Display Main Screen:"T/L Power Offline""T/L Short Circuit""No PSCs Detected"

• ECP Maintenance Menu Maintenance Log: "T/L Short Circuit"

If the problem is within the locomotive consist, continue to move the TILT towards the Lead Locomotive until the problem locomotive is determined. Once the problem locomotive is determined, either wrap around the locomotive with an ECP wrap around cable to electrically bypass the problem, or physically remove the locomotive from the train consist to continue train operations.

If the problem is not found to be within the lead consist, continue troubleshooting the T/L by moving back in the train 5 - 10 vehicles at a time, and repeating the above procedure until the problem car or cars are found.

5.2 Using the TILT for Switch Mode TerminationThe TILT can be used to operate in ECP Switch Mode with T/L power activated. This is accomplished by using the TILT as a T/L Termination Device, and ensuring the HET is connected at the Lead Locomotive. The TILT can NOT be used in ECP Run Mode under any circumstance due to built in restrictions

5.2.1 With the TILT installed on the trailing end of the section of train to be moved, and the locomotive HET terminated, ECP Switch Mode can be achieved by selecting the SWITCH and EXECUTE keys within the ECP MAIN MENU. While operating in Switch Mode using the TILT, the Locomotive EOT BPP will be displayed as "***" or the equivalent of 254 psi depending on the locomotive display. The T/L PWR will display "ON". T/L Power can be monitored, activated, and deactivated as done in normal Switch Mode operation.

Figure 4: Locomotive Display EOT BPP

IFC OR CCA (***) OIU or LCDM(English Units PSI)

OIU or LCDM(SI Units KPa)





Figure 5: Trainline Power Monitor

Before removing the TILT from the rear of the train, ensure Trainline Power is OFF.

Special measures will need to be taken to secure the TILT to the rear of the last car for Switch Mode operation.





6.1 Replaceable PartsThere are no replaceable parts for the TILT. Contact NYAB as outlined in Section 8.0 for service or repair.

Figure 6: TILT Assembly

6.2 Inter-Car CableIn the event that the trainline interface of the TILT becomes damaged and needs to be repla-ced, refer to Section 8.0 to contact a NYAB representative.

Figure 7: Inter-Car Cable

6 Maintenance





7.1 TILT LED Troubleshooting Matrix

7 Troubleshooting

RED GREEN GREEN DESCRIPTION CORRECTIVE ACTION

Off Off Off Will not power up. 1. T/L Integrity Issue Present2. Refer to section 5.0 to contact NYAB representative.

On Flashing Off Transmission Receive LED Will Not Flash.

1. TILT Not Receiving HEU Beacon Transmissions From Lead Locomotive2. Faulty Transmission Receive LED3. Refer to section 5.0 to contact NYAB representative.

On Off Flashing Transmission Sent LED Will Not Flash.

1. TILT Not Sending EOT Beacon Transmissions To Lead Locomotive2. Faulty Transmission Sent LED3. Refer to section 5.0 to contact NYAB representative.





All material returned from the field to New York Air Brake (NYAB)/Knorr, must have a Return Material Authorization (RMA) number. A NYAB/Knorr representative will provide the RMA number. To receive a RMA number and to get additional information regarding the RMA process, call:

KBL/KNORR Telephone: (613) 389-4660 Ext. 328Kingston, Ontario, CANADA

OR

NYAB/KNORR Telephone: (315) 786-5494Watertown, New York

OR

KBSA/KNORRKempton Park, South Africa-SA Telephone: (011) 961-7800

8 Return Material Authorization Process





9.1 Abbreviations

9 Appendix

AAR Association of American Railroads

BPP Brake Pipe Pressure

ECP Electrically Controlled Pneumatic

EOT End Of Train Device

CCD Car Control Device

HET Head End Termination

HEU Head End Unit

I/C Inter-Car

LED Light Emitting Diode

S/W Software

T/L Trainline

TILT Trainline Integrity and Locomotive Test Device

VDC Volts Direct Current

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