Locomotive Electronic Air Brake Equipment Installation...

© Copyright New York Air Brake All rights reserved. CONFIDENTIAL

Locomotive Electronic Air Brake Equipment

Installation Guide

IP-221

Issue No. 4

August 17, 2009

LOCOMOTIVE ELECTRONIC AIR BRAKE EQUIPMENT INSTALLATION GUIDE

IP-221 of 36 August 17, 2009 © Copyright New York Air Brake All rights reserved. CONFIDENTIAL

INTRODUCTION................................................................................................................. 3 1. EQUIPMENT INSTALLATION......................................................................................... 3

1.1. General Requirements .......................................................................................... 3 2. Piping Requirements ....................................................................................................... 5

2.1 General Piping Standards:......................................................................................... 5 2.2 Specific Piping requirements ..................................................................................... 5

3. Electrical Wiring & Cabling Requirements ....................................................................... 6 3.1 Electrical wiring Requirements................................................................................... 6

3.3 Wiring categories................................................................................................. 10 4. Equipment Orientation Reference: ................................................................................ 11 5. Detailed Installation Instructions.................................................................................... 12

5.1 EBV......................................................................................................................... 12 5.2 LCDM...................................................................................................................... 12 5.3 RIM ......................................................................................................................... 13 5.4 EPCU...................................................................................................................... 14 5.5 TCC ........................................................................................................................ 15 5.6 TPS......................................................................................................................... 16 5.7 CJB (Center junction box)....................................................................................... 17 5.8 JB1, JB2 (End junction boxes)................................................................................ 18 5.9 CABLE ASSEMBLIES ............................................................................................ 19

5.9.1 ECP CABLES................................................................................................... 19 5.9.1.1 Cables between ends of locomotive ................................................................. 19 5.9.1.2 Inter-car cables ................................................................................................. 20 5.9.1.3 Termination Cables............................................................................................ 22 5.9.2 Other Cable Assemblies ...................................................................................... 22 5.10 IPM ........................................................................................................................ 23 5.11 TIM........................................................................................................................ 24 5.12 TMCM................................................................................................................... 25 5.13 CIRCUIT BREAKERS (May be supplied by others).............................................. 26 5.14 Air Brake Terminal Block (ABTB)........................................................................... 27 5.15 AUXILIARY JUNCTION BOX (AJB)....................................................................... 27 5.16 PROFILER............................................................................................................ 28 5.17 VENT VALVE (No. 8 or KM-2) .............................................................................. 29 5.18 821 VENT VALVE............................................................................................... 30 5.19 PPS....................................................................................................................... 31 5.20 ANTENNA, GPS ................................................................................................... 32 5.21 EVC ....................................................................................................................... 32 5.22 Conductor’s Emergency Valve (May be supplied by others)............................... 33

6. LIST OF ACRONYMS ................................................................................................... 34


August 17, 2009 of 36 IP-221 © Copyright New York Air Brake All rights reserved. CONFIDENTIAL

INTRODUCTION This document defines recommended practices to install equipment supplied by New York air Brake Inc, including Air Brake, Wire DP and EP-60 equipment (i.e. equipment boxes, pneumatic components, electrical wiring, etc.) on locomotives. CCB, ECP overlay and integrated locomotive systems and overlay systems shall be governed by these instructions. Additionally, once the equipment has been installed on the locomotive, the system must be subjected to an approved system functional verification test. A NYAB Engineering Test Code, or locomotive builder’s test code will be assigned to each system as appropriate. NYAB test codes will be identified by the procedure number NYT-xxxx. This test must be performed on each NYAB equipped vehicle following completion of the installation. A list of relevant acronyms is provided at the end of this document. REFERENCE DOCUMENTS: AAR Manual of Standard and Recommended Practices, Section M National Electric Code (NEC code) (US) Relevant National Safety Standards

1. EQUIPMENT INSTALLATION

1.1. General Requirements 1. For general system requirements, refer to component installation drawings. These

requirements shall be used in conjunction with locomotive builder’s standard practices.

2. Refer to system Wiring Diagram W/D-xxxx and Inter-connection Diagram I/D-xxxx for electrical wiring interface requirements. (E.g. WD-1620)

3. Deviations from these equipment installation instructions require engineering approval.

4. In order to achieve good quality of installation, the requirements for quality related “hold

points” and inspections shall be established as required by local workshop standard practice.

5. The customer’s safety requirements for isolation of battery and high voltage power sources must be observed before starting work. This includes tagging of switches, pantograph lock-down and/or earthing switches etc. Handbrakes must be applied and/or wheels chocked per customer’s rules. All pipes and reservoirs shall be drained of all air and water before starting work.

6. All electrical connections, mounting or installation bolts, nuts or screws must be tightened

securely, with final tightening to be verified using certified torque screwdrivers or wrenches before the job is completed.

7. All fasteners shall be tightened to torques as specified on drawings or if not specified to

international rail industry standards for the relevant material and grade. Self-locking nuts must be replaced with new every time they are removed for any purpose.



8. Any fasteners that have may have been tightened but not verified for correct torque may be

tested for looseness by application of 90%of the tightening torque in the reverse direction. 9. No electrical power, air or vacuum source shall be applied to the locomotive before final

tightening with calibrated tools to achieve the specified torque. Locking compounds must only be applied as shown on the appropriate installation drawings. Lock washers, flat washers, self-locking nuts etc. must be used as shown in the installation drawings.

10. “Loctite” or similar material must not be used unless its use is required by an installation

drawing or it is part of accepted standard practice. Care must be taken to ensure that the appropriate quantity and correct grade are used.

11. The use of “Torque stripe” is recommended. This is commonly applied to all fasteners and

connections after final torquing. The “torque striping” shall readily indicate if a fastener has moved from its tightened position at the time of marking. The use of torque stripe shall be determined by the required QC/QA standards in use at the place of installation.

12. All existing and new cables must be properly protected against chafing and damage due to

vibration, by suitable clamping and application where required of “safe-edge” material. 13. All air pipes must be properly aligned and tightened according to approved design

specifications, with pipe thread sealant etc., applied as directed in the installation drawings. 14. All pipe connections shall be clean and undamaged before connection. 15. All pipes and cables must be securely clamped to prevent vibration. 16. Precautions must be taken to observe critical pipe lengths and/or wire lengths. 17. When installing piping, especially functionally critical pipes such as BP, ER, use shall be

made of bends rather than elbows when ever possible to avoid restriction of air flow. 18. Precautions must be taken against contamination of pipes by protection during

cutting/machining etc. All open ends shall be sealed and not left open when waiting for adjacent parts.

19. All pipes shall be purged or blown out with low pressure compressed air before connection

to devices to prevent the transmission of debris into sensitive components. 20. All non-rustproof material surfaces such as mild steel shall be surface treated after

installation to prevent corrosion if they were subjected to machining or other processes with may have removed any protective coating.

21. All mounting bolts are to be of the correct grade as shown on the installation drawings,

typically grade 5 unless otherwise specified. 22. Ground connections must always be made to clean unpainted surfaces. Any painted

surfaces must be scraped clean and coated with conductive paste before connections are made.



23. Electrical connections, including those for grounding purposes, must be arranged to pass current through adjacent mating surfaces, current shall not pass through bolt or screw threads.

24. Selected location for all items must provide adequate space to allow connections of cables

while observing minimum bend radii.(Reference installation drawings, minimum bend radius is typically 10 times wire diameter unless installation drawings are more restrictive)

25. Dissimilar metals: Protection must be provided against damage through electrolysis where

dissimilar metals are in contact with each other, e.g. aluminum/steel. 26. Proper sized tools must be used for SAE or metric sized fasteners as appropriate. The use

of adjustable spanners, “crescent wrenches” or “vise-grips” shall be avoided if at all possible. The surface of pipes shall be protected from damage during installation, especially when the use of pipe-wrenches etc. is unavoidable. Any damaged surfaces, should be refinished after installation if necessary to prevent rust.

27. When mounting components with printed circuit boards, the orientation of the PCB’s will

dictate the recommended mounting orientation (to minimize vibration/deflection of the PCB), (unless the components are OK for any orientation). Printed circuit boards shall not normally be mounted horizontally (laterally or longitudinally) unless this is shown on the installation drawing.

2. Piping Requirements

2.1 General Piping Standards:

Piping shall be in accordance with AAR Manual of Standards, Section M, Recommended Practice RP-505, as applicable to the piping being installed.

2.2 Specific Piping requirements:

• The free flow of air in the Brake Pipe between vehicle ends is very critical for proper operation, and all piping shall utilize large radius bends wherever possible, and minimize the use of fittings, tees and elbows in order to prevent restriction to the free flow of air. Refer to piping diagrams for information on limitations of minimum internal diameters (I/D), and equivalent lengths for certain pipes. Equivalent lengths for fittings shall be calculated using a Mechanic’s handbook.

• Care shall be taken when arranging piping to avoid generation of non-drainable “traps” that may collect water.

• Minimum piping internal diameters (I/D) shall be as follows: Brake Pipe: 1.25 inches Main Reservoir: 1.0 inches Brake Cylinder: 0.75 inches (piping shall include a choke of 0.3125 inches diameter integral in or adjacent to the cut-out cock for each bogie (truck)

• Care shall be taken to avoid excessive use of pipe sealant which can interfere with small orifices and check valves. The use of Teflon tape is prohibited.



3. Electrical Wiring & Cabling Requirements

3.1 Electrical wiring Requirements

A. All wiring shall be performed by qualified, experienced personnel using appropriate tools for stripping insulation, cutting, terminating, and attaching mechanical crimp type terminals with the correct tools as recommended by the terminal manufacturer.

B. To the extent possible, wiring shall be in accordance with Chapter 3 of the National Electric

Code and the AAR Mechanical Division Manual of Standards, S-538, "Wiring Practice and Rolling Stock Standard". Unless otherwise specified, all wires and cables shall be enclosed in raceways having sufficient junction boxes and pull boxes to permit easy replacement of wires and cables. Wherever removable apparatus, components and equipment are provided, a bayonet type circular connector shall be provided.

C. To the extent possible, all wire bundles and cables within an enclosure shall be supported by

the use of tape rails, and shall be free from the equipment box structure, metal edges, bolt heads and other interference points, and shall have electrical clearance from the covers regardless of the insulation properties of the covers.

D. A drip loop shall be provided in each wire or cable where water could otherwise run along the

wire or cable to the point where it enters a box or enclosure.

E. All wire, including that in ducts and conduit shall be free of kinks and insulation abrasions and shall not be subject to accumulation of water, oil, or other foreign matter. All wires and cables shall be cleated where they pass through bulkheads and structural members, enter or leave raceways.

F. Wire dress shall allow sufficient slack for removal and re-application of the wire termination

without excess tension (minimum requirement to provide two (2) re-terminations). Alternatively, the Locomotive Builder's standard may be used as appropriate for each application.

G. Wire tying devices shall be of such material and construction that they will adequately retain the wiring for the life of the wiring, and shall be ozone and ultraviolet light proof.

H. Circuit breakers ratings shall be chosen so that the wiring to which they supply power is

protected at all times without the risk of excessive “nuisance” trips.

I. All wire must meet AAR S-501 or approved equivalent standard.

J. All connections shall be made using approved crimp style terminal lugs, preferably “ring terminal type” unless specifically approved by the customer concerned.

K. Wire without a terminal shall not be used for connections.



L. Slack shall be provided in cables at equipment terminals to prevent the risk of mechanical

stress upon them causing failure. M. “Nylock” nuts shall not be used on terminals for wiring. N. Wires and cables must be protected from sharp edges, moisture and other contaminants. O. Wiring must not be allowed to lie on the bottom surface of enclosures. P. Splicing of wires shall not be permitted. Q. Strain relief fittings shall be provided for all places where wiring and cables enter or leave

enclosures

3.1.1 Connectors

A. To the extent possible, cable connectors shall be of quarter-turn, environmental watertight variety, with removable crimp contacts of the correct size for the wire being terminated. Hardened inserts shall be provided where contact with the locking pins is made. Unused connector pin positions shall be sealed with either connector contacts or plastic sealing plugs designed for that propose. Alternatively, the Builder's standard may be used as appropriate for each application.

B. Cable connectors shall be equipped with sealing gaskets when necessary so that the

connector interface is sealed completely.

C. Whenever 2 or more connectors are used in close proximity, they shall be prevented from incorrect insertion by plug coding configuration or cable restraint.

D. Extension backshells shall be provided, if necessary, to ensure that there is sufficient room to

terminate the cable wires within the connector body and have the cable jacket extend within the body, be held by a clamp, and have a gasket seal the entrance.

E. Connectors/receptacles shall be manufactured by VEAM "CIR", Pyle-National, Amphenol or

approved equivalent.

3.1.2 Under-Floor Wiring

A. All under car wiring shall be run in closed wire ducts, conduits, or open wire-way in an approved manner and shall be securely clamped. Wire and cable shall be secured in the ducts to prevent chafing movement. The wire ducts and conduits shall be of water proof construction.

B. Watertight strain-relief bushings shall be used where wires enter equipment enclosures and

shall have insulated throat liners and compression type rubber sleeves inside the enclosure.

C. Cables shall be installed with sufficient slack at the bends so that cables will clear the inside bend surface of the duct, thereby preventing crushing of insulation.



D. All jumpers, jumper heads, and jumper receptacles shall be designed to prevent the entry of

water under all conditions and operating speeds.

E. All wires, 10 AWG or smaller, shall be in raceways or be part of a jacketed cable assembly suitable for exterior exposure. The exterior exposure of such cable shall be limited to a maximum of 3' and shall be securely clamped in watertight strain-relief bushings (insulated throat) at the point of exit from a raceway.

3.1.3 Cleating of Cables

A. All cable which is not installed in conduit, shall be cleated using split-block or other approved cleats of molded neoprene rubber or fabricated plastic with neoprene cushion inserts. Each cleat shall have a stiffener on the side away from the mounting bracket which shall act to spread the bolt clamping force over the entire length of the cleat. The bolts shall be provided with locknuts. Maximum distance between cleats shall be 18 to 24 inches. Wires and cables so cleated shall be securely clamped in watertight strain relief bushings (insulated throat) at the point of exit from a raceway or junction box.

B. Where possible, the terminals used shall be of the type which securely grips and holds the insulation. Conductors which will be subject to motion relative to the terminal are protected by suitable means to prevent breakage of the conductor at or near the terminal.

C. All electrical terminal points and terminal boards shall have brass or zinc plated studs.

Connections shall be locked using double nuts, single nut with brass or zinc plated flat washer and plated spring-type lock washer, barrel nuts, or approved lock nuts. Studs and washers may also be made of corrosion resistant steel. Where practical, each terminal block shall have designated spare terminals.

D. Only stranded wires shall be used that are suitable for rail vehicle service, with acceptable

insulation.

E. Each board or connector shall have the required number of terminations plus a minimum of ten (10) percent spares, but not fewer than two (2) spares unless otherwise approved.

3.1.4 Grounding and Bonding Connections

A. Grounding and bonding connections shall be made through copper or bronze pads, silver soldered or brazed to the car-body. Grounding pads may consist of copper pads, brazed to stainless steel pads with stainless steel studs and welded to the carbody. Battery and Low voltage circuits shall be floated. All equipment enclosures shall be grounded. Shock mounted auxiliary equipment shall have flexible, "strap" type grounding leads (shunts). The grounding shunts shall have a fully compressed termination at each end. Acceptable ground resistance when measured between locomotive frame and any grounded device shall be <0.2 ohms. The cross sectional area of the enclosure bond to earth should not be smaller than AWG 12 wire 3mm2.



B. All grounding and bonding jumpers and straps shall be sized to handle fault currents and

lightning discharge current, for which the voltage drop shall not exceed 25 volts.

C. The bonding method shall produce a DC resistance not in excess of .0025 ohms, or more than .025 ohms at 150 kilohertz for any applied AC voltage.

D. All grounding and bonding jumpers and straps and their connections shall be sized to carry

the maximum fault current available from the source(s) for the maximum times permitted by the protective circuit breakers or fuses.

E. All equipment enclosures and mounted equipment shall be grounded with approved insulated

wire, preferably colored green / yellow, or tinned copper flexible strap type grounding leads. 3.1.5 Conduit

A. Material selection, size and installation requirements to be per the AAR Specification S-538, or equal.

B. All conduit edges shall be de-burred and cleaned inside and out to remove sharp edges and

all pieces blown out with compressed air to remove filings before installation. Conduit shall be securely clamped with all runs electrically grounded.

C. All conduits shall be arranged to prevent moisture traps and shall drain toward control boxes.

All open-end conduit shall be installed in such a manner as to ensure gravity drainage out the end.

D. Flexible conduit (Sealtite) shall be used only where absolutely required and shall be subject

to engineering approval.

E. All equipment enclosures and junction boxes subjected to water spray, driven rain, water run-off, etc. shall include either a water tight and dust tight seal or a drain hole. Drain holes may be provided at the lower most point of an enclosure or box, unless the environment contains excessive saline, corrosive or conductive material. The drain holes shall be equipped with cotter keys with the ends turned up, or similar system as approved by engineering.

F. The use of electrical tape shall be minimized and shall not be used without the prior approval

of engineering. If used, electrical tape shall be 1) polyvinyl chloride as specified in Section 10, Chapter 2, Part 1 of the AAR Electrical Manual of Standards and Recommended Practices, or equivalent, 2) UL Listed, and 3) a minimum of .007" thick. Where possible, shrink tubing should be used. Either option should be limited to when only absolutely necessary and all other options are exhausted.



3.2 Insulation Resistance:

A. Insulation resistance to ground circuit group, when measured with a 1000 volt "megger" on a locomotive with all circuit breakers closed and all circuits installed under all humidity conditions, shall be at least the following values:

Nominal Voltage: Resistance

Below 90 volts: 2 megohms

90 to 600 volts: 4 megohms

above 600 volts: 5 megohms

3.3 Wiring categories Each Cable assembly shall be identified as in one of the following groupings and shall comply with the separation as noted on the applicable installation drawings. Cables are to be separated for every category. Individual duct, conduit or cable assembly shall be provided.

1. HV: High Voltage AC and DC, 150v to 1.5 kv;> 150A (Includes auxiliary power) 2. Control Power AC and DC, 24V to 150V, 20 – 150A 3. Control Voltages, 24 – 150 V AC or DC <20A 4. Sensor and Electronic signals, computer data etc. 5. ECP Power and Computer Data, nominal 230 VDC <15A

The following table shall be observed (in mm)

Distance between cables (inches/mm):

HV CONTROL POWER

CONTROL VOLTAGE

DATA ECP POWER

HV CONTROL POWER

4/100

CONTROL VOLTAGE

4/100 2/50

DATA 4/100 4/100 4/100 ECP POWER

4/100 4/100 4/100 4/100



4. Equipment Orientation Reference:

Longitudinal

Transverse Vertical

Longitudinal

FWD



5. Detailed Installation Instructions

5.1 EBV

A. Purpose of this Component: Control of automatic and independent brakes (air and vacuum)

B. General Requirements: The EBV is installed in place of the existing brake valve. There are four mounting bolts, one electrical connector and one air connection to the 21 pipe. The valve shall be securely mounted leaving adequate room for the electrical cable and the air connections.

C. Mechanical Installation: Resiliently mounted.

D. Required Orientation: Mounted to suit, on either a desktop or vertical surface, never to be mounted upside down.

E. Earthing/Grounding Requirements: Discrete ground wire not required unless mounted to non-conductive surface. If the console is not solidly grounded an additional ground wire from console to locomotive frame may be required.

F. Cable Length Considerations: N/A

G. Pipe Length Considerations: The 21 pipe connecting to the EPCU or Brake application Valve: MUST NOT EXCEED 30 FEET (9.14 metres) EQUIVALENT LENGTH of ½” pipe. Note: minimum I/D of pipe shall be 0.5 inches. Exhaust vent: This is to be piped to the nearest available location under the cab, for the purpose of noise reduction. This vent must not be obstructed by other nearby equipment.

H. Acceptable Environment: Cab interior

I. Hi-Pot Test Requirement: Must be disconnected from wires being tested.

5.2 LCDM

A. Purpose of this Component: Selection of air brake modes, operating configuration, display of brake system and locomotive information.



B. General Requirements:

The angle of installation shall be chosen carefully to avoid reflections or glare from compromising the visibility of the display. Adequate space must be left to allow connections of cables while observing minimum bend radii. The LCDM will normally be in a location where it will replace air gauges etc. that are no longer required. Adequate ventilation / air space is required to prevent overheating.

C. Mechanical Installation: Solid

D. Required Orientation: UP TO 30 DEG FROM VERTICAL, Transversely or Longitudinally.

E. Earthing/Grounding Requirements: Discrete ground wire required, to be attached to bare or suitably conductive plated surfaces on both the RIM and the locomotive console frame. If the console is not solidly grounded an additional ground wire from console to locomotive frame may be required. Selected location must provide adequate space to allow connections of cables while observing minimum bend radii.

F. Cable Length Considerations:

SEE WD FOR LIMITS ON DATA CABLES

G. Pipe Length Considerations: N/A

H. Acceptable Environment: Cab interior


5.3 RIM

A. Purpose of this Component: Interface between IPM and locomotive I/O

B. General Requirements: The RIM is to be resiliently mounted with a discrete ground wire, to be attached to bare or suitably conductive plated surfaces on both the RIM and the locomotive console frame. If the console is not solidly grounded an additional ground wire from console to locomotive frame may be required. Selected location must provide adequate space to allow connections of cables while observing minimum bend radii. A location close to the IPM and ABTB is preferred.


D. Required Orientation: Mounting feet DOWN, Transversely or Longitudinally



E. Earthing/Grounding Requirements:

Discrete ground wire required to be connected to terminal on front panel, connections may only be made to bare or suitably conductive plated surfaces. If the enclosure is not solidly grounded an additional wire from mounting location to locomotive frame may be required.

F. Cable Length Considerations: None G. Pipe Length Considerations: N/A H. Acceptable Environment:

Inside equipment cabinet


5.4 EPCU

A. Purpose of this Component: Electro-pneumatic control unit containing pneumatic and electronic controls.

B. Mechanical Installation:

Solid. The mounting surfaces must be plane and parallel. (refer to flatness requirements on installation drawing), typically within +/-0.010 inches Welding consideration: If the mounting feet are to be welded all cables except the circular loop cable shall be disconnected before start of welding. The ground clamp for the welding current shall be placed on the locomotive platform as close as possible to the framer being welded. Temporary ground cables may also be used to connect the mounting brackets to the locomotive platform during welding operations.

C. Required Orientation: Mounting feet down preferable longitudinal to direction of travel, transverse mounting requires additional stiffening support by means of center-point bolting or clamping on lower edge of manifold, or other means.



D. General Requirements: 1. To be mounted in a location with shortest possible direct connection to BP with

minimum possible number of bends, use of elbows shall be prohibited unless approval obtained form NYAB engineering.

2. EPCU requires clearance for removal/replacement of LRU’s, see installation drawing. 3. Due to the high weight of this unit (478lb, 217 Kg) extreme care shall be exercised

when handling to prevent injury or damage. Only industry approved and inspected lifting devices shall be used, they must only be attached to the lifting lugs using the correct “D” links at approved locations.

4. All ports on the EPCU shall be protected from ingress of foreign matter until piping is ready for connection. During installation of associated piping NO pipes are shall be connected to the EPCU until they have been purged, swabbed, or flushed out and blown clear of all moisture, oil, metal cuttings, debris etc. All pipe connection points on the EPCU shall be kept covered or plugged until the permanent pipes are ready for final connection after cleaning.

5. No electrical power shall be applied to the EPCU until all cables on the entire systems have been checked for proper connection and all other required system components have been installed.

6. See Section 5.13 regarding requirements for the circuit breaker feeding the EPCU. 7. See also 5.17, Vent Valves, for consideration of relative piping.

E. Earthing/Grounding Requirements: Manifold and frame shall have electrical continuity to locomotive frame.

F. Cable Length Considerations: None

G. Pipe Length Considerations: See Piping diagram

H. Acceptable Environment: Inside equipment cabinet


5.5 TCC

A. Purpose of this Component: Control of EP communication and Trainline power.

B. General Requirements: This unit has ESD sensitive components inside. Contact with exposed pins shall be avoided including when plugging in cables during installation. All body parts and cables shall be connected to ground momentarily before making contact with pins of the device. A shorting plug with a ground wire can be used for this purpose.

C. Mechanical Installation:

Hard mounted or on resilient mount



D. Required Orientation:

Horizontally or vertically, transversely or longitudinally

E. Electrical Connections: 4 connectors used – covers required on unused connections

F. Earthing/Grounding Requirements: Discrete ground wire required, connections may only be made to bare or suitably conductive plated surfaces. If the enclosure is not solidly grounded an additional wire from mounting location to locomotive frame may be required.

G. Cable length considerations: Maximum length of cable to CJB: (refer to cable assembly in its section) is 90 inches, 2.2 meters

H. Pipe Length Considerations: N/A

I. Acceptable Environment: Inside equipment cabinet

J. Hi-Pot Test Requirement: Must be disconnected from wires being tested.

5.6 TPS

A. Purpose of this Component: Provide power to EP Trainlines


This component shall be mounted in such a location as to be protected from the elements while maintaining a good air flow to allow cooling air to easily flow over the vertical cooling fins. May generate considerable heat under certain conditions.

C. Mechanical Installation: Solid. Care to be taken to ensure solid structure (minimize cantilevers from structure)


Must be mounted vertically, with sufficient clearance for heat dissipation as defined on installation drawing. OK transversely or longitudinally.

E. Earthing/Grounding Requirements: Discrete ground wire required, to be attached to bare or suitably conductive plated surfaces on both the TPS and the mounting location. If the mounting location is not solidly grounded an additional wire from console to locomotive frame may be required.



F. Cable Length Considerations:

Connection to CJB shall be kept as short as possible




5.7 CJB (Center junction box)

A. Purpose of this Component: Main connection point between EP trainlines, TPS and TCC. This is connected to the trainlines at a “central” location between the two ends of a locomotive and contains IDM for identification of the vehicle upon which it is mounted. (May not be exact centre of locomotive.

B. Sequencing Orientation for IDM: If the locomotive short hood or No. 1 end (A) Cab is connected to terminal 3, set the IDM parameter “sequencing orientation” to 0. If the locomotive short hood or No. 1 end (A) Cab is connected to terminal 2, set the IDM parameter “sequencing orientation” to 1. Note: The default setting is 0.

C. General Requirements: Mounting location must be selected carefully so that there will be sufficient clearance for installation tools as specified on the installation drawing.

D. Mechanical Installation:

Solid

E. Required Orientation: None OK vertical or horizontal, transversely or longitudinally.

F. Earthing/Grounding Requirements: Discrete ground wire required, to be attached to bare or suitably conductive plated surfaces on both the CJB and the locomotive frame. If the mounting point is not solidly grounded an additional wire to locomotive frame may be required.

G. Cable Length Considerations: Maximum length of cable to TCC is 90 inches, 2.2 meters


I. Acceptable Environment: Inside/Exterior



J. Hi-Pot test Requirement:

Must be disconnected from wires being tested.

5.8 JB1, JB2 (End junction boxes)

A. Purpose of this Component: Main connection point at ends of the locomotive between hardwired EP trainlines and intercar trainline cables.

B. General Requirements: Location is critical for acceptable inter-car cable dynamic movement. Mounting location must also provide sufficient clearance for installation tools. Care shall be taken to correctly attach the lanyard connection to support the inter-car cables as shown in the installation drawing. Correct installation is critical for reliable operation of inter-car cables.

C. Mechanical Installation: Solid. Location is critical for acceptable cable geometry between coupled vehicles due to their dynamic motion.

D. Required Orientation: Suitable for proper operation of intercar cables. (I.e. cables will not be stretched, trapped or damaged during dynamic train movement.) Mounting orientation shall consider the removal of cover and maintenance of the inside if replacement of wires is required (it is difficult to work upside down …)

E. Earthing/Grounding Requirements: Discrete ground wire required to be attached to bare or suitably conductive plated surfaces on both the CJB and the locomotive frame. If the mounting point is not solidly grounded an additional wire to locomotive frame may be required.



H. Acceptable Environment: Inside/Exterior




5.9 CABLE ASSEMBLIES

5.9.1 ECP CABLES Purpose of this Component: To connect EP trainlines between ends of locomotive, between locomotives, and between locomotives and cars.

5.9.1.1 Cables between ends of locomotive

A. General Requirements The car’s AAR approved trainline cable is routed between the junction boxes. The car’s trainline cable can be supplied as armored or non-armored. The non-armored style is recommended for installation by OEM car builders and must be installed inside rigid conduit for protection. The rigid conduit shall be connected, at each end, with a seal-tite or liquid-tight type of conduit for connection to junction boxes. The trainline cable has 2 conductors that are used to form the trainline network that continues the length of the train. For field retro-fit installations, the armoured type cable is required. The cable will normally run along the pipe side of the locomotive. If non-armoured type is used it shall be passed through a combination of rigid and watertight non-rigid conduit. NYAB recommends that conduit shall be routed through the car in a manner similar to that of the brake pipe. The conduit must have a minimum opening of one (1) inch to accommodate the trainline cable. Any bend radius made along the conduit path must be no less than six (6) inches in radius, not to exceed 180 degrees over the length of the conduit. It will often be necessary to make new brackets to support the cables or conduit, which shall be welded to the existing pipe brackets. The new brackets will need to be designed, manufactured and installed. Several different designs of brackets may be required since the existing brackets vary from place to place along the underframe. Welding to the locomotive frame shall be avoided unless approved by the locomotive’s original manufacturer or an authorized company representative. At both ends of the locomotive the cables will probably need to go through the end plate below level of the end junction box (both ends). The cable will need to be supported at approximately 2 ft (60 cm) intervals along the side of the locomotive, if not in conduit. There shall be a sufficient number of brackets to keep the cables from vibrating or swinging during operation of the locomotive. Cables will need to be protected from chafing with suitable padding at each mounting bracket.

B. Required Orientation:

As shown in installation drawings

C. Electrical Connections: Screw terminals in End JB’s

D. Earthing/Grounding Requirements: N/A



E. Cable Length Considerations:

Verify Cables To be installed are the correct ones for the application concerned (lengths used varies from project to project)

F. Pipe Length Considerations: N/A

G. Acceptable Environment: Interior/Exterior

H. Hi-Pot Test Requirement: Must be disconnected from all components before testing.

5.9.1.2 Inter-car cables

A. Special considerations for Intercar cables 1. Inter-car cable assemblies are used to connect the EP-60® trainline between all

vehicles in a train. Inter-car cables are provided with an AAR approved hermaphroditic style connector on one end and a connector with a threaded backshell on the other. The hermaphroditic connector will mate to the connector on the adjacent vehicle to which it is connected. The threaded connector mates to a receptacle at the end of the car. This connector is typically found on the vehicle’s end junction box, but may also be remote from the junction box if it is not suitably located at the very end of the vehicle.

2. Included with the Inter-car cable assembly is an integrated lanyard. This lanyard is

manufactured from high strength, low-stretch weather-resistant nylon and is used for two purposes. The lanyard’s primary function is to provide a strength member for disconnecting Inter-car cable assemblies during switching type operations. The secondary purpose for the strength member is to support the hermaphroditic end of the Inter-car cable assembly a minimum of 4 inches off the rail with a fully loaded vehicle, or when disconnected from another vehicle.

3. Correct design for installation of inter-car cables is critical for reliable ECP operation.

The location of the junction box must be carefully selected to allow for dynamic movement of the EP cables, air hoses, MU cables or vacuum hoses between the locomotive and the adjacent coupled vehicle. The vehicle to which it is coupled could be another locomotive, or a passenger or freight vehicle, each of which may have different relative motion. Check that no conflicts can occur when coupled to other classes of locomotive. Note that not all types of diesel or electric locomotives have the same dimension from coupler hook to headstock, so distance between adjacent headstocks and hence variations in the length of the cable loop can occur. EP cables may need to cross under coupler on cars or locomotives, depending on makeup orientation.



B. Mechanical installation:

The circular connector end of the Inter-car cable must be threaded into the End of Car (EOC) receptacle on the end of the vehicle. Proper alignment and installation can be accomplished by performing the following steps sequentially:

1. Slide the aluminum nut up and away from the end of the cable assembly. 2. Align the flat portion of the cable end with the flat on the EOC receptacle. 3. With the pins of the cable aligned properly with the sockets on the receptacle, push the

cable firmly into position. 4. Slide the threaded backshell down the cable toward the EOC receptacle. Once at the

receptacle, begin to engage threads by hand, the cable nut can then be secured by use of a 2-1/4” wrench. The typical wrench for installation of BP hose can be used.

5. Once the cable has been secured to the receptacle the lanyard can be attached. The

lanyard attachment point shall be located no more than four (4) inches from the centerline of the EOC receptacle and be a similar distance from the face of the striker.

6. Once the lanyard has been attached to its fastening point, insure that the free hanging hermaphroditic end of the cable will be a minimum of four (4) inches off the rail when the car is fully loaded.

7. Verify that when the cable assembly is held fully extended in the horizontal plane that force is applied only to the lanyard and not to the cable assembly. This is required so that the cable, junction box and connector are not damaged during pull-apart type uncoupling.

C. Required Orientation: As shown in installation drawings

D. Earthing/Grounding Requirements: N/A

E. Cable Length Considerations: Verify Inter car Cables to be installed are the correct ones for the application concerned (lengths used may vary from project to project)

F. Pipe Length Considerations: N/A

G. Acceptable Environment: Exterior

H. Hi-Pot Test Requirement: Must be disconnected from all components before testing.



5.9.1.3 Termination Cables

A. Mechanical installation: Connected to end junction boxes. Electrical connections must be tightened and checked before securing strain relief fitting and box cover.

B. Required Orientation: As shown on installation drawing.

C. Earthing/Grounding Requirements: N/A

D. Cable length considerations: N/A

E. Pipe Length considerations: N/A

F. Acceptable Environment: Exterior

G. Hi-Pot test Requirement: Must be disconnected from all components before testing.

5.9.2 Other Cable Assemblies

A. Purpose of this Component: To connect together all electrical components on the locomotive.

B. General Requirements: 1. Must meet all required standards for operation on the railway system concerned (e.g.

Spoornet, BNSF) Normally Irradiated cross-linked polyolefin (XPLO) wire is required, some circuits may use mineral filled Teflon or Tefzel. Polyvinyl chloride (PVC) wire is strictly prohibited due to flammability and toxicity.

2. All wiring not connected by means of plug-in connectors must be suitably protected by

running in raceway or conduit, all sharp edges must be protected to prevent chafing, suitable bushings or grommets must be used where wires/cables pass in or out of enclosures etc. Wire tie bars must be used inside enclosures to prevent movement that could cause damage. All wires shall be kept off the bottom surfaces of the interior of cabinets where they could potentially lie in accumulated water. When installing wires or cables their minimum bend radius must be observed in order to prevent damage to the jacket or conductors.



3. Shields shall be connected where continuity is shown on wiring diagrams, shall not be

connected where continuity is not indicated on wiring diagrams. After installation, required shield continuity must be tested (per the drawing) and every shielded cable shall be tagged as “Shield Inspected”. This applies to all cables, related connectors and electronic components after installation, before connectors are finally plugged in and before power is turned on.

C. Required Orientation:

N/A

D. Electrical Connections: Ring terminals required at all hard-wired locations, except when certain equipment requires special terminals. All connectors require crimp connections to pins, solder connections are prohibited except for certain shield connections where indicated on an approved drawing. All wires must have approved compression terminals, no “bare” wires allowed.

E. Earthing/Grounding Requirements: Ground wires are required ONLY when shown on a drawing or in these instructions. Ground wires, shall only be connected to bare or suitably conductive plated surfaces. If a suitable good connection point cannot be found, connection may be made to a stainless steel plate welded to the locomotive frame or to a copper pad brazed to a steel pad, with a stainless steel stud; which is then welded to the locomotive frame.

F. Cable Length Considerations: See related wiring diagram


H. Acceptable Environment: Protected from weather

I. Hi-Pot test Requirement: All sensitive equipment must be disconnected from wires being tested. Hi-Pot and Megger testing shall be conducted in accordance with the standards and other requirements of the end user (railway/supplier) concerned.

5.10 IPM

A. Purpose of this Component: ( E-IPM) Extended Integrated Processor Module B. General Requirements:

See Section 5.13 regarding requirements for the circuit breaker feeding the IPM.

C. Mechanical Installation: Resilient (See installation drawing). Requires vibration isolation in the range 100 to 300 Hz frequency range.




Mounting feet down, (preferred longitudinally, but OK transversely.

E. Earthing/Grounding Requirements: Discrete ground wire required to be connected to terminal on front panel, connections may only be made to bare or suitably conductive plated surfaces. If the enclosure is not solidly grounded an additional wire from mounting location to locomotive frame may be required.





5.11 TIM

A. Purpose of this Component: Trainline interface module

B. General Requirements: None

C. Mechanical Installation: Resilient (See installation drawing). Requires vibration isolation in the range 100 to 300 Hz frequency range.

D. Required Orientation: Mounting feet down preferred longitudinally, but transversely OK

E. Earthing/Grounding Requirements: Discrete ground wire required to be connected to terminal on front panel, connections may only be made to bare or suitably conductive plated surfaces. If the mounting location is not solidly grounded an additional wire from mounting location to locomotive frame may be required.





H. Acceptable Environment:



5.12 TMCM

A. Purpose of this Component: To detect current in (usually) No. 2 traction motor

B. General Requirements: 2 kV wire must be used for the input wiring. This component must be mounted as close as possible to the signal input, either the ammeter or the traction motor shunt.


D. Required Orientation: Vertical, horizontal, transverse and longitudinal OK.

E. Electrical Connections: Special crimp terminals required.

F. Earthing/Grounding Requirements: Discrete ground wire required. Connections may only be made to bare or suitably conductive plated surfaces. If the mounting location is not solidly grounded an additional wire from mounting location to locomotive frame may be required.

G. Cable Length Considerations: N/A






5.13 CIRCUIT BREAKERS (May be supplied by others)

A. Purpose of this Component: To protect wiring going to new equipment.

B. General Requirements: Circuit breakers must be of suitable size to protect the wiring being connected to them. Location shall be carefully selected to minimize length of associated wiring and prevent nuisance trips. Wires must be labelled with identification and rating adjacent to breakers, not on the breakers, or as specified by the car builder. The EPCU and IPM require a 10a time delay circuit breaker, with a minimum time delay of 7mSec. @100amps. Other devices may be powered from this breaker as approved by NYAB Engineering.

C. Mechanical Installation: Solid.

D. Required Orientation: Mounted on a Vertical surface, “ON” in up position.

E. Electrical Connections: Ring terminals required

F. Earthing/Grounding Requirements: N/A

G. Cable Length Considerations: N/A



J. Hi-Pot Test Requirement: OK if all sensitive circuits are disconnected



5.14 Air Brake Terminal Block (ABTB)

A. Purpose of this Component: Used on integrated locomotives, provides connection points for power and data wiring between major components.


This component shall be mounted in a convenient location connection to related components without excessive wire lengths.


D. Required Orientation: Vertical surface preferred. OK transversely or longitudinally.

E. Electrical Connections: Hard wired to

F. Earthing/Grounding Requirements: Discrete ground wire required, to be attached to bare or suitably conductive plated surfaces on both the ABTB and the mounting surface.

G. Cable Length Considerations: See wiring diagram for any constraints




5.15 AUXILIARY JUNCTION BOX (AJB)

A. Purpose of this Component: Used on ECP non-integrated locomotives, provides connection points for power and data wiring between major components, contains a transducer for monitoring of brake pipe pressure. Options:

1. GPS receiver to provide speed data (requires connection to a GPS antenna) 2. Cab selection switch for dual cab locomotives.




This component shall be mounted in a central location for convenient connection to related components without excessive wire lengths.


D. Required Orientation: Vertical surface preferred. OK transversely or longitudinally.

E. Electrical Connections: Hard wired to up to 6 cables, TNC female connector for GPS antenna

F. Earthing/Grounding Requirements: Discrete ground wire required, to be attached to bare or suitably conductive plated surfaces on both the AJB and the mounting surface.

G. Cable Length Considerations: See wiring diagram for any constraints




5.16 PROFILER A. Purpose of this Component:

Event recorder

B. General Requirements: N/A


D. Required Orientation: Vertical surface required. Transversely or longitudinally OK

E. Earthing/Grounding Requirements: Discrete ground wire required. Ground wire shall only be connected to bare or suitably conductive plated surfaces.




G. Pipe Length Considerations: N/A H. Acceptable Environment:



5.17 VENT VALVE (No. 8 or KM-2)

A. Purpose of this Component: To cause rapid venting of brake pipe when an emergency application is detected (pressure falling at a rate greater than 12 psi/sec).


Must be installed in accordance with the piping requirements as shown in section 2.0

C. Branch Pipe Requirements: • Must be located not more than 28 equivalent feet (8.5 metres) from the nearest

threaded hose connector • Not less than 20 equivalent feet (8.5 metres) nor more than 70 equivalent feet (21.3

metres) from each other if more than one is required by the railway concerned. (2 required in N. America)

• Not less than 20 equivalent ft. from the EPCU (The BPVV sensing pipe must be 3/8 I/D, not more than 40 equivalent ft. long, and connected to the BP as close as possible to the Vent Valve)

• Not to exceed 6ft (1.83 metres) with no more than one tee attached, for a total of 13 feet (3.96 metres) of equivalent ft. of piping.

• Shall be taken from the top of the Brake Pipe with an upward slope of not less than 1 inch in 12 inches (or mm)


Solid

E. Required Orientation: As shown on assembly drawing, bowl facing down, no obstructions near the exhaust port.


G. Cable Length Considerations: None

H. Pipe Length Considerations: See above



I. Acceptable Environment:

Inside/outside

J. Hi-Pot Test Requirement: N/A

5.18 821 VENT VALVE

A. Purpose of this Component: This valve is used to vent brake pipe air on the locomotive on which it is installed, locally and at a high flow rate to ensure that a rapid reduction of brake pipe air is transmitted to the following cars. This valve Is designed to be used on locomotives using CCB II and CCB-26 brake equipment. It provides two methods of initiation. Method one is the traditional sensing of a pneumatic emergency rate of brake pipe reduction. Method two is sensing the venting of 21 pipe pressure.

B. General Requirements: Must be installed in accordance with the piping requirements as shown in section 2.0

C. Branch Pipe Requirements: • Must be located not more than 28 equivalent feet (8.5 metres) from the nearest

threaded hose connector • Not less than 20 equivalent feet (8.5 metres) nor more than 70 equivalent feet (21.3

metres) from each other if more than one is required by the railway concerned. (2 required in N. America)

• Not less than 20 equivalent ft. from the EPCU (The BPVV sensing pipe must be 3/8 I/D, not more than 40 equivalent ft. long, and connected to the BP as close as possible to the Vent Valve)

• Not to exceed 6ft (1.83 metres) with no more than one tee attached, for a total of 13 feet (3.96 metres) of equivalent ft. of piping.

• Shall be taken from the top of the Brake Pipe with an upward slope of not less than 1 inch in 12 inches (or mm)


When replacing an existing 821 Vent Valve; • A valve portion along with and installation kit (see PC-785260 & PC-785261) will be required. • See installation drawing for required torque values When converting from an existing No. 8 or KM-2 vent valve; • A valve portion and an upgrade kit (see PC-785260 & PC-785261) will be required. • See installation drawing for required torque values.

E. Required Orientation: As shown on assembly drawing, bowl facing down, no obstructions near the exhaust port.




G. Cable Length Considerations:

None

H. Pipe Length Considerations: For brake pipe branch pipe, see 5.18.C above. For 21 pipe, the maximum volume must not exceed 95 cubic inches and may be accomplished using one of the following pipe sizes; • If using 1/2" OD copper tubing – not more than 54 feet. • If using 3/8" OD copper tubing – not more than 55 feet. • If using 1/2" ID iron/steel pipe – not more than 40 feet. If a combination of the above pipe sizes are used, it must be validated that the total 21 pipe volume has not exceeded 95 cubic inches.

I. Acceptable Environment: Inside/outside

J. Hi-Pot Test Requirement: N/A

5.19 PPS

A. Purpose of this Component: Provides 24 vdc power to Profiler

B. General Requirements: N/A


D. Required Orientation: Vertical surface preferred Transversely or longitudinally OK

E. Earthing/Grounding Requirements: Discrete ground wire required. Ground wire shall only be connected to bare or suitably conductive plated surfaces.



H. Acceptable Environment: Waterproof enclosure




5.20 ANTENNA, GPS A. Purpose of this Component:

Provides satellite communication for GPS information to Profiler.

B. General Requirements: Mounts on roof or horizontal flat surface. Must be at least ½ wavelength from other antennas. (Usually around 2 metres) Angular line of sight to the horizon is required to comply with the installation drawing.

C. Mechanical Installation: Solid – using mounting plates and gasket (part numbers _____ as example??)

D. Required Orientation: Mounts on horizontal surface at highest possible point with no obstruction on adjacent horizontal surface, see installation drawing for details.

E. Electrical Connections: One RF connector, 50 ohm cable required


G. Cable Length Considerations: See wiring diagram and installation drawing; length shall be kept to minimum possible, maximum approx 15m, maximum permitted losses 20 dB.+/-


I. Acceptable Environment: Outside

J. Hi-Pot test Requirement: Must be disconnected from wires being tested.

5.21 EVC

A. Purpose of this component: Vigilance computer

B. General Requirements: This device will be connected to several existing components, such as bell, horn, control buttons etc.

C. Mechanical installation: Solid



D. Required Orientation: N/A

E. Electrical connections: N/A

F. Earthing/Grounding Requirements: Discrete ground wire required. Ground wire shall only be connected to bare or suitably conductive plated surfaces.

G. Cable length considerations: N/A

H. Pipe Length considerations: N/A


J. Hi-Pot test Requirement: Must be disconnected from wires being tested.

5.22 Conductor’s Emergency Valve (May be supplied by others)

A. Purpose of this Component: To manually cause rapid venting of brake pipe when an emergency application is required.

B. General Requirements: Must be installed in accordance with the piping requirements as shown in section 2.0

C. Branch Pipe Requirements: • Shall be as short as possible, shall be located as close as possible to Vent Valve (see

section 5.17) 1.25 I/D pipe required. • Length not more than 17 equivalent feet (5.2 metres) • If the exhaust is piped, this shall use a 1.25 I/D pipe nipple, a 1.25 to 1.5 inch reducing

fitting, and up to 11 equivalent feet of 1.5 inch I/D extra heavy pipe, air flow shall not be restricted by obstructions etc.


Solid

E. Required Orientation: As shown on assembly drawing, no obstructions near the exhaust port.

F. Pipe Length Considerations: See above

G. Acceptable Environment: Cab Interior



6. LIST OF ACRONYMS

AAR Association of American Railroads

AJB Auxiliary Junction Box (includes BP transducer)

BC Brake Cylinder

BCCP Brake Cylinder Control Portion

BCEP Brake Cylinder Equalizing Pipe

BP Brake Pipe

BPCP Brake Pipe Control Portion

CB Circuit Breaker

CCBII Computer Controller Brake – generation 2

CJB Center junction box (For ECP-60)

DBI Dynamic Brake Interlock

DBTV Triple Valve

DP Distributed Power

EAB Electronic Air Brake System

EBV Electronic Brake Valve

ECP Electronically controlled Brakes

E-IPM Extended Integrated Processor Module

ELV Emergency Limiting Valve

EPCU Electronic Pneumatic Control Unit

EP-60 Electronically Controlled air Brakes (NYAB Brand Name)

ER Equalizing Reservoir

ERBU Equalizing Reservoir Back-up

ERCP Equalizing Reservoir Control Portion

EVC Electronic Vigilance Computer

FV Feed Valve

GPS Global Positioning System

JB1-JB2 Junction Box (at ends of vehicles using EP-60)



LCDM Locomotive Cab Display Module

MR Main reservoir

MVEM Magnet Valve, Emergency

PCS Power Cut-Off Switch

PIR Power Interrupt Relay

PPS Profiler Power supply

PSJB Power Supply Junction Box

RIM Relay Interface Module

TCC Trainline Communication Controller

TIM Trainline Interface Module

TMCM Traction Motor Current Module

TPS Trainline Power Supply

WSP Wheel Slide Prevention



REVISION HISTORY

Issue No. 1 Original Issue December 18, 2006 Issue No. 2 Updated document to include international and local standards. January 12, 2007 Changed formatting of Section 3. Issue No.3 Section 5.17.C in the last bullet item, not less than was less than. June 30, 2008 Issue No. 4 Added 5.18 821 Vent Valve. August 17, 2009

Locomotive Electronic Air Brake Equipment Installation...

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