STC SmartScanIS User manual

EUD-2016026-00 Rev.2
SmartScanIS
User's Guide
for Union Pacific
14 January 2021

© 2021 Southern Technologies Corporation (STC). All rights reserved.
Printed in the USA.
Because products evolve and system configurations change, this manual may not be
an exact representation of the products and systems that you are using.
STC assumes no responsibility for errors or omissions in this document. Nor does STC
make any commitment to update the information contained herein.
Product and company names mentioned herein are
trademarks or registered trademarks of their respective owners.
CAUTION
Contact with electrically active parts could result in sparks, burns,
and electric shock. Because of this, you should avoid
all electrical hazards when installing, wiring, operating,
maintaining, and using the SmartScanIS. Failure to do so could
result in damage to the equipment or serious injury to you.
STC's web site is www.southern-tech.com
their email address is [e-mail]
their fax number is 423-499-0045
their telephone number is 423-892-3029

EUD-2016026-00 Rev.2, SmartScanIS User’s Guide for Union Pacific, 14 January 2021 3
Contents
This section lists the headings of this guide in sequential order with their page references.
Contents...................................................................................................................... 3
Chapter 1 Introduction .............................................................................................. 9
1.1 Purpose of This Guide................................................................................................9
1.2 SmartScanIS..............................................................................................................9
1.3 Cautions...................................................................................................................11
1.4 Disclaimers...............................................................................................................11
1.5 How to Comment on This Guide...............................................................................11
1.6 How to Order More Copies of This Guide.................................................................12
1.7 Standard Warranty ...................................................................................................12
Chapter 2 Track Components................................................................................. 12
2.1 Scanners..................................................................................................................13
2.1.1 Bearing Scanners............................................................................................15
2.1.2 Wheel Scanners ..............................................................................................19
2.2 Transducers .............................................................................................................23
2.3 Auxiliary-Alarm Detectors.........................................................................................26
2.4 AEI Antennas ...........................................................................................................26
2.4.1 Sinclair SRL470 Antennas...............................................................................26
2.4.2 Scala HP9-915 Parapanel Antennas................................................................27
2.5 Track Circuit.............................................................................................................28
Chapter 3 Adjustment Components....................................................................... 29
3.1 2066-000 Alignment Fixture......................................................................................29
3.2 2100-810NG Calibrated Heat Source.......................................................................32
3.2.1 Temperature Knob...........................................................................................35
3.2.2 Gating Switch ..................................................................................................35
3.2.3 Temperature Meter..........................................................................................36
3.2.4 Function Connectors........................................................................................36
3.2.5 Fuse ................................................................................................................36
Chapter 4 Bungalow Components ......................................................................... 37
4.1 SmartScanIS Enclosure ...........................................................................................37
4.2 2200-750 Reader Module.........................................................................................40
4.2.1 Module Views..................................................................................................40
4.2.2 Front Panel......................................................................................................41
4.2.3 Pinout on AI1200.............................................................................................41
4.2.4 LEDs on AR2200.............................................................................................41
4.2.5 Operation.........................................................................................................42
4.3 2200-500 Presence Detector Module.......................................................................42
4.3.1 Module Views..................................................................................................43
4.3.2 Pinout..............................................................................................................44
4.3.3 2300-528 Zepic III Board .................................................................................44
4.3.4 2150-500 SOTC Interface Board .....................................................................45

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4.4 2200-205 Power Supply Module...............................................................................46
4.4.1 Power Supply Board.........................................................................................47
4.4.2 Power Converter and Battery Charger..............................................................50
4.5 2200-600 Modem Module.........................................................................................51
4.5.1 Power Connection (Power Jack) ......................................................................52
4.5.2 System Connection (RS232 Connector)...........................................................53
4.5.3 Line Cable Connection (Line Jack)...................................................................53
4.5.4 Telephone Connection (Phone Jack)................................................................54
4.5.5 Status LEDs.....................................................................................................54
4.6 2300-350 Controller Module......................................................................................55
4.6.1 2300-200 System Interface Board....................................................................56
4.6.2 2300-100 Processor Board...............................................................................67
4.6.3 2058-305 Talker Board.....................................................................................69
4.6.4 2300-300 Scanner Interface Board...................................................................71
4.7 Surge Protection Subassembly.................................................................................75
4.7.1 Ground Lug......................................................................................................76
4.7.2 Coaxial Arresters..............................................................................................76
4.7.3 Surge Arrester for Track Circuit........................................................................76
4.7.4 Terminal Blocks for Incoming Track Circuit.......................................................76
4.7.5 Universal Transient Barriers.............................................................................77
4.7.6 AC Surge Protector..........................................................................................78
4.7.7 AC and DC Breakers........................................................................................78
4.7.8 Terminal Blocks for Incoming AC .....................................................................78
4.7.9 Terminal Blocks for Incoming DC.....................................................................78
4.8 2300-357 Efficiency Test Panel.................................................................................79
4.8.1 Radio-Test Switch............................................................................................80
4.8.2 LED..................................................................................................................80
4.8.3 Detector-Selection Switch ................................................................................80
4.8.4 Side-Selection Switch.......................................................................................80
4.8.5 Car-Selection Thumbwheels ............................................................................80
4.9 Shielded Temperature Probe (2090-100)..................................................................81
Chapter 5 Preparation..............................................................................................83
5.1 Selecting a Site.........................................................................................................83
5.2 Preparing the Scanner Location................................................................................83
5.3 Preparing the AEI Antenna Masts.............................................................................84
5.4 Preparing the Bungalow............................................................................................85
5.5 Preparing the Pull Box and PVC Pipes .....................................................................87
5.6 Receiving Your System.............................................................................................87
5.7 Returning Damaged or Defective Hardware..............................................................88
5.8 Getting Help with the Installation...............................................................................88
5.9 Identifying the Installation Tools................................................................................89
Chapter 6 Installing the Track Components...........................................................91
6.1 Bearing Scanners .....................................................................................................92
6.2 Transducers............................................................................................................102
6.3 Wheel Scanners......................................................................................................111
6.4 Track Circuit............................................................................................................118
6.5 AEI Antennas..........................................................................................................118
Chapter 7 Adjusting the Track Components........................................................121

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7.1 Bearing Scanners...................................................................................................121
7.2 Wheel Scanners.....................................................................................................126
Chapter 8 Installing the Bungalow Components ................................................ 131
8.1 Grounding System..................................................................................................131
8.2 SmartScanIS Enclosure .........................................................................................131
8.3 Bearing Scanners...................................................................................................132
8.4 Wheel Scanners.....................................................................................................134
8.5 Gating Transducers................................................................................................135
8.6 Advance Transducers.............................................................................................137
8.7 Dragging-Equipment Detector................................................................................138
8.8 Track Circuit...........................................................................................................139
8.9 Telephone..............................................................................................................140
8.10 Shielded Temperature Probe................................................................................141
8.11 Radio Antenna......................................................................................................143
8.12 AEI Antennas .......................................................................................................144
8.13 Batteries...............................................................................................................145
8.14 Wind Monitor........................................................................................................148
8.14.1 Configuring the SmartScanIS for RS485 Communication............................148
8.14.2 Connecting the Wind-Monitor Hardware......................................................149
8.15 High-Load Detector ..............................................................................................150
Chapter 9 Placing a System into Service............................................................. 151
9.1 Checking the Trackside Components.....................................................................151
9.2 Checking the Bungalow Components.....................................................................152
9.3 Powering-up the SmartScanIS ...............................................................................153
9.4 Adjusting the Battery Float Voltage.........................................................................156
9.5 Adjusting the Track Circuit......................................................................................157
9.6 Checking the Scanner Shutters..............................................................................158
9.7 Calibrating the Scanners........................................................................................160
9.7.1 Bearing Scanners..........................................................................................161
9.7.2 Wheel Scanners ............................................................................................166
9.8 Checking the Broadcast .........................................................................................169
9.9 Checking the Speech Data.....................................................................................171
9.10 Checking the Number of Axles.............................................................................173
9.11 Checking for Hot Bearing......................................................................................174
9.12 Checking Communication with Harriman Dispatch Center....................................175
9.13 Checking a Train Summary Report.......................................................................176
Chapter 10 Defect Detection................................................................................. 179
10.1 System Activation.................................................................................................179
10.2 System Deactivation.............................................................................................180
10.3 Speed Calculation ................................................................................................180
10.4 Train Direction......................................................................................................181
10.5 Transducer Pulse Processing...............................................................................181
10.6 Axle Scanning ......................................................................................................182
10.7 Hot Bearing Alarms ..............................................................................................183
10.7.1 Bearing Scan Process .................................................................................183
10.7.2 Referencing System ....................................................................................185
10.7.3 Pyrometer Linearity......................................................................................186

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10.8 Hotwheel Alarms...................................................................................................186
10.9 Auxiliary Alarms....................................................................................................188
10.10 Cold Wheel Alarms .............................................................................................189
10.11 Sliding Wheel Alarms..........................................................................................190
Chapter 11 Serial Interface ....................................................................................191
11.1 Serial Ports; RS232 Devices.................................................................................192
11.2 Main Menu............................................................................................................193
11.3 Setup Menu ..........................................................................................................195
11.3.1 Date and Time..............................................................................................196
11.3.2 Milepost........................................................................................................197
11.3.3 Track Number ..............................................................................................198
11.3.4 Alarm Limits .................................................................................................200
11.3.5 Equipment....................................................................................................214
11.3.6 Messages.....................................................................................................228
11.3.7 System Functions.........................................................................................235
11.3.8 Polling System .............................................................................................247
11.3.9 Serial Ports...................................................................................................250
11.3.10 Amtech Reader Parameters.......................................................................253
11.3.11 Modem Setup.............................................................................................255
Chapter 12 Producing Reports..............................................................................259
12.1 Train Summary Report..........................................................................................261
12.2 Train Detail Report................................................................................................266
12.3 Exception Summary Report ..................................................................................275
12.4 Exception Detail Report (extended).......................................................................279
12.5 Exception Detail Report (abbreviated)...................................................................288
12.6 System Status Report...........................................................................................291
12.7 Last Train Report..................................................................................................296
12.8 Range of Trains Report.........................................................................................296
12.9 Event Log Report..................................................................................................298
12.10 T94 Train Detail Report.......................................................................................303
Chapter 13 Radio Announcements.......................................................................313
13.1 Arrival Messages ..................................................................................................313
13.2 Real-Time Messages............................................................................................314
13.3 Post-Train Messages............................................................................................315
13.3.1 Nothing Detected..........................................................................................316
13.3.2 Only an Integrity Failure Detected................................................................317
13.3.3 Exception Alarms Detected..........................................................................318
13.4 Rebroadcasting Post-Train Messages ..................................................................323
Chapter 14 Using the Efficiency Test Panel.........................................................325
14.1 Arming the Efficiency Test Panel...........................................................................325
14.2 Disarming the Efficiency Test Panel......................................................................326
Chapter 15 Replacing Chips..................................................................................327
15.1 Replacing Firmware Chip on Talker Board............................................................327
15.2 Replacing Speech Data Chips on Talker Board ....................................................329
Chapter 16 Customer Service................................................................................333
16.1 Reaching STC.......................................................................................................333
16.2 Returning Equipment for Repair............................................................................333

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16.3 Reporting Problems or Suggestions.....................................................................334
16.4 Ordering Spare Parts............................................................................................334
16.5 Checking on Shipments and Orders.....................................................................334
Appendix A System Alarms.................................................................................. 335
A.1 AC Power Is Off! Alarm..........................................................................................335
A.2 Advance Turn-On Failure Alarm.............................................................................335
A.3 Basetime Error Reader 1 Alarm.............................................................................335
A.4 Basetime Error Reader 2 Alarm.............................................................................336
A.5 Blind Pyro Alarm....................................................................................................336
A.6 Cold Rail Alarm......................................................................................................336
A.7 Cold Resistor Alarm...............................................................................................337
A.8 Cold Wheel Scanner Alarm....................................................................................338
A.9 Cold Wheel Scanner Resistor Alarm......................................................................339
A.10 Dead Wheel Scanner Resistor Alarm...................................................................339
A.11 Efficiency Test Panel in Use Alarm ......................................................................340
A.12 Equal Heats Test Failed Alarm.............................................................................340
A.13 Integrity Failure Alarm..........................................................................................340
A.14 Low Battery Alarm................................................................................................340
A.15 No Basetime Reader 1 Alarm...............................................................................340
A.16 No Basetime Reader 2 Alarm...............................................................................341
A.17 Reverse Direction Detected Alarm.......................................................................341
A.18 Short Train Alarm.................................................................................................341
A.19 Sliding Wheel Alarm.............................................................................................341
A.20 Stuck Dragger Alarm............................................................................................342
A.21 Successive Cold Wheels Exceeded Alarm...........................................................342
A.22 Successive Cold Wheel Resistors Exceeded Alarm.............................................342
A.23 Test Train Alarm...................................................................................................342
Appendix B Integrity Failures............................................................................... 343
B.1 Dead Battery Alarm................................................................................................343
B.2 Dead Resistor Alarm..............................................................................................343
B.3 Max Equal Heat Test Failures Exceeded Alarm.....................................................344
B.4 Maximum Exception Alarms Exceeded Alarm........................................................344
B.5 Maximum Transducer Spikes Exceeded Alarm......................................................345
B.6 Pretrain Stuck Dragger Alarm ................................................................................345
B.7 Pretrain Stuck HiLoad Alarm..................................................................................345
B.8 Pretrain Stuck WideLoad Alarm .............................................................................345
B.9 Slow Train Alarm....................................................................................................345
B.10 Successive Cold Rails Exceeded Alarm...............................................................346
B.11 Successive Cold Resistors Exceeded Alarm........................................................346
B.12 Very Slow Train Alarm .........................................................................................346
Appendix C System Functions............................................................................. 347
C.1 Radio Test.............................................................................................................349
C.2 Vocabulary Test.....................................................................................................349
C.3 Gate Test...............................................................................................................350
C.4 1KHz Test Tone.....................................................................................................350
C.5 Auto-Calibration.....................................................................................................350
C.6 Reset the COP Counters .......................................................................................351

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C.7 Remote System Reset............................................................................................351
C.8 Clear All Stored Train Data.....................................................................................351
C.9 Clear Event Log......................................................................................................351
C.10 Send JC Message................................................................................................351
C.11 Send JM Message................................................................................................351
C.12 Send JP Message................................................................................................352
C.13 Send JS Message................................................................................................352
C.14 Real-Time Diagnostics .........................................................................................352
Appendix D Replacing Scanner Cover-and-Module Assemblies.......................353
D.1 Bearing Scanners...................................................................................................353
D.2 Wheel Scanners.....................................................................................................358
Appendix E Calibration of Scanners.....................................................................361
E.1 Bearing Scanners...................................................................................................361
E.2 Wheel Scanners.....................................................................................................366
Appendix F Lens Cleaning of Scanners...............................................................371
F.1 Type II Scanners.....................................................................................................371
F.2 Type III Scanners....................................................................................................373
Appendix G Predictive Gate Scanning.................................................................377
G.1 Overview................................................................................................................377
G.2 Scanning Process..................................................................................................378
G.3 Reporting the Pyrometer Saturation Alarm.............................................................379
Appendix H Central Reporting System.................................................................381
H.1 Overview................................................................................................................381
H.2 Polling Port (COM2) ...............................................................................................381
H.3 Polling Address ......................................................................................................382
H.4 Messages...............................................................................................................382
H.5 Supported Message Types from Union Pacific.......................................................382
H.6 Unsupported Message Types from Union Pacific...................................................383
H.7 Supported Message Types to Union Pacific...........................................................383
H.8 Modification of Talker Mode....................................................................................384
Index.........................................................................................................................385

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Chapter 1
Introduction
This chapter summarizes the purpose of this guide, describes the SmartScan Integrated
System, tells how to comment on this guide, tells how to order more copies of this guide, and
covers STC's standard warranty. It also covers the cautions and disclaimers of which the
customer should be aware of.
1.1 Purpose of This Guide
The technical staff at Southern Technologies Corporation (STC) created the SmartScan
Integrated System (SmartScanIS). This guide describes that system.
The SmartScanIS monitors moving trains and reports certain conditions detected on these
trains. Parts of the system, like the bearing scanners, are installed on the tracks. Other parts
of the system, like the controller module, are installed near the tracks.
The SmartScanIS is modular and firmware driven. Hardware and firmware can be changed to
meet the unique needs of a given railroad. Thus, some of the components that make up a
SmartScanIS differ from railroad to railroad.
This guide is for those who purchase, install, maintain, troubleshoot, manage, or use the
SmartScanIS at Union Pacific.
1.2 SmartScanIS
The SmartScanIS is a full-featured detection and reporting system. It monitors moving trains,
providing real-time detection of:
Overheated bearings
Overheated wheels, when wheel scanners are installed and enabled
Dragging equipment, when dragging-equipment detectors are installed and enabled
Shifted loads, when wide-load detectors are installed and enabled
Oversized loads, when high-load detectors are installed and enabled
Automatic Equipment Identification (AEI) tags, when AEI hardware is installed and
enabled
Direction of the train
Arrival and exit speeds of the train

10 14 January 2021, SmartScanIS User’s Guide for Union Pacific, EUD-2016026-00 Rev.2
The SmartScanIS runs well in the harsh environments found along right of ways. It runs under
the most adverse weather conditions, functioning over a temperature range of -40°F to +160°F
(-40°C to +71°C). It runs in high vibration situations. It runs unattended, carrying out all tasks
without human intervention.
The SmartScanIS monitors trains traveling from 7 to 90 mph (11.3 to 145 kph). It monitors
trains heading in either direction on the track.
The SmartScanIS reports defects in three ways.
Announcements made via the road channel
Detailed defect information downloaded to a computer
Communications sent to the Harriman Dispatch Center
When the SmartScanIS detects a defect, it informs the crew of the affected train. This is done
by a voice transmission over an assigned radio channel. The voice is computer generated
from previously digitized human speech. It tells the crew the milepost of the reporting
SmartScanIS, a warning that a defect has been detected, and other defect-related information.
When no defect is detected, the voice tells the crew that the train was scanned and found free
of defects. If you configure the system for "Talk On Defect" operation, it won't make any
announcements for defect-free trains.
There are three types of messages. Real-time messages are announced as the train is
passing over the site. Post-train messages are announced after the train has left the site and
all the recorded train data has been processed by the SmartScanIS. When enabled, there are
also arrival messages. Arrival messages are announced as the train enters the site. The
content and use of these three message types are railroad specific.
The results of train scans are also stored for later use. With this stored data, the system can
create formatted reports. To get them at the site, you need a computer. With a modem and a
computer, you can retrieve them remotely.
Some site preparation is needed before installing the SmartScanIS. Among the things to do is
to supply the site with a stable AC power source of at least 110 volts at 20 amperes. This and
other preparations are covered in Chapter 5 - Preparation. Also covered in that chapter is
how to install the antenna masts, bungalow (aka wayside enclosure), and PVC pipes.