AF-902 and AF-904

1000 Technology Drive Pittsburgh, PA 15219-3120
SM8051
AF-902 and AF-904 Digital FSK Track Circuit Controller Systems
FIELD MAINTENANCE MANUAL
COPYRIGHT 2001 UNION SWITCH & SIGNAL PRINTED IN USA
July 2001 Revision 2.0
Union Switch & Signal, Inc.
REVISION HISTORY
REV 0.0 1.0 1.1 2.0 DATE 10/9/98 2/19/99 4/20/99 7/20/01 REVISION DESCRIPTION Initial 902/904 manual Revised per Shanghai and QA comments Revised for submittal to Copenhagen Revised for submittal to Copenhagen
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TABLE OF CONTENTS
1 GENERAL INFORMATION.............................................................................................. 1-1 1.1 INTRODUCTION ...........................................................................................................1-1 1.2 PHYSICAL DESCRIPTION ...........................................................................................1-1 1.2.1 1.2.2 1.2.3 Cardfile.....................................................................................................................1-1 Printed Circuit Boards..............................................................................................1-3 Wayside Components...............................................................................................1-7
1.3 SPECIFICATIONS........................................................................................................1-10 2 Typical Applications ............................................................................................................ 2-1 2.1 Mainline Track Circuits ...................................................................................................2-2 2.1.1 Track Circuit ID and Cab Signal Transmission.......................................................2-2
2.2 Yard Track Circuits..........................................................................................................2-4 2.3 Cab-Only Transmission in Crossovers.............................................................................2-5 2.4 Train Detection Only in Double Crossover......................................................................2-6 2.5 SYSTEM CONNECTION DIAGRAMS.........................................................................2-6 3 FUNCTIONAL OPERATION ............................................................................................ 3-1 3.1 INTRODUCTION ...........................................................................................................3-1 3.2 WAYSIDE TO TRAIN MESSAGE FORMATION .......................................................3-1 3.2.1 3.2.2 3.2.3 Data Routing.............................................................................................................3-1 Data Protocol............................................................................................................3-2 Message Commands, Functions, and Formation.....................................................3-2
3.3 FSK SIGNAL TRANSMISSION ....................................................................................3-3 3.3.1 3.3.2 Message Verification................................................................................................3-4 Equipment Room To Rails.......................................................................................3-5
3.4 TRAIN DETECTION......................................................................................................3-6 iii SM8051
3.4.1
Signal Level Sensing................................................................................................3-6
3.5 MONITORING AND FAILOVER..................................................................................3-6 3.5.1 3.5.2 3.5.3 4 MICROLOK II Monitoring......................................................................................3-7 AF-902/904 Monitoring...........................................................................................3-7 Failover (AF-902 System Only)...............................................................................3-9
FRONT PANEL MENU OPERATION .............................................................................. 4-1 4.1 INTRODUCTION ...........................................................................................................4-1 4.2 FRONT PANEL DISPLAYS AND CONTROLS ...........................................................4-1 4.2.1 4.2.2 Displays ....................................................................................................................4-1 Controls ....................................................................................................................4-3
4.3 FRONT PANEL OPERATION.......................................................................................4-3 4.3.1 Front Panel Menu Interface......................................................................................4-4
4.4 MENU HIERARCHY......................................................................................................4-5 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 5 Main Menu...............................................................................................................4-5 Display Menu...........................................................................................................4-5 Blocking Speed Menu..............................................................................................4-6 Events Menu.............................................................................................................4-6 Configuration Menu.................................................................................................4-7
INSTALLATION AND ADJUSTMENT............................................................................ 5-1 5.1 INTRODUCTION ...........................................................................................................5-1 5.2 RECOMMENDED TEST EQUIPMENT........................................................................5-1 5.3 Serial Link Configuration.................................................................................................5-1 5.4 INITIAL POWER CHECKS ...........................................................................................5-1 5.5 TUNING PROCEDURE..................................................................................................5-2 5.6 CALIBRATION PROCEDURE......................................................................................5-2
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5.6.1 5.6.2 5.6.3 5.6.4
Testing Codes and Abbreviations ............................................................................5-3 Test Equipment And Tools ......................................................................................5-3 Transmit Power Adjustments...................................................................................5-4 Set-up Overview.......................................................................................................5-5
5.7 AF-902/904 TRACK CIRCUIT SYSTEM SET-UP AND TEST...................................5-6 5.7.1 AF-902/904 350 or 500 MCM Track Circuit Set-Up ..............................................5-7
5.8 TEST DOCUMENTATION AND DATA SHEETS.....................................................5-13 6 PREVENTIVE MAINTENANCE....................................................................................... 6-1 6.1 INTRODUCTION ...........................................................................................................6-1 6.2 IMPORTANCE OF PREVENTIVE MAINTENANCE..................................................6-1 6.3 PREVENTIVE MAINTENANCE TASKS .....................................................................6-1 6.3.1 6.3.2 Equipment Cleaning Procedure................................................................................6-1 Track Circuit Inspection...........................................................................................6-2
6.4 TRACK CIRCUIT CHECKS ..........................................................................................6-4 6.4.1 7 Track Circuit Sensitivity..........................................................................................6-4
TROUBLESHOOTING....................................................................................................... 7-1 7.1 INTRODUCTION ...........................................................................................................7-1 7.2 APPROACH TO TROUBLESHOOTING ......................................................................7-1 7.3 TROUBLESHOOTING PROCEDURES ........................................................................7-2 7.3.1 7.3.2 Fault Symptoms........................................................................................................7-2 Error Code Observation...........................................................................................7-3
7.4 PCB FRONT PANEL INDICATORS AND CONTROLS .............................................7-8 7.4.1 7.4.2 7.4.3 AF-902/904 CONTROLLER PCB ..........................................................................7-8 AF-902/904 Auxiliary PCB ...................................................................................7-10 AF-902/904 Power Supply PCB............................................................................7-10
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CORRECTIVE MAINTENANCE ...................................................................................... 8-1 8.1 INTRODUCTION ...........................................................................................................8-1 8.2 REPLACEMENT REPAIR..............................................................................................8-1 8.2.1 8.2.2 8.2.3 AF-902/904 PCB Replacement ................................................................................8-1 Coupling Unit Replacement.....................................................................................8-2 Bond Replacement ...................................................................................................8-5
8.3 VERIFICATION OF SYSTEM REPAIR........................................................................8-5
TABLE OF FIGURES
Figure 1-1 Typical Wayside Room Equipment...........................................................................1-2 Figure 1-2 AF-902/904 Cardfile Configuration..........................................................................1-3 Figure 1-3 Track Circuit Controller PCB.....................................................................................1-5 Figure 1-4 Auxiliary PCB............................................................................................................1-6 Figure 1-5 Power Supply PCB.....................................................................................................1-8 Figure 1-6 Track Coupling Unit, 350 or 500 MCM Bond, and Track Loop ...............................1-9 Figure 2-1 Application of Cab Signal Frequencies to Track Circuits..........................................2-3 Figure 2-2 Cab Signal Sequencing...............................................................................................2-3 Figure 2-3 Single Rail Track Circuit............................................................................................2-4 Figure 2-4 Typical Interlocking Cab-Only Transmission Loop..................................................2-5 Figure 2-5 Double Crossover (Train Detection Only) ................................................................2-6 Figure 2-6a Inductive Coupling Unit, Terminal Identification...................................................2-7 Figure 2-6b Direct Injection Coupling Unit, Terminal Identification.........................................2-7 Figure 2-7a AF-902 Track and AC Connectors and Typical Wiring...........................................2-8 Figure 2-7b AF-902 Typical Serial Link Connections ................................................................2-9 Figure 2-8 AF-904 Track and AC Connectors and Typical Wiring...........................................2-10
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Figure 4-1 Controller PCB Front Panel........................................................................................4-2 Figure 4-2 Menu System Hierarchy................................................................................. 4-9, 4-10 Figure 5-1 AF-902/904 Upper Cardfile Rear Views....................................................................5-4 Figure 7-1 Controller PCB Front Panel........................................................................................7-9 Figure 7-2 Auxiliary PCB Front Panel.......................................................................................7-11 Figure 7-3 Power Supply Front Panel........................................................................................7-12 Figure 8-1 Power Supply PCB.....................................................................................................8-3
TABLE OF TABLES
Table 5-1. Entering The AF902/904 Restricted Menu For Set-Up.............................................5-6 Table 5-2. AF-902/904 MLOK Address and Track Circuit ID Settings.....................................5-6 Table 5-3. Af-902/904 350 or 500 MCM Tuning Instructions ...................................................5-7 Table 5-3A Coupling Unit (Nominal Capacitance Setting).........................................................5-8 Table 5-4. AF-902/904 350 or 500 MCM Calibration Procedure...............................................5-8 Table 5-4B Rail Current Settings (350 MCM, 500 MCM, and Cab Loop Circuits) .................5-10 Table 5-4C Rail Current Settings (Direct Inject Circuits)..........................................................5-10 Table 5-5. AF-902/904 Cab Loop Track Circuit Set-Up ...........................................................5-11 Table 5-6. AF-902/904 Direct Inject Track Circuit Set-Up .......................................................5-12
LIST OF ABBREVIATIONS
AAR ac ATC ATP BFSK Association of American Railroading Alternating Current Automatic Train Control Automatic Train Protection Binary Frequency Shift Keyed vii SM8051
BPF CMOS CPS CRC CTC CU DC EEPROM ESS FET FSK IC IF LCP LED LO LPF LRU MCM MCP MCU MLOK MPU NCO NRZI
Band Pass Filter Complementary Metal Oxide Semiconductor Conditional Power Supply Cyclic Redundancy Check Centralized Traffic Control Coupling Unit Direct Current Electrically Erasable Programmable Read Only Memory Emergency Stop System Field Effect Transistor Frequency Shift Keyed Integrated Circuit Intermediate Frequency Local Control Panel Light Emitting Diode Local Oscillator Low Pass Filter Lowest Repairable Unit thousands (M) of Circular Mils Master Control Panel Micro Controller Unit MICROLOK II Micro Processor Unit Numerically Controlled Oscillator Non-return-to-zero inverted
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NVLE PC PCB PMI PVC PWM RAM RF rms SDLC SER SIM SPDT TCCB TWC V VHM
Non-vital Logic Emulator Personal Computer Printed Circuit Board Preventive Maintenance Inspection Poly Vinyl Chloride Pulse Width Modulator Random Access Memory Radio Frequency root mean square Synchronous Data Link Control Signal Equipment Room System Integration Module Single Pole Double Throw Train Control and Communications Building Train to Wayside Communications Volts Vehicle Health Monitor
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1 GENERAL INFORMATION
1.1 INTRODUCTION
This service manual is intended for use with both the AF-902 and AF-904 digital Frequency Shift Keyed (FSK) track circuit controller systems. The AF-902 system includes redundant equipment for failover operation, while the AF-904 system does not. When describing features common to both systems, the term "AF-902/904" is used. The AF-902/904 system is part of the wayside portion of an Automatic Train Control (ATC) system. It is the primary communications interface between the wayside and the carborne equipment. The AF-902/904 system provides both train detection and transmission of digital cab signaling data for the Automatic Train Protection (ATP) function of an ATC system. Figure 1-1, Typical Wayside Room Equipment shows the equipment that is contained in a typical wayside room. To perform its primary functions of train detection and cab signaling, the AF-902/904 system encodes data from the track logic processor on the wayside and puts it on the track where it is picked up and decoded by the carborne ATP equipment. This data is used for line speed, target speed, track length, grade, direction, door control, next frequency, and coupling/uncoupling information. Vital track logic is performed by the Track MICROLOK II system. Interlocking logic and control of switch machines and signals are performed by the Interlocking MICROLOK II. Non-vital logic is performed by Non-Vital Logic Emulator (NVLE) units. Routing is performed automatically by the train ID (through the wayside communications system), from the local control panel, by fleeting, or from central control. The AF-902/904 system is comprised of the trackside equipment and processing equipment within the signal equipment room. The trackside equipment consists of track coupling units, wire bonds, and track loops. As shown in Figure 1-1, Typical Wayside Room Equipment, the processing equipment for an AF-902 system contains the primary and backup circuits. The MICROLOK II units and NVLE units are also duplicated for failover conditions. Transit Lines requiring multiple track circuits can be equipped with a maximum of 12 AF902/904 track circuits per track MICROLOK II system.
1.2 PHYSICAL DESCRIPTION

1.2.1 Cardfile The AF-902/904 cardfile is comprised of electronic PCBs housed in a chassis that is compatible with a 19" wide AF rack. This equipment is located in the equipment room and requires a power input of 110/240V ac@50/60 Hz (nominal). This rack mount unit shares many design features with US&S's highly successful MICROTRAX Coded Track Circuit and MICROCAB Cab Signal Systems, including integral PCB front edge 1-1 SM8051
AF902
Figure 1-1 Typical Wayside Room Equipment control/display panels, menu-driven alphanumeric Light Emitting Diode (LED) displays, and 9pin serial data ports. Figure 1-2, AF-902/904 Cardfile Configuration, shows the layout of the AF-902/904 cardfiles. Each cardfile contains ten PCBs, all of which plug into a motherboard that is mounted to the back of the cardfile. The motherboard is a printed circuit board that provides connections between the PCBs. Connectors for each PCB are mounted on the motherboard. When the PCBs are installed in the cardfile, the edge connectors on the PCBs slide into the connectors on the motherboard. In the AF-902 system, the cardfile contains two track circuits. Each track circuit contains five PCBs. These five PCBs are configured to provide redundant primary and backup units. The primary unit consists of: One track circuit controller PCB One auxiliary PCB Half of a power supply PCB
Likewise, the backup track circuit unit consists of: One track circuit controller PCB One auxiliary PCB Half of a power supply PCB
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One power supply PCB, with two independent supply systems, is common to the primary and backup sections of one track circuit. The AF-904 cardfile has the same exact PCB layout, but does not provide redundant track circuit units. Instead the ten PCBs are configured as four separate track circuits. Each track circuit consists of: One track circuit controller PCB One auxiliary PCB Half of a power supply PCB
One power supply PCB, with two independent supply systems, is common to two separate track circuits. 1.2.2 Printed Circuit Boards The AF-902/904 cardfile PCBs are modular in design which allows for easy removal and replacement should repair become necessary. Since the stored programming is located on
CPS ACTIVE ON - L IN E SEL F HEAL TH PARTN E R U - L OK C OMM

BL OCK SPEED SET
+5 V
CPS ACTIVE
C P ACTIVE S O N- L I NE SEL F H E TH AL PAR TN ER U - L OK COMM

B LOC K SPEE D SET
+5 V +15 V - 1 5V +5 V +15 V - 1 5V GND 0 O FF ON
C P ACTIV E S
RIGHT POW SUPPL Y ER
+15 V - 15 V +5 V +15 V - 15 V GND 0 O FF ON
O N- L I NE SEL F HEAL TH PARTN E R U - L OK COMM

B LOCK SPEED SET
RIGHT POW SUPPL Y ER
O N- L I NE SEL F H EALTH PAR TNER U - L OK COMM

B LOC K SPEE D SE T
W
DI R.
L EVEL
TRACK DATA CL EAR
W
DI R.
L EVEL
TRACK D ATA CL EAR
W
DI R.
L EVEL
TRACK D ATA CL EAR
W
DI R.
L EVEL
TRACK D ATA CL EAR
E
DEBUG PORT STAT US LEDS I N RESE T W HEN LI T P RES S T O RES ET MODE
UP D OW N E SCAPE AUX 1
E
DEBUG PORT
E
DEB UG PORT
P1 P2
E
DEB UG P ORT
1 2
P 1 P 2 RECE VER I INPU T
1 2
RECEIVER IN PUT
1 2
P1 P2 RECEIVER IN PUT
1 2
P1 P2 RECEIVER I NPUT
XMFR
STAT US LEDS I N RES ET WHEN LI T P RES S T O RES ET
STA TUS LEDS I N RES ET WHEN LI T PRES S TO RES ET MODE

UP DOW N
X MFR
STA TUS LEDS I N RE SET WHEN LI T PRE SS TO RESET
BA ND PASS FI LTER
XMFR +5 V
B AND PASS F LTER I
B AND PASS F LTER I
X MFR +5 V
B AND PASS FILTER
ANA LOGGROUND
A NA LOGGROUND
A NA LOGGROUND
A NALOGGROUND
L EFT POWER SU PPLY
ADJ
- 15 V +5 V +15 V - 15 V GND 0 O FF ON
MODE
UP
ADJ
ADJ
L EFT POWER SU PPLY
+1 2V VITAL +5 V O UTPUTS
SY ST EM GROUND
+15 V
+12V VITAL +5V O UTPUTS

S YST EM GROUND
+12 V VITAL +5V OUTPU TS

S YST EM GROUND
+15 V - 1 5V +5 V +15 V - 1 5V GND 0 O FF ON
MODE
UP
ADJ
+12 V VI TAL +5 V OUTPU TS

S YS TEM GROUND
+4 4V + TRANSMIT TER OUTPUT
DOW N E APE AU X 1 SC
+44V + T RA NSMIT TE R OUTP UT
+44 V + T RANS M TE R IT O UTP UT
DOWN ESCAPE AU X 1
+44 V + T RA NS M TTE R I O UTP UT
ESCAPE AU X 1
ENTER AUX 2
CPS 50 0 Hz
ENTER AUX 2
CPS 5 00 Hz
ENTER AUX 2
C P 5 0 0H z S
ENTER AUX 2
C P 5 0 0 Hz S
T RK CKT CT RLR N1236 03 -01 DIAG PORT
AUXIL IARY BOARD N1236 040 1
T RK CKT CTRLR POW SUPPLY N1236 03 ER N12 36 05 01 -01 DIAG PORT
T RK CKT CT RLR N1236 0 3 -0 1 DIAG PORT
T RK CKT CTRL R POW SUPPL Y N123 60 3 ER N12 36 05 01 - 01 DIAG PORT
AUXILIARY BOARD N123 60 401
AF-902: AF-904:
TRACK CIRCUIT #1 TRACK CIRCUIT #1 TRACK CIRCUIT #2
TRACK CIRCUIT #2 TRACK CIRCUIT #3 TRACK CIRCUIT #4
Figure 1-2 AF-902/904 Cardfile Configuration
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EEPROMs that are mounted on the cardfile backplane, replacement of any logic PCB may be done with little reprogramming. A calibration procedure should be performed to verify proper track circuit operation. Adjustments are also made via jumpers on the cardfile backplane so that a system reset is not required with changeout of the track interface circuitry. All power is supplied to the PCBs via the backplane motherboard. The ll0/240V ac@50/60 Hz is connected to the power supply PCB, which in turn supplies the controller and auxiliary circuitry with the required voltages. Since this system operates directly from the ac mains, caution should be taken when working near the backplane or on the power supply, especially when on an extender board. Both primary units within the AF-902 cardfile are powered from the same ac feed. Likewise, both backup units are powered from the same second ac feed.
1.2.2.1 Track Circuit Controller PCB
Figure 1-3, Track Circuit Controller PCB, shows the front panel of the track circuit controller PCB and the location of these PCBs in the cardfile. The heart of the track circuit controller is a Motorola MC68HC16Z1 Complementary Metal Oxide Semiconductor (CMOS) Microcontroller. Many of the support functions necessary for the make-up of a microprocessor-based device are internally incorporated in the 68HC16's System Integration Module (SIM). In addition to the SIM, the 68HC16 contains several on-chip peripherals that reduce the PCB's chip count. This contributes greatly to the compactness of the AF-902/904 unit. The end user is provided with: Two alphanumeric displays. These are used to monitor the data used in set-up and operation of the track circuit. The upper display is red and the lower display is green.. Four momentary contact Single Pole Double Throw (SPDT) toggle switches. These switches are used for inputting data that is required for set-up conditions. Five LEDs. These supply additional information, as described in Section 5.2.1. A PC-compatible serial port. A female DB9 connector provides an RS-232 DTE port used for detailed monitoring and diagnostics of the AF-902/904 logic and memory. Background Debugging Port. This port is used for direct control of the 68HC16 microprocessor. It is primarily for factory use.
1.2.2.2 Auxiliary PCB
Figure 1-4, Auxiliary PCB, shows the front panel of the auxiliary PCB and the location of these PCBs in the cardfile. The auxiliary PCB contains both the power amplifier for track data transmissions and the front end part of the receiver for incoming track signals, as well as the Conditional Power Supply (CPS) subsystem. Relays used for failover to the alternate subsystem are located on this PCB, making it an ideal system monitoring point.
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ALPHANUMERIC LED DISPLAYS
MOTOROLA BACKGROUND DEBUG PORT (FACTORY USE ONLY)
W
DIR.
E
DEBUG PORT STATUS LEDS IN RESET WHEN LIT PRESS TO RESET
1 2
SYSTEM MONITOR LEDS
CONFIGURATION SETUP SWITCHES MOMENTARY CONTACT SWITCHES (SPRING RETURN TO CENTER)
MODE
UP
ADJ
SYSTEM RESET PUSHBUTTON
DOW N ESCAPE AUX 1
ENTER AUX 2
TRK CKT CTRL R N123 603 - 01 DIAG PORT
9-PIN PORT FOR PORTABLE PC (RE-232DTE)
AF-902 / AF-904 CONTROLLER PCB

Figure 1-3 Track Circuit Controller PCB
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The following are located on the auxiliary PCB front panel: Eight LEDs. These indicate the status of various key parameters in a readily interpreted format. Eleven maintenance test points. These provide accessible test points for voltage and signals covering the controller and auxiliary PCBs.
CPS ACTI VE ON- LI NE SELF HEALTH PARTNER U- LOK COMM

BLO CK SPEED SET
SYSTEM MONITOR LEDS
L EV EL
TRACK DATA CLEAR
P1 P2
RECEIVER I NPUT
BANDPASS FILT ER
ANAL OG GR OUND
MAINTENANCE TEST POINTS
+12V
VI TAL +5 V OUTPUTS
SYSTEM GR OUND
+44V + TR ANSMITTER OUTPUT
CPS 5 0 0 Hz
AUX IL IARY BOARD N12 36 0 40 1
AF-902 / AF-904 AUXILIARY PCB
Figure 1-4 Auxiliary PCB
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1.2.2.3 Power Supply PCB
Figure 1-5, Power Supply PCB, shows the front panel of the power supply PCB and the location of these PCBs in the cardfile. The single power supply PCB in each AF-902/904 subsystem provides both subsystems with regulated operating power for internal components. This PCB interfaces standard ac commercial power to the system. For safety purposes, a solderside cover is provided to reduce the risk of electrical shock when removing the PCB from the cardfile. WARNING Dangerous voltages are exposed when operating the power supply PCB on an extender board. Use extreme caution when working near exposed terminals. Failure to do so could result in serious physical injury or loss of life. The front panel has the following features: Fourteen LEDs. There are seven LEDs for the primary power monitoring and seven for the backup power monitoring. Two separate power switches. The upper power switch energizes the two PCBs to the immediate right of each power supply PCB. The lower power switch energizes the two PCBs to the immediate left of each power supply PCB. (Note: These switches are locking-lever type switches that must be pulled out to toggle.) Four Key Voltage Test Points. There are test points for both subsystem supplies.
Note that each subsystem is driven from a separate ac feed for improved system reliability. 1.2.3 Wayside Components The required supporting trackside components for the AF-902/904 are the track coupling units, wire bonds, and track loops. From the equipment room, track leads of up to several kilometers total loop length connect the trackside coupling units to the direction relays. The track leads are twisted pairs with an intrinsic impedance (Zo) of approximately 100 ohms.
1.2.3.1 Coupling Units
Figure 1-6, Track Coupling Unit, 350 or 500 MCM Bond, and Track Loop, shows a track coupling unit. The AF-902/904 track coupling unit interfaces the track signals with the cardfile receiver and transmitter circuits, and provides for tuning to the track circuit carrier frequency. The coupling units are housed in weather tight enclosures, and consist of two totally independent and isolated coupling circuits. Each circuit has its own transformer and a jumper-adjusted capacitor bank for frequency tuning as required for the track loops.
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- 15V +5V +15V - 15V GND 0 OFF ON
DC POWER TEST POINTS LOCKING SUBSYSTEM POWER SWITCH
AC POWER TEST POINTS POWER MONITOR LEDS DC POWER TEST POINTS

0
XMFR
XMFR +5V
- 15V +5V +15V - 15V GND
LOCKING SUBSYSTEM POWER SWITCH
OFF
ON
POW SUPPLY ER N12 36 050 1
AF-902 / AF-904 POWER SUPPLY PCB

Figure 1-5 Power Supply PCB
1-8
LEFT POWER SUPPLY
+15V
RIGHT POW SUPPLY ER
POWER MONITOR LEDS
+5V +15V
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23 FT. (7 m) AF-902/904 TM 350 OR 500 MCM BOND 1-TURN LOOP 350 (177 mm 2 ) OR 500 (253 mm2 ) MCM CABLE 1-TURN LOOP (#12) (4 mm 2 ) LOOP CABLE
AF-902/904 TRACK COUPLING UNIT
TM
COLLAR FOR CABLES
BOND CABLE COUPLING UNIT BOND AND LOOP CABLE MOUNTING
TO EQUIPMENT HOUSE
2 TWISTED 2 PAIRS (#14) (2.08 mm )
MAX. CABLE LENGTH = 6000 FT. (1,830 m)
Figure 1-6 Track Coupling Unit, 350 or 500 MCM Bond, and Track Loop Track Coupling Unit: Dimensions: 16"W x 8"H x 10"L (40.64 cm x 20.32 cm x 25.4 cm) Mounting: Wayside Ground Base or Wall. Coupling Unit Feed: 6000 ft. (1,830 m) (maximum) twisted pair #14
1.2.3.2 350 or 500 MCM BONDS
Signals and messages in the rails are communicated to and from the AF-902/904 cardfiles via simple but highly effective cabling type bonds known as "350MCM" or "500MCM" bonds. Insulated joint rails are not required. AF-902/904 track coupling units are tuned to the carrier frequency and provide impedance matching to/from the track. The 350 or 500 thousands (M) of Circular Mils (MCM) bond consists of a few meters of 350 or 500 MCM cable that is connected between the two rails in an "S" shape or an O shape with the end of the "S" or O bonded to each rail. Single turn track loops are mounted inside the upper and lower parts of the "S" or in the O part. S bonds are used in areas where there are no insulated joints that define the track circuit boundaries. O bonds are used in areas where an insulated joint is used in each rail to define the track circuit boundaries. Which track does the transmitting or receiving is determined by the direction relays located at the rear of the cardfile.
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1.3 SPECIFICATIONS
A. Track Carrier Frequencies Odd Frequencies F0 9.5 kHz F2 11.5 kHz F4 13.5 kHz F6 15.5 kHz Frequency Shift: Modulation: Baud Rate: Even Frequencies F1 F3 F5 F7 10.5 kHz 12.5 kHz 14.5 kHz 16.5 kHz
+ 200 Hz BFSK carrier 200 BPS
B. Cab Signal Data Transmission Signal Message: Protocol: Encoding: Bits 12 1 2 3 7 4 4 1 Name Track Circuit ID Primary/Backup Direction Next Frequency Distance to Go Line Speed Target Speed Berthed (Door) 37 data bits, 8 header bits, 16 Cyclic Redundancy Check (CRC) validation bits. Synchronous, bit oriented (similar to Synchronous Data Link Control (SDLC)) NRZI Function Identification of present track circuit (0 to 4095) Identification of which controller is providing the message Train direction of travel Carrier frequency of the next track circuit Distance of target speed Maximum speed permitted within track circuit Desired speed at track circuit target OK to open vehicle doors at station
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2 1
Couple/Uncouple Bifurcation
Couple/Uncouple of trains for makeup Bifurcation
Security: Speed Commands:
Two messages, CRC continuous reception. 0 mph to 80 kph
C. Track MICROLOK II Data Transmission Signal Message: Protocol: 24 data bits, 8 header bits, 8 address bits, 24 Cyclic Redundancy Check (CRC) validation bits. US&S vital serial link protocol
Data from Track MICROLOK II to AF-902/AF-904: Bits 2 3 6 4 4 1 Name Direction Next Frequency Distance to Go Line Speed Target Speed Berthed Function Traffic/Direction Next Frequency Target Distance to Go Line Speed Target Speed Berthed Description 10 = East 01 = West See next frequency chart below See distance chart below See speed chart below See speed chart below 1 = train not in platform 0 = train in platform 10 = couple to train 01 = uncouple from train 00 = no action 1 = point N 0 = point R See distance chart below
Couple/Uncouple
Couple/Uncouple
1 1
Bifurcation Target Distance
Bifurcation Target Distance
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Next Frequency Chart

Frequency (kHz) 9.5 10.5 11.5 12.5 13.5 14.5 15.5 16.5 0 0 0 0 1 1 1 1 Binary Value 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1
Speed Chart
Speed (kph) 0 3 5 10 15 30 35 40 45 50 55 60 65 70 75 80 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 Binary Value 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
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Distance Chart
Distance (meters) 0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 126 132 138 144 150 156 162 168 174 180 186 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Binary Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Distance (meters) 192 198 204 210 216 222 228 234 240 246 252 258 264 272 278 284 290 296 302 308 314 320 326 332 338 344 350 356 362 368 372 378 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Binary Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
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Distance (meters) 384 390 396 402 408 414 420 426 432 438 444 450 456 462 468 472 474 478 480 484 486 490 496 500 506 512 518 524 530 536 540 546 552 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
Binary Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0
Distance (meters) 558 564 570 600 630 660 690 720 750 780 810 840 870 900 930 960 990 1020 1050 1080 1110 1140 1170 1200 1350 1500 1650 1800 1950 2400 2900 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Binary Value 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
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D. Data from AF-902/AF-904 to MICROLOK: Bits 1 1 1 1 Name Direction Standby Health Occupancy Correspondence Function Block Speed Standby Health Track Occupancy Correspondence Description 0 = no block speed set 1 = block speed set 0 = standby unit not available 1 = standby unit is available 0 = track occupied 1 = track unoccupied 0 = direction not in correspondence 1 = direction is in correspondence Spare bits that are not used
Spare
Spare Two messages per CRC 0 80 Kph
Security: Speed Commands: E. Track Circuit
Track Circuit Length: 1000 ft. (305 m) maximum; 65 ft. (19.812 m) minimum Shunt Sensitivity: Pre/Post Shunting: F. Control Cardfile Power Input: Environmental: Circuits: G. Coupling Unit Coupling Feed: Tuned Circuit: H. 350 or 500 MCM Bond: Cable Bond: Signal exchange: 1V+: Impedance: Cab signal current: 6000 ft. (1,828.8 m) maximum, with twisted pair of #14 AWG Connected to 1-turn loop 110/240V ac@50/60 Hz (50 watts per track circuit) 10 Amp fuse -25C to 70C with 95% humidity (non-condensing) Primary and backup track circuit in each Input Power Protection:
< 0.25
ohms
< 5.0 ft (1.524 m)
350 or 500 MCM conductive Inductive Coupling Break rail film for shunting (direct connection to coupling unit only) 1.0 ohm (approximately) 100 ma @ 9.5 kHz 1-15 SM8051
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2 Typical Applications
This section provides an overview of the AF-902/904 system and its functional responsibilities within the wayside application. The AF-902/904 system has been designed as a communication interface between the interlocking logic, processed by MICROLOK II units, and the equipment on the vehicle used for controlling the movement and speed of a train. The AF-902/904 equipment takes serial input from MICROLOK II, adds any local information, and transmits this combined data to the train through the rails. The interface to MICROLOK II is a bi-directional serial link as described in the MICROLOK II service manuals. The communication interface to the train is a one-way link where the car receives only. The AF-902/904 transmits, into one end of the track circuit, information such as track circuit ID, target speed, line speed, distance-to-go, berthed, direction, next cab carrier frequency, coupling/uncoupling and bifurcation. It also monitors the other end of the track circuit to detect train occupancy. Vital wayside logic is typically performed by the US&S MICROLOK II system. A typical wayside system is illustrated in Figure 1-1, Typical Wayside Room Equipment. A. AF-902/904 circuits are used for both train detection and cab signaling. Crossovers and turnouts use the PF track circuits for train detection and AF-902/904 cab loops for data communications to the carborne ATC system. PF track circuits are described in US&S Service Manual 6087.
B. The AF902/904 signals are coupled into the track via S bonds, O bonds or direct injection as
described in sections 1.2.3.2.

C. When the AF902/904 receiver senses a low amplitude or incorrect data, as compared to the
predetermined threshold level and track ID, it indicates that the track circuit is shunted by an occupying vehicle. D. The track circuit continuously transmits digitally formatted data to the vehicle using BFSK modulation.
E. As the vehicle travels from track circuit to track circuit, the carborne ATC system tunes a
filter on the vehicle to the correct frequency, allowing the vehicle to receive the data for the correct track frequency only.
F. Upon notification of the next track circuit carrier frequency, a filter is electronically selected
to receive and decode the vital information on one of the eight carrier frequencies that is assigned to the upcoming track circuit.
G. The vehicle's ATP subsystem uses the FSK-formatted vital information decoded data to perform the ATP functions .
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2.1 MAINLINE TRACK CIRCUITS

The AF-902/904 system is configured for simple, highly-reliable track interface applications using jointless track circuits. The carrier signals and modulated data signals are coupled to the rails via the 350 or 500 MCM bond and coupling unit located at each end of the track circuit. The amplitude of the carrier and the track ID data signals are used to determine track occupancy. The modulated FSK data signal is used to transmit vital and non-vital data to the vehicle. 2.1.1 Track Circuit ID and Cab Signal Transmission As the train travels from track circuit to track circuit within the mainline territory (station-tostation), track occupancy and isolation of commands between track circuits is accomplished by alternating eight available data carrier frequencies. Frequencies range from 9.5 to 16.5 kHz in 1 kHz steps and are numbered F0 through F7. Three frequencies (F1, F3, and F5) are assigned to westbound or northbound track circuits, and three frequencies (F2, F4, and F6) go eastbound or southbound. The two remaining frequencies (F0 and F7) are usually used in special work areas. Specifically, the layout of the mainline track circuits should follow the two three-frequency rotations shown in Figure 2-1, Application of Cab Signal Frequencies to Track Circuits. If it is not possible to separate two track circuits of the same carrier frequency by two intervening track circuits, then separation by one intervening track circuit plus a set of insulated joints is acceptable. Since the train must be informed of the next track circuit frequency, and its occupancy, the track MICROLOK II will not transmit the frequency of an occupied track circuit to the following train. Instead, the frequency of the track circuit the following train is currently occupying is repeated. This initiates a High Rate Service Braking action. The train remains stopped until either the operator initiates a Search for Next Frequency Command from the vehicle's Master Control Panel (MCP) or until the same command is received via a Radio Release Message. As shown in Figure 2-1, Application of Cab Signal Frequencies to Track Circuits, carrier frequency F1 contains data that informs the train of the next cab signal frequency (F3). Onboard the train, one receiver is tuned to F1 and the other to F3. As the train approaches the 350 or 500 MCM bond, signal F1 drops out. Once valid data and level is detected on F3, the vehicle ignores the data arriving from the old F1 receiver. The new data is then decoded and the vehicle logic retunes the receiving filter (previously tuned to F1) to the next cab signal frequency in the sequence of track circuit frequencies (see Figure 2-2, Cab Signal Sequencing). The track circuit is arranged so that the train is always heading towards the transmitter. This is controlled by the two assigned Direction Control bits within the message format. Each wayside track circuit continuously transmits digitally-formatted data to the vehicle using FSK modulation. The track MICROLOK II determines most of the information in the 37 data bits and passes this data on to each AF-902/904 track circuit, via vital serial communication links, where the data is encoded.
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The first 8 bits are used for synchronizing the onboard decode function. The next 36 bits contain data. The last 16 bits of the message are the CRC bits for error detection. Message configuration and bit assignments are described in Section 3. Once the system knows the track ID and the train's direction of travel, it can initiate speed restrictions. Two types of speed restrictions are initiated by the ATC system: block speed restrictions and zone speed restrictions. Block speed restrictions are selected by the Maintainer for each AF-902/904 track circuit. Zone speed restrictions limit the target speed for a control line. The AF-902/904 is designed to enable selection of the maximum line speed and target speed permitted to be transmitted by a track circuit.
T.C. 2103 F1 = 10.5 kHz REC. 1: F1 REC. 2: F3 TRAFFIC DIRECTION T.C. 2102 F3 = 12.5 kHz T.C. 2101 F5 = 14.5 kHz T.C. 2100 F1 = 10.5 kHz T.C. 2099 F3 = 12.5 kHz TRAIN IN TRACK CIRCUIT 2103 RECEIVER #1 TUNED TO F1 RECEIVER #2 TUNED TO F3 APPROACH T.C. 2102 F1 OUT F3 RECEIVED
T.C. 99 F4 = 13.5 kHz
T.C. 100 F6 = 15.5 kHz
T.C. 101 F2 = 11.5 kHz
T.C. 102 F4 = 13.5 kHz
T.C. 103 F6 = 15.5 kHz
T.C. 2103 F1 = 10.5 kHz TRAIN IN TRACK CIRCUIT 2102 RECEIVER #1 TUNED TO F3 RECEIVER #2 TUNED TO F5 APPROACH T.C. 2101 F1 OUT F5 RECEIVED TRAFFIC DIRECTION T.C. 99 F4 = 13.5 kHz
T.C. 2102 F3 = 12.5 kHz REC. 1: F3 REC. 2: F5
T.C. 2101 F5 = 14.5 kHz
T.C. 2100 F1 = 10.5 kHz
T.C. 2099 F3 = 12.5 kHz
T.C. 100 F6 = 15.5 kHz
T.C. 101 F2 = 11.5 kHz
T.C. 102 F4 = 13.5 kHz
T.C. 103 F6 = 15.5 kHz
Figure 2-1 Application of Cab Signal Frequencies to Track Circuits
F1 RECEIVED F3 RECEIVED
F3
350 OR 500 MCM BOND TF 1
Figure 2-2 Cab Signal Sequencing
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The Distance-to-Go bits represent the distance to the target speed, which is the desired speed of the train at the end of the control line. Train Detection and signal communications are similar to those of the mainline continuous rail territory with the exception of the Berthed recognition bits contained in the message. Wayside and carborne signals are used to determine if the train is totally within the limits of the platform. A relay, called Berthed, is used to indicate to the wayside to turn on the Berthed bit. The train must be positioned in the platform track circuit for five seconds before this command is transmitted to the train via the AF-902/904 track circuit. When the command is transmitted, this enables the train doors to open. This is described in more detail in Section 3.
2.2 YARD TRACK CIRCUITS

In addition to their use for station-to-station operations, the AF-902/904 track circuits are employed in the storage yard. Here, the system allows automatic movement of cars for the purpose of making up new train configurations. The AF-902/904 is ideally suited for short track circuits and slow train movement in the yard. Yard track circuits use the same carrier frequency assignments and rotations as the mainline track circuits - F1, F3, and F5 for west/north circuits and F2, F4, and F6 for east/south circuits. However, for yard track circuits, it is only necessary to separate two track circuits of the same carrier frequency by one intervening track circuit. Figure 2-3, Single Rail Track Circuit, shows this configuration. The cab signal is injected into the rails via direct-inject connection of the coupling unit to the rails (see Figure 2-6b). The direct injection method is used because only one rail of the track
INSULATED JOINTS
RUNNING RAILS
TWC LOOP (OPTIONAL) DIRECT COUPLING UNIT DIRECT COUPLING UNIT
AF-902/904 TRAIN DETECTION AND CAB SIGNAL
Figure 2-3 Single Rail Track Circuit
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circuit contains insulated joints. S bond and O bond coupling methods will not function in areas where one rail of the track circuits are tied together. Vital commands for speed, coupling/uncoupling, direction, etc., are transmitted to the vehicle via the cab signaling system. Non-vital, bi-directional data, including vehicle health information, diagnostics, and testing commands, is transmitted via the TWC system. (Please refer to the TWC manual, SM8054.)
2.3 CAB-ONLY TRANSMISSION IN CROSSOVERS

A typical crossover arrangement of a cab-only transmission loop is shown in Figure 2-4, Typical Interlocking Cab-Only Transmission Loop. A transmission loop is installed within the rails of the crossover. The loop is transposed approximately every 13 feet (4m) to prevent induced electrical interference between the cab loop and the rails. The loop is connected to a coupling unit, which in turn is connected to the output of one of the two transmitter PCB groups. In these crossovers, train detection is done via standard power frequency track circuits. Note that in certain applications, crossovers may also be controlled by AF902/904 equipment in a direct injection configuration, as shown in Figure 2-3.
TO SER CU (TO COUPLING UNITS) F7 (TO COUPLING UNITS) (TO COUPLING UNITS)
F6
F4
F2
F6
VANE RELAY 60 HZ
TO MICROLOK
F3
F5
F1
F3
(TO COUPLING UNITS)
(TO COUPLING UNITS)
(TO COUPLING UNITS)
Figure 2-4 Typical Interlocking Cab-Only Transmission Loop
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2.4 TRAIN DETECTION ONLY IN DOUBLE CROSSOVER

Figure 2-5, Double Crossover (Train Detection Only) shows one specific application for a double-crossover where only the train detection function is supplied (no cab signal is provided).
DIRECT INJECT COUPLING UNIT (TRANSMIT)
DIRECT INJECT COUPLING UNIT (RECEIVE)
DIRECT INJECT COUPLING UNIT (RECEIVE)
DIRECT INJECT COUPLING UNIT (TRANSMIT)
Figure 2-5 Double Crossover (Train Detection Only)
2.5 SYSTEM CONNECTION DIAGRAMS

The AF-902 cardfile is a self-contained unit consisting of the primary track circuit (A) and its redundant backup track circuit (B). The AF-904 cardfile contains four independent track circuits. Refer to Figure 2-6a, Inductive Coupling Unit, Terminal Identification for cabling terminal identification. Refer to Figure 2-6b, Direct Injection Coupling Unit, Terminal Identification for the cabling terminal identification. Figure 2-7a, AF-902 Track and AC Connectors and Typical Wiring, illustrates the typical wiring connections for track circuits1 and 2. Figure 2-7b, AF-902 Typical Serial Link Connections, shows the typical serial link connections between the Microlok II ports and the AF-902 connectors. Figure 2-8, AF-904 Track and AC Connectors and Typical Wiring, illustrates the typical connections between the AF-904 connectors and track circuits 1, 2, 3, and 4.
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TB1-1 TRANSMITTER 1 TB1-2 TB1-3 TRANSMITTER 2 TB1-4
TB2-1 TRANSMISSION LOOP 2 TB2-2 TB2-3 TRANSMISSION LOOP 1 TB2-4
Figure 2-6a Inductive Coupling Unit, Terminal Identification
GND
Figure 2-6b Direct Injection Coupling Unit, Terminal Identification
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2-8
SM8051 Figure 2-7a AF-902 Track and AC Connectors and Typical Wiring
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SM8051 Figure 2-7b AF-902 Typical Serial Link Connections
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Figure 2-8 AF-904 Track and AC Connectors and Typical Wiring
3 FUNCTIONAL OPERATION
3.1 INTRODUCTION
The heart of the AF-902/904 track circuit is a Motorola 68HC16 Micro Controller Unit (MCU). This MCU receives vital asynchronous data from the track MICROLOK II, adds local track circuit data, and converts the data into a synchronous protocol (see section 1.3 for a description of this data). The data is then sent to the transit car via the transmitter, transmitter coupler and bonds. The MCU monitors the transmitted signal, via the assigned receiver coupling unit, to detect the presence of a train in the track circuit and reports non-interlocking track circuit track occupancy back to the Interlocking MICROLOK II, along with system health and local speed reductions, via an RS-485 serial data link.
3.2 WAYSIDE TO TRAIN MESSAGE FORMATION

The protocol of the AF-902/904 track communications link is an asynchronous, bit-oriented protocol. This asynchronous protocol dictates that the clocking information (data timing) be embedded in the message. This embedded signal allows proper decoding of the serial data string. 3.2.1 Data Routing When a signal is received from MICROLOK II, the MCU extracts the data from the MICROLOK II protocol and vitally stores it to Random Access Memory (RAM). The MCU performs vital logic with the MICROLOK II data and other data stored locally in an Electrically Erasable Programmable Read Only Memory (EEPROM). Since EEPROMs do not use a battery to retain their memory when power is removed, they require no maintenance. The only battery requirement is for the event logging operation. This EEPROM is mounted on the motherboard so that when a controller PCB is replaced, no reprogramming is necessary. However, the Maintainer will need to run the track circuit calibration procedure to verify settings and calculate new thresholds. Each of the four controller PCBs in a cardfile has its own EEPROM. The local data used by this logic is the unique 12-bit ID number of a given track circuit, and possibly a speed restriction, which was entered via the switches on the front of the controller PCB. In addition, configuration information for the unit, such as the MICROLOK II slave address, carrier frequency, track circuit threshold voltages, and any other non-volatile information needed to operate the AF-902/904, is vitally stored in the EEPROM. If the speed commanded by MICROLOK II is greater than that of the present local speed restriction (if any) the slower of the two is used. If the restriction speed is greater than that commanded by MICROLOK II (or is nonexistent) the speed commands will be sent as requested by MICROLOK II. Once the proper message has been constructed, the MCU converts the data into a synchronous protocol, using an NRZI format. As configured, the AF-902/904 uses a 200 baud BFSK carrier to both transmit and detect the presence of a train in the track circuit. The digitally formatted message is transmitted to the vehicle using FSK modulation and contains a total of 61 to 72 bits. The FSK modulation process is explained in more detail in Section 3.3.
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3.2.2 Data Protocol The messages delivered to the track by the AF-902/904 system consist of 37 bits of data, an 8 bit header/synchronization character, 16 bits of CRC and 10 bits of zero insertion or additional fill bits to make a total of 71 bits. The message is formed by appending the 16 bits of CRC to the data bits, inserting zeros as needed to prevent the uncoded header 0x7E (hexadecimal) from appearing within the message, inserting fill characters to make the message a fixed length, appending the header to the beginning of the message, and encoding the message using NRZI encoding. The following is a summary of the track message formulation: Speed: Protocol: 200 bits per second (200 Baud) Synchronous, bit oriented (similar to SDLC) Header: Data: CRC: 0x7E 37 bits CRC-16
Zero-Bit insertion Rounding bits to make constant size, 71 bit messages Encoding: NRZI
Modulation: BFSK A typical bit representation for a message would be as follows: Header 8 bits Data 37 bits Stuffed Bits 0 to 10 bits CRC 16 bits
61 to 71 Bit NRZ1 Encoded Message (Less Rounding Bits) 3.2.3 Message Commands, Functions, and Formation The data stream is used for both train detection and instructional messages. The number of assigned bits and their assigned instructions are shown in the following table. BITS 13 2 3 FUNCTION Track ID - Including Primary/Backup Indication Direction Next cab carrier frequency (9.5 kHz to 16.5 kHz) DEFINITION Allows for separate track circuits Commands the direction of travel Identifies the upcoming track circuit cab signaling frequency
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BITS 7 4 4 1
FUNCTION Distance-to-go to the target speed Line speed (65 to 0 mph in 5 mph steps plus 8 mph) Target speed (65 to 0 mph in 5 mph steps plus 8 mph) Berthed
DEFINITION Represents the distance to the target speed Represents the maximum speed permitted by the train within the control line Represents the desired speed of the train at the end of the control line Indicates the vehicle's doors are within the bounds of the usable portion of the station platform Used during the make up of trains Used for bifurcation
2 1
Couple and uncouple commands Bifurcation
These messages are used on adjacent track circuits along the entire length of the identified transit line. In order to isolate these commands between track circuits, eight available carrier frequencies are alternated throughout the transit line. Each AF-902/904 track circuit is assigned one of eight base frequencies. Bits, which are made up of MARKS and SPACES, are identified by the frequency they are assigned. The base frequencies and the corresponding SPACE and MARK frequencies are shown in the following table. Center Frequency (kHz) 9.5 10.5 11.5 12.5 13.5 14.5 15.5 16.5 SPACE Frequency (kHz) 9.3 10.3 11.3 12.3 13.3 14.3 15.3 16.3 MARK Frequency (kHz) 9.7 10.7 11.7 12.7 13.7 14.7 15.7 16.7
3.3 FSK SIGNAL TRANSMISSION

BFSK is a method of modulating a center frequency which uses two distinct frequencies to convey the information. One, and only one, of these two frequencies is on at a given time. As listed in the preceding table, the higher of the two frequencies is called "MARK" and the lower is called "SPACE." The two frequencies are separated by 400 Hz. When combined with the NRZI format, the result is a signal, which changes its frequency each bit time, to represent a logical ZERO, and continues to transmit the frequency of the last bit time to represent a logical ONE. This means that a string of ZEROs would be represented by a carrier with a frequency that 3-3 SM8051
toggles between MARK and SPACE (or SPACE and MARK) every 5 ms. To send a string of six ONEs, the carrier would remain at MARK or SPACE (depending on the last frequency before the first ONE) for six bit times (30 ms). To make a synchronous protocol practical, a means of recovering the synchronization clock at the receiving end must be provided. A method similar to that of SDLC is employed. On the receiving end (the train), a Phase Locked Loop (PLL) is used to extract the clock by synching to the time between MARK to SPACE, SPACE to MARK toggles. Since, in an NRZI format, a long string of ONEs would provide no toggles, a method called "bit stuffing" is used to force a toggle if more than five ONEs are sent. This allows the PLL to remain locked, so it can continue to produce a valid clock signal for the receiving SCC. The bit stuffing is performed at five consecutive ONEs to allow a unique Header byte to frame the message (bit stuffing is not applied to the header). The header is the same as used by SDLC, logical 0111,1110. Due to bit stuffing, this 0111,1110 pattern cannot appear in the data or CRC part of the message. The receiver strips the inserted zeros when the data is decoded. After manipulating the MICROLOK II and local data into the track protocol, the MCU keys the data out through the Modulation Numerically Controlled Oscillator (NCO). The Modulation NCO and four other NCOs take a 1.8432 MHz clock and directly synthesize the necessary audio frequency signals, under software control. The Modulation NCO is programmed with two frequencies that are 20 times higher than the desired MARK and SPACE frequencies. The MCU then uses a discrete I/O line to select the frequency needed for the present data bit. 3.3.1 Message Verification To ensure that the proper message is being sent at all times (even when track occupancy is stopping the receiver from picking up the transmitted message), a frequency monitor circuit is used to check that each bit has the correct frequency. The uniqueness of the signal is contained in a complex digitally coded message, instead of in a simple periodic code rate, which could be falsely generated by an oscillating circuit. Because of this complex code, no further checking is needed downstream since the "unintelligent" power circuits could never oscillate in a manner so as to produce a valid message. The bit frequency check also serves to detect faulty time bases in either the MCU internal clock synthesizer or in the 1.8432 MHz clock Integrated Circuit (IC). From the Modulation NCO, the carrier passes through a digital Pulse Width Modulator (PWM) controlled by the MCU. This PWM divides the incoming square wave into 20 equal parts, and asserts the output for 1 to 19 of the 20 parts. This results in a pulse train with a 5 to 95 percent duty cycle and a frequency of one tenth that of the incoming square wave. The MCU uses this duty cycle control to make fine adjustments to the transmitted signal level. The duty cycle is selected when the track circuit is set up via a menu option on the controller PCB. The selected value is saved to the motherboard-mounted EEPROM. The output of the PWM is sent to the auxiliary PCB. On the auxiliary PCB, the carrier is applied to a flip-flop, which divides the frequency in half and provides two opposing phase signals as its output. These signals are applied to a pair of high-current, high-speed Field Effect Transistor (FET) drivers, which boost the signal up to the levels needed to properly drive the four power MOS FETS that form the full bridge power amplifier. The power amplifier gets its "B+"
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(approximately 44V dc) from an onboard rectifier and voltage regulator. A nominal 48V ac for this supply comes from transformers mounted on the rear of the cardfile. These transformers isolate and step down the 120V ac mains. Two transformers are used for each controllerauxiliary PCB pair (8 per cardfile) to provide good power supply margins. The output of the power amplifier is fed to the output transformer. This transformer has five secondary taps which provide coarse transmitter level adjustment. The transformer also has an auxiliary winding which is used to monitor the transmitter output level. When transmitting a BFSK message, the signal has almost a constant power output. To ensure that the transmitted level does not increase (due to a failure of the B+ regulator, the PWM, or anything else) the signal from the monitor winding of the output transformer is rectified and averaged. The resulting DC voltage is read by the MCU Analog to Digital Converter and checked to make sure that it falls within a preset value. If the voltage is outside of this range, the track circuit Clear Signal is dropped, and the unit transfers control to the standby unit. The range for the power amplifier monitor is set during unit configuration. After the track circuit has been properly adjusted, the Installer selects a menu command which measures the voltage coming from the power amplifier monitor, adds a fixed tolerance to it, and vitally stores this range (window) away to EEPROM. The taps of the output transformer secondary are selected using jumpers on the motherboard, so that when a PCB is replaced no adjustments are necessary, except for signal level calibration. On the common side of the secondary is a relay, which can isolate the output from the rest of the system. This form "C" relay is wired to use only the normally open contact set. The relay is controlled by switched power from the CPS so that if the CPS is dropped, the contacts open. The switch is used to allow the contacts to be open when the CPS is up. This is necessary so that the off-line unit may run diagnostic tests on its transmitter circuits. The switch is controlled by the MCU via an I/O port, which also drives the seven LED indicators on the auxiliary PCB. After leaving the cut-out relay and selector taps, the two output leads are routed through a set of direction relays. These are Hengstler safety-style relays with check contacts that indicate the status of the main contacts. If the check contacts are closed, then the main contacts are guaranteed to be open. By monitoring the check contacts, the controller PCB ensures that only the correct direction relay is energized. 3.3.2 Equipment Room To Rails From the relay/equipment room, track leads of up to several kilometers total loop length connect the trackside coupling units to the direction relays. The track leads are twisted pairs with an intrinsic impedance (Zo) of approximately 100 ohms. The coupling units are housed in weather tight enclosures, and consist of two totally independent and isolated coupling circuits. Each circuit has its own transformer and capacitor bank. The transformer steps down the high voltage on the leads from the relay room to a low voltage suitable for driving the single turn track loop. The capacitors are jumper-selected to tune the track loop. This tuning raises the reactance of the track loop to the selected carrier frequency. This raises transmitter efficiency since smaller currents are required to flow in the long track leads. Likewise, when a track loop has been selected to be a receiver, the low voltage from the track
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loop is stepped up to drive the leads back to the relay room. The tuning of the track loop provides a small increase in received signal strength. Due to the differences in transmitter and receiver impedance, the coupling unit is adjusted, so as to provide some benefit to both transmitter and receiver. The tuning is necessarily very broad and does not result in any appreciable frequency selectivity between the jointless track circuits. The AF-902/904 does not use a conventional impedance bond. Instead, a few meters of 350 or 500 MCM cable is connected between the two rails in an "S" shape, with an end of the "S" bonded to each rail. Single turn track loops are mounted inside of the upper and lower parts of the "S." Currents circulating in the transmitting track loop are induced into the "S" and onto the track. Likewise, currents from the track circulate in the "S" and are induced into the receiving track loop. This type of bond has a strong directionality, with the ratio of the length to the width of the "S" determining the directivity (like the front to back ratio on an RF directional antenna). Which track loop does the transmitting or receiving is determined by the direction relays located on the rear of the cardfile.
3.4 TRAIN DETECTION

Each AF-902/904 system vitally monitors the status of a single track circuit. The FM, audio frequency carrier that is transmitted at one end of the track circuit and received at the other end, is used not only for the digital cab signal data, but also for train detection. The carrier level and a part of the digital message are monitored by the receiver to determine track occupancy. When a train shunts the rails of the monitored track circuit, the signal is blocked. This condition is recognized by the receiving AF-902/904 circuits as a drop below a preset signal threshold, and is reported to the associated interlocking MICROLOK II system as an occupied circuit. While the shunting train bridges adjacent track circuits, both are reported as occupied. When the train clears a track circuit, the received signal threshold is restored and the AF-902/904 system responds accordingly. 3.4.1 Signal Level Sensing From the selected receive cable, the returning signal passes through a disconnect relay before being applied to the receiver transformer. This relay is also wired to operate in a normally open manner, and is closed only when the CPS for the unit is up and the MCU has switched on the relay. The receiver disconnect relay is controlled by the same switched CPS power as the transmitter disconnect relay. A single relay could not be used due to the safety requirement of preventing a direct short between the transmitter and receiver. The receiver transformer has five taps. These taps allow the AF-902/904 to be adjusted for different operating conditions, such as track lead length, direct inject vs. bond injection, and loop driving without a bond. The selected tap is clamped by a tranzorb to protect the receiver circuits.
3.5 MONITORING AND FAILOVER

Since the AF-902/904 track circuit unit is an interface between the MICROLOK II system and the trackside equipment, it is necessary to monitor the vital communication data and hardware
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performance. This requires that the communications between the MICROLOK II unit and the AF-902/904 unit is functioning properly and that the internal data processing of signals within the AF-902/904 is also functioning properly. This also requires that the data or signals levels to and from the rails are accurate and available to the cab. 3.5.1 MICROLOK II Monitoring The MICROLOK II unit acting as the protocol master monitors various aspects of the data communication link between the AF-902/904 unit and itself. AF-902/904 faults pertaining to incorrect message contents, message length, or response time will result in a system error and cause the message to be discarded. Additional fault details are described in Section 7. 3.5.2 AF-902/904 Monitoring The AF-902/904 unit must monitor the communications link between the MICROLOK II unit and itself, internal reliability, and the transmit and receive signals to the rails.
3.5.2.1 MICROLOK II RS-485 Communications Link
The following is a set of possible fault conditions that could be detected by an AF-902/904 system acting as a protocol slave unit. The faults pertain to master polling messages sent by the MICROLOK II unit to the AF-902/904 system. Timeouts If an AF-902/904 system does not receive a poll from the MICROLOK II in 3 seconds, it will declare the link to be down. If a CRC does not match for a message received from MICROLOK II, the AF-902/904 system will discard the invalid message. If a response message from the MICROLOK II is either too long or too short because of any data bytes or CRC mismatch, the incomplete message will be discarded.
CRC Mismatch
Incorrect Length
No Acknowledgment If an acknowledgment indication is not received by the AF 902/904 system from MICROLOK II, the AF-902/904 system will declare the link to be down.
3.5.2.2 AF-902/904 Cardfile Unit
Each AF-902/904 subsystem must pass its own continuous internal diagnostics. In the event of a failed vital diagnostic, the controlling microprocessor stops transmitting a 500 Hz vital signal to the subsystem CPS on the auxiliary PCB. When this signal is removed, the CPS shuts down, preventing cab signal data transmission and indications of a clear track. In AF-902 systems, if the primary track circuit controller fails, the backup track circuit automatically switches into operation. This automatic failover is transparent to the operation of the system.
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3.5.2.2.1 Transmit Data Monitoring To ensure that the proper message is being sent at all times (even when track occupancy is stopping the receiver from picking up the transmitted message), a frequency monitor circuit is used to check that each bit has the correct frequency. Because of this complex code, no further checking is needed downstream since the "unintelligent" power circuits could never oscillate in a manner so as to produce a valid message. The frequency check also serves to detect faulty time bases in either the MCU internal clock synthesizer or in the 1.8432 MHz clock IC.
3.5.2.3 Receiver Systems Monitoring
The AF-902/904 unit is constantly transmitting to the track circuit for occupancy or broken rail indications. These transmissions are also used to verify and monitor the accuracy and integrity of the data and signal levels. To ensure that the receiver systems are operating correctly, a test signal is added to the track signals just before the input BPF. This signal is of known frequency and amplitude and, as such, must fall within a fixed range when monitored on the designated test channel. All three receivers are checked by reprogramming their NCOs at the end of each message, in the following manner: Receiver Channel 1 2 3 Function at MSG1 Mark Space Test Function at MSG2 Space Test Mark Function at MSG3 Test Mark Space Function at MSG4 Space Mark Test Function at MSG5 Mark Test Space Function at MSG6 Test Space Mark
The source of the test signal is an NCO located on the auxiliary PCB. This NCO is set to a frequency other than that of the MARK or SPACE used in the track circuit. The NCO drives an analog switch that chops a DC voltage from the TEST Digital to Analog Converter (TEST DAC). By changing the TEST DAC output, amplitude of the test signal can be changed. Once the MCU has determined that the track circuit is clear, unoccupied and unbroken, it asserts the vital output on the MICROLOK II. The vitality of the output is accomplished by switching off the output transistor and measuring the output voltage. If more than a predetermined voltage (to account for leakage currents) is preset, the MCU shuts down the CPS. With the CPS dropped, there is no power source for the output circuit. All control and monitor lines to the vital output circuit are of very high controller PCB. This output switches CPS power OFF or ON to a vital input on the interlocking impedance, so they cannot pick or hold-up the MICROLOK II vital input. To ensure that the voltage measurement is accurate, a test voltage is summed in with the voltage on the vital output. By varying the known test voltage, a predetermined offset should occur in the measured voltage. If not, the gain check will fail and the MCU will drop the CPS.
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A non-vital, normally open disconnect relay allows the vital output to be tested on the standby unit. Power for the coil of this relay is provided by the CPS, so that a coil to contact short will not be able to assert the output when the CPS is dropped. As a check that this non-vital relay is closed when the unit is online, an independent non-vital circuit checks that when the vital output of the online unit is on, voltage is present on the line to MICROLOK II. A diode is used to isolate the relay from the wire to the MICROLOK II so that if the relay should fail to open, it will
not prevent the back up unit from driving the line. If both the relay and the diode fail, the system is still in a safe state since a low signal on this line indicates track occupancy.
3.5.3 Failover (AF-902 System Only) The CPS is a class 1 vital circuit that only produces power when a 500 hertz square wave is provided to it from the MCU. The MCU runs many complex diagnostic tasks on itself and on the rest of the AF-902 unit. These test range from testing of CPU memory and logic processing to full closed-loop tests of the vital output, transmitter and receiver circuits. If any of these diagnostics fail, the MCU stops toggling the 500 Hertz line and the CPS drops out. The CPS is the sole power source for the vital output, and the modulation oscillator clock source. When the CPS is dropped, the unit cannot transmit or indicate a clear track, no matter what the failure. The CPS also has a non-vital output which provides power for the disconnect relay coils, except for the relay that disconnects the vital output. The vital output relay gets its coil power from the vital supply, so that a coil to contact short will not be able to energize the circuit when the CPS is down. If the CPS is down, all coils lose power and the AF-902 unit drops off-line. The CPS interlock on the disconnect relays makes it very unlikely that a failed unit could keep its standby unit from restoring proper operation to the track circuit. However, even if a disconnect relay were to become welded in the closed state, the design of the circuits is such that no safety problems will arise since the CPS vitally removes power from the vital class 2 circuits. AF-902 units have been configured to provide full redundancy for each individual track circuit. Each 19-inch (48.26 cm) cardfile can house the electronics for two track circuits, with each track circuit having two controller/auxiliary PCB pairs and a common power supply PCB. The power supply PCB has two independent supply systems, with switches to cut the ac mains for each. Each supply provides +15V dc, +5V dc, -15V dc and a nominal 48V ac. The two-track-circuit cardfile is wired such that the two primary units are powered by one 120V ac main, and the two backup units are powered by a second independent 120V ac main. The left controller/auxiliary PCB pair of each track circuit is called the primary, and the right pair is called the backup. These terms refer to the physical placement of the PCBs. Whichever unit is operating the track circuit is called the online unit, the other unit is called the standby unit. This logical distinction is needed because a failed or powered-off primary unit could be replaced and/or powered up, without it becoming the online unit. The primary unit will remain the standby unit until either the power is cycled to both units or the backup unit fails. When the AF-902 units are simultaneously powered up and operating properly, the primary pair (left) is the online unit and the backup pair (right) is the standby unit. The hard-wiring on the motherboard determines which AF-902 unit is the primary unit and which AF-902 unit is the backup unit. The standby unit is up and running the same software as the primary unit, except that it is isolated by the disconnect relays. The two units communicate to each other through a
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dedicated serial link. Two DC lines cross link the primary MCU to the backup CPS, and the backup MCU to the primary CPS, to provide a second check on the health of each unit. A standby unit will not try to go on-line unless it is not receiving communications from the old online unit and it has detected that the old online unit CPS is dropped. If this happens, the standby unit will become the online unit, the old online unit will be off-line and the new online unit will inform MICROLOK II that the track circuit is not healthy. The health bit in the MICROLOK II message is only set when both primary and backup units are working properly. If the online unit stops receiving communications from the standby unit or detects that the standby unit CPS is dropped, it informs MICROLOK II that the track circuit is not healthy. A Maintainer should be dispatched to correct the problem whenever the health bit is not set.
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4 FRONT PANEL MENU OPERATION

4.1 INTRODUCTION
The front panel menu system of the AF-902/904 unit is used to modify and display vital and nonvital system parameters and to execute system functions. Any Operator can access any menu function, except for the configuration functions, which can be accessed only by authorized Operators. The operation of the switches is consistent across all functions.
4.2 FRONT PANEL DISPLAYS AND CONTROLS

The menu control system consists of two, four-character alphanumeric scrolling displays and four up-down SPDT toggle switches that are used to enter and examine data used in the set-up and operation of the track circuit. Five LEDs provide additional information. In addition, a front panel PC-compatible serial port and a background mode debugging port are available. The serial port can be made available to the end user, but the background port is for factory use only. Figure 4-1, Controller PCB Front Panel, shows the switches and displays as well as the corresponding names and identification. 4.2.1 Displays The display section is composed of two four-character alphanumeric displays and five LEDs. The upper display is red and the lower display is green. The upper display is wired so as to prevent an address decode failure. This wiring method prevents both displays from displaying the same data. There are four system monitoring LEDs on the controller PCB that are controlled by three different sources. These LEDs are mapped as shown in the following table: Controller LED W Significance when On WEST/NORTH/ NORMAL relay PICKED EAST/SOUTH/ REVERSE relay PICKED FAILOVER link GOOD CONFIGURATION MODE Significance when Off WEST/NORTH/ NORMAL relay DROPPED EAST/SOUTH/ REVERSE relay DROPPED FAILOVER link BAD ONLINE or STANDBY mode Significance when Flashing WEST/NORTH/ NORMAL relay PICKED TRACK SHUNTED EAST/SOUTH/ REVERSE relay PICKED TRACK SHUNTED N/A UNCONFIGURED or ERROR-TRAP mode
1 2
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W
DIR.
E
1 2
SYSTEM MONITOR LEDS
MODE
UP
ADJ
DOW N ESCAPE AUX 1
ENTER AUX 2

Figure 4-1 Controller PCB Front Panel
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4.2.2 Controls Each menu of the AF-902/904 system uses the control switches for the following purposes: Mode Up Mode Down Adjust Up Scrolls forward through selections or display parameters. Scrolls backward through selections or display parameters. Increases the current parameter. Where appropriate, when the maximum value is reached, the parameter rolls over to the minimum value. In the Display submenus, the Adjust Up switch is used to modify the display code. Decreases the current parameter. Where appropriate, when the minimum value is reached, the parameter rolls over to the maximum value. In the Display submenus the Adjust Down switch is used to modify the display code. Enters a submenu or confirms a parameter value. Backs out of a submenu or cancels an operation. Enters the blocking speed menu. This switch has no effect from the restricted access menus. (Same as Aux 2.) Enters the blocking speed menu. This switch has no effect from the restricted access menus. (Same as Aux 1.)
Adjust Down
Enter Escape Aux. 1 Aux. 2
4.3 FRONT PANEL OPERATION

On-site set-up of operating parameters is accomplished using the front panel controls and displays. Parameter adjustments available on the AF-902/904 system include: Unique 12 bit track circuit ID (number between 1 and 4095) Slave address for MICROLOK II serial link Transmit carrier frequency and signal strength Train detection threshold voltage Blocking Speed restriction (when required) New password
All of the parameter set-up functions, except Blocking Speed, are password-protected. Controller PCB displays and controls also permit real-time examination of data received from the track MICROLOK II system and the monitored track circuit, including:
Current line and target speeds Target distance
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State of berthing data bit States of east/west direction-of-travel data bits States of couple/uncouple data bits Next transmit frequency Current track circuit ID number Bifurcation bit
Detailed monitoring and diagnostics of the AF-902/904 logic and memory can be performed using a portable PC plugged into a 9-pin serial port on the front of the controller PCB front panel. The portable PC may use any standard terminal emulation software. 4.3.1 Front Panel Menu Interface The front panel menus are divided into two categories, restricted and unrestricted, based on access privileges. In addition to access restrictions, there are several other properties that characterize the operation of the AF-902/904 interface, including password entry, cardfile configuration, key repeat rate, key repeat delay, and time-out.
4.3.1.1 Restricted Access Menu
The Configuration submenu is a restricted access menu that can be used only by an authorized Operator to configure critical system parameters (restricted access parameters). Erroneous entry of restricted access parameters may cause the system to behave in an unsafe manner. It is therefore necessary that these parameters be configured only by qualified personnel. Restricted access parameters can be modified only after a password is entered, and the modified parameters can be made operational only after the password is reentered and all changes are confirmed. When an Operator enters the Configuration submenu, both the online unit and the standby unit suspend normal operations. The online unit suspends track transmission and MICROLOK II response, and all outputs on both units are put into a safe state. Normal operation resumes only after the system is reset.
4.3.1.2 Unrestricted Access Menus
Unrestricted access menus permit an Operator to perform functions that cannot result in unsafe system operation. All of the system submenus, except the Configuration menu, are considered unrestricted access menus.
4.3.1.3 Password Protection
In order to enter the Configuration menu and to save modified parameters, a password is required. Entering the password is similar to modifying the track ID number, and is described in Section 5.4.5.1. The default password can be modified via the Password Modification menu.
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4.3.1.4 Cardfile Configuration
When a restricted access parameter is changed, it must be changed to the same value in both the primary and backup units in an AF-902 system. The only exception is the Blocking Speed setting. This value is communicated between the primary and backup unit, with the most recently set value communicated to both units. If the primary and backup have different values at startup, the most restrictive (lowest) speed will be used by both units. Since the AF-904 does not have a backup unit, this function does not apply.
4.3.1.5 Key Repeat Delay
If a key is held in the same position for longer than the key repeat delay, it will begin to repeat at the key repeat rate. The key repeat delay is set to 2/5 second. The key repeat rate is set to 5 per second.
4.3.1.6 Time-out
To prevent unauthorized Operators from using the Configuration menu, the system will automatically time-out if this menu is active and 20 minutes have passed without the Operator pressing a switch. The system will automatically reset, and any changes that may have been made to the system parameters will be lost.
4.4 MENU HIERARCHY

The menus are arranged in a hierarchical manner. The Main menu is used to select various submenus, from which it is possible to display and modify specific system parameters. Figure 42, Menu System Hierarchy, at the end of this section, shows the menu hierarchy. The remainder of this section describes each menu. The hierarchy of the text in this section matches the hierarchy of the diagram. 4.4.1 Main Menu This menu is used to select a top level submenu. The following submenus are available from the Main menu: Display, Blocking Speed, Events, and Configuration. These submenus are described in more detail below. Since the Main menu is at the top of the hierarchy, the Escape switch has no effect from this menu. 4.4.2 Display Menu This menu contains submenus that can be used to display current system information. The following submenus are available from the Display menu: MICROLOK II Message, Track Message and System Parameters. The Escape switch will move out of any Display submenu.
4.4.2.1 MICROLOK II Message
This menu contains submenus that can be used to display the current message to MICROLOK II from the AF-902/904 and the current message from MICROLOK II to the AF-902/904.
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4.4.2.2 Track Message
This menu contains submenus that can be used to display the following information: Current message that is being delivered to the track by the AF-902/904 (Transmit menu). Level of the received signal as a percent of the threshold (Receive menu, Signal Strength (STR) submenu).
4.4.2.3 System Parameters
This menu can be used to display the current system parameters. The following parameters are displayed: block speed, MICROLOK II address, track ID, primary/ backup, frequency, configured transmit power West, and configured transmit power East. 4.4.3 Blocking Speed Menu This menu can be used to select the Blocking Speed Adjust submenu from which it is possible to set or modify a blocking speed. This menu also can be immediately reached from any unrestricted access menu by pressing the Aux Up/Aux Dn switch.
4.4.3.1 Blocking Speed Adjust Menu
This menu is used to set a blocking speed. The Adj Up/Adj Dn switch modifies the current value (the value displayed on the lower display), and the Enter switch is used to enter the value. The Operator must then confirm the value by pressing the Enter switch again, or reject the value by pressing the Escape switch to exit. 4.4.4 Events Menu This menu can be used to select a submenu from which it is possible to display events and manage the event logging system. The following submenus are available from the Events menu: View Events, Clear Events, and Dump Events.
4.4.4.1 View Events Menu
The View Events menu allows the maintainer to view in reverse order the event numbers logged by the AF-902 / AF-904 system.
4.4.4.2 Clear Events Menu
The Clear Events menu will erase all recorded event numbers from the AF-902 / AF-904 memory.
4.4.4.3 Dump Events Menu
Selecting the Dump Events menu will cause the event data to be transmitted to a serial data communications terminal connected to the front panel "DIAG PORT."
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4.4.5 Configuration Menu This menu contains submenus that are used to modify system parameters. The Password Entry submenu allows the user to enter the password. The Restricted submenu contains other submenus that allow the user to modify critical system data.
4.4.5.1 Password Entry Menu
This menu is used to enter and validate the restricted access password. The four-character password is entered one character at a time. The active character flashes, while inactive characters are displayed constantly. Initially, "AAAA" is displayed and the leftmost character is active. The Adj Up/Adj Dn switches are used to advance the active character through the elements of the password character set. The Enter switch selects the current value of the active character and activates the next character.
4.4.5.2 Restricted Menu
This menu is used to select a restricted access submenu. If the proper password has not been entered using the Password Entry menu, the submenus of the Restricted menu are not available. To enter the restricted access menus, the AF-902 / AF-904 will automatically go through a reset cycle. If there is a backup unit in an AF-902 system it must be turned off prior to entering the Restricted menu.. The following sections describe the submenus that are available from the Restricted menu. Exiting from the Restricted menu will cause the unit to reset. After the reset three menu selections are available: Set-up, Utility, and Accept. 4.4.5.2.1 Set-up Menu Selecting this menu, by pressing the Enter switch, will make four submenu selections available to the Maintainer: Tune, MICROLOK II, ID, and Calibration.
4.4.5.2.1.1 Tune Menu
The Tune submenu is used to configure the AF-902 / 904 for train detection and cab signaling. The Tune menu contains several sequential submenus that are to be used in conjunction with the track circuit set-up and tuning procedure. Due to the sequential nature of the tuning procedure, a menu item may have both a function and a submenu. The Frequency Adjust menus are used to change the carrier frequency in either the West to East or East to West signal transmission direction. The Adj Up/Adj Dn switches are used to modify the value that is displayed, and the Enter switch moves to the Power Output menu. The Power Output menus are used to adjust the power of the transmitter. The Adj Up/Adj Dn switches are used to modify the value that is displayed, and the Enter switch moves to the submenu.
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4.4.5.2.1.2 MICROLOK II Menu
This menu is used to select the MICROLOK II Address Adjust submenu, which can be used to change the MICROLOK II station address.
4.4.5.2.1.3 ID Menu
The Track ID menu is used to enter the track identification number (1 to 4095).
4.4.5.2.1.4 Calibration Menu
The Calibration menu is used to set the operating parameters of the AF-902 / AF-904 system. The function and use of each submenu is described in Section 6 of this manual. 4.4.5.2.2 Utility Menu This menu can be used to access two submenus: New Password and Clear Configuration (operating parameters).
4.4.5.2.2.1 New Password Menu
The New Password function allows the user to change the default password. The password is modified using the Adj Up/Adj Down switches, and the Enter switch sequentially confirms each character. The Escape switch backs up by one character or cancels the operation if the first character is displayed. After the password has been entered, the user is asked to confirm the value. A password that is modified and then confirmed immediately becomes the system password. The default password can only be restored by physically replacing the EEPROM on the motherboard.
4.4.5.2.2.2 Clear Configuration Menu
This function allows the maintainer to erase all configuration parameters of the AF-902/904 system. Attempting to operate the system after this selection is made will cause the system to enter the unconfigured mode. 4.4.5.2.3 Accept Menu This menu is used to confirm the changes that have been made to the restricted access system parameters. The Accept menu is a group of menus that sequentially prompt the maintainer to confirm the modifications that have been made to the system parameters. The parameter identifier is displayed first followed by the new value shown on both the top and bottom displays. The Operator must press either the Enter switch to confirm that both displays indicate the correct parameter or the Escape switch to abort the modification. After each modified parameter has been confirmed, a Password Entry menu is activated. This menu is similar to the menu described above. If the correct password is entered, the system parameters are written to the system EEPROM and will be used for all subsequent operation.
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MAIN MENU
BKSP MENU Denied Cancel bksp .35 SYS MENU
DISP MENU
EVNT MENU
CNFG MENU Cancel
Denied
MLOK MENU
T RK MENU
VIEW EVNT
CLR EVNT
DUMP EVNT
PSWD MENU Cancel
RSTR MENU Sure ? WAIT
CONF IRM
.35 .35
WAIT
bksp 35 Mlok 1 TkID 2199 Prim Yes Fr eq 13.5 Pwr W 10% PwrE 10%
RX MENU EW 10 Nxfq 15.5 TD 9000 LS 65 TS 65 Brth 0 Cpl 0 Ucpl 0 Bifr 0
TX MENU Bksp set Hlth ok Tr k ok Crsp 0
TX MENU EW 10 Nxfq 15.5 TD 9000 LS 65 TS 65 Br th 0 Cpl 0 Ucpl 0 Bifr 0
RX MENU Str xxx%
#17 0033 #16 0059 #1 0033
Done
Done pswd AAAA
Invalid
System Reset
System Reset
SET UP
UT IL MENU
ACPT MENU CONFIRM Mlok Addr 1 1 T kID
Done
Denied
Cancel
TUNE MENU
MLOK MENU Cancel addr 1
ID MENU Cancel T kID 2199
CALI BRAT Cancel freq 13.5 DIR W->E WAIT
NEW PSWD
CLR CNF G
Cancel pswd AAAA Sur e ?
AF-902 / AF-904 Menu System Navigation

A
DIR W->E Cancel freq 10.0
DIR E- >W Invalid Cancel fr eq 10.0
2199 2199 New Pswd AAAA AAAA Prim Bkup Prim Prim F req 13.5 13.5 Pout W->E
Invalid
Move from menu "A" to menu "B" by depressing the "Enter" switch
pwr 10% DIR E- >W
Denied
Move from menu "B" to menu "A" by depressing the "Escape" switch
WAIT
WAIT
WAIT
pwr 10%
Denied
pwr 10%
Denied
pwr 10% Levl 95% Var i 2%
Denied
Move "left/r ight" with the "Mode - Up" and "Mode - Down" switches A dashed line indicates the move will happen automatically when the task is completed
WAIT
WAIT
Denied 10% 10% Pout E->W 10% 10% pswd AAAA
Denied
Denied Shnt 70% DIR W- >E
A 0 B 0
Move between stacked information menus with the "Mode - UP" and "Mode - Down" swi tches
WAIT Levl 98% Vari 2% Shnt 70% WAIT ACCEPT ( To Accept Menu) Denied Denied
Note: When a menu al lows a value to be adjusted, press the "ADJ - Up" to increase the value and "ADJ - Down" to decrease the value.
Denied
Invalid Denied
WAIT Done
Figure 4-2, Menu System Hierarchy SM8051, 4-9, 4-10
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5 INSTALLATION AND ADJUSTMENT

5.1 INTRODUCTION
The track circuit installation and adjustment depends on the assigned block frequency and track coupling methods. Installation procedures should be in accordance with those recommended by the equipment manufacturers for any equipment that is interfacing with the AF-902/904 unit. Each installation requires cable interfacing for the assigned system. Refer to the specific site plans for detailed installation and track coupling requirements such as track circuit lengths, frequency assignments, track circuit identifications, and wiring sheets.
5.2 RECOMMENDED TEST EQUIPMENT

The following equipment is recommended for use in testing the AF-902/904 unit: A Fluke 8060A with a Fluke 80i-1000s Current Transformer calibrated for the measurement range of 40-150ma ac (rms) and documented. AAR Style 1/2 in. hex socket wrench used for loosening/tightening AAR standard terminal posts. Red tags for identifying failed PCBs. Two VOLTREX 855-B Insulated Tip Plugs for PCB Front Panel test probes. Handheld radios with 2-mile (3.2 km) range minimum.
5.3 SERIAL LINK CONFIGURATION

Typically, a MICROLOK II communicates to multiple AF-902/AF-904 units through a multidrop RS-485 link. Terminating resistors must be connected at the physical end of the link, i.e. at the AF unit farthest from the MICROLOK II. Connecting the terminating resistors at the end unit is accomplished by closing the four SW1 rocker switches located on the back of the AF motherboard (refer to Figure 5-1). Otherwise, the four SW1 rocker switches should remain open.
5.4 INITIAL POWER CHECKS

Because of the large dynamic range imposed by the needs of different track circuits, the AF902/904 Control cardfile incorporates five adjustable transformer taps for both track receiver circuits. These allow for variables such as different track lead lengths. Adjustments are made via jumpers on the cardfile backplane so that a system reset is not required with changeout of the track interface circuitry. Output power is varied by two means:
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Coarse: Output Transformer Taps (1 through 5) on back of the AF-902/904 motherboard. Taps act to double output amplitude with each increased setting. (TXA= Primary; TXB = Backup) Fine: Pulse width, the "ON" duty cycle percentage of a Full Cycle. Set from front panel 'PWR' menu.
5.5 TUNING PROCEDURE

Installation of the track circuit requires a "set-up" procedure. This procedure is comprised of two alignment procedures. The first of these procedures is called the "tuning procedure." Tuning is performed first, in order to tune the two associated coupling units to the desired track circuit frequencies. These frequencies range from 9.5KHz to 16.5KHz in l kHz increments. Specific steps and details of the tuning procedure are given in Table 5-3.
5.6 CALIBRATION PROCEDURE

The second of the "set-up" alignment procedures is called the "calibration procedure". This procedure must be performed after the tuning procedure, since it is affected by the resulting tuning signal levels. Specific steps and details of the calibration procedure are given in Table 5-4. Tuning is done at the coupling units mounted near the track bond. The coupling unit contains two identical circuits, which are separated by a dashed line down the middle of the PCB. The Operator should take care in determining which of these circuits is to be tuned before proceeding. NOTE The following procedures distinguish the two identical circuits by using standard text for the left unit circuit, and {BRACKETS} for the {RIGHT UNIT} circuits. Tuning affects both the transmitted and received signal levels, making it MANDATORY that the tuning procedure be performed first as part of the set-up routine. For preventive maintenance purposes, since the system is operational and tuning has been completed at some earlier date, calibration alone can be performed as the sensitivity check. However, if calibration is marginal, it may be necessary to perform both the tuning procedure and calibration procedures.
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5.6.1 Testing Codes and Abbreviations

5.6.1.1 Controller Board Display Abbreviation Codes
Basic character and case assignments used for performing the test procedures are as follows: [AAAA] [Aaaa] [BKSP] [MLOK] [TUNE] [Levl] [CALI] [BRAT] [Shnt] [MLOK] [aaaa] [ID] [tkid] [PSWD] [pwr] [RSTR] Upper Menu or Command Label Parameter Block Speed MICROLOK II Tuning Procedure Input Rec Level Calibration Procedure Shunted w.r.t./Levl MICROLOK II Address Set Menu Changeable Parameter Track Circuit ID Set Menu Track Circuit ID Parameter Password Output Pulsewidth Restricted Menu
5.6.2 Test Equipment And Tools The equipment and tools required for the tuning and calibration procedures are listed below. The Test Engineer should select the appropriate tools for the required test procedure.

An HP3560A Dynamic Signal Analyzer with a Fluke 80i 1000s, Current Transformer calibrated for the measurement range of 40-150ma ac (rms) and documented. AAR style 1/2 inch hex socket wrench, used for loosening and tightening AAR standard terminal posts. Red tags for use in identifying failed PCBs or components. Two VOLTREX 855-B Insulated Tip Plugs for PCB front panel test probes. Handheld radios with a 2-mile (3.2 km) range minimum.
Track Shunt 0.25 ohms total resistance. The track shunt resistor itself is 2 ohms and the leads to the rails are 0.05 ohms.
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5.6.3 Transmit Power Adjustments During the test procedure, it may become necessary to adjust the output power in order to meet specifications. Output power can be varied by two means: Coarse: Referring to Figure 5-1 AF-902/904 Upper Cardfile Rear Views, the Output Transformer Taps (1 through 5) on back of the AF-904/904 motherboard are selected by means of jumper wires connected between the numbered taps and Signal Common points (labeled COM for AF-902, and R1 through R4 and T1 through T4 for AF-902). Taps act to double the output amplitude with each increased setting. (TXA=Primary; TXB=Backup) Pulse width, the ON duty cycle percentage of, in 5% increments from 25 to 95% of Full Cycle. This is set from the front panel 'pwr' menu. It is done during the calibration
procedure, and can be done only after the Operator has traversed the Configuration menu with the correct password. There is a separate pulse width setting for each direction of track circuit transmission. After these are SET and ACCEPTED, they are stored in EEPROM.
.
5 4 3 5 4 3 2 1 T4 TRACK 4 5 4 3 2 1 R3 TRACK 3 5 4 3 2 1 T3
1 1
Fine:
J4
RX4
RX3
RX2
RX1
TX4
TX3
TX2
TX1
5 4 3 2
5 4 3 2 1 T2 TRACK 2
5 4 3 2 1 R1 TRACK 1
5 4 3 2 1 T1
TRK3&4
J2
TRK1&2
J1
1
2 1 1 R4
J3 SW1
1 R2
AF-904 Upper Cardfile Rear View
5 4 3
5 4 3 2 1 COM
5 4 3 2 1
5 4 3 2 1 COM
J4
RXB
RXA
TXB
TXA
TXB
TXA
RXB
RXA
5 4
5 4 3 2 1 COM
5 4 3 2 1
5 4 3 2 1 COM
TRK2
J2
TRK1
J1
1
3 2
2 1 1
J3 SW1
AF-902 Upper Cardfile Rear View
Figure 5-1 AF-902/904 Upper Cardfile Rear Views
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5.6.4 Set-up Overview There are several parts to the set-procedure, as described in the following subsections.
5.6.4.1 350 or 500 MCM Bond Set-Up Procedure
To set-up the AF-902/904 using a 350 or 500 MCM Bond in either an "S" or "O" configuration, follow the procedure given in Tables 5-1, 5-2, 5-3 and 5-4, and use the Data Sheet at the end of this section. Setting the MLOK address and the track circuit ID (Table 5-2) can be performed at any time in the sequence. Tuning (Table 5-3) must be performed before calibration.
5.6.4.2 Cab Loop Set-up Procedure
Follow the procedure in Tables 4-1 and 4-5, and use the data provided at the end of this section. Setting the MLOK address and track circuit ID (Table 5-2) can be performed at any time in the sequence. The AF-902/904 performs track signal transmission only.
5.6.4.3 Direct Inject Track Circuit
For setting-up the AF-902/904 using a track cab loop, follow the procedure in Tables 5-1, 5-2, and 5-6, and use the Data Sheet at the end of this section. Tuning is not required for a direct inject circuit.
5.6.4.4 System Reset
Upon power-up or reset, the unit goes through reset, tests RAM, tests PROM, initializes the system, reads configuration from EEPROM, checks standby communications to determine its primary/standby status, then goes to [MAIN] [MENU]. If the unit has been calibrated, it will then begin to transmit and operate. All of the procedures require that the Operator first go to the [CNFG] [MENU] from the [MAIN][MENU] and enter the proper password. Once the password is entered, the unit enters the [SET] [UP] menu. This initial procedure is detailed in Table 5.1. From there, the track circuit can be tuned and calibrated, and the MICROLOK II address and track ID can be set.
5.6.4.5 Tuning Test Procedure
NOTE Words in single [BRACKETS] are exact display output characters for the specific step.
A. Set Receiver RXA and RXB, and Transmitter TXA and TXB Taps, to position 3 on the back
of the cardfile motherboard. B. Power-up the primary and backup units. C. Input the front panel menus as described in the set-up and test procedures.
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5.7 AF-902/904 TRACK CIRCUIT SYSTEM SET-UP AND TEST

Table 5-1. Entering The AF902/904 Restricted Menu For Set-Up Restricted Menu Access Procedure From [MAIN][MENU] press ENTER Toggle MODE to [CNFG][MENU] Press ENTER for [PSWD][MENU] Press ENTER for [pswd][AAAA] ADJUST characters and ENTER Unit enters [RSTR][MENU] Press ENTER. If pswd is OK, unit goes through Reset and into [SET ][ UP ]
Table 5-2. AF-902/904 MLOK Address and Track Circuit ID Settings Step 1 Setting the MLOK Address Obtain track circuit MLOK address from hardware drawings. Traverse restricted menu as described in Table 5-1. [SET ][ UP ] Press ENTER for [TUNE][MENU] Toggle MODE to [MLOK][MENU] Press ENTER for [addr][ xx] ADJUST addr (1-31) 3 Press ENTER for [MLOK][MENU] Press ESCAPE for [SET ][ UP ] Toggle MODE to [AC- ][CEPT] Press ENTER for [CON-][FIRM] 4 Press ENTER to scroll through all parameter settings. * Accept by pressing ENTER. * Reject by pressing ESCAPE. Setting the Track Circuit ID Number Obtain track circuit ID from Control Line drawings. Traverse restricted menu as described in Table 5-1. [SET ][ UP ] Press ENTER for [TUNE][MENU] Toggle MODE to [ ID ][MENU] Press ENTER for [tkid][xxxx] ADJUST tkid (0-4095) Press ENTER for [ ID ][MENU] Press ESCAPE for [SET ][ UP ] Toggle MODE to [AC- ][CEPT] Press ENTER for [CON-][FIRM] Press ENTER to scroll through all parameter settings. * Accept by pressing ENTER. * Reject by pressing ESCAPE.
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Step
Setting the MLOK Address
Setting the Track Circuit ID Number
If all parameters are CONFIRMED, unit If all parameters are CONFIRMED, unit will will write set-up parameters to EEPROM write set-up parameters to EEPROM and and [DONE] [DONE] Press ENTER for system reset. Record track circuit MLOK Addr on Track Circuit Data Sheet Press ENTER for system reset. Record track circuit ID on Track Circuit Data Sheet
5.7.1 AF-902/904 350 or 500 MCM Track Circuit Set-Up For set-up of an AF-900/904 350 or 500 MCM track circuit, proceed with Table 5-3 and 5-4.
Table 5-3. Af-902/904 350 or 500 MCM Tuning Instructions Step 1 AF-900 Operator Obtain track circuit frequency, (Fc) from Control Line Drawings. Track/Coupling Unit Technician(s) Set both coupling units to nominal capacitor setting vs. frequency from Table A
Traverse restricted menu as described in Table Verify that coupling unit JMP9 5-1 to {JMP16} is set to NORM position. 2 [SET ] [ UP ] Press ENTER for [TUNE][MENU] 3 Press ENTER to automatically set direction of signal travel (West to East) Press ENTER for [freq][ 0.0] 4 Toggle AUX to set frequency to Fc-400. Press ENTER for [pwr ][ xx%] Set pulsewidth to [pwr ][ 50%] Unit is now transmitting. 5 6 Record final capacitance (W->E) on Track Circuit Data Sheet. Press ENTER to automatically set direction of signal travel (East to West) Using Fluke Scopemeter 97 in V ac mode Monitor voltage at: TP2 and TP1 {TP5 and TP6}. Tune EAST coupling unit. Vary capacitance with JMP1-JMP8 {JMP10-JMP17} to peak voltage across: TP2 and TP1 {TP5 and TP6}
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Step
7
AF-900 Operator Press ENTER for [freq][ 0.0] Toggle AUX to set frequency to Fc-400. Press ENTER for [pwr ][ xx%] Set pulsewidth to [pwr ][ 50%] Unit is now transmitting.
Track/Coupling Unit Technician(s) Tune WEST coupling unit. Vary capacitance with JMP1-JMP8 {JMP10-JMP17} to peak voltage across: TP2 and TP1 {TP5 and TP6}
8 9
Record final capacitance (W->E) on Track Circuit Data Sheet Press ENTER to complete tuning sequence and return to [TUNE][MENU]
Table 5-3A Coupling Unit (Nominal Capacitance Setting) Note: Final tuned settings will be nominal +/- 2.0 F (micro farads). Freq.(Fc) NOM. CAP. 9.5KHz 10.5 11.5 12.5 13.5 14.5 9.47 F 15.5 16.5 20.0 F 17.33 F 15.00 F 13.00 F 11.00 F 8.47 F 7.33 F
Table 5-4. AF-902/904 350 or 500 MCM Calibration Procedure Step 1 AF-902/904 Operator Obtain track circuit frequency, (Fc) from Control Line Drawings. Traverse restricted menu as described in Table 5-1 to 2 [SET ] [ UP ] Press ENTER for [TUNE][MENU] Toggle MODE to [CALI][BRAT] Press ENTER for [freq][xx.x]
ADJUST frequency to Fc.
Track/Coupling Unit Technician(s)
Press ENTER to automatically set direction of signal travel (West to East) 3 Press ENTER for [pwr ][ xx%] Unit is now transmitting.
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Step
AF-902/904 Operator Select appropriate transmitter tap and ADJUST [pwr ][ xx%] to set Irail for W to E. (For Irail setting, refer to Table 5-4B or Table 5-4C)
Track/Coupling Unit Technician(s) Using the HP3560A in V ac (rms) mode with the 80i-1000s Current Transformer (x100), attach Probe to Center of 350 or 500 MCM Bond and monitor/report rail current (Irail) at East track bond.
5 6
Record Irail, transmitter tap and pwr for NOTE: At cross-bonding points, the S-bond is W->E on Track Circuit Data Sheet. doubled. The resulting Irail is the sum. Press ENTER to automatically set Move to West track bond. direction of signal travel (East to West) Using the HP3560A in V ac (rms) mode and ADJUST [pwr ][ xx%] to set Irail for E the 80i-1000s Current Transformer (x100), attach Probe to Center of 350 or 500 MCM to W. Bond and monitor/report rail current (Irail) at (For Irail setting, refer to Table 5-4B or West track bond. Table 5-4C) Record Irail and pwr on Track Circuit Data Sheet. Press ENTER for [Levl][ xx%] Set Receiver tap that produces lowest Levl within range of 18% < Levl < 77% Record receiver tap and Levl for E->W on Track Circuit Data Sheet Press ENTER for [Vari][ x%] Record [Vari][ x%] for E->W < Vari is the MAX variance of < Fm or Fs from Fc and should be within 0-7%. < Shnt displays received level < w.r.t. shunt threshold. Press ENTER for [pwr ][ xx%]
10
Press ENTER for [Shnt][151 - 171%] Record [Shnt][151 - 171%] for E->W when unshunted.
11 12
Note: When SHUNT applied, check that [Shnt][ xx%] < 100%. Record [Shnt][ xx%] when shunted Press ENTER to automatically set direction of signal travel (West to East)
Apply 0.2ohms shunt to track at center of West Bond.
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Step
AF-902/904 Operator Press ENTER for [Levl][ xx%]
Track/Coupling Unit Technician(s)
13
Check that 20% < Levl < 80% Record [Levl][ xx%] Press ENTER for [Vari][ x%] Record [Vari][ x%] for W->E Press ENTER for [Shnt][151 - 171%] Record [Shnt][151 - 171%] for W->E when unshunted.
14
NOTE: When SHUNT applied, check that [Shnt][ xx%] < 100%. RECORD [Shnt][ xx%] when shunted Press ENTER for [AC- ][CEPT] Press ENTER for [CON-][FIRM]
Shunt track w/0.2ohms at East Bond.
15
Note: During accept mode, parameter values will be written to both displays. DO NOT ACCEPT if display values differ.
Press ENTER and scroll through all parameter settings. * Accept by pressing ENTER. * Reject by pressing ESCAPE. If all parameters are CONFIRMED, unit will write set-up parameters to EEPROM and [DONE]. Press RESET button for system reset. After reset, system LEDs should show by being lit: CPS ACTIVE, ON-LINE, SELF, MLOK COMM, LEVEL, DATA
16
Table 5-4B Rail Current Settings (350 MCM, 500 MCM, and Cab Loop Circuits) Nominal Irail current +/- 2 mA. Freq.(Fc) kHz 9.5 kHz NOMINAL IRAIL (mA)
105
10.5
95
11.5
87
12.5 80
13.5
75
14.5
70
15.5
65
16.5
60
Table 5-4C Rail Current Settings (Direct Inject Circuits) Nominal Irail current +/- 2 mA. Freq.(Fc) kHz 9.5 kHz NOMINAL IRAIL (mA)
210
10.5
190
11.5
175
12.5 160
13.5
150
14.5
140
15.5
130
16.5
120
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For the AF-902, power down the primary unit and repeat the calibration procedure for the backup unit. NOTE Backup unit must have same MLOK Address, TRK ID, Fc, password and Exec. software version as the primary unit. Table 5-5. AF-902/904 Cab Loop Track Circuit Set-Up Step AF-902/904 Operator Traverse restricted menu as described in Table 5-1 to [SET ] [ UP ] 1 Press ENTER for [TUNE][MENU] The AF902/904 does not receive a signal back Toggle MODE to [CALI][BRAT] from the track. Press ENTER for [freq][xx.x] ADJUST freq. to [freq][16.5] 2 Press ENTER for [DIR ][W->E] Press ENTER for [pwr ][ xx%] Check cab loop wiring to insure proper connections. AF902/904 signal wire to 1,2 {4,5} Cab loop wire to 7,8 {10,11} Select appropriate transmitter tap and ADJUST [pwr ][ xx%] to set ICabloop to 275mA for Cab loop. 3 Record Iloop, transmitter tap and pwr for CAB LOOP on Track Circuit Data Sheet. Press ENTER for [DIR ][E->W] Check cab loop wiring to ensure proper connections. AF902/904 signal wire to 1,2 {4,5} Cab loop wire to 7,8 {10,11} Press ENTER for [pwr ][ xx%] 7 ADJUST [pwr ][ xx%] to the same pwr value set in step 3. Check that the ICabloop > 250mA. Using the HP3560A in V ac (rms) mode with the 80i-1000s Current Transformer (x100): Attach Probe to Cab loop wire and monitor/report loop current (Icabloop) to TCCB. Using the HP3560A in V ac (rms) mode with the 80i-1000s Current Transformer (x100), attach probe to cab loop wire and monitor/report loop current (Iloop) to the Train Control and Communications Building (TCCB). If location is a double crossover, proceed to other cab loop. Track/Coupling Unit Technician(s) Note: All cab loops employ a single coupling unit located at the transmit end.
4 5 6
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Step 8
AF-902/904 Operator Record Icabloop and pwr on Cab Loop Circuit Sheet. (see NOTE ->> ) Press ENTER to scroll through remaining menus to: [AC][CEPT]
Track/Coupling Unit Technician(s) Note: Connect VOLTREX jumper wires from auxiliary PCB transmitter outputs to Rec. inputs Note: During accept mode, parameter values will be written to both displays. DO NOT ACCEPT if display values differ.
(Disregard Levl, Vari and Shnt readings, see NOTE ->> ) Press ENTER for [CON-][FIRM] Press ENTER and scroll through all parameter settings. * Accept by pressing ENTER * Reject by pressing ESCAPE If all parameters are CONFIRMED, unit will write setup parameters to EEPROM and [DONE] Press RESET button for system reset. Note: After reset, system LEDs should show by being lit: CPS ACTIVE, ON-LINE, SELF, MLOK COMM,(LEVEL & DATA off)
10
Table 5-6. AF-902/904 Direct Inject Track Circuit Set-Up Step AF-902/904 Operator Proceed step by step with the calibration procedure in Table 5-4. Track/Coupling Unit Technician(s) Proceed step by step with calibration procedure in Table 5-4. Exception Notes: (STEP 4 & STEP 8) Check coupling unit wiring. AF902/904 signal wire to 1,2 {4,5} Track Inject wire to 6,8 {9,11} Irail settings to be done with 0.20 ohm shunt in place across rail at receive end. Current transformer on shunt.
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5.8 TEST DOCUMENTATION AND DATA SHEETS

The results of the set-up and test procedures must be fully documented, using the approved circuit plans and the test data sheets. For specific information concerning a particular locations AF-902/904 installation, refer to that locations circuit drawings, book of plans, test record sheets, and any other installation data that may be available. The type of information that is available may vary and is dependent upon the railroad or transit authoritys record keeping policy. The approved circuit test plans are used to record the results of the set-up procedure. A circuit that has been tuned only should be checked in blue. A circuit that has been both tuned and calibrated should be checked in green. If corrections to the circuit plans are required as a result of any procedure, the Test Engineer should document the changes using Yellow=Out and Red=In color coding. In addition, the Test Engineer is required to initial and date the changes and to further document the changes by using the Standard Discrepancy/Action Item List to fully describe the discrepancy and the action taken. The data sheets provided on the following pages are to be used to record the results of the tests. The top portion of the data sheet should be filled in before beginning the test. As part of this, the Test Engineer should record the track circuit length and the approximate cable length from the TCCB to the nearest coupling unit.
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AF-902 Track Circuit Data Sheet Location __________________________________________________________ Track Circuit Length (100-1000 ft, 30-305 m)_______________Feet/Meters Cable Length to Nearest Bond (100-1000 ft, 30-305 m)________Feet/Meters Track Circuit ID# (1-4095)______________ MLOK Address (1-127)__________ Tuning Procedure Frequency (kHz) Direction Coupling Unit Capacitance 9.5 10.5 11.5 West to East ___________________________F Calibration Procedure Transmitter Tap Setting Direction AF-902 Unit [pwr] Pulse Width (20% - 95%)
12.5
13.5
14.5
15.5
16.5
East to West ___________________________F
1 Primary
2 West to East Backup
4 East to West Primary
5 Backup
____________%
____________%
____________% ___________mA 4 ____________% 20-80% ____________% 0-7% ____________% 151 - 171% ____________% < 100%
____________% ___________mA 5 ____________% 20-80% ____________% 0-7% ____________% 151 - 171% ____________% < 100%
RAIL(mA)
___________mA ___________mA 1 2 3 ____________% 20-80% ____________% 0-7% ____________% 151 - 171% ____________% < 100%
Receiver Tap Setting Receiver Level [Levl] [Vari] Shunt Level [Shnt] Unshunted [Shnt] Shunted
____________% 20-80% ____________% 0-7% ____________% 151 - 171% ____________% < 100%
Inspector___________________________________________ Date____________________
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AF-902 Cab Loop Data Sheet Location __________________________________________________________ Cable Length to Cab Loop Coupling Unit (100-1000 ft, 30-305 m)_____Ft/m Track Circuit ID# (1-4095)____________ MLOK Address (1-127)___________ Calibration Procedure Frequency (kHz) Transmitter Tap Setting Direction AF-902 Unit [pwr] Pulse Width (20% - 95%)
9.5 1
10.5
11.5 2 West to East
12.5 3 Backup
13.5
14.5 4
15.5
16.5 5
East to West Primary Backup
Primary
____________%
____________%
____________% ___________mA
____________% ___________mA
CABLOOP(mA) 250mA < I < 300mA Receiver Tap Setting
___________mA ___________mA
3 (Not Applicable)
Inspector___________________________________________ Date____________________
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AF-904 Track Circuit Data Sheet Location __________________________________________________________ Track Circuit Length (100-1000 ft, 30-305 m) _______________Feet/Meters Cable Length to Nearest Bond (100-1000 ft, 30-305 m)________Feet/Meters Track Circuit ID# (1-4095)______________ MLOK Address (1-127)__________ Tuning Procedure Frequency (kHz) Direction Coupling Unit Capacitance 9.5 10.5 11.5 West to East ___________________________F Calibration Procedure Transmitter Tap Setting Direction [pwr] Pulse Width (20% - 95%)
12.5
13.5
14.5
15.5
16.5
East to West ___________________________F
2 West to East
4 East to West
____________% ___________mA 1 2 ____________% 20-80% ____________% 0-7% ____________% 151 - 171% ____________% < 100% 3
____________% ___________mA 4 5
RAIL(mA)
Receiver Tap Setting Receiver Level [Levl] [Vari] Shunt Level [Shnt] Unshunted [Shnt] Shunted
____________% 20-80% ____________% 0-7% ____________% 151 - 171% ____________% < 100%
Inspector___________________________________________ Date____________________
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AF-904 Cab Loop Data Sheet Location __________________________________________________________ Cable Length to Cab Loop Coupling Unit (100-1000 ft, 30-305 m)_____Ft/m Track Circuit ID# (1-4095)____________ MLOK Address (1-127)___________ Calibration Procedure Frequency (kHz) Transmitter Tap Setting Direction [pwr] Pulse Width (20% - 95%)
9.5 1
10.5
11.5 2 West to East
12.5 3
13.5
14.5 4
15.5
16.5 5
East to West
____________% ___________mA
____________% ___________mA
CABLOOP(mA) 250mA < I < 300mA Receiver Tap Setting 1
3 (Not Applicable)
Inspector___________________________________________ Date____________________
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6 PREVENTIVE MAINTENANCE
6.1 INTRODUCTION
This section describes the maintenance tasks required for the AF-902/904 track circuit unit, coupler and AF-902/904 350 or 500 MCM bond. These preventive maintenance tasks are to be performed on as-scheduled basis, whereby the components are inspected, cleaned, tested, and adjusted at periodic intervals to ensure the proper operation of the AF-902/904 unit.
6.2 IMPORTANCE OF PREVENTIVE MAINTENANCE

Regular Preventive Maintenance Inspection (PMI) can prevent failures and system malfunctions. The responsibility of the maintenance personnel is to keep the AF-902/904 unit in safe and satisfactory operating condition at all times. This is accomplished through regular inspections, cleaning and testing and through required adjustments of the unit. By maintaining up-to-date repair and PMI records, and reviewing the history of these activities, maintenance schedules can be set to prevent circuit performance deterioration. PMI can lead to the discovery of questionable conditions before major malfunctions can occur, potentially causing train traffic problems and eventually total train stoppage.
6.3 PREVENTIVE MAINTENANCE TASKS

The following tasks are to be performed on a scheduled basis, as determined by past performance and reliability records. As in the case of any operational equipment where safety and reliability are of prime concern, it is recommended that the minimum PMI interval be no less than every six months. This interval may be reviewed and changed accordingly, based on the equipment's ongoing performance. 6.3.1 Equipment Cleaning Procedure Cleaning is necessary to remove all accumulated dirt and other foreign matter from the AF902/904 track circuit unit, coupler and track bonds that form the AF-902/904 system. While cleaning any of these system components, the Maintainer must exercise the necessary caution in order not to damage or dislodge any wires or connectors.
6.3.1.1 Cleaning Materials
The following cleaning materials are required to effectively clean the unit and remove unwanted debris. The cleaning supplies are of commercial grade and may be purchased from any cleaning
supplier.
Item Household Cleaner Lint-Free Cloths
Use Mild liquid cleaner used to clean exterior surfaces. Used to clean and dry exterior surfaces.
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Soft Bristle Brush Air in Aerosol Can
Used to remove dust and foreign matter from terminal blocks, electrical connections, and equipment surfaces. Used to blow out dust and foreign matter from delicate components and electrical surfaces.
6.3.1.2 Room Equipment Cleaning Procedures
When cleaning the AF-902/904 track circuit cardfile located in the equipment room, safety warnings should be adhered to and precautions should be taken to prevent personal injury. WARNING Hazardous voltages and current may be present. Use extreme caution when working near exposed terminals. Never use wet cloths near exposed electrical terminals. The following procedures are to be used: A. Remove dust and dirt from all accessible surfaces using a soft bristle brush. B. Using compressed air, blow out dust and dirt from inaccessible areas around terminal blocks, fuse holders, and other areas where live electrical conductors are exposed. CAUTION When using compressed air to blow out dirt and dust particles from cardfiles, always direct air at an angle relative to the PCBs so that damage will not occur to the mounted components.
C. Wipe exterior and interior surfaces, not exposed to electrical circuitry, with a lint-free cloth
dampened with a solution of water and household cleaner to remove all dirt and foreign matter. D. Dry all surfaces with lint-free cloth. E. Using compressed air or a soft bristle brush, remove all dust and dirt particles from cardfiles, wiring and other areas that may not be accessible using standard cleaning methods. 6.3.2 Track Circuit Inspection Track circuit inspection should take place at least once per year or more frequently if desired. This inspection procedure consists of observing the physical condition of the equipment and performing any actions or operations that may affect the function of the item under test. It may be necessary to take appropriate cleaning steps prior to inspection. Knowledgeable maintenance personnel who are familiar with the operational functions of the system should inspect for
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appearance, smell, sound and feel of the equipment. Any of these observation methods can alert the maintenance personnel of fault conditions.
6.3.2.1 AF-902/904 Room Equipment
The following inspection procedures should be used: A. Check the AF-902/904 front panel to ensure that all PCBs are fully inserted.
B. Verify that all PCBs, primary and backup for all track circuits, are inserted into their proper
slots. C. Verify that all PCBs are securely mounted in the guides at the top and bottom. D. Check that the cable connections to the rear of the cardfile are intact, tight, and free from nicks, cuts, and fraying.
6.3.2.2 Track Side Components
The following inspection procedures should be used:

A. Check all cable connections from the AF-902/904 unit's auxiliary PCB connectors on the rear
panel to the track circuit coupling units for any signs of nicks, breaks, kinks, corrosion or fraying.
B. Check all cable connections from the AF-902/904 coupling units to the appropriate 350 or
500 MCM bond locations for any signs of nicks, breaks, kinks, corrosion or fraying.
C. Verify that the inside of the track coupling unit is free from water and any moisture.
D. Check all 350 or 500 MCM bond connections for damage, corrosion, and tightness. E. Check that all PVC tubing is properly secured against the 350 or 500 MCM cable.
F. Check all wayside components for any signs of physical damage, such as cracks in loop PVC
tubing, etc. Check all mounting hardware for tightness and to see if any of the hardware needs to be replaced.
G. Remove any debris or foreign objects that may hinder the proper operation of the AF-902/904 track circuit system.
NOTE If any fault condition is observed during inspection, it should be corrected immediately. Inform your supervisor at once for proper procedures.
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6.4 TRACK CIRCUIT CHECKS

Track circuit PMI testing is performed to ensure that all circuits are working properly. It can be assumed that the circuits are performing their function to some degree since failures have not been reported prior to the PMI efforts. It also can be assumed that the circuits are within operational tolerance. The track circuit checks are performed to verify how much the circuit is in tolerance, or how close is it to failure. The purpose of the following procedure is the set-up of the AF-902/904 FSK track circuit using a 350 or 500 MCM Bond. It contains two main sections, tuning and calibration. The tuning portion must be performed prior to the calibration procedures. The tuning portion is performed in order to tune the associated coupling units to the frequency of use. The calibration portion is done to set rail current, shunt detection and sensitivity. At least two people will be required to perform these procedures: one Operator at the AF902/904 cardfile and one track coupling unit Technician. 6.4.1 Track Circuit Sensitivity As part of the calibration portion of the routine, the regularly scheduled PMI will require testing for track circuit sensitivity. Before this test can be performed, tuning should be performed in order to tune the two associated coupling units to the desired track circuit frequencies (9.5, 10.5, 11.5, 12.5,13.5, 14.5, 15.5, 16.5 kHz). The tuning frequency and track circuit sensitivity information can be found on the initial installation track circuit data sheet.
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7 TROUBLESHOOTING
7.1 INTRODUCTION
This section describes the methods and procedures that can be used by qualified Maintainers to identify, test, isolate and repair faulty conditions in the AF-902/904 track circuit. All repairs will be to the Lowest Repairable Unit (LRU) that is practical for field maintenance situations.
7.2 APPROACH TO TROUBLESHOOTING

The process of isolating a failed or faulty component(s) is called "troubleshooting." This is a carefully planned approach that will lead to identifying the cause of a system's stoppage or abnormal operation. The responsibility of the maintenance personnel is to locate the cause of failure and repair the condition as soon as possible. This can be accomplished only if a systematic approach is taken by qualified personnel who are familiar with the test equipment and testing procedures. The following basic concepts apply to any troubleshooting situation: Observe and analyze the symptom Sectionalize the system The symptom may identify the site location, sub-system, hardware vs. software causes, or cable/communications link. If it is difficult to identify the faulty subsystem, the Maintainer should proceed to sectionalize the system in halves until the site and subsystem are known. Identify the LRU and test by using available software or control panel diagnostics. Continue troubleshooting the LRU for modular replacement or adjustment. The trouble can be corrected by adjustment, component replacement, or wire repair. Verify that the repair has been properly done by checking the operation of the system for any other fault symptoms and irregularities. Never assume that the first fault found was the only fault.
Localize the fault within the Subsystem Isolate the cause Repair the failure Check repair and operation
The priority of field maintenance personnel is to get the system up and running. This calls for prompt action, fault isolation, and trouble repair. In order to achieve this, the Maintainer may not be required to troubleshoot beyond the modular component level, commonly referred to as the LRU level. The entire troubleshooting process can be quickened by performing "Go-No Go" replacement checks and repair. The key to identifying the probable cause of failures is the use of a process of elimination. This is a most powerful approach to troubleshooting and fault isolation on any system.
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7.3 TROUBLESHOOTING PROCEDURES

7.3.1 Fault Symptoms Every abnormal symptom is a result of a cause that has a remedy. The Maintainer must determine how severe the cause (how much damage resulted) and how difficult the repair process (quick replacement versus system down-time). The table at the end of this subsection gives a brief listing of symptoms, probable causes, and suggested remedies. These remedies are to the LRU level to assist in swift repair. The AF-902/904 FSK track circuit system is designed to notify the Maintainer of most faults through the front panel indicators. Before performing any troubleshooting tests or diagnostics, the Maintainer should first make the following observations: A. Are the power supply LEDs ON?
B. Are the controller, auxiliary, and supply LEDs NORMAL?
C. Is a backplane connector loose or off? D. Is there any physical damage anywhere near the track circuit's equipment? If no obvious faults are observed, the Maintainer should proceed with the standard troubleshooting techniques.
Symptom Track is unoccupied, but low or no receive signal.
Probable Cause Broken 350 or 500 MCM bond Bad coupling unit Defective auxiliary PCB Conductive debris across track
Remedy Check track bond and cabling. Check input and output cable connectors to coupling unit. Remove and replace. Inspect and remove debris. Adjust or replace. Check tuning procedure. Verify coupling unit adjustment.
Intermittent track occupancy indications Speed commands interfere from track circuit to adjacent track circuit
Signal threshold level setting on auxiliary PCB not correct Track carrier frequencies are out of specification limits
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Symptom When performing the tuning or calibration procedures, the proper carrier frequency cannot be achieved.
Probable Cause Adjacent track circuit ON Adjusting wrong circuit in coupling unit
Remedy Turn power OFF of adjacent track circuit. Check for correct TX or RX side of PCB. Auxiliary or controller PCB faulty. Remove and replace. Check for false track occupancy indications. Check LEDs on defective circuit and replace defective module.
Voltage not online (LED OFF) CPS voltage dropped to MICROLOK II No 500Hz signal on auxiliary PCB test point HEALTH indicator OFF MCU failed diagnostic Primary or backup unit is faulty
The MCU is continually running diagnostics on the entire AF-902/904 track circuit system. Any failure of these diagnostics will signal the MICROLOK II unit of track occupancy. This will maintain the track circuit in a safe state, not allowing any train traffic until the system is once again operating correctly. 7.3.2 Error Code Observation Critical Error Code 9 Remedy Description More than two MICROLOK II re-polls occurred in a single AF-902/904 system cycle (360ms) Check polling settings for MICROLOK unit. Cannot send more than 1 message to a given station every cycle (360 msec). To allow for message delays, minimum time should be 400 msec. The track ID, center frequency or MICROLOK address are not the same for both units. Check configuration and reconfigure units as necessary.
14
Primary and backup units have configuration data which does not match
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Critical Error Code 16
Remedy Description The CRC for the EEPROM data is not correct Error with EEPROM (configuration) data. If error persists, re-configure unit. If error still persists, replace the EEPROM (attached to the cardfile). Error with EEPROM (configuration) data. If error persists, re-configure unit. If error still persists, replace the EEPROM (attached to the cardfile). Error with EEPROM (configuration) data. If error persists, re-configure unit. If error still persists, replace the EEPROM (attached to the cardfile). Error with EEPROM (configuration) data. If error persists, re-configure unit. If error still persists, replace the EEPROM (attached to the cardfile).
17
The system was unsuccessful in trying to save data to the EEPROM
19
Copy 1 of the EEPROM record (in RAM) did not match copy 2 of the EEPROM record (in RAM)
20
The EEPROM data has had an unexpected revision number
22
Copy 1 (EEPROM) of configuration data does not Error with EEPROM match Copy 2 (EEPROM) (configuration) data. If error persists, re-configure unit. If error still persists, replace the EEPROM (attached to the cardfile). Copy 1 (EEPROM) of block speed does not match Copy 2 (EEPROM). The block speed is over-written to be zero for both copies Error with blocking speed in EEPROM (configuration) data. Re-set the blocking speed. If error persists, reconfigure unit. If error still persists, replace the EEPROM (attached to the cardfile).
23
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Remedy Description Incorrect code was returned by the keyboard encoder If the error occurs once, ignore it. If this error persists, it indicates a hardware failure of the CPU board. Replace board. Normally associated with a failure of the Controller board. Replace board. Normally associated with attempting to calibrate a unit with other units in operational mode. All adjoining track circuits should be turned off when calibrating a unit. This is a test of the calibration of the track receivers. This is often due to noise from adjoining track circuits causing saturation of the band pass filter. This can normally be corrected by recalibrating the circuit with a lower tap setting on the track receiver. Normally associated with a failure of the Controller board. Replace board. Normally associated with a failure of the Controller board. Replace board.
32
Number of accumulated frequency monitor range errors exceeded the limit Frequency monitor for center frequency was requested during normal (not configuration mode) operation
33
34
Incorrect gain was detected for a receive channel. Channel number can be read using dump events feature.
35
Rejection level incorrect for low-pass filter. Channel number can be read using dump events feature Rejection level incorrect for band-pass filter. Channel number can be read using dump events feature
36
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Remedy Description Vital parallel output monitor read an incorrect state at the output This usually indicates noise on the vital output when the output is deenergized. Check for, and correct, any external noise sources. This error can also be logged by the standby unit if fail-over messages are temporally disrupted at the same time that the occupancy changes state. Can also be associated with a failure of the Controller board. If failure persists, replace board. If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the CPU board. Replace board. If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the CPU board. Replace board. If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the CPU board. Replace board. If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the CPU board. Replace board.
38
Vital parallel output monitor read an inconclusive state at the output
39
Test of the vital parallel output control monitor circuit failed
40
Pulse test of the vital parallel output failed
47
Ramp test of the digital-to-analog converter and analog-to-digital converter failed
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Remedy Description Track transmit power amplifier is too high or too low, possibly due to a CPS failure. If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the AUX board. Replace board. This can also occur when an AUX board is replaced and the unit is not re-configured. Re-configure unit. If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the AUX board. Replace board. This can also occur when an AUX board is replaced and the unit is not reconfigured. Reconfigure unit. Normal Operation Normal Operation If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the Executive PROM or the CPU board. Replace the Executive PROMs or the CPU board. If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the CPU board. Replace board.
49
Malfunction was detected in the power amplifier monitor circuit
55 56 65
System mode change from standby to off-line or on-line to standby User requested a change in system mode to configuration mode EPROM error was detected
66
RAM error was detected
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Remedy Description System cycle did not complete within 360ms This can be caused by noise on the serial link lines during the end-of-cycle processing. Check for, and correct, noise conditions on the serial link. Software error. Normal operation. Software error Software error If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the CPU board or the direction relays. Replace board or cardfile. If this is a single occurrence, it is normally noise related. If this error persists, it indicates a hardware failure of the CPU board or the direction relays. Replace board or cardfile.
69 70 71 75 88
Elapsed time between two MSEC interrupts was greater than 2 ms Power-up or front panel reset occurred Processor watchdog timed out with no critical error logged Fixed register in CPU was found to contain an incorrect value Direction relay failed
89
Direction relay monitor failed
All other critical error codes correspond to internal system errors. Contact Union Switch and Signal for repair information.
7.4 PCB FRONT PANEL INDICATORS AND CONTROLS

7.4.1 AF-902/904 CONTROLLER PCB This front panel consists of two, four-character alphanumeric scrolling displays, and four updown SPDT toggle switches that can be used to enter and examine data used in the set-up and operation of the track circuit. Five LEDs provide additional information. In addition, a front panel PC-compatible serial port and a Background Mode Debugging Port are available. The serial port can be made available to the end user, but the background port is for factory use only.
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Additional detailed information is presented in Section 4.2, which describes the full panel controls, indications and functions. Refer to Figure 7-1, Controller PCB Front Panel, for identification and location of Indicators and Test Points.
W
DIR.
E
1 2
SYSTEM MONITOR LEDS
MODE
UP
ADJ
DOW N ESCAPE AUX 1
ENTER AUX 2

Figure 7-1 Controller PCB Front Panel
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7.4.2 AF-902/904 Auxiliary PCB Eight front panel LEDs on the auxiliary PCB indicate the status of various key parameters in a readily interpreted format. State of Conditional Power Supply, LED On = CPS On Status of unit, LED On = Online, LED Off = Standby Health (availability) of this unit, LED On = unit available Health (availability) of partner unit, LED On = unit available Status of the link to track MICROLOK II system, LED On = communication established Special Block Speed Restriction Status, LED On = block speed set Track Signal Level, LED On = track clear Track Data Signal, LED On = track clear
Eleven maintenance test points are also available on the auxiliary PCB front panel. These test points allow for quick checking of system voltages and signal status without removing the PCB for extender mounting. Refer to Figure 7-2, Auxiliary PCB Front Panel, for identification and location of Indicators and Test Points. 7.4.3 AF-902/904 Power Supply PCB The power supply PCB was designed specifically for application in the AF-902/904 track circuit cardfile. It occupies one double-width 6U card slot. Two separate power switches are located on the front panel. They are locking-lever type switches that need to be pulled out in order to toggle. Test points and LED indicators for each supply output (6 total) are provided and are accessible through the front panel. Each Power Amplifier Transformer output is also accessible at the front panel. All test points are fed through appropriate current limiting resistors so as to avoid shorting the outputs. All resistors will not exceed the 50% rating even when shorted to ground. A solderside cover is provided to reduce the risk of electrical shock, as there are high voltages (ll0/240V ac) on the PCB. Refer to Figure 7-3, Power Supply Front Panel, for identification and location of Indicators and Test Points.
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CPS ACT IVE ON- L INE SELF HEALTH PARTNER U- LOK COMM
BLOCK SPEED SET
SYSTEM MONITOR LEDS
LEVEL T RACK DAT A CLEAR
P1 RECEIVER P2 INPUT
BANDPASS FILTER
ANALOG GROUND
MAINTENANCE TEST POINTS
+12V
VIT AL +5 V OUT PUT S

SYST EM GROUND
+44V + TRANSMITT ER OUTPUT
CPS 50 0Hz
AUXILIARY BOARD N12360 40 1
AF-902 / AF-904 AUXILIARY PCB

Figure 7-2 Auxiliary PCB Front Panel
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- 15V +5V +15V - 15V GND 0 OFF ON

0
XMFR
XMFR +5V
- 15V +5V +15V - 15V GND
OFF
ON
POW SUPPLY ER N12 36 050 1

Figure 7-3 Power Supply Front Panel
7-12
LEFT POWER SUPPLY
+15V
RIGHT POW SUPPLY ER
POWER MONITOR LEDS
+5V +15V
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8 CORRECTIVE MAINTENANCE
8.1 INTRODUCTION
This section describes the procedures necessary to access, replace and repair the AF902/904 track circuit system's components to the LRU level that is practical at field maintenance level. Corrective Maintenance is an unscheduled process instigated by a system failure or resulting from unsatisfactory preventive maintenance data. After a system fault has been localized by performing the necessary troubleshooting and diagnostic testing, the Maintainer is required to adjust or replace the component. Following the component adjustment or replacement, the Maintainer is required to perform system repair verification.
8.2 REPLACEMENT REPAIR

The AF-902/904 track circuit system is comprised of three major components. These are: AF-902/904 FSK cardfile AF-902/904 track coupling unit 350 or 500 MCM bond
The suggested repairs at the field level are designed to minimize system downtime and reduce the need for specialized or sophisticated test equipment. The EEPROM is integral to the motherboard and cardfile. Replacing the EEPROM requires the cardfile to be replaced. 8.2.1 AF-902/904 PCB Replacement The AF-902/904 cardfile is comprised of electronic PCBs housed in a chassis that is compatible with a 19" wide AF rack. This equipment is located in the equipment room and requires a power input of 110/240V ac@50/60 Hz (nominal). Section 1.3.1.1 describes the physical configuration of the PCBs.
8.2.1.1 Required Tools
The only tool required is a medium-sized, flat-blade screwdriver.

8.2.1.2 Procedure
After having identified the faulty PCB, the following steps are to be used for its replacement:
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A. Identify the power supply PCB associated with the track circuit PCB to be replaced.
Figure 8-1, Power Supply PCB, identifies the top circuit of the PCB as the backup power and the bottom circuit as primary power. Turn OFF the corresponding Locking Subsystem Power Switch. CAUTION Turning "OFF' the wrong Power Switch will cause a general system failure. B. Turn the captive thumb screws, located at the top and bottom of the defective PCB module, counterclockwise until loose.
C. Grasp the Module Ejectors, located next to the thumb screws at the top and bottom,
pull the PCB straight out from the board guides and remove it from the cardfile. D. Install the replacement PCB in the board guides and slide it in until the PCB engages the cardfile connector.
E. Turn the PCB thumb screws clockwise until they are finger-tight and the PCB is
firmly positioned against the cardfile frame.

F. Turn ON the associated Power Switch.
NOTE When any of the three PCBs is replaced, the calibration procedure should be rerun to verify the settings and update the threshold calculations. Power supply PCB replacement requires both of the locking subsystem power switches to be turned OFF prior to removing the PCB. This is considered a total system failure and an emergency repair. 8.2.2 Coupling Unit Replacement The PCB is mounted in an aluminum box, which is installed within 15 feet (4.572 m) of the rail. The coupling circuit is mounted on a PCB (9" x 13" x 3/32" (22.86 cm x 32.02 cm x .238 cm) thick). This PCB incorporates two identical circuits and two terminal strips for external connection of inputs and outputs. This single PCB is used for two track circuits, the local transmit circuit and the receiver circuit for an adjacent track circuit. This unit could be replaced due to either: Circuit failure Aluminum box is not water tight.
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8.2.2.1 Tools Required
To remove the PCB, a medium-sized, flat-blade screwdriver is required. Refer to aluminum box, part number X451003-2701, for specific tool requirements.
+15V - 15V +5V +15V - 15V GND 0 OFF ON

0
XMFR
XMFR +5V
- 15V +5V +15V - 15V GND
OFF
ON
POW SUPPLY ER N123605 01
Figure 8-1 Power Supply PCB
8-3
LEFT POWER SUPPLY
+15V
RIGHT POW SUPPLY ER
POWER MONITOR LEDS
+5V
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8.2.2.2 Procedures
8.2.2.2.1 PCB Replacement Refer to PCB Part number N12360x01 for detail information on assembly and circuit diagrams. A. Turn OFF track circuit power supply on the AF-902/904 FSK cardfile unit located in the equipment room. NOTE Make sure that the correct power supply PCB circuit is turned OFF. WARNING All power is to be turned off to the track circuit coupling unit prior to maintenance or replacement. Hazardous voltages and current are present when power is on. B. Open coupling unit box with recommended tool(s).
C. Remove terminal wires, labeled 1 through 4, at terminal blocks TBl and TB2. Record
wire location and color for reinstallation purposes.

D. Remove the three PCB mounting screws located at the corners of the board. E. Remove the PCB by lifting straight up from the box. F. Replace defective PCB with new PCB.
G. Reinstall PCB mounting screws. H. Attach wires to TBl and TB2, according to wire location and color.
I.
Perform adjustment and calibration procedures outlined in Section 6.
J. Close and secure aluminum box to ensure water tightness. 8.2.2.2.2 Coupling Box Replacement Refer to manufacturer's equipment manual for specific tool requirements. WARNING All power is to be turned off to the track circuit coupling unit prior to maintenance or replacement. Hazardous voltages and current are present when power is on.
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A. Detach input and output cables from box connectors. (Two Transmit/Receive cables
and two of the One-Loop cables for the track signal.) B. Remove aluminum box mounting screws at base if mounted to secured surface.
C. Replace defective coupling unit with operational unit and secure, if required.
D. Reconnect input and output cable wires. E. Perform Steps A, H and I of Section 8.2.2.2.1. 8.2.3 Bond Replacement The bond track circuit is very simple, in both material hardware and function. It consists of a few meters of 350 or 500 MCM heavy conductive cable, typically arranged in an "S" shape between the rails, and connected at end points to the rails. The cables from the coupling units are single loop wires that induce signals into the Loop and into the rails. Once these cables are installed and verified as operational, there is very little, if anything, that may require replacement. If any damage occurs to this hardware, it will be necessary to refer to the site's equipment and cable plans and the manufacturer's equipment manual.
8.3 VERIFICATION OF SYSTEM REPAIR

To ensure that the repairs have been performed correctly and that all replacement modules are fully functional, a system verification must be performed. This verification procedure uses the AF-902/904 track circuit system test. This specific test is described in Section 6.4 and consists of two procedures, tuning and calibration. The AF-902/904 tuning procedure performs the following functions: A. Enter carrier frequency. B. Tune both coupling units. The AF-902/904 calibration procedure carries out the following system functions: A. Enter Carrier Frequency, Track ID, and MLOK Address.
B. Set Transmitter Tap and Vout in order to set rail current (Irail). C. Set the Receiver Tap and Shunt/Data Threshold. D. Verify 0.20 ohm shunt sensitivity.
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NOTE Depending on the repair or replacement that was performed, the tuning procedure may not be required. This is performed as a set-up procedure and when track setting versus frequency changes is required. Replacement of AF-902/904 track circuit PCBs does not warrant the tuning procedure. The calibration procedure should, however, be performed to verify the repairs. The following tables contain a summary of these test procedures. Refer to Section 6 for the detailed procedures.
AF-902/904 Tuning Summary Step 1 2 3 4 AF-902/904 Operator From front panel, set Carrier Frequency Set direction (automatic) (Transmit East to West) Set direction (automatic) (Transmit West to East) Set direction (automatic) (Transmit East to West) and verify tuning Track/Coupling Unit Tech Set both coupling units to nominal capacitor setting vs. frequency. Tune West coupling unit using capacitor jumpers in coupling unit. Tune East coupling unit using capacitor jumpers in coupling unit.
AF-902/904 Calibration Summary Step 1 AF-902/904 Operator From front panel, set Carrier Frequency, Track ID, MLOK Address Set direction (automatic) (Transmit West to East) Adjust transmitter taps and Vout to Monitor and report rail current set IRAIL (IRAIL) at East track bond. Track/Coupling Unit Tech
2 3
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AF-902/904 Calibration Summary Step 4 5 6 7 8 9 AF-902/904 Operator Set direction (automatic) (Transmit East to West) Adjust Vout to set IRAIL for E to W Monitor received signal and adjust receiver taps Initiate threshold calculation. Verify threshold value Set direction (automatic) (Transmit West to East) Initiate threshold calculation. Verify threshold value Shunt track with 0.2 ohms at east track bond Shunt track with 0.2 ohms at west track bond Monitor and report rail current (IRAIL) at West track bond. Track/Coupling Unit Tech
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AF-902 and AF-904

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1000 Technology Drive Pittsburgh, PA 15219-3120

AF-902 and AF-904 Digital FSK Track Circuit Controller Systems

FIELD MAINTENANCE MANUAL

COPYRIGHT 2001 UNION SWITCH & SIGNAL PRINTED IN USA

July 2001 Revision 2.0

Union Switch & Signal, Inc.

Union Switch & Signal, Inc.

3.4 TRAIN DETECTION......................................................................................................3-6 iii SM8051

Union Switch & Signal, Inc.

Signal Level Sensing................................................................................................3-6

4.3 FRONT PANEL OPERATION.......................................................................................4-3 4.3.1 Front Panel Menu Interface......................................................................................4-4

Union Switch & Signal, Inc.

5.6.1 5.6.2 5.6.3 5.6.4

6.4 TRACK CIRCUIT CHECKS ..........................................................................................6-4 6.4.1 7 Track Circuit Sensitivity..........................................................................................6-4

Union Switch & Signal, Inc.

8.3 VERIFICATION OF SYSTEM REPAIR........................................................................8-5

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Union Switch & Signal, Inc.

Union Switch & Signal, Inc.

Union Switch & Signal, Inc.

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1.2 PHYSICAL DESCRIPTION

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Union Switch & Signal, Inc.

CPS ACTIVE ON - L IN E SEL F HEAL TH PARTN E R U - L OK C OMM

C P ACTIVE S O N- L I NE SEL F H E TH AL PAR TN ER U - L OK COMM

+5 V +15 V - 1 5V +5 V +15 V - 1 5V GND 0 O FF ON

RIGHT POW SUPPL Y ER

+15 V - 15 V +5 V +15 V - 15 V GND 0 O FF ON

O N- L I NE SEL F HEAL TH PARTN E R U - L OK COMM

RIGHT POW SUPPL Y ER

O N- L I NE SEL F H EALTH PAR TNER U - L OK COMM

TRACK DATA CL EAR

TRACK D ATA CL EAR

TRACK D ATA CL EAR

TRACK D ATA CL EAR

STAT US LEDS I N RES ET WHEN LI T P RES S T O RES ET

STA TUS LEDS I N RES ET WHEN LI T PRES S TO RES ET MODE

STA TUS LEDS I N RE SET WHEN LI T PRE SS TO RESET

B AND PASS F LTER I

B AND PASS F LTER I

B AND PASS FILTER

L EFT POWER SU PPLY

L EFT POWER SU PPLY

+12V VITAL +5V O UTPUTS

+12 V VITAL +5V OUTPU TS

+15 V - 1 5V +5 V +15 V - 1 5V GND 0 O FF ON

+12 V VI TAL +5 V OUTPU TS

+4 4V + TRANSMIT TER OUTPUT

+44V + T RA NSMIT TE R OUTP UT

+44 V + T RANS M TE R IT O UTP UT

+44 V + T RA NS M TTE R I O UTP UT

T RK CKT CT RLR N1236 03 -01 DIAG PORT

AUXIL IARY BOARD N1236 040 1

T RK CKT CTRLR POW SUPPLY N1236 03 ER N12 36 05 01 -01 DIAG PORT

AUXIL IARY BOARD N123 6040 1

T RK CKT CT RLR N1236 0 3 -0 1 DIAG PORT

AUXIL IARY BOARD N1236 040 1

T RK CKT CTRL R POW SUPPL Y N123 60 3 ER N12 36 05 01 - 01 DIAG PORT

AUXILIARY BOARD N123 60 401

TRACK CIRCUIT #1 TRACK CIRCUIT #1 TRACK CIRCUIT #2

TRACK CIRCUIT #2 TRACK CIRCUIT #3 TRACK CIRCUIT #4