digitair model 6680 communication ... - hitachi rail sts · two-way mode, the ciu receives...

Union Switch & Signal Inc., an Ansaldo Signal company1000 Technology Drive, Pittsburgh, PA 15219 ● 645 Russell Street, Batesburg, SC 29006 SM 7072

Copyright © 2004 Rev. 1, March 2004Union Switch & Signal Inc.

DIGITAIR® Model 6680

Communication Interface Unit (CIU)

♦ Installation

♦ Configuration

SM 7072, Rev. 1 March 2004 i

Proprietary Notice

This document and its contents are the property of Union Switch & Signal Inc.hereinafter US&S). This document has been furnished to you on the followingconditions: no right or license under any patents or any other proprietary right in respectof this document or its content is given or waived in supplying this document. Thisdocument or its content are not to be used or treated in any manner inconsistent with therights of US&S, or to its detriment, and are not to be copied, reproduced, disclosed toothers, or disposed of except with the prior written consent of US&S.

Important Notice

US&S constantly strives to improve our products and keep our customers apprised ofchanges in technology. Following the recommendations contained in the attached servicemanual will provide our customers with optimum operational reliability. The datacontained herein purports solely to describe the product, and does not create anywarranties.

Within the scope of the attached manual, it is impossible to take into account everyeventuality that may arise with technical equipment in service. Please consult your localUS&S Account Executive in the event of any irregularities with our product.

We expressly disclaim liability resulting from any improper handling or use of ourequipment, even if these instructions contain no specific indication in this respect. Westrongly recommend that only approved US&S spare parts be used as replacements.

Record of Revisions

ii SM 7072, Rev. 1, March 2004

Revision HistoryRev. Date Nature of Revision

- May 1998 Original Issue

Rev. 1 March 2004 Incorporated ECOs 139702-3, 139702-6, and 139715-1 toinclude revised software changes and updates to the

Interface PCB.

Table of Contents

SM 7072, Rev. 1 March 2004 iii

1. Purpose of Manual..................................................................................................................................1-11.1. General Overview of Two-Way End of Train Telemetry..............................................................1-11.2. CIU General Overview and Functional Description.....................................................................1-21.3. Radio Message Protocol Compatibility........................................................................................1-31.4. Compliance with Locomotive System Integration (LSI) and IntegratedFunctional Computer (IFC) Communications Specifications .....................................................................1-31.5. CIU Ordering Information ............................................................................................................1-31.5.1. CIU Part Number.............................................................................................................1-31.5.2. CIU Diagnostic and Configuration Software Disk ............................................................1-31.5.3. CIU Executable Software and Load Utility Disk ...............................................................1-41.6. CIU Major Hardware Assemblies ................................................................................................1-41.7. MODEL 6680 CIU........................................................................................................................1-42. Installation of the CIU.............................................................................................................................2-12.1. Items Required for Installation and Configuration .......................................................................2-12.2. Mounting the CIU.........................................................................................................................2-12.2.1. Mounting the CIU in an Integrated Cab Electronics (ICE) or LSI Rack ...........................2-12.2.2. Mounting the CIU in a Non-ICE Equipped Locomotive....................................................2-12.3. Host Interface Connections .........................................................................................................2-22.4. Host Interface Cable and Connections........................................................................................2-22.5. Antenna Installation .....................................................................................................................2-32.6. CIU Power Up and Operational Verification ................................................................................2-42.6.1. CIU System Operational Verification ...............................................................................2-43. Configuration and Diagnostics ............................................................................................................3-13.1. DIGITAIR® Diagnostic Software ..................................................................................................3-13.2. Running the Diagnostic Software ................................................................................................3-13.3. Main Menu ...................................................................................................................................3-33.3.1. Diagnostic Items...............................................................................................................3-43.3.2. Configuration Items Menu ................................................................................................3-53.3.3. Enable UDE/E-Brake Input ............................................................................................3-133.3.4. Set Protocol....................................................................................................................3-144. CIU Software Upgrades .........................................................................................................................4-14.1. Flash Loader Utility Program.......................................................................................................4-14.2. Using “load.exe”...........................................................................................................................4-14.3. Procedure for Downloading CIU Software Upgrades..................................................................4-25. RAIL Team and Technical Support......................................................................................................5-1

Table of Contents

Table of Contents

iv SM 7072, Rev. 1, March 2004

List of Figures

Figure 1-1 - Two-Way End-of-Train Telemetry Functions .......................................................................1-1Figure 1-2 - DIGITAIR® Model 6680 Communications Interface Unit......................................................1-2Figure 1-3 - DIGITAIR® Model 6680 CIU Hardware Assemblies.............................................................1-4Figure 2-1 - Typical Installation Connections to CIU Host Interface Connector ......................................2-3Figure 3-1 - Diagnostic Set-Up Screen ....................................................................................................3-2Figure 3-2 - Initial Diagnostic Screen.......................................................................................................3-3Figure 3-3 - Start Main Diagnostic Screen...............................................................................................3-3Figure 3-4 - Main Menu............................................................................................................................3-4Figure 3-5 - Diagnostic Items Menu.........................................................................................................3-4Figure 3-6 - Transmitter Test Options Screen .........................................................................................3-5Figure 3-7 - Configuration Items Menu ....................................................................................................3-6Figure 3-8 - EOT ID Code Menu ..............................................................................................................3-6Figure 3-9 - One-Way Protocol Menu ......................................................................................................3-7Figure 3-10 - Two-Way Protocol Screen..................................................................................................3-7Figure 3-11 - Two-Way Mode Menu ........................................................................................................3-8Figure 3-12 - Auto Selection of Mode Menu ............................................................................................3-9Figure 3-13 - Low Pressure Threshold Menu ..........................................................................................3-9Figure 3-14 - Customer String Screen ...................................................................................................3-10Figure 3-15 - CIU Serial Number Screen...............................................................................................3-11Figure 3-16 - Automatic Arming Screen.................................................................................................3-12Figure 3-17 - Transmit Power Level Screen ..........................................................................................3-12Figure 3-18 - UDE/E Brake Input Screen...............................................................................................3-13Figure 3-19 - Protocol Screen ................................................................................................................3-14

List of Tables

Table 1-1 - CIU General Specifications ...................................................................................................1-5Table 1-2 - Radio Specifications (CIU Equipped with Motorola RNET 450 Transceiver)........................1-6Table 1-3 - Radio Specifications (CIU Equipped with Johnson Data Telemetry Transceiver) ................1-6Table 2-1 - Model 6680 CIU Host Interface Connector Pin Assignments ...............................................2-2

Purpose of Manual

SM 7072, Rev. 1, March 2004 1-1

Section 1. Purpose of ManualThis manual provides an overview of two-way End-of-Train (EOT) Telemetry and detailed informationregarding the installation and operation of the US&S DIGITAIR® Model 6680 CommunicationInterface Unit (CIU).

1.1. General Overview of Two-Way End of Train Telemetry

A two-way End-of-Train (EOT) telemetry system consists of an EOT Cab Unit, which is mounted inthe locomotive cab, and an EOT End Unit, which is mounted on the coupler of the last train car (Figure1-1). These two EOT units communicate with each other via radio.

The Cab Unit incorporates all of the functions necessary to communicate with the End Unit. When thelocomotive is equipped with an Integral Locomotive Computer (ILC), a CIU such as the US&SDIGITAIR® Model 6680 CIU is typically used as the EOT Cab Unit. The CIU interfaces to the ILC,which displays all relevant EOT information for the locomotive operator. The CIU, together with anEOT End Unit and an ILC, operating as a system, provides the following information and capability:

• A digital display of the brake pipe pressure at the rear of the train;

• An indication of motion of the last car (moving/stopped) and its initial direction (forward/reverse);

• The status (weak or replace) of the End Unit battery;

• A warning of low brake pipe pressure (typically less than 45 psig);

• The status (On/Off) of the Highly Visible Marker (HVM) light if supplied on the End Unit;

• The status of the radio link (rear-to-front and front-to-rear communications);

• An emergency braking function from the rear of the train, when operating in two-way mode;

• A digital display of secondary air pressure if a dual pressure type End Unit is used.

HVM

END UNIT

BRAKE PIPE AIR

LAST CAR

RADIO LINK

- BRAKE PIPE PRESS.- BATTERY STATUS- HVM STATUS- CAR MOTION

VEHICLEBATT.

LOCOMOTIVE

- COMMS LINK TEST- EMERGENCY ACTIVATION

CIU

Figure 1-1 - Two-Way End-of-Train Telemetry Functions

Purpose of Manual

1-2 SM 7072, Rev. 1, March 2004

1.2. CIU General Overview and Functional Description

The DIGITAIR® Model 6680 CIU receives and processes EOT telemetry radio messages from an EOTEnd Unit and sends the data extracted from these messages to an Integral Locomotive Computer (ILC)via an asynchronous serial connection for subsequent display. When the EOT system is operating intwo-way mode, the CIU receives Emergency Brake and Communications Test commands from theILC and transmits these commands via radio to the EOT End Unit.

The CIU is a single unit (Figure 1-2) which mounts in an Integrated Cab Electronics (ICE) type rack. Itcommunicates with the ILC via a cable connected to the Host Interface connector on the front panel ofthe CIU. The Host Interface connector provides the lines required for an external DC power source andCIU-to-ILC serial communications. The CIU is connected to a UHF 1/4-wave antenna via the frontpanel mounted “N” type RF antenna connector.

COMMUNICATIONINTERFACE UNIT

(CIU) ENCLOSURE

STATUSINDICATOR

“N” TYPEANTENNACONNECTOR

CARRY HANDLE

HOST INTERFACECONNECTOR

Figure 1-2 - DIGITAIR® Model 6680 Communications Interface Unit

Purpose of Manual

SM 7072, Rev. 1, March 2004 1-3

1.3. Radio Message Protocol Compatibility

The CIU is compatible with the American Railway Engineering and Maintenance of Way Association(AREMA) End-of-Train message protocol as defined in Section.22.3.1 of the AREMACommunications and Signals Manual dated 2000.

The CIU meets or exceeds the current requirements of the U.S. Federal Communications Commission(FCC) and Industry Canada (IC) regulations.

1.4. Compliance with Locomotive System Integration (LSI) and IntegratedFunctional Computer (IFC) Communications Specifications

The CIU interfaces to either an Integral Locomotive Computer (ILC) or an Integrated FunctionalComputer (IFC) via an asynchronous RS-232C serial communications link.

The CIU has been designed to comply with the current Locomotive System Integration (LSI)Communications Specification prepared for the AAR. The CIU’s communications electricalcharacteristics, data format, and message block protocol operate as defined in the LSI CommunicationsSpecification, Appendix A and Appendix G. Per Appendix G, the LSI specifications have beenestablished to facilitate forward and backward compatibility with units fielded on GE LSI and EMDFIRE and ICE locomotives. EMD's Integrated Cab Electronics (ICE) requirements are a subset of theLSI specification.

1.5. CIU Ordering Information

To order the DIGITAIR® Model 6680 Communication Interface Unit (CIU) and related accessories,please contact US&S Customer Service at 1-800-652-7276 or your local US&S Sales Representativefor technical information, pricing, and additional sales information.

1.5.1. CIU Part Number

The CIU bears US&S part number N24300102. It will operate with either an IFC or LSI/ICE/FIREsystem when appropriately configured.

1.5.2. CIU Diagnostic and Configuration Software Disk

The CIU does not rely on a dedicated external device for system diagnostics or configuration. All ofthe unit diagnostic tests and configuration functions are included on a Diagnostics and ConfigurationSoftware Disk that runs on a standard DOS-compatible personal computer (PC). The PC is connectedto the CIU’s internal DB-9 style Diagnostic Port or it can be optionally accessed via the Host Interfaceconnector.

The Diagnostic and Configuration Software permits easy customization of the CIU’s operation. Mostof the variable default values and functions are user selectable. These variables are set by the factory atthe time of purchase or by railway technicians via a PC at installation. The Diagnostic andConfiguration Software program on the disk is named “diagunit.exe” and its use is described inSection Section 3.

Purpose of Manual

1-4 SM 7072, Rev. 1, March 2004

The Diagnostic and Configuration Software Disk (3.5”) can be ordered under US&S part numberN451232-1264.

1.5.3. CIU Executable Software and Load Utility Disk

The CIU uses FLASH type, programmable, non-volatile memory to store its application software.This type of memory eliminates the need to disassemble the unit and physically replace an EPROM inthe event that software upgrades are required.

The Executable Software and Load Utility disk allows the user to download software upgrades into theCIU’s internal FLASH memory. It contains two files: (1) the latest upgrade version of the CIUexecutable software named “ciu.hex”, and (2) the Cab Unit Flash Loader program named “load.exe”.The use of this disk is described in Section 4.2.

This disk is will only be issued by US&S when an upgrade is deemed necessary. The latest version ofthe CIU Executable Software and Load Utility disk is available on a 3.5” diskette under US&S partnumber N451232-0822.

1.6. CIU Major Hardware Assemblies

Figure 1-3 shows the major hardware assemblies of the CIU and the location of the DiagnosticConnector and fuses.

Figure 1-3 - DIGITAIR® Model 6680 CIU Hardware Assemblies

1.7. MODEL 6680 CIU

Table 1-1 through Table 1-3 list the physical and electrical specifications of the EOT system.

Purpose of Manual

SM 7072, Rev. 1, March 2004 1-5

Table 1-1 - CIU General Specifications

PARAMETER SPECIFICATIONPhysical

Overall Dimensions H = 9.25”, W = 2.50”, D = 11.60”Weight 4 lbs.

EnvironmentalOperating Temperature Range -40°C to +70°CStorage Temperature Range -55°C to +100°CHumidity 95% non-condensing at 40° C, 96 hour exposureVibration - Vertical and Lateral (Peak)

1 – 15 Hz 0.25 g15 - 500 Hz 2.5 g

Vibration - Longitudinal (Peak)1 – 15 Hz 1.5 g15 - 500 Hz 2.5 g

Shock - any axis, peak (half sine wave, 11 msduration)

10 g

Power RequirementsDC Power 12 VDC to 15 VDC @ 2A

PC Diagnostic InterfaceAsynchronous Serial Data Rate 9600 Baud, 8 Data Bits, 1 Stop Bit, No ParityVoltage Level EIA RS-232-C, Data Terminal Equipment (DTE)

Host Interface (ILC)Asynchronous Serial Data Rates:

LSI/Fire/ICE 1200 Baud, 8 Data Bits, 1 Stop Bit, Even ParityIFC 9600 Baud, 8 Data Bits, 1Stop Bit, No Parity

Voltage Level EIA RS-232-C, Data Terminal Equipment (DTE)

Purpose of Manual

1-6 SM 7072, Rev. 1, March 2004

Table 1-2 - Radio Specifications (CIU Equipped with Motorola RNET 450 Transceiver)

PARAMETER SPECIFICATIONRadio Transceiver (CIU Equipped with Motorola RNET 450 Transceiver)

Radio Frequencies:Front-to-Rear Messages 452.9375 MHz Rear-to-Front Messages 457.9375 MHz

Transmit Power 2 Watts (standard), 4 Watts (requires 15 VDC), or 2/4Watts

Transmit Frequency Stability 5 ppmEmission 16K0F3DDeviation 3.0 kHzReceive Sensitivity (-12 dB SINAD) 0.45 µV (max)Receive Frequency Stability 10 ppm (max)Selectivity 60 dB (min)Intermodulation Immunity 60 dB (min)Spurious Rejection 55 dB (min)Image Rejection 50 dB (min)

Table 1-3 - Radio Specifications (CIU Equipped with Johnson Data TelemetryTransceiver)

PARAMETER SPECIFICATIONRadio Transceiver (CIU Equipped with Johnson Data Telemetry Transceiver)

Radio Frequencies:Front to-Rear Messages 452.9375 MHz (programmable 450-470 MHz)Rear-to-Front Messages 457.9375 MHz (programmable 450-470 MHz)

Transmit Power 2 Watts (standard), 4 Watts (requires 15 VDC), or 2/4Watts

Transmit Frequency Stability +/- 1.5 ppmEmission 16K0F3DSpurious and Harmonic FM -37 dBmDeviation 3.0 kHzReceive Sensitivity (-12 dB SINAD) 0.40 µV (max)Receive Frequency Stability +/- 1.5 ppmSelectivity 70 dB (min)Intermodulation Immunity 70 dB (min)Spurious Rejection 70 dB (min)Image Rejection 70 dB (min)

Installation of the CIU

SM 7072, Rev. 1, March 2004 2-1

Section 2. Installation of the CIUThis section describes the installation of the CIU. Installation includes mounting the unit andconnecting the unit to a DC power source, the Integral Locomotive Computer (ILC), and a UHFantenna.

Configuration and verification of proper operation after power-up are also described.

2.1. Items Required for Installation and Configuration

Items required to install the CIU include the following:

• CIU (P/N: N24300102)

• Diagnostic Software Disk (P/N: N451232-1264)(Section 1.5.2)

Items to be supplied by the user include:

• DC Power Source, 15 VDC nominal

• ILC Host Interface Cable

• 1/4-wave UHF Antenna terminated with an N-type RF connector

• PC serial communications cable, 9-pin “D” type, straight-through, male-to-female connectors.

2.2. Mounting the CIU

The CIU is housed in a Communications Interface Unit (CIU) style enclosure, designed to be mountedin an Integrated Cab Equipment (ICE) rack. However, the CIU may also be mounted in any availablelocation in locomotives equipped with other types of on-board integrated cab equipment.

2.2.1. Mounting the CIU in an Integrated Cab Electronics (ICE) or LSI Rack

To mount the CIU in an ICE or LSI rack, align the two rear mounting holes with the two mating pegsat back of the rack. Secure the CIU in place by tightening the rack’s fastener nut over the front panelbracket.

2.2.2. Mounting the CIU in a Non-ICE Equipped Locomotive

If the CIU is to be installed in a non-ICE equipped locomotive, it can be mounted in any suitablelocation such as an empty equipment shelf as deemed appropriate. However, because the CIU is meantto be rack mounted, it does not incorporate mounting tabs and appropriate mounting hardware for thelocation must be used to secure the CIU.


2-2 SM 7072, Rev. 1, March 2004

2.3. Host Interface Connections

The CIU connects to the Integral Locomotive Computer (ILC) via its front panel mounted HostInterface connector which is a Cannon MS3102A-20-29P connector with 17 pins assigned as shown inTable 2-1.

Table 2-1 - Model 6680 CIU Host Interface Connector Pin Assignments

PIN FUNCTION COMMENTA + 8 VDC No Connection (not used)B Diagnostics Port Transmit PC External Diagnostics Port TX OutputC Protocol Select Return Return Line for Protocol Select Pin PD + 15 VDC DC Power Supply PositiveE CTS No Connection (not used)F ILC Receive Data Receive Input from ILCG Program Enable No Connection (not used)H Diagnostics Port Receive PC External Diagnostics Port RX InputJ DC Power Ground Ground for +15 VDC Power Supply K PC Diagnostics Common Ground Common for PC Diagnostics Port CommsL +15 VDC No Connection (Pin D is used)M ILC Transmit Data Transmit Output to ILCN ILC Communications Data Common Common for ILC CommunicationsP Protocol Select Connected to Pin C : Protocol = LSI/FIRE/ICE

No Connection: Protocol = IFCR Remote Test No Connection (not used)S Shield Termination No Connection (not used)T UDE Input/E-Brake Request To Activate optional remote E-Brake Request

Command, close connection to Pin K momentarily

2.4. Host Interface Cable and Connections

US&S does not supply the Host Interface cable because of the many variations that can exist in thetype of integrated cab computer used in the locomotive and the location where the CIU may bemounted within the locomotive. The Host Interface cable shall be provided by the user. Figure 2-1,Host Interface connection diagram, can be used as a basis for typical connections to the CIU.

It should be noted that Protocol selection is usually handled by the installation of a single jumper wirewithin the shell of the Host Interface Connector on the locomotive wiring harness. The installation ofthe jumper wire between pins P and C configures the CIU for LSI, FIRE, and ICE operation. Theabsence of the jumper wire configures the CIU for IFC operation. In a situation where the desiredmode of operation is LSI, FIRE, or ICE and no protocol select jumper wire exists in the locomotive'swiring harness, the CIU can be configured using the diagnostics utility to always operate in theLSI/FIRE/ICE mode regardless of the wiring configuration. When this is done the CIU should be


SM 7072, Rev. 1, March 2004 2-3

labeled "CONFIGURED FOR LSI ONLY OPERATION" to prevent the unit from being installed in anIFC system without first reconfiguring the CIU.

2.5. Antenna Installation

The antenna is generally mounted on the locomotive roof. If interference from nearby transmittingantennas (e.g., voice radio) is likely to be a problem, locate the antenna as far away from competingsignal sources as possible.

The recommended antenna is a 1/4-wave UHF-type unit with the required cable length terminated inan N-style RF connector. A low-loss coax cable is recommended. Connection to the CIU isaccomplished by attaching the “N”-type connector onto the CIU’s front panel mounted Antennaconnector.

MS3106A-20-29-SF

M

N

ILC RX DATE

ILC TX DATA

ILC DATA COMMON

PROTOCOL SELECT

D

J

+15 VDC

15 VDC RETURN

TO +15 VDC POWER SUPPLY

PROTOCOL SELECT JUMPER

CLOSE: LSI/ICEOPEN: IFC

HOTDCIU HOSTINTERFACECONNECTOR

DB9-F

3

2

5

SERIAL LINK TO ILC

PROTOCOL SELECT RETURNC

P

DB9-F

3

2

5

PC EXTERNALDIAGNISTICSPORT*

PC DIAGNOSTICS RX DATA

PC DIAGNOSTICS TX DATA

PC DIAGNOSTICS DATA COMMON, GROUND

H

B

*OPTIONAL MAY BE USED FOR CLOSED CASE SOFTWARE UPGRADES AND SYSTEM CONFIGURATION IN PLACE OF THE INTERNAL J6 CONNECTION.

UDE INPUT REMOTEEMERGENCYBRAKEREQUEST(OPTIONAL)

UDE RETURNK

T

Figure 2-1 - Typical Installation Connections to CIU Host Interface Connector


2-4 SM 7072, Rev. 1, March 2004

2.6. CIU Power Up and Operational Verification

The CIU has no power switch and normally receives its power from the locomotive radio circuitbreaker or ILC power source. After the CIU has been properly installed, perform the following stepsto ensure proper operation:

1. Power-ON the unit via the locomotive radio circuit breaker or ILC power source.

2. Confirm that the green STATUS indicator on the front panel is flashing. This indicates that theCIU software is running and that the processor board is operational.

3. The CIU is now ready for operational verification.

2.6.1. CIU System Operational Verification

The following basic system functional checks should be performed after a new CIU is installed. Thefunctional checks are designed to verify that the CIU is transmitting and receiving EOT radio messagesto/from an operational End Unit, and is communicating with the ILC:

1. Obtain a known operational End Unit. (It may be operated outside the locomotive. No pressurizedair is necessary.)

2. With the CIU powered, use the ILC console to enter the ID code of the End Unit.

3. Press the TEST button on the End Unit to activate it.

4. Initiate a Test Request command from the ILC console. Verify that the CIU responds by observingthat the ILC displays “Self test passed.”

If the End Unit is not connected to a pressurized air source, the Pressure field should indicate 0psig. This should be accompanied by a Low Pressure indication on the ILC since the pressure isbelow the standard 45 psig threshold.

5. Initiate a Communication Test Request/Arm command from the ILC. Verify that the ILC indicates“Confirmation received.” This confirms proper operation of the CIU’s RF transceiver andassociated control circuits.

This completes the basic system functional checks.

Configuration and Diagnostics

SM 7072, Rev. 1, March 2004 3-1

Section 3. Configuration and DiagnosticsThe CIU incorporates a Diagnostics Port to access built-in configuration and diagnostic functions.

This port, which is comprised of a 9-pin “D” type RS-232-C serial connector, is located on theprocessor board (J6) inside the CIU’s enclosure. However it can also be accessed without removing theCIU cover via its Host Interface connector.

The port connects to a DOS compatible PC via a standard straight-through, male-to-female 9-pin “D”type serial computer cable which is available at most computer and office supply outlets.

3.1. DIGITAIR® Diagnostic Software

DIGITAIR® Diagnostic Software running on a PC provides a full set of user friendly, menu drivenconfiguration and diagnostic functions. The Diagnostic Software is a single program named“diagunit.exe” supplied on a floppy disk. The software can be ordered under US&S part numberN451232-1264 (3.5” disk).

NOTEThis manual provides detailed information on CIU configurationwith limited examples of the diagnostic functions. For detaileddiagnostic information and procedures, refer to US&S ServiceManual SM 7073 (Shop Maintenance).

3.2. Running the Diagnostic Software

To run the Diagnostic Software, perform the following:

1. Turn OFF power to the CIU.

2. Plug the PC serial cable into the CIU’s Diagnostics Port by either removing its cover, or via theHost Interface connector located on the CIU. (See Figure 1-2 for the location of the Host InterfaceConnector and Table 2-1 for pin assignments. See Figure 1-3 for location of the DiagnosticConnector.)

CAUTION

The CIU contains static-sensitive components. Always observeproper ESD handling procedures or equipment damage may result.

3. With the diagnostic PC powered-on, execute the Diagnostic Software from the floppy disk (or fromthe PC’s hard disk if it has been copied there) by typing “diagunit” followed by <Enter> at theDOS prompt.


3-2 SM 7072, Rev. 1, March 2004

4. The Diagnostic Start-Up Screen will appear as shown in Figure 3-1. The program name andversion appear at the top of the screen. The box at the bottom of the screen displays any promptsfor user input. The last line shows applicable PC function keys.

To quit the program at any time, press <F4>. The program will prompt with “Really quit? [Y, N]:”If “Y” is selected, the program will terminate. If “N” is selected, the program continues.

Figure 3-1 - Diagnostic Set-Up Screen

5. The Diagnostic Software defaults to PC serial port COM1. If use of COM2 is required, press <F2>to use COM2. Press <F1> to return to COM1.

NOTEThe CIU’s Diagnostic Port is permanently set for 9600 baud, 8 databits, 1 stop bit, and no parity. The Diagnostic Software sets the PC’sserial port to these same values; therefore no configuration should berequired.

6. Note that the CIU has no switches or buttons. To proceed, apply power to the CIU.

7. The diagnostic PC will then display the Initial Diagnostic screen as shown in Figure 3-2:


SM 7072, Rev. 1, March 2004 3-3

Figure 3-2 - Initial Diagnostic Screen

8 To access the primary diagnostic/configuration screen, type “1” (Start Main Program Diagnostics)and press <Enter>. The Start Main Diagnostic screen as shown in Figure 3-3 will appear.

Figure 3-3 - Start Main Diagnostic Screen

9. Press <Esc> to proceed to the Main Menu. Also observe that the green “STATUS” light on theCIU front panel begins to flash indicating that the main application program is now running.

3.3. Main Menu

To select one of the submenus associated with Diagnostic Items or Configuration Items, (Figure 3-4)type the desired menu item number and press <Enter>.


3-4 SM 7072, Rev. 1, March 2004

Figure 3-4 - Main Menu

3.3.1. Diagnostic Items

This Diagnostic Items Menu displays selections that may show information about, or perform adiagnostic test on specific elements of the CIU (Figure 3-5).

Figure 3-5 - Diagnostic Items Menu

Select a diagnostic test from this menu by typing in a menu item number followed by <Enter>. Toreturn to the Main Menu, press <Esc>.


SM 7072, Rev. 1, March 2004 3-5

NOTEThe use of the Diagnostic Items is beyond the scope of this manual.They are each described in detail in the CIU Shop MaintenanceManual, SM 7073.

3.3.1.1. Transmitter Tests

The Diagnostics Items Menu contains a submenu for Transmitter Tests. To access Transmitter Testsfor routine calibration and service, select item “5” (Transmitter Tests) from the Diagnostics ItemsMenu and press <Enter>. The Transmitter Test Options will appear as shown in Figure 3-6.

Figure 3-6 - Transmitter Test Options Screen

3.3.2. Configuration Items Menu

The Configuration Items Menu displays selections which enable or disable CIU functions; the menualso allows customization of certain functions. This section describes the purpose and use of eachmenu item in the Main Configuration Menu (Figure 3-7).


3-6 SM 7072, Rev. 1, March 2004

Figure 3-7 - Configuration Items Menu

To select an item from this menu, type in a menu item number and press <Enter>. To return to theMain Menu, press <Esc>.

3.3.2.1. Set ID Code

To read the currently stored EOT ID code or modify the EOT ID code, select item “1” (Set Id Code)from the Configuration Items Menu and press <Enter>. The current ID screen will appear (Figure3-8).

Figure 3-8 - EOT ID Code Menu

To modify the ID code, type in a new 5-digit ID code and press <Enter>. The new ID code will beupdated on the PC screen and stored in the CIU’s parameter storage EEPROM. To return to theConfiguration Items Menu, press <Esc>.


SM 7072, Rev. 1, March 2004 3-7

3.3.2.2. Set One-Way Protocol Type

To read the current One-Way protocol setting or modify the protocol, select item “2” (Set One-WayProtocol Type) from the Configuration Items Menu and press <Enter>. The screen showing thecurrent protocol will appear as shown in Figure 3-9.

Figure 3-9 - One-Way Protocol Menu

To modify the protocol, type in the number of the desired protocol and press <Enter>. The selectedprotocol will be used by the CIU when it is requested to switch to One-Way operation.

To return to the Configuration Items Menu, press <Esc>.

3.3.2.3. Set Two-Way Protocol Type

To read the current Two-Way protocol setting or modify the protocol, select item “3” (Set Two-WayProtocol Type) from the Configuration Items Menu and press <Enter>. The Two-Way Protocol screenwill appear (Figure 3-10).

Figure 3-10 - Two-Way Protocol Screen


3-8 SM 7072, Rev. 1, March 2004

To modify the protocol, type in the number of the desired protocol and press <Enter>. The selectedprotocol will be used by the CIU when it is requested to switch to Two-Way operation.


3.3.2.4. Enable Two-Way Mode

To read the current Mode setting or enable/disable the two-way mode, select item “4” (Enable Two-Way Mode) from the Configuration Items Menu and press <Enter>. The current mode screen willappear (Figure 3-11).

Figure 3-11 - Two-Way Mode Menu

To default the initial power-up mode to One-Way or Two-Way Mode, type in the number of thedesired mode and press <Enter>. (If one-way mode is desired, type in 0, this turns two-way modeoff.For two-way mode, type in 1, this turns two-way mode on.) The selected mode will be used by theCIU when it is powered ON. Subsequent requests to change modes will be stored in the CIU’sparameter storage EEPROM. The type of one-way or two-way protocol used will be the one that wasselected using the menus in Sections 3.3.2.2 and 3.3.2.3.


3.3.2.5. Enable Auto-Selection of One-way vs. Two-way Mode

This feature is useful for railroads operating with a mixture of One-Way and Two-Way EOT EndUnits. When enabled, this feature allows the CIU to automatically switch its communications protocolbetween One-Way and Two-Way to be compatible with the type of End Unit installed at the rear of thetrain.

This mode of operation may be needed where the ILC operator interface does not provide for selectionbetween one-way and two-way operating modes.

To enable or disable this capability, select item “5” (Enable Auto-Selection of One-way vs. Two-wayMode) from the Configuration Items Menu and press <Enter>. The current mode screen will appear(Figure 3-12).


SM 7072, Rev. 1, March 2004 3-9

Figure 3-12 - Auto Selection of Mode Menu

Enter “0” or “1” to disable/enable the feature and then press <Enter>. To return to the ConfigurationItems Menu, press <Esc>.

3.3.2.6. Set Low Pressure Threshold

To read the current Low Pressure Threshold value or change the value, select item “6” (Set LowPressure Threshold) from the Configuration Items Menu and press <Enter>. The current value screenwill appear (Figure 3-13).

Figure 3-13 - Low Pressure Threshold Menu

The factory default setting is 45 psig (this is the typical industry standard). When the brake pipepressure drops below this threshold value, the CIU will send a Status message to the ILC indicating aLow Pressure ALARM condition. The ILC, in turn, displays this condition as a warning to thelocomotive operator. To change the low-pressure threshold, type in the new threshold value and press<Enter>.



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3.3.2.7. Configure Customer String for LSI Protocol

This menu item allows the user to store a unique customer string into the CIU’s parameter storageEEPROM. This provides a means to tag the ownership of the unit. To view or modify the customerstring, select item “7” (Configure Customer String) and press <Enter>. The currently stored customerstring will appear (Figure 3-14).

Figure 3-14 - Customer String Screen

To modify the Customer String, type in the desired alphanumeric string up to 32 characters (e.g.,“XYZ Railway Inc.”) and press <Enter>.


3.3.2.8. Enter CIU Serial Number For IFC Protocol

This menu item allows the user to store the CIU’s serial number in EEPROM. This provides a meansfor the Host Computer to identify the CIU installed. To view or modify the serial number string, selectitem “9” (Enter CIU Serial Number (IFC)) and press <Enter>. The currently stored serial numberscreen will appear (Figure 3-15).


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Figure 3-15 - CIU Serial Number Screen

To modify the Serial Number, type in the desired numeric string up to 7 digits (e.g., serial number inCIU product label) and press <Enter>.


3.3.2.9. Enable Automatic Arming

For railroads that do not use the ARMING security feature, Automatic Arming can be enabled via thismenu item. Enabling Automatic Arming, in effect, puts the CIU into an “always-armed” mode. In thiscase, no operator action is required at the rear of the train and the initiation of an Emergency commandwill always cause the transmission of an emergency brake command containing the currently enteredID Code.

To view the current setting or to enable/disable Automatic Arming, select item “10” (EnableAutomatic Arming) and press <Enter>. The Automatic Arming screen will appear (Figure 3-16).


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Figure 3-16 - Automatic Arming Screen

To enable or disable this function, type in the menu item number and press <Enter>.


3.3.2.10. Enable Transmit Power Level

The CIU normally transmits at 2 watts and then transmits Emergency brake commands to the End Unitat 4 watts. However, the unit has the capability to transmit at either Always 2-Watts, or Always 4-Watts if required by the Railroad and regulations permitting. To select the transmit power level, typein “11” (Enable Transmit Power Level) and press <Enter>. The Transmit Power Level screen showsthe currently selected setting (Figure 3-17).

Figure 3-17 - Transmit Power Level Screen


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The factory default setting is typically “1” for "Use High Power When Needed." The transceivermodule in the CIU supports transmissions at 4 watts as deemed necessary by the Railroad andregulations permitting.

NOTESetting and using the CIU at transmit power levels above 2 wattsmay require special licensing from the FCC.

To change the transmit power level setting, type in the menu item number and press <Enter>.


3.3.3. Enable UDE/E-Brake Input

To read the current UDE/E-Brake setting or to enable or disable the UDE/E-Brake Input, select item“12” (Enable UDE/E-Brake Input) from the Configuration Items Menu and press <Enter>. TheUDE/E Brake Input screen showing the current protocol will appear (Figure 3-18).

Figure 3-18 - UDE/E Brake Input Screen

Disabling the UDE/E-Brake Input will disable the operation of the Remote Emergency Brake Input althoughEmergency Brake commands will still be accepted via serial messaging from the ILC.

Enter “0” or “1” to disable/enable the feature and then press <Enter>. To return to the MainConfiguration Menu, press <Esc>.


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3.3.4. Set Protocol

To read the current Host or ILC protocol setting or modify the protocol, select item “13” (Set Protocol)from the Configuration Items Menu and press <Enter>. The Protocol screen showing the currentprotocol will appear (Figure 3-19).

Figure 3-19 - Protocol Screen

This option allows the user to "force" the CIU to operate with either ILC protocol, regardless of thelocomotive's jumper wire configuration. The default option is 0 (USE JUMPER) in which case theinstallation of the jumper wire selects LSI, FIRE, or ICE automatically. Absence of the jumper wireselects IFC protocol.

To modify the ILC protocol, type in the number of the desired protocol and press <Enter>.


CIU Software Upgrades

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Section 4. CIU Software UpgradesThe CIU uses FLASH type, programmable, non-volatile memory to store its application software, asopposed to an EPROM chip. This eliminates the need to disassemble the unit and physically replacethe EPROM for software upgrades.

Software upgrades are supplied by US&S on a CIU Executable Software Disk containing two files:(1) the latest upgrade version of the CIU executable software named “ciu.hex,” and (2) the FlashLoader program named “load.exe.” This is a 3.5” disk and is available under US&S part numberN451232-0822.

Software upgrades are downloaded into the CIU’s Flash memory from a PC connected to the unit’sinternal Diagnostics connector via the same 9-pin “D” type serial cable used for performingdiagnostics. Downloads can also be performed without the need to remove the cover via the CIU’sHost Interface connector as shown in the connection diagram (Figure 2-1). The download function isperformed by running the Flash Loader Software as detailed in the following sections.

4.1. Flash Loader Utility Program

The Flash Loader program is named “load.exe” and runs on a DOS compatible PC.

Although this program may be run from the floppy disk drive, it is preferable to copy it to a directoryon the PC’s hard drive. The new Upgrade Version of “ciu.hex” must reside on the same floppy diskor hard drive directory containing “load.exe.”

4.2. Using “load.exe”

At the PC DOS prompt, the command syntax for “load.exe” can be viewed by typing in load followedby pressing <Enter>. The PC will display the command structure as follows:

Cab Unit Flash Loader (Rev 1) Thu Jul 18 16:11:41 EDT 1996

Usage:load -<serial port> <filename> [-r]

where-<serial port> is -COM1 or -COM2<filename> is the executable to be loaded

in Motorola Exormax format.-r means run the program after loading (optional)Use a straight-through cable from the PC to the Unit.

Therefore, the typical command line, depending on the PC serial port being used, will be:load -COM1 ciu.hex -r <Enter> if PC serial port 1 is being used;orload -COM2 ciu.hex -r <Enter> if PC serial port 2 is being used.

RAIL Team and Technical Support

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4.3. Procedure for Downloading CIU Software Upgrades

To download CIU software upgrades, perform the following:

1. On the PC, copy the new Upgrade Version of the file “ciu.hex” to the floppy disk or hard drivedirectory containing the Flash Loader Software “load.exe.”

2. Turn OFF power to the CIU.

3. Remove the CIU’s cover and connect one end of the serial cable to the CIU’s internal Diagnosticsconnector and the other end to one of the PC’s serial ports (either COM1 or COM2). Note that thisis connected in the same fashion as described in Section Section 3 - Configuration and Diagnostics.

Alternately, the PC can be connected to the CIU’s Host Interface connector. This eliminates theneed to remove the CIU’s cover.

4. Apply power to the CIU.

5. On the PC, enter the load command for the Flash Loader as follows:

load -COM1 ciu.hex -r <Enter> if PC serial port 1 is being used;

or

load -COM2 ciu.hex -r <Enter> if PC serial port 2 is being used.

The PC will display the progress of the download process as follows:

Cab Unit Flash Loader (Rev 1) Thu Jul 18 16:11:41 EDT 1996

Press a key at any time to quit this program.

Initiating target diagnostics:

Cab Unit Boot Prom (REV 1) Thu Jul 18 9:37:47 EDT 1996

ROM test PASSED

RAM test PASSED

Erasing flash ... done.

Writing to flash ... #### records downloaded.

6. Upon completion of the download, the CIU will begin running the new upgrade software in thenormal fashion just as it does on standard power-up. The green STATUS indicator mounted on theCIU’s front panel should be flashing, indicating that the new upgrade program is operatingcorrectly.

7. Remove power, unplug the serial cable from the CIU, and reinstall its cover (if applicable). TheCIU is now ready for operation.


SM 7072, Rev. 1, March 2004 5-1

Section 5. RAIL Team and Technical SupportThe Rapid Action Information Link (RAIL) Team is comprised of experiencedproduct and application engineers ready to provide assistance and resolvetechnical issues concerning the CIU End-of-Train equipment or any US&Sproduct.

Questions regarding the contents of this Service Manual should be directed tothe RAIL Team via telephone at 1-800-652-7276 or via Internet e-mail at:[email protected].


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!UNION SWITCH & SIGNAL!~

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