IP-224 EP60 Single Car Test Device - NYABnyab.com/media/nyab_1/documents_1/technical/instructionpamphletsip/...05 8/28/07 MP Cover Added picture to ... 3.7 50 Mega Ohms Pass Fail Criteria

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

IP-224 Rev 16 2/22/18 - en

Instruction Manual

EP60 Single Car Test Device (EPSCTD) (Customer Version) For 220V EPSCTD 783490 Serial Prefix D0 and earlier and 110V EPSCTD 783491 Serial Prefix D0 and earlier. For later configurations (E0 and later) use IP-224-1.

Instruction Manual EP60 Single Car Test Device Doc.-No.: IP-224 Revision: 16 2/22/18 - en

Copyright 2018© New York Air Brake. All rights reserved, including industrial property rights applications. New York Air Brake retains any power of disposal, such as copying and transferring.

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Contact Address

New York Air Brake

748 Starbuck Avenue

Watertown, NY 13601

USA

Phone: +1 315 786 5200

Fax: +1 315 786 5676

www.nyab.com

The original document was issued in English language.



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Revision History

Rev Date Name Para Description of change

01 2/15/07 JRT All Initial Release

02 3/7/07 JRT All Updated

03 4/7/07 JRT All Updated

04 8/9/07 MP All Updated

05 8/28/07 MP Cover Added picture to cover Pg. 10 removed P/N 784738, added P/N 778509 and 739709 New Illustration for Fig. 14 and 15 Pg. 17 Item E revised text Added note on pg. 68

06 1/8/08 JRT All Revised to match EPSCTD software per SCN 1727EPSCTDSW-07D-SCN

07 10/1/08 MP 2.0 Removed P/N 784738 from 2.1.6.2 on pg. 17

08 9/14/10 MP All Updated EPSCTD Procedure To Incorpo-rate: - Consolidated Pneumatic Tests - Added New Configuration Box - Alternate BPP Feed Valve Setting - Added Megger Test - Added IDM Sequence Set Up - Added Section 8 Troubleshooting

09 11/29/11 MP 2.1.1 3.7 9.1 9.2

2.1.1 Clarified EPSCTD Procedure for Applying power to the car pg. 10 3.7 50 Mega Ohms Pass Fail Criteria Was 100 Mega Ohms. 9.1 Inserted Appendix 9.1 NYAB EPSCTD

Test Check Sheet. 9.2 Inserted Appendix 9.2 EPSCTD

“SAMPLE” Test Result.

10 11/30/11 MP 9.1 9.1 Corrected NYAB EPSCTD Test Check Sheet

11 4/12/12 MP 5.0 5.3.1 6.0 figures

5.0 Updated Sections H, I, J, K, L to incorporate the differences between the Stand Alone Test Version and the

Overlay Test Version. 5.3.1 Corrected Pass / Fail Criteria for system leakage to be more consistent with S-4286 6.0 Updated Section 6.1 to reflect the

changes In Section 5.0. Updated figures for above changes

12 11/13/12 PRM 2.1 4.2 4.4

2.1.4 Added Win 7 and updated hardware requirements / recommendations

2.1.5 Updated EPSCTD icon Figs Updated screens to accurately depict

more recent versions 4.2 Updated menu descriptions 4.4 Inserted section differentiating



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Rev Date Name Para Description of change

5.0 6.4 -

between possible test devices 5.0 Updated sections A and B to note

location of log files 6.4 Updated for Win7 (directories) - Misc. grammar and punctuation fixes,

formatting changes, and replaced table of contents with auto-generated table of contents

13 6/30/14 All 3.9

Reformat to COPE Added illustration

14 9/30/14 SG 3.9 Added “and set the IDM Parameter Sequenc-ing Orientation” to paragraph 3.9 and to Figures 3-3, 3-4, and 3-5.

15 7/20/17 LV Page 2 Deleted Confidentiality Statement 16 2/22/18 JT All General update and cleanup, making it more

similar to IP-224-1.



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Table of Contents

1 GENERAL INFORMATION 6

Introduction 6 1.1

Technical Changes 6 1.2

Target group for this document 6 1.3

Related Documents 7 1.4

Danger, Warning, Caution, and Notice Messages 7 1.5

2 EQUIPMENT REQUIRED 8

EPSCTD Components and Accessories 9 2.1

3 EPSCTD TEST SETUP 17

4 EPSCTD TEST START-UP 21

5 STAND ALONE TEST - PRELIMINARY 29

5.1 (AAR Type S486 Test) Preliminary Procedures and Inspections 29

(AAR Type S486 Test) Connecting the Device to a Car 30 5.2

(AAR Type S486 Test) System Leakage Test 30 5.3

(AAR Type S486 Test) Handbrake Inspection Test 31 5.4

(AAR Type S486 Test) Emergency Test 32 5.5

6 CONCLUDE TEST 35

7 EPSCTD TROUBLESHOOTING 38

EPSCTD Troubleshooting Table 38 7.1

8 SPECIAL FUNCTIONS 39

Manual Control 39 8.1

9 APPENDIX 41

NYAB EP-60 Single Car Test Check Sheet 41 9.1

EPSCTD “Sample” Test Results 42 9.2

Abbreviations 44 9.3



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1 General Information

DANGER

Please read this document from start to finish to ensure safety of operation and to avoid personal injuries and damage to equipment.

Introduction 1.1

The purpose of this document is to describe the setup and operation of the NYAB EP60 Single Car Test Device (EPSCTD).

This EPSCTD document and test were created to single car test freight cars equipped with ECP braking systems. The EPSCTD includes an EP60 Single Car Test Device with associated accessories as out-lined in Section 2.0 of this document. Using the EPSCTD, a computer, and compressed air, power and communications are provided to the Car’s CCD (Car Control Device) in order to test ECP functionality, along with the integrity of the conven-tional pneumatic braking components of a freight car as outlined in AAR S-486.

Within this document, various steps are identified to perform a single car test, including the set up and operation of the EPSCTD. While following this document you will begin the EPSCTD through various setup procedures, and then be prompted by the EPSCTD software to complete all single car test func-tions. When testing a stand-alone ECP car, certain tests of the conventional AAR Single Car Test S-486 need to be performed. When testing an overlay ECP car, both the CCD (Car Control Device) and the conventional DB60 Valve need to be tested per EPSCTD and AAR Single Car Test S-486, respectively.

Technical Changes 1.2

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

Target group for this document 1.3

This document is intended for use by trained service technicians who

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

remove and install the equipment,

inspect, maintain and troubleshoot the equipment,

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

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

NOTE

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



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Related Documents 1.4

Doc. No Issue Title

AAR S-486 current AAR Single Car Test

IP-265 current IDM Junction Box Assy Kit 788248 Installation Instructions

Danger, Warning, Caution, and Notice Messages 1.5

Warning messages are subdivided into the following hazard levels in this document:

DANGER

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

WARNING

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

CAUTION

Failure to comply with these instructions may lead to personal injuries and/or damage to the unit or the environment.

Safety notes have a specific structure which is explained here for DANGER:

DANGER

Source of the danger

Consequences of the danger

Remedial measures

Notes do not contain any messages relevant to safety and are included only for the sake of completeness.

NOTE

Notes contain useful hints and additional information about the unit.

Warning messages in other parts of this document draw your attention to the individual risks concerning your use of the product. Warning messages and notes generally precede the descriptions of the relevant applications.



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2 Equipment Required

Figure 2-1 Equipment Required



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EPSCTD Components and Accessories 2.1

NYAB EP60 Single Car Test Device 2.1.1

Figure 2-2 NYAB EPSCTD

The EPSCTD connects to the freight car’s ECP inter-car connector. It also connects to a laptop or desktop through a USB 2.0 cable, and communicates through an Echelon PL-20 Power Line Commu-nications Network. There are two models of the EPSCTD: one which utilizes 110-120 VAC input, and another that utilizes 220-240 VAC input. Each of these two models can be purchased in a kit through NYAB as identified below.

NYAB EPSCTD 110-120 VAC KIT: P/N 784251

Includes: EP-60 Single Car Test Device: P/N 783491 ECP Inter-car Connector 6’ Long USB 2.0 Cable 6’ Long Power Cable Trainline Test Light Assembly

Pump & Dump Test Device: P/N 783991 Software CD, EPSCTD: P/N 784249 Strap Assembly: P/N 778509 F2 Dummy Coupling: P/N 739709 Trainline Insulation Tester (Megger) P/N 787923

ABOVE KIT WITHOUT PUMP & DUMP: P/N 784734

NYAB EPSCTD 220-240 VAC KIT: P/N 784252

Includes: EP-60 Single Car Test Device: P/N 783490 ECP Inter-car Connector 6’ Long USB 2.0 Cable 6’ Long Power Cable Trainline Test Light Assembly

Pump & Dump Test Device: P/N 783991 Software CD, EPSCTD: P/N 784249 Strap Assembly: P/N 778509 F2 Dummy Coupling: P/N 739709 Trainline Insulation Tester (Megger) P/N 787923



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ABOVE KIT WITHOUT PUMP & DUMP: P/N 784735

The above VAC power cable is supplied with a US standard female three (3) prong plug at one end, and a US standard male three (3) prong plug at the other. In such applica-tions that have a standard 220 VAC power source, an adaptor plug (not supplied by NYAB/KNORR) will be required to connect the three (3) prong power plug to the 220 VAC receptacles.

The EPSCTD will output approximately 120 VAC to the trainline for powering up the CCD.

GFIC Reset On front side of EPSCTD

Power LED will illuminate Orange when properly reset

NOTE: For EPSCTD Serial Prefix E0 and later, refer to manual IP-224-1.

Figure 2-3 NYAB EPSCTD Front Panel

POWER TO THE CAR “POWER TO THE CAR” – To On/120VAC. LED’s will all turn solid Red; No Output Power to the car. “PUSH TO START TEST” Push Button: 1x All LED’s to turn solid Orange; No Output Power to the car. 2x LED’s turn from solid Orange to Flashing Red; 120 VAC Output to the car.

OFF / TIT TEST “POWER TO THE CAR” – To OFF / TIT. “PUSH TO START TEST” Push Button: 1x To Start TIT Test 2x To Reset Failed TIT

Power To The EPSCTD Place the “INPUT POWER SWITCH” To “ON” (I).

Reset the GFIC on the bottom side of the EPSCTD

15VDC / IDM Test “POWER TO THE CAR” – To 15VDC / IDM. “PUSH TO START TEST” Push Button: 1x To Start IDM Test



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NYAB Pneumatic Single Car Test Device (Pump & Dump) 2.1.2

Figure 2-4 NYAB Pump & Dump

The testing of an ECP Standalone Car requires only a means of charging and venting brake pipe and verifying system leakage. Other than the NYAB Pump & Dump (Figure 2-4), this can also be done by the following alternative pneumatic flow control devices:

NYAB Manual Single Car Test Device with Flowrator: P/N 770604 or P/N 770606 NYAB CSCTD: P/N 777274

It is important to point out that the NYAB EPSCTD must be used with the licensed software in order to completely single car test an EP-60 equipped freight car.

NYAB Pump & Dump: P/N 783991



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Alternate Pneumatic Single Car Test Devices 2.1.3

Alternate SCTD: NYAB Flowrator 2.1.3.1

NYAB SCTD with Flowrator: P/N 770604 or 770606

Figure 2-5 Freight SCTD with Flowrator

NOTE

For testing an Overlay ECP car, the freight SCTD with Flowrator needs to be used in order to test the conventional DB60 type brake equipment in accordance with the AAR Single Car Test Standard S-486.



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Laptop or Desktop Computer 2.1.4

Figure 2-6 Laptop or Desktop Computer

NOTE

A laptop or desktop computer is not included in the EPSCTD kits and is not supplied by NYAB.

System Requirements:

Operating System: Windows XP (32-bit) or Windows 7 (32 or 64-bit) Processor: 600 MHz Pentium equivalent or higher Memory: 128 MB RAM or more as required by Windows Disk Space: 121 MB Minimum Monitor: 256 Color VGA Ports: One USB 2.0 or higher (two preferred) Removable Disc: CD Drive

It is recommended that a rugged PC be obtained for the railroad environment.



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EPSCTD Software 2.1.5

NYAB EPSCTD Software CD: P/N 784249

Figure 2-7 NYAB EPSCTD Software CD

NYAB EPSCTD licensed software is a windows based program that is installed on a laptop or desktop computer using the above CD.

Figure 2-8 NYAB EPSCTD Software Installation



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EPSCTD Software Installation Instructions

Using a computer with operating systems as outlined in 2.1.4

Check to make sure the EPSCTD USB Cable Is Not connected to the computer.

Insert the EPSCTD Software CD into the computer.

The Windows Setup Program will then prompt the user to install software.

Follow prompts until software is installed.

Once successfully installed, an EPSCTD shortcut will appear on your computer desktop:

If the setup program does not automatically start following insertion of the CD, double-click on the removable storage drive. Double-click on the “CD Directory”, and then double-click on the “Install.bat” file. Follow the prompts until the software is installed.

Miscellaneous Items 2.1.6

Pneumatic Test Gauge for Brake Cylinder (Not supplied by NYAB/KNORR) 2.1.6.1

Figure 2-9 Calibrated Test Gauge

A calibrated test gauge is required for monitoring brake cylinder pressure. The gauge will include a quick disconnect fitting to connect to the car’s brake cylinder test fitting.



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Test Light 2.1.6.2

Figure 2-10 NYAB Test Light

A Trainline Test Light is supplied to verify a car’s trainline continuity.

2.1.6.3 F2 Dummy Coupling

Figure 2-11 F2 Dummy Coupling

A brake pipe Dummy Coupling is required for blocking the exhaust of brake pipe air at the opposite end of the car to which the pneumatic SCTD in connected. Note that some car builders incorporate such dummy couplings as part of the car’s brake system components.

2.1.6.4 Air Hose (Not supplied by NYAB/KNORR)

An air hose of at least 1/2” (13mm) diameter is required in order to connect clean dry compressed air equal or greater to 95 psi (655 Kpa) to the pump and dump test device. The air hose is to include quick disconnect fitting(s) in order to connect to the Pump & Dump Test Device. As a rule of thumb, it is typi-cally suitable to connect the Test Device to the car glad hand using a ¾” id hose with ½” fittings that is no more than 8 ft. long.

2.1.6.5 Electrical Extension Cord (Not supplied by NYAB / KNORR)

An extension cord may be required in order to connect an electrical power source.

EPSCTD P/N 783490 requires a power source providing 230 VAC +/-10%.

EPSCTD P/N 783491 requires a power source providing 120 VAC nominal.



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3 EPSCTD Test Setup

WARNING

High Pressure air is present in the rail car being tested. Pressure will vent from cocks and/or valve exhaust ports when test rack cocks are manipulated or when control devices are operated. To minimize risk of personal injury from high pressure air, ensure that all personnel stand clear of the exhaust path and that hearing pro-tection and eye protection are worn at all times.


WARNING

Electrical power (AC and/or DC) is present. To minimize the risk of personal injury from electric shock, ensure that power and/or switches are turned off prior to making any electrical connections.


3.1 Before EPSCTD setup, chock car wheels to prevent movement.

3.2 Take the EPSCTD and push both the power switch to the test device and the “Power To The Car” toggle to the “OFF” position.

3.3 Completely vent the brake pipe to 0 psi (0 Kpa). Once the brake pipe is vented to 0 psi, close the angle cock to which the pneumatic device will be connected and open the angle cock at the opposite end of the car.

CAUTION

By venting brake pipe to 0 PSI, a pneumatic emergency brake application will result in which the brake cylinder will extend and the brakes will be applied.

3.4 Connect a source of clean dry air of not less than 95 psi (655 Kpa) to the pneumatic device as outlined in Section 2.1.2 of this document.

3.5 Connect the glad hand end of the pneumatic device to one end of the car in which the angle cock is closed per 3.3 above. Adjust the pneumatic device regulating valve to supply 90-92 psi (620-648 Kpa), or to whatever applicable brake pipe pressure setting is specified for that appli-cation within +/- 1 psi. The pneumatic device is now ready for use. Leave the Angle Cock closed at this end of the car.

3.6 Ensure the EPSCTD USB cable is connected to the computer’s USB port.



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3.7 T/L Shield To Ground Continuity Test: In order to perform the following T/L Shield to Conti-nuity Test, the I/C Connector must be removed from one end of the car using a 2-1/4” open end wrench exposing the 3 T/L contacts per the following illustration:

Figure 3-1 End of Car Junction Box EOC Connection

Using the Trainline Insulation Test Device (Megger) set to the Ohmmeter setting, measure the resistance between the T/L Shield and Car Body (Ground Reference). This must produce a reading less than 1 ohm to pass this test.

Any failed test results must be further investigated to resolve the issue.

NOTE

A jumper wire (14-18 gauge) with 3/8” exposed conductive wire may be required to make contact with the T/L Shield Female Socket to perform this test.

With the above T/L Shield to Ground Continuity Test complete, reinstall the I/C Connector hand tight plus 1/3 turn using a 2-1/4” open ended wrench.

NOTE

If testing a married pair or multi-platform configuration, the above T/L Shield to Ground Continuity Test must be performed at each individual car, wagon, or platform for each has its own isolated circuit to ground.

T/L Shield

T/L Black

T/L White



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3.8 T/L Megger Test: The following T/L Megger Testing will be performed at one end of a single, married pair, or multiplatform car, using the I/C Connector:

Figure 3-2 End of Car I/C Connector

Using the Trainline Insulation Test Device (Megger) set to 250 VDC, test the I/C Connector Fe-male to Car Body (Ground Reference). This must produce a reading greater than 50 Mega Ohms to pass this test. Test the I/C Connector Male to Car Body (Ground Reference). This must produce a reading greater than 50 Mega Ohms to pass this test.

Any failed test results must be further investigated to resolve the issue.

CAUTION

The body of the car under test must be at the same electrical po-tential as the power source ground to which the EPSCTD is con-nected. If not certain, verify this before proceeding to the next step. Failure to ground the car body is likely to damage the EP-SCTD when the signal ground clamp from the test device is con-nected to the car.

3.9 Connect the EPSCTD Power Cable to a VAC power Source (110VAC or 230VAC depending on

the country of application).

3.10 Connect the EPSCTD Inter-car connector to the Inter-car connector of the car being tested. If testing a multiplatform car with more than one CCD, then the Inter-car connector between the two cars must be disconnected along with the brake pipe hose so that only one CCD and car is tested at a time.

3.11 Clamp the EPSCTD ground cable to a conductor (ex: metal rail, aluminum edge, etc.) on the car being tested to establish an electrical ground.

3.12 Turn the Power “ON” to the EPSCTD. Once powered, the Ground Fault Circuit Interrupt (GFCI) on the side of the tester must be reset. This can be verified visually through an illuminated “Yellow” LED on the GFCI “Green Reset Pad”. Without resetting the GFCI, the EPSCTD will not power up.

NOTE

If the GFCI will not reset, check for system faults. If a ground fault is not found, the GFCI may be faulty and in need of replacement.

T/L Male

T/L Female



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3.13 Trainline Integrity Test: Once the EPSCTD is powered up and connected to a car as outlined above, a Trainline Integrity Test can be performed by placing the “Power To The Car” toggle switch to the “OFF/TIT” position, and by pressing the “PUSH TO START TEST” button on the EPSCTD. Once pushed, the EPSCTD will automatically go through its Trainline Integrity Sequence. During the test, the EPSCTD will look for low resistance between conductors A-B, A-ground, and B-ground. As each test is performed a light will illuminate giving results of the test. If the measured resistance is high enough within a circuit, the light for that circuit will illumi-nate green. If all three tests pass, the EPSCTD is ready for use. If a low resistance is found dur-ing the sequence of tests, the light for that circuit will illuminate red. If a test portion is failed, in order to reset the Trainline Integrity Test, it is necessary to push the “PUSH TO START TEST” button again. An investigation will be required to determine the cause of low resistance.

Figure 3-3 Trainline Integrity Test

NOTE

If the “PUSH TO START TEST” button is pressed in the middle of a single car test, a temporary loss of communication to the CCD valve will result. This could result in a failed portion of the single car test. Repeat test if necessary.

3.14 Continuity Test: To conclude the EPSCTD setup, a Trainline Continuity Test will be per-formed. Attach the trainline test light, shown in Figure 2-10, to the opposite end of the car to which the EPSCTD is connected. With the toggle switch in the “ON/120VAC” position and the GFCI indicator light ON, depress the “PUSH TO START TEST” button twice, holding for 1 sec-ond each time (see Figure 2-3). Power to the car should now be ON and the trainline test light’s red light at the opposite end of the car should be illuminated. If the red light is not illuminated, the car may have an open circuit (such as the ECP trainline) or the test box may have a fault or a blown fuse.

NOTE

With the test setup performed as outlined above, proceed to Section 4.0, EPSCTD Test Start Up.

GREEN LIGHT = PASSED TEST

RED LIGHT = FAILED TEST



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4 EPSCTD Test Start-Up

Once the EP Single Car Test has been set up, you are ready to begin the test. The following steps help identify start-up of the EPSCTD.

Figure 4-1 EPSCTD Icon on Desktop

4.1 Using a laptop or a PC on which the EPSCTD software is installed as outlined in 2.1.4, double-click on the “EPSCTD” icon located on the computer’s desktop (Figure 4-1). This will take you to the main screen of the EPSCTD (Figure 4-2):

Figure 4-2 EPSCTD Main Screen

EPSCTD ICON



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4.2 With the main screen in view, you will notice four drop down menu choices on the upper left screen:

File The file menu is used to exit the program

Options The options menu is used to select the units of measure. If a particular configuration is saved, it becomes the default; other-wise it is used for one session only.

Language The language menu is used to change the display language.

Special Functions Refer to Section 8 of this manual.

Help The help menu is used to view software version information and equipment setup instructions.

4.3 There are also two buttons available on the main screen: “Start” and “Exit”. Press the “Start” button to begin a test.

4.4 The Test Device Confirmation Screen (Figure 4-3) will appear, prompting the tester to select the test device being used. Click on the image that corresponds to the test device being used.

Figure 4-3 Test Device Confirmation Screen



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4.5 The Equipment Setup Screen (Figure 4-4 or 4-5) will appear prompting if the test has been set up per Section 3 of this manual. Once confirmed that the test setup is correct, press the “OK” button using your mouse. You have now started the EPSCTD for the car in which you are con-nected to.

Figure 4-4 Equipment Setup Screen: Two-Position

Figure 4-5 Equipment Setup Screen: Three-Position

NOTE If the system was not setup properly as outlined in Sections 3 and 4 of this document, the user will be prompted with a “Test Setup Error”. Repeat Sections 3 and 4 above if this is the case (reference Section 7.0 EPSCTD Troubleshooting).



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4.6 Starting the Test Procedure 4.6.1 With the test started from section 4.5, the EPSCTD will find the car control device (CCD) and veri-

fy the car’s configuration. The EPSCTD will automatically verify and update the car software as needed; results will be recorded in a software log in the following location:

On Windows XP: C:\Documents and Settings\All Users\Documents\EPSCTD\logs\ On Windows 7: C:\ Users\Public\Public Documents\EPSCTD\logs\ 4.6.2 The EPSCTD software will display a car number and ask the tester to confirm if the car’s number

is correct. If the car’s road number is correct, click the “Accept” button. The EPSCTD will update car parameters as needed (results will be stored in the same directory as the software update) and will prompt the tester that the CCD set-up is complete. Click the “OK” button to proceed to step 4.6.6.

4.6.3 To change the car’s road number, vehicle owner, or vehicle type, click the “Reject” button. The

EPCSTD will display a “Vehicle Owner” selection. Click on the drop down list to select the vehicle owner, and then click “Accept”.

4.6.4 Next, the EPSCTD will display a “Vehicle type” selection. Click on the drop down list to select the

vehicle type from those available for the vehicle owner selected in the previous step. Select the vehicle type and then click the “Accept” button. A new window will display both the “Vehicle Owner” and “Vehicle type” with both “Accept” and “Reject” buttons displayed, providing the tester with an opportunity for correction if a mistake was made. Click “Accept” to continue to next step.

4.6.5 The EPSCTD will then prompt the tester to enter the car road number in the format for that car

owner (an example entry will be displayed). Once the road number is entered, click “Accept” and the road number will be displayed and the tester will be asked, “Is the road number correct?”. Click the “Yes” or “No” button to confirm or to change the road number. After clicking “Yes”, a message will be displayed; “Car setup completed.” Click “OK” to continue.

4.6.6 Click the “Run Test” button to start the test procedure (Figure 4-6).



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Figure 4-6 EPSCTD Run Test

4.6.7 The tester will be prompted to enter their name or ID. After clicking “OK”, a screen is provided

prompting the tester to the next step in the test. The next step will differ depending upon whether the system is Stand-Alone (See section 4.7) or Overlay (See section 4.8).

4.7 EP-60 Stand-Alone System 4.7.1 The tester will be prompted to perform “Single Car Test – Preliminary Inspections and Ad-

justments”. Brake cylinder piston travel and slack adjuster operation must be adjusted in accord-ance with manufacturer’s instructions or AAR Field Manual 3. If applicable, the empty / load valve must also be inspected and adjusted in accordance with manufacturer's instructions. Click “Ad-just” to perform these adjustments before proceeding with the test. If adjustments have already been done, click “Adjustment OK” and proceed to section 4.7.5.

4.7.2 If the “Adjust” button is pressed the following prompt will be displayed:



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Figure 4-7 BC Control Link

4.7.3 Clicking the “BC CONTROL” button will open a control panel that allows direct user control of the CCD for applying and releasing brake cylinder pressure.

Figure 4-8 BC Control Panel



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4.7.4 Once adjustments are completed, click the "Done" button and then click “Adjustment OK” to continue the test.

4.7.5 If the vehicle type entered at the start of the test is not programmed to have a mechanical Emp-ty/Load device, the EPSCTD test software will skip this step.

If the vehicle type that was entered at the beginning of the test is equipped with a mechanical Empty/Load device, the tester will be prompted at this point to enter the number of Empty/Load devices. Click “Continue” after entering the number.

4.7.6 If there is no Empty/Load device, the tester will now be prompted to “Install Brake Cylinder tap and gauge”.

If there is an Empty/Load device, the tester will be prompted to “Install a BC tap and gauge downstream of all Empty/Load systems that are associated with the CCD under test.”

Install a calibrated pressure gage as directed and click “OK” when ready.

4.7.7 The tester will be prompted to “Place the Power to Car switch in the OFF (OFF/TIT) position.” Once the switch is in the OFF/TIT position, verify that power to the car is off, by looking at the Trainline Test Light. Click the “Continue” button.

NOTE

If the power is left on when the “Continue” key was pushed, the user will be prompted “Test Setup Error” and returned to the main menu.

4.7.8 Once the CCD has shut down, the test will proceed to section 5.1.

4.8 EP-60 Overlay System

4.8.1 If the vehicle type entered at the start of the test is not programmed to have a mechanical Emp-ty/Load device, the EPSCTD test software will skip this step.

If the vehicle type that was entered at the beginning of the test is equipped with a mechanical Empty/Load device, the tester will be prompted at this point to enter the number of Empty/Load devices. Click “Continue” after entering the number.

4.8.2 If there is no Empty/Load device, the tester will now be prompted to “Install Brake Cylinder tap and gauge”.

If there is an Empty/Load device, the tester will be prompted to “Install a BC tap and gauge downstream of all Empty/Load systems that are associated with the CCD under test.”

Install a calibrated pressure gage as directed and click “OK” when ready.

4.8.3 The tester will be prompted to “Place the Power to Car switch in the OFF (OFF/TIT) position.” Once the switch is in the OFF/TIT position, verify that power to the car is off, by looking at the Trainline Test Light. Click the “Continue” button.



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NOTE

If the power is left on when the “Continue” key was pushed, the user will be prompted “Test Setup Error” and returned to the main menu.

4.8.4 The tester will be prompted to perform the Single Car Test from AAR Standard S-486 to test the pneumatic equipment on the overlay car prior to completing the EP single car test using the EP-SCTD. The tester will be prompted to verify the results. Click “Yes” if passed. The test will pro-ceed to section 6.1.

Figure 4-9 AAR S-486 Test Results Window



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5 Stand Alone Test - Preliminary

5.1 (AAR Type S486 Test) Preliminary Procedures and Inspections

5.1.1 With the car previously chocked and with brake pipe vented to 0 psi as outlined in Section 3 of this manual, pull and hold the manual release valve’s rod and vent brake cylinder and reser-voir pressure to zero (0). Ensure the brake cylinder piston(s) have returned into the brake cyl-inder(s). Ensure the handbrake is in the Released Position. Note that the Brake Cylinder Push Rod(s) have returned into the Brake Cylinder(s).

Check for worn, missing, or incorrect brake shoes and replace with the correct shoe, as re-5.1.2quired.

Check for worn brake levers and pins and replace as required. 5.1.3

Check to ensure brake rigging, levers, and rods do not bind or foul. 5.1.4

Check all air brake hoses for cuts, breaks, or age cracking. Replace as required. Apply new 5.1.5air hose coupling gaskets.

Single-click on the “Yes” key to verify that you have successfully completed this portion of the test (Figure 5-1). If you don’t accept this test, single-click on the “No” key. By selecting the “No” key this portion of the test will be failed and the test continued. Single-click on the “Cancel Test” key if you wish to cancel the test.

Figure 5-1 Preliminary Procedures Test Pass/Fail



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(AAR Type S486 Test) Connecting the Device to a Car 5.2

Before attempting to charge the car, ensure the Dirt Collector Cut Out Cock is open to the EP-5.2.160 CCD and Vent Valve.

With the Pneumatic Test Device connected to one end of the uncharged car as outlined in 5.2.2Sections 3.1 through 3.5 of this manual, open the car’s angle cock to which the Pump & Dump is connected. By opening this angle cock, air is supplied through the car.

At this time take the glad hand dummy coupling as outlined in Section 2.1.5 of this document 5.2.3and proceed to the opposite end of the car. There should be a continuous blow of air through the glad hand. Close the angle cock and lock the glad hand dummy coupling in place. Reopen the angle cock.

To continue to the next section, single-click on the “Yes” key to verify that you have success-fully completed this portion of the test (Figure 5-2). If you don’t accept this test, single-click on the “No” key. By selecting the “No” key, this portion of the test will be failed and the test con-tinued. Single-click on “Cancel Test” key if you wish to cancel the test.

Figure 5-2 Connecting the Device to Car Test Pass/Fail

(AAR Type S486 Test) System Leakage Test 5.3

NOTE

The car is now charging from the previous Section 5.2. Wait eight (8) minutes to allow the system to completely charge.

NOTE

The hand brake inspection per Section 5.4 can be performed at this time while the car is charging.



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Leakage of the entire system, including the brake pipe (glad hand to glad hand), reservoirs, 5.3.1separate venting devices, and the control valve, must not exceed 225 scim with the system charged to 90 +/-2 psi. Flow in excess of 225 scim indicates the system is not completely charged or there is an excessive leak.

Open the supply air on the pneumatic test device and make a complete check for leakage. 5.3.2Check all pipe connections, reservoir separation plate gaskets, CCD gaskets, and Vent Valve gaskets.

WARNING

Before making any repairs to correct excessive leakage ensure that all air pressure on the car is vented to zero (0).


Correct any excessive leakage that is found and repeat the system leakage test 5.3.

To continue to the next section, single-click on the “Yes” key to verify that you have successfully com-pleted this portion of the test (Figure 5-3). If you don’t accept this test, single-click on the “No” key. By selecting the “No” key, this portion of the test will be failed, and the test continued. Single-click on “Cancel Test” key if you wish to cancel the test.

Figure 5-3 System Leakage Test Pass/Fail

(AAR Type S486 Test) Handbrake Inspection Test 5.4

NOTE

This Handbrake Inspection Test can be performed while the car is charging for eight (8) minutes as outlined in Section 5.4 of this manual.

Lubricate the handbrake winding shaft and oil cups, if so equipped, with a good Grade 30W 5.4.1

oil. With the handbrake in the released position, note that the brake cylinder piston push rod(s) have returned into the brake cylinder(s).



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NOTE

New or reconditioned handbrakes do not require lubrication at the time of application. Handbrakes requiring lubrication shall be in accordance with MSRP Section HS.

Apply the handbrake. Observe that the bell crank, if so equipped, is in a normal working 5.4.2

range. Using a bar, determine that all shoes applied by the handbrake are firmly set against the wheels to verify that associated linkage does not bind or foul.

Release the handbrake using the operating wheel and/or lever. Note that the drum chain is 5.4.3fully unwound, and that the bell crank, if so equipped, drops to the lower limit, and there is minimal slack in the horizontal chain. Verify that the brake shoes have released from the wheels and the brake linkage is not bound.

To continue to the next section, single-click on the “Yes” key to verify that you have successfully completed this portion of the test (Figure 5-4). If you don’t accept this test, single-click on the “No” key. By selecting the “No” key, this portion of the test will be failed, and the test continued. Single-click on “Cancel Test” key if you wish to cancel the test.

Figure 5-4 Handbrake Inspection Test Pass/Fail

(AAR Type S486 Test) Emergency Test 5.5

NOTE

Determine how many Emergency Venting Device(s) are present within the single car, married pair, or rake of 2 cars that are being tested.

If there is only one (1) emergency venting device (vent valve), only perform Steps 5.5.1 to 5.5.5.

If there is more than one (1) emergency venting device (vent valve), only perform step 5.5.6 to 5.5.13.



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Check that the Dirt Collector Cut-out Cock is open to the EP60 CCD vent valve as previously 5.5.1instructed per step 5.3.1 of this manual.

With the brake pipe charged to 90 psi (620 kPa), or at the railroad application specific feed 5.5.2valve setting +/- 1 psi, close the air supply to the pneumatic test device, and vent brake pipe. This must produce a Vent Valve Emergency Application as indicated by the rapid venting of brake pipe pressure to zero and brake cylinder pressure development as indicated on the brake cylinder pressure gauge. Is the brake cylinder piston extended, and are the brakes ap-plied? Verify that the Emergency Brake Cylinder Equalization Pressure is between 73 – 80 psi (for 90 psi BPP applications), or per the application specified requirements, as read on the BC pressure gauge. Please note that where allowed, some railroad owners set their emer-gency equalization pressures outside of the 73-80 psi range, and should be handled on an in-dividual basis. Wait 1 minute to allow the vent valve to reset.

Close the venting device on the pneumatic test device, and open the air supply to recharge 5.5.3the brake pipe to 90 psi (620 kPa), or the railroad application specific feed valve setting +/- 1 psi.

Verify that the brake cylinder pressure releases by noting that the brake cylinder piston re-5.5.4tracts.

With successful completion of above Section 5.0, proceed to Section 6: Conclude Test of 5.5.5this document.

NOTE

Complete only test Steps 5.5.6 through 5.5.14 if there are more than one (1) emergency venting device (vent valve).

Plug the exhaust vent of the additional emergency venting valve device in order to nullify its 5.5.6emergency venting function. If this emergency venting device (vent valve) is located on a pipe bracket and has a brake pipe cut-out-cock, then close the cock instead of plugging the valves exhaust vent.

Check that the Dirt Collector Cut-out Cock is open to the EP60 CCD and vent valve being 5.5.7tested.



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With the brake pipe charged to 90 psi (620 kPa), or at the railroad application specific feed 5.5.8valve setting +/- 1 psi, close the air supply to the pneumatic test device, and vent brake pipe. This must produce a Vent Valve Emergency Application as indicated by the rapid venting of brake pipe pressure to zero and brake cylinder pressure development as indicated on the brake cylinders pressure gauge. Is the brake cylinder piston extended, and are the brakes are applied. Verify that the Emergency Brake Cylinder Equalization Pressure is between 73 – 80 psi (for 90 psi BPP applications), or per the application specified requirements, as read on the BC pressure gauge. Please note that where allowed, some railroad owners set their emer-gency equalization pressures outside of the 73-80 psi range, and should be handled on an in-dividual basis. Wait 1 minute to allow the vent valve to reset.

Close the venting device on the pneumatic test device, and open the air supply to recharge 5.5.9the brake pipe to 90 psi (620 kPa), or the railroad application specific feed valve setting +/- 1 psi.

Remove the plug from the additional emergency venting valve that was installed during step 5.5.105.5.6. Open the cut-out-cock if equipped with such also outlined in 5.5.6.

Close the dirt collector cut-out cock on the EP-60 CCD and vent valve previously tested in 5.5.11sections 5.5.6 through 5.5.10. If no cut-out cock is available, plug the venting portion of the vent valve as described in step 5.5.6.

With the brake pipe charged to 90 psi (620 kPa), or at the railroad application specific feed 5.5.12valve setting +/- 1 psi, close the air supply to the pneumatic test device, and vent brake pipe. This must produce a vent valve emergency application as indicated by the rapid venting of brake pipe pressure to zero as noted by the loud sound of air venting thru the vent valve.

Open the dirt collector cut-out cock on the EP-60 CCD and vent valve that was closed in step 5.5.135.5.11. Close the venting device on the pneumatic test device, and open the air supply to re-charge the brake pipe to 90 psi (620 kPa), or the railroad application specific feed valve set-ting +/- 1 psi.

Having followed either steps 5.5.1 through 5.5.5 or steps 5.5.6 through 5.5.13, you have now completed the requirements of the emergency test. To continue to the next section, single-click on the “Yes” key to verify that you have successfully completed this portion of the test. If you don’t accept this test, single-click on the “No” key. By selecting the “No” key, this portion of the test will be failed, and the test continued. Single-click on “Cancel Test” key if you wish to cancel the entire test:

Figure 5-5 Emergency Test



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6 Conclude Test

6.1 Stand-Alone or Overlay

6.1.1 The Tester will be guided to “Recharge and Powerup”. Once the system has fully charged, click “Continue”.

6.1.2 The EPSCTD program will prompt the tester to enter the brake cylinder pressure. If more than one mechanical empty/load device was entered previously, the brake cylinder pressure for each will need to be entered. This will be true at each step that the brake cylinder pressure is required. Click “Continue”.

6.1.3 If the system includes an Empty/Load device, the tester will be directed to “Block all Empty/Load systems associated with the CCD under test in the Loaded position.” Click “Continue” when done.

6.1.4 The tester will now be prompted to, “Place the Power to Car switch in the ON (ON/120VAC) position, press the Start button, wait three seconds, and then press the Start button again.”

The newest versions of the EPSCTD, E0 and later, require the start button to be pressed three times. Each button press should be held a minimum of 2 seconds with a minimum pause of 2 seconds between each button press. The last button press may need to be held for up to 5 sec-onds to allow current to the car to stabilize if the car is very long or if it is a married pair unit.

6.1.5 The EPSCTD software will guide the tester through the rest of the test. Test steps will be deter-mined in part by whether or not the car under test is equipped with an Empty/Load device and whether or not its handbrake is equipped with a sensor. If the handbrake has a sensor, the first test will check that the CCD detects the state of the sensor correctly. Every test performed will produce a test log entry with the results.

6.1.6 The test will check both empty and loaded pressures whether or not there is an Empty/Load de-vice. The test will also check brake cylinder leakage and manual release.

6.1.7 The last step of the EPSCT will be a check of the battery condition. If the battery test is failed, the tester will be prompted to replace the battery and will have the opportunity to re-run that portion of the test.

6.1.8 The test software will display a message indicating whether the test was passed or failed. Clicking “OK” will take the tester to the Main Menu.



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Figure 6-0-1 EP-60 Single Car Test Results

6.2 Main Menu

Figure 6-0-2 EP-60 Single Car Test Main Menu



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From this screen the tester can:

Re-run Test: Re-run the entire test on the same car.

Next Car: Start a new test on a different car.

View Results: View the results of the test that was just completed.

Exit: Exit the test program.

6.2.1 The test results can be viewed at any time by going to the Test Results folder in the following direc-tory locations:

For Windows XP:

C:\Documents and Settings\All Users\Documents\EPSCTD\Test Results\

For Windows 7:

C:\ Users\Public\Public Documents\EPSCTD\Test Results\

See APPENDIX 9.2 to review sample test results for Stand-Alone and Overlay systems.



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7 EPSCTD Troubleshooting

EPSCTD Troubleshooting Table 7.1

EPSCTD Troubleshooting Procedure

Issue Resolution Upon startup of EPSCTD Program, "Unable To Initialize USB Interface

Ensure USB Cable Is Connected To Computer

Too many LON USB devices detected Under Computer Control Panel, LON Works Interfac-

es, USB, Show Detached Interfaces, Remove All De-tached Interfaces

Unable To Verify IDM Configuration Check EPSCTD Set Up Make Sure Power To Car Is On = CCD Power LED Illuminated RED (Check Opposite End Of Car With Voltage Meter > 100 VAC or Continuity Test Device Light Verify IDM Wiring Terminals 5, 6, 7, & 8 Replace IDM

Cannot Find CCD Check EPSCTD Set Up

Make Sure Power To Car Is On = CCD Power LED Illuminated RED (Check Opposite End Of Car With Voltage Meter > 100 VAC or Continuity Test Device Light

Make Sure J1 Drop Cable Is Connected To CCD

Verify Center Junction Box Wiring Is Correct (Which Should Have Been Done In Previous TIT / Continuity Light Tests) Replace CCD

Low BP Pressure Check End Cocks

Check Test Device Air Supply

No Power To The EPSCTD Check Input Voltage Supply To The EPSCTD

Reset GFI On Side Of Box With Power Button "On" (I) Check that the lid is fully closed.

Check 2A Fuse Within Box (Located On Lower Bot-tom Right PCB: Caution - Make Sure Voltage Supply Is Disconnected From EPSCTD Box), Replace If Necessary

Waiting For Reservoir To Charge “Continuously”

Check Pneumatic Device Air Supply

Failed Battery Test (Battery Voltage < 11.0 VDC)

Charge Battery For A Minimum 4 Hours Using EP-SCTD With Power Applied To The Car



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8 Special Functions

Manual Control 8.1

The manual control function within this software is a brake simulation tool in which the CCD can be used to manually control brake cylinder pressure on the car. This may be desired in order to accomplish tasks such as checking / setting slack adjuster operation, piston stroke, or perform-ing brake shoe force measurements etc. This is also a valuable tool for demonstrating the ability of an EP-60 brake system to perform graduated brake applications without the depletion of brake pipe pressure.

In order to use this function, follow the instructions outlined in Section 4 of this document locat-ed on page 23. The Special Functions drop down can be seen on the main menu. Single-click on “Special Functions” to access the “Manual Control” function. You will be prompted to “Turn power to car on”. Single-click on the “Manual Control” option to access the following screen (Figure 8-1):

Figure 8-1 Special Functions

The brake cylinder pressure can be controlled by changing the desired brake command (%) from 0 to 120%. This can be done by several means:



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Clicking on the Release, Min Service, Full Service and Emergency tabs

Clicking and dragging the slide bar tab right or left to the desired brake command (%), or by clicking on the “Change Command” button and typing in the desired brake command %.

The load condition can be changed by clicking on either the Empty or Loaded condition.

NOTE

Brake Cylinder must be fully released to change to Empty/Load setting.

The brake command (%) is displayed. The brake pipe pressure, reservoir pressure, and the brake cylinder pressure as sensed by the CCD is displayed. The status of the CCD is also dis-played (CUT IN, CUT OUT, Or ***).

If brake pipe pressure is vented to zero (0), the CCD status will change to CUT OUT due to a “Low Reservoir” condition. The reservoir and brake cylinder equalization pressures achieved will be displayed. A message will be displayed that indicates low brake pipe pressure – charge brake pipe to recover. Once brake pipe and the reservoir are recharged the CCD status will change to CUT IN and the desired brake command can be entered again.



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9 Appendix

NYAB EP-60 Single Car Test Check Sheet 9.1



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EPSCTD “Sample” Test Results 9.2

EP-60 Stand Alone Vehicle EPSCTD Test Results 9.2.1



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EP-60 Overlay Vehicle EPSCTD Test Results 9.2.2



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Abbreviations 9.3

CCD Car Control Device EPSCTD EP60 Single Car Test Device GFCI Ground Fault Circuit Interrupt EOC End Of Car JB Junction Box I/C Inter Car SCIM Standard Cubic Inches Per Minute psi Pounds Per Square Inch kPa Kilopascals