Ionx Edge E Series Operating and maintenance instructions

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303350 Installation Manual E-Series CMU Confidential
Revision Date: 9-July-18 Revision: H
Process Owner: Engineering Page 1of 47
IONX Technical Data
Installation Manual
for the
Edge E-Series
Communications Management Unit (CMU)
IONX LLC
515 S. Franklin St.
West Chester, PA 19382
www.ionxlive.com
484.653.2600

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303350 Installation Manual E-Series CMU Confidential
Revision Date: 9-July-18 Revision: H
Process Owner: Engineering Page 2of 47
1) Warnings
These instructions are not designed to imply or replace any operating or safety rules.
It is the responsibility of the installer to understand and follow all company safety practices.
WARNING In order to comply with hazardous classification, only those items
specifically listed can be used and must be used only as shown. Substitution of components
may affect intrinsic safety.
WARNING Installation shall be carried out in accordance with the applicable code of
practice by suitably-trained personnel.
WARNING Repair of this equipment shall be carried out in accordance with the
applicable code of practice.
WARNING Any machining, drilling, and/or sanding related to the installation of this
system should be pre-approved by the authorized department before work is started.
WARNING If the equipment is likely to come into contact with aggressive substances,
then it is the responsibility of the user to take suitable precautions that prevent it from being
adversely affected, thus ensuring that the type of protection is not compromised.
WARNING RF Device: Unit cannot be painted or coated with any material. Coating can
adversely affect the performance of the device. Unit shall be masked appropriately if post
installation coating is required.
WARNING EXPLOSION HAZARD: The equipment temperature Class is T4 and only
certified for use in ambient temperatures. Product is rated from -40C to +55Cand should not
be used outside this range in an explosive environment.
WARNING EXPLOSION HAZARD: Installation shall be carried out in accordance with
the applicable code of practice by suitable trained personnel.
WARNINGPOTENTIAL ELECTROSTATIC CHARGING HAZARD: Under certain extreme
circumstances, the non-metallic parts incorporated in the enclosure of this equipment may
generate an ignition-capable level of electrostatic charge. Therefore the equipment shall not be
installed in a location where the external conditions are conducive to the build-up of electrostatic
charge on such surfaces. This is particularly important if the equipment is installed in a zone 0
location.
WARNINGPOTENTIAL ELECTROSTATIC CHARGING HAZARD: Suitable for hose down
cleaning only. Do not clean unit with a dry cloth. Static can be generated when two dry parts are
rubbed together.
WARNING DO NOT OPEN WHEN EXPLOSIVE ATMOSPHERE IS PRESENT. Battery
replacement shall be done in an area known to be non-hazardous. Use only replaceable battery
pack IONX model 303382 (19 mAH) or 303406 (76 mAH). See battery replacement procedure in
Appendix F.
WARNINGProducts contain Primary Lithium batteries. Proper disposal procedures are
required at end of life conditions. Use local regulatory disposal method for lithium Thionyl
chloride batteries. For example, disposal procedure 49 CFR 173.185.

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303350 Installation Manual E-Series CMU Confidential
Revision Date: 9-July-18 Revision: H
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1) Avertissements
Ces instructions ne sont pas conçues pour impliquer ou remplacer des règles d'utilisation ou de sécurité.
Il est de la responsabilité de l'installateur de comprendre et de suivre toutes les pratiques de sécurité de l'entreprise.
Instructions complètes pour utiliser CMU en français en attente.
AVERTISSEMENT Afin de se conformer à la classification des matières dangereuses,
seuls les éléments spécifiquement énumérés peuvent être utilisés et doivent être utilisés uniquement
comme indiqué. La substitution de composants peut affecter la sécurité intrinsèque.
AVERTISSEMENT L'installation doit être effectuée conformément au code de pratique
applicable par du personnel dûment formé.
AVERTISSEMENT La réparation de cet équipement doit être effectuée conformément au
code de pratique applicable.
AVERTISSEMENT Tout usinage, perçage et / ou ponçage lié à l'installation de ce système
doit être préalablement approuvé par le service autorisé avant le début des travaux.
AVERTISSEMENTSi l'équipement est susceptible d'entrer en contact avec des substances
agressives, il est de la responsabilité de l'utilisateur de prendre les précautions appropriées qui empêchent
qu'il soit affecté de manière négative, garantissant ainsi que le type de protection n'est pas compromis.
ATTENTION Dispositif RF: L'unité ne peut être peinte ou revêtue d'aucun matériau. Le
revêtement peut nuire aux performances de l'appareil. L'unité doit être masquée de manière appropriée si
un revêtement post-installation est requis.
ATTENTION DANGER D'EXPLOSION: La classe de température de l'équipement est T4 et
seulement certifiée pour une utilisation à des températures ambiantes. Le produit est évalué de -
onnement explosif.
ATTENTION DANGER D'EXPLOSION: L'installation doit être effectuée conformément au code
de pratique en vigueur par du personnel qualifié.
ATTENTION DANGER DE CHARGE ÉLECTROSTATIQUE POTENTIEL: Dans certaines
circonstances extrêmes, les pièces non métalliques incorporées dans l'enveloppe de cet équipement
peuvent générer un niveau de charge électrostatique capable d'amorçage. Par conséquent, l'équipement
ne doit pas être installé dans un endroit où les conditions externes favorisent l'accumulation de charges
électrostatiques sur ces surfaces. Ceci est particulièrement important si l'équipement est installé dans un
emplacement de la zone 0.
ATTENTIONDANGER DE CHARGE ÉLECTROSTATIQUE POTENTIEL: Convient uniquement au
nettoyage par tuyau. Ne nettoyez pas l'appareil avec un chiffon sec. Statique peut être généré lorsque deux
parties sèches sont frottées ensemble.
ATTENTION NE PAS OUVRIR LORSQU'UNE ATMOSPHÈRE EXPLOSIVE EST PRÉSENTE. Le
remplacement de la batterie doit être effectué dans une zone connue comme non dangereuse. Utilisez
uniquement une batterie remplaçable IONX modèle 303382 (19 mAH) ou 303406 (76 mAH). Voir la procédure
de remplacement de la batterie à l'annexe F.
ATTENTION Les produits contiennent des batteries au lithium primaire. Des procédures
d'élimination appropriées sont requises en fin de vie. Utiliser une méthode d'élimination réglementaire
locale pour les piles au lithium-chlorure de thionyle. Par exemple, procédure d'élimination 49 CFR 173.185.

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303350 Installation Manual E-Series CMU Confidential
Revision Date: 9-July-18 Revision: H
Process Owner: Engineering Page 4of 47
2Unpacking the CMU
Required Tools/Materials
Tool Name
(Part No)
Description
3/8” Magnetic Drive
Socket
Securing self-drilling screws
T-27 Tamper-Resistant
Torx driver
Securing CMU to bracket
If using a knife to cut the tape, do not let the blade extend more than ½ inch inside of the
cardboard box.
2.1 Inspect shipping box/s to make sure there is no damage.
2.2 Carefully unpack the shipping box making sure to open the top of the box.
There will be instruction guide/s for modules associated with the system order.
2.3 Open shipping box/s and verify that the internal contents match the shipping receipt.
Contact IONX Support Center (Appendix C) in the event of any above problems.
[WDL1]
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Revision Date: 9-July-18 Revision: H
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3Activating the CMU
Warning: NFC tag reader is not for use in potentially explosive atmospheres. Activate the CMU
on a benchtop in a non-hazardous area.
ATTENTION: Le lecteur d'étiquette NFC ne doit pas être utilisé dans des atmosphères
potentiellement explosives. Activer la CMU sur une paillasse dans une zone non dangereuse.
3.1 Before starting
3.1.1 Confirm your email address is set-up in the IONX TARA system by emailing
[email protected]m with “help” in the subject line.
3.1.2 If there is no reply, contact the IONX Support Center (Appendix C) to get your email
address set-up to use TARA and IONXlive.net.
3.1.3 Download the IONX E-series application for NFC reader.
3.1.4 Start Ionx application.
3.2 Place NFC reader device near yellow label of CMU. This wakes the CMU from deep sleep.
3.3 Confirm device wake up message was received using IONX E-series application.
3.4 Alternately, some CMU devices may be activated by removing a magnet, under tape, on the top
surface of the CMU.
3.5 Attach the CMU to the mounting plate or car using the supplied hardware.
3.6 See mechanical installation drawings in Appendix A for specific mounting details
3.7 If the CMU is being mounted to a hatch, be sure the hatch is closed after the CMU has been
mounted (Figure 6).
Figure 6: Final CMU connection to mounting plate
3.8 Associate the CMU with the car according to Section 4.

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4 Associating the CMU
The IONX Totally Autonomous Reporting Agent (TARA) is used to associate the car number with the
CMU. This is completed by email using an email-enabled smart phone or any computer with email
access.
4.1 Before starting
4.1.1 Confirm your email address is set-up in the IONX TARA system by emailing
[e-mail] with “help” in the subject line.
4.1.2 If there is no reply within 60 minutes, contact the IONX Support Center
(Appendix D) to get your email address set-up to use TARA and IONXlive.net.
4.2 Associating the Car Number to the CMU
4.2.1 Start a new email message
To: type [e-mail]
Subject: type
‘I’ or ‘i’
period ‘.’
The serial number of the CMU
Period ‘.’
The Car initials
Period ‘.’
The Car number which the CMU is installed on
Period ‘.’
Company Name
Example: I.SerialNumber.CarInitial.CarNumber.CompanyName
Example: I.E6AA015000.ABCX.1234.ABCRailroad
4.2.2 Send the message
4.2.3 A response message confirming the installation will be sent from TARA (Figure
7)
Success!
Unit E6AA015000 now installed on ABCX 1234
associated to ABC. If this is not correct -
Contact IONX Support at–484-653-2600.
**This is an automated report email, please do
not reply directly to this message as it will be
discarded.
Figure 7: Sample Installation Response

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303350 Installation Manual E-Series CMU Confidential
Revision Date: 9-July-18 Revision: H
Process Owner: Engineering Page 7of 47
4.2.4 The CMU is associated with the car number. The installation is complete. The car now
can be released into service.
4.3 For replacing a device on a car, start a new email message
To: type [e-mail]
Subject: type
o‘R’ or ‘r’
operiod ‘.’
oThe serial number of the old replaced CMU
oPeriod ‘.’
oThe serial number of the new CMU being installed
oPeriod ‘.’
oThe Car initials
oPeriod ‘.’
oThe Car number which the CMU is installed on
Example: R.OldSerialNumber.NewSerialNumber.CarInitial.CarNumber
Example: R.E5AC011001.E4AB011000.ABCX.1234
4.3.1 An email response message confirming the replacement will be sent from TARA.
4.3.2 To see details of all TARA email service commands, go to Appendix C.
4.4 Using the TARA web site
4.4.1 Click on the link below and log in using the same credentials you use to access the IONX web
site:-
https://www.ionxlive.net/IonxLiveMassTARA/
Note: If you receive the error message ‘User is not a valid TARA user’, please contact IONX
support to be added to the list of valid TARA users.
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303350 Installation Manual E-Series CMU Confidential
Revision Date: 9-July-18 Revision: H
Process Owner: Engineering Page 8of 47
4.4.2 After logging in, you should see the following screen. This is the ‘Install’ tab and should be used
if installing a device on a new car. If replacing a device on a car, please see the ‘Replace’
command instructions in section 6.3.3.
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303350 Installation Manual E-Series CMU Confidential
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4.4.3 If installing only one device, fill in the serial number of the CMU to be installed, the car name
and number (format ABCD 123456) and choose the customer name from the dropdown. Then
press the ‘Install’ button.
The following message should be displayed:-
'Success! Unit <Serial Number> is now installed on <Car Mark> associated to
<Customer>. If this is not correct - Contact customer support at IONX - 484-653-
2600.'
If the above message is not displayed and an error message displayed which you do not
understand, please capture the message and send to IONX Support for further investigation.
Note that IONX installers will have access to all customers from the dropdown list.
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Revision Date: 9-July-18 Revision: H
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4.4.4 If installing multiple devices, please use the section at the bottom of the page. Up to five (5)
devices can be installed at one time. Success messages will be displayed for all installed devices
and they will be removed from the table. Unsuccessful installs will still remain in the table for
correction and error messages will be displayed for them.
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4.5 Other TARA Web Site Commands.
The TARA web site also can be used to send other TARA commands namely uninstall, replace, change,
wireless sensor monitor (WSM), detailed status and change battery (certain customers). Below is a short
description of each function. Note that descriptions for TARA commands not used during installation can
be found in Appendix B.
4.5.1 Uninstall
Used when uninstalling IONX CMU devices from cars.
Enter the serial number and car name for the device to be uninstalled. Check the RMA check box
if the device is to be returned to IONX and press the ‘Uninstall’ button. If the RMA checkbox is
selected, the unit will be moved to the IONX uninstalled fleet, otherwise it will be moved to the
customer uninstalled fleet. Note that the car name entered must be in the format ‘ABCD
123456’ unless the customer is designated as a European customer. European customers may
enter the car name in any format.
For multiple uninstalls, up to 5 devices can be uninstalled using the ‘Uninstall Multiple Devices’
table at the bottom of the web page above.

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4.5.2 Change battery. See Appendix F.
4.5.3 Replace
Used when replacing an IONX CMU device on a car with another IONX CMU.
Enter old CMU serial number (to be replaced), new CMU serial number (replacement)
and car name. Press the ‘Replace’ button.
Note that the car name must be of the format ‘ABCD 123456’ unless the customer is
designated as a European customer.
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4.5.4 Wireless Sensor Monitor (WSM) –For information purposes only.
Car sets are CMU devices plus Wireless Sensor Nodes (WSNs). WSM is used to
determine if a CMU is awake and all WSNs have joined the network.
Following the instructions on the web page and then enter the IONX CMU serial number
and press the ‘Monitor’ button.
A table of the WSNs (serial number, node number and status) for the car set should be
displayed.
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5Miscellaneous
Translations available upon request.
Traductions disponibles sur demande.
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Appendix A: Mechanicals
A.1 E4S and E5S Dimensions
Warning: Mounting bracket is required for CMU-E4S and CMU-E5S models when commissioning for use
in potentially explosive atmosphere. IONX part number 302262, Isolation mount bracket for ExS, is
approved for use in explosive atmosphere.
Attention: Le support de montage est requis pour les modèles CMU-E4S et CMU-E5S lors de la mise en
service pour une utilisation dans une atmosphère potentiellement explosive. Le numéro de pièce IONX
302262, support de montage d'isolation pour ExS, est approuvé pour une utilisation en atmosphère
explosive.
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A.2 E4S and E5S Installation with Bracket

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A.3 E4S and E5S Installation with Magnetic Bracket and Safety Tether
Required Tools/Materials for Safety Tether
Tool Name
(Part No)
Description
Electricians’ Crimping
Pliers
Crimps ferrules to wire rope
1/16 inch or 1.58 mm
Ferrules - 2 per tether
Ferrules for wire rope
1/16 inch or 1.58 mm
Wire Rope –6 foot each
Wire rope for safety tether

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STEP 1 CHOOSE A LOCATION FOR THE CMU BRACKET THAT WILL SEE A CLEAR VIEW OF THE SKY. THIS
WILL ENSURE GOOD GPS RECEPTION.
STEP 2 ENSURE MOUNTING SURFACE IS FREE OF ANY IMPERFECTIONS THAT MAY PREVENT THE
MAGNETS FROM MATING FLUSH AND SECURING TO THE RAILCAR SURFACE.
STEP 3 THREAD THE WIRE ROPE THROUGH THE FERRULE AND AROUND ONE OF THE BRACKET FEET AND
BACK THROUGH THE FERRULE AS SHOWN BELOW.
MAKE THE WIRE LOOP TAUT AROUND THE BRACKET FOOT SO THE SAFETY TETHER CAN NOT BE
REMOVED OVER THE MAGNET. (SEE SECOND PHOTO BELOW) USE ELECTRICIAN PLIERS TO CRIMP THE
FERRULE.
STEP 4 TAKE CAUTION THAT THE TETHER DOES NOT CAUSE A TRIPPING HAZARD OR GET TANGLED IN
OTHER EQUIPMENT.
STEP 5 IF THE ENTIRE LENGTH OF THE WIRE ROPE IS NOT NEEDED, PULL THE EXCESS WIRE THROUGH
THE SECOND FERRULE, CRIMP, AND CUT OFF ANY EXCESS WIRE ROPE.

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DIFFERENT TYPES OF PLIERS THAT CAN BE USED - SHOWS THE FERRULES IN EACH PLIER TYPE
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A.4 E4S and E5S Dome Mounted