UTE 16814-00 Manual

DRAFT
INSTRUCTION and OPERATIONS MANUAL
for
MU CABLE TESTER
MODEL NUMBER 16814-00
CAUTION
All operators are expected to read and become thoroughly familiar with the entire contents of this
manual before attempting to operate the MU Cable Tester.

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DOCUMENT NO. 16814-99
16814-99 Rev. A

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TABLE OF CONTENTS
..................................................................................................................................GENERAL DESCRIPTION 4
.........................................................................................................................................System Components 4
.............................................................................................................................EQUIPMENT DESCRIPTION 4
...............................................................................................................................The Designated Slave Unit 4
.............................................................................................................................The Designated Master Unit 5
........................................................................................................................Battery Charger/Power Adapter 5
.......................................................................................................................................................OPERATION 5
............................................................................................................................................Setup – Slave Unit 5
The internal battery can be used if no AC power is available. Make sure the battery is sufficiently charged to be able
.................................................................................................................to complete the desired MU testing. 6
..................................................................................................................Startup – Slave Unit – Auto Testing 6
..............................................................................................................................................SPECIFICATIONS 8
............................................................................................................................................................Physical 8
Size 8
...........................................................................................................................................................Electrical 8
..................................................................................................................................................Environmental 9
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1. GENERAL DESCRIPTION
The MU Cable Tester System performs shorts testing, continuity testing, and ground-leakage testing for
each of the 27 Multi-Unit control lines normally found on freight locomotives. The MU Cable Tester
System can be used to test MU lines within the railcar as well as MU jumper cables connected to them.
The tester system is able to perform these tests on a locomotive consist of up to eight railcars while the
locomotive is powered up and stationary. MU jumper cables can also be tested individually.
A failsafe mechanism (Emergency Shut Off) is designed into the test system to immediately disconnect
the test units in the event that an unexpected movement of the locomotive occurs during testing. The
emergency shut off switch immediately removes testing signals from the MU control lines without
removing power from the test unit itself; the emergency shut off function can be accessed from either
the slave or master unit and disconnects both slave and master when activated.
1.1. System Components
The MU Cable Tester System is comprised of two identical tester units. Each unit is installed in a heavy
duty, water resistant, plastic Pelican case. Either unit can be designated as a Slave unit or a Master
Unit. Each unit contains an MU cable receptacle that mates with the typical railcar MU jumper cable. A
snap-on vinyl pouch on the outside cover of each unit provides storage for the battery charger/power
adapter and the chassis test lead. Every MU Cable Tester System contains two of the following:
1. MU Cable Tester Unit (16814-00)
2. AC Power Adapter (16944-01)
3. Chassis Test Lead (17034-01)
2. EQUIPMENT DESCRIPTION
The MU Cable Tester System is a complete, stand-alone tester for MU Jumper cables and MU control
lines found within freight locomotives. The test operator selects one test unit to be used as a slave and
the other as a master. Typical equipment configuration for the MU Cable Tester System is one
designated Slave unit connected to one designated Master unit by way of one MU jumper cable. Up to
eight railcars can be added between the slave and master units with nine jumper cables connecting the
entire chain. All MU railcar lines and MU jumper cables connected between the slave unit and master
unit will be tested as a group.
The enclosure cover-hinges separate from the test unit as the cover is opened; this removes the cover
completely to allow free access to the MU cable receptacle as well as operator test functions. The
control panel is mounted so the operator can typically view the display and operate the function buttons
from the side of the case. The emergency stop button is centrally located within the enclosure to allow
quick access from almost any location around the test unit.
The designated master unit activates the driving circuitry that switches a low-level signal onto each of
the train lines, one at a time. The designated slave unit completes the communication link required for
testing. Both MU Cable Tester units can be powered by the internal battery or the AC power adapter /
battery charger. In addition, the 72 volt locomotive battery provides battery charging through an isolated
charging circuit. This connection is disconnected while tests are being executed.
2.1. The Designated Slave Unit
The MU Cable Tester designated as the slave unit performs a self test when powered ON. After a
preliminary shorts test between conductors, the designated slave unit waits for a communication link
from the master unit. The slave unit monitors a preselected set of possible communication conductors
chosen from spare conductors. The slave unit responds to commands from the master unit after the
two-way communication link has been established.
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A vacuum fluorescent display provides indication that the unit has been selected as the slave unit. LEDs
provide status indication of power ON and battery charging status. The emergency shut off switch
provides an instantaneous disconnect of all testing signals and controls to the MU railcar lines and MU
jumper cables should unsafe conditions occur for any reason. Note that the emergency shut off switch
does not remove power from the entire test unit.
2.2. The Designated Master Unit
The MU Cable Tester Unit designated as the master unit controls the operation of the entire test system.
The master unit performs a self test, a test for short circuits between conductors, and a test for leakage
to chassis. It establishes a two-way communication link with the slave unit and controls the operation of
the slave through this link. The conductor continuity test is performed by the master commanding the
slave unit to connect a capacitive coupled path between selectable conductor pairs. Any conductor pair
combination may be measured for normal or open conductivity.
Each designated master unit contains a control panel, an MU connector receptacle, a locomotive
chassis lug terminal, an internal battery, and a battery charger/power adapter. The front panel controls
and indications allow the operator to perform the desired tests and view indicated test parameters. A
vacuum fluorescent display provides textual indication that the unit has been selected as the master
unit; the display also provides test system status and function control options of the tests while in
operation.
Control panel function buttons become illuminated when a control function is available for any given test
option at any given stage of the testing process. LEDs provide status indication of power ON and battery
charging status. The emergency shut off switch provides an instantaneous disconnect of all testing
signals and controls to the MU railcar lines and MU jumper cables should unsafe conditions occur for
any reason. Note that the emergency shut off switch does not remove power from the entire test unit.
2.3. Battery Charger/Power Adapter
The battery charger/power adapter power cable plugs into any standard 120 VAC power receptacle; the
output from the charger plugs into a power input connector in the control panel of each MU Cable Tester
unit. The charger provides operational power to the MU Cable Tester and is used to recharge the
sealed lead-acid battery housed within the unit. The battery charger/power adapter is stored in the
external storage pouch for transport.
3. OPERATION
Operation of the MU Cable Tester System requires two tester units, one to first be designated as Slave
and the other designated as Master. These units must be operated from a stable surface capable of
physically supporting the unit while connecting and disconnecting an MU jumper cable to the test units
as well as to a railcar MU Cable receptacle.
3.1. Setup – Slave Unit
3.1.1.Open and remove the cover of either test unit.
3.1.2.Set the On/Off Power switch to the OFF position.
3.1.3.Set the Emergency Shut Off switch to the home (reset) position
A. Twist the red button clockwise to release it to the home state.
3.1.4.Designated slave unit does not use Chassis Test Lead.
3.1.5.Locate the AC Power Adapter from the storage pouch
A. Insert the delta shaped power cord plug into the matching adapter block receptacle.
B. Plug the 18VDC power connector to the matching receptacle on the MU Cable Tester
control panel labeled: 18VDC POWER.
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C. Insert the 120V AC power plug to any standard 120V AC 60 Hz receptacle.
D. The internal battery can be used if no AC power is available. Make sure the battery is
sufficiently charged to be able to complete the desired MU testing.
3.2. Startup – Slave Unit – Auto Testing
3.2.1.Set the On/Off Power switch to On; allow the unit to completely power up.
3.2.2.The Green power LED is illuminated; the Red emergency shut off button is illuminated.
3.2.3.“MU Cable Tester” menu is displayed as power up procedure is completed.
3.2.4.The 3 function buttons found on the control panel show the option of “Master” or “Slave.”
A. The F1 and F3 buttons are illuminated, indicating master and slave options.
3.2.5.Designate this unit as Slave by pushing the illuminated F3 button.
A. View the display to confirm “Slave Unit” designation.
CAUTION: Before the MU Cable tester is connected to the locomotive railcar, the Operator must be aware
of the location and function of the Emergency Shut Off switches. The emergency shut off switch provides an
instantaneous disconnect of all testing signals and controls to the MU railcar lines and MU jumper cables
should unsafe conditions occur for any reason. The emergency shut off switch is located in the center of
each MU Cable Tester Unit and is functional from the designated Slave unit or the designated Master unit. If
necessary, press the emergency shut off switch to disconnect the test unit.
3.3. Self test - Slave unit
3.3.1.From the “Slave Unit” menu. Press F1 to Start the Self-test sequence.
3.3.2.Wait for designated slave unit to complete self test.
A. When unit displays “Self Test Pass, proceed to step 3.3.3.
B. If self test fails, resolve source of failure and retest. Indications found on the display can
be used to help determine cause of failure.
3.3.3. Connect one end of an MU Jumper Cable to the MU socket on the designated Slave unit.
A. Connect the other end of the MU jumper cable to the MU receptacle on the locomotive.
B. Additional jumper cables and locomotives can be added to the chain.
C. The MU railcar lines of up to 8 locomotives can be tested at one time.
3.3.4.If a specific test is required, press F2 Select
A. Use the Prev (F1) and Next (F3) buttons to navigate to the desired test.
B. Press Select (F2) to select the test.
3.3.5.The entire test or a subset of the selected test may be selected.
A. If the entire test is required, press Select (F2) for the All Tests selection.
B. Use the Prev (F1) and Next (F3) buttons to navigate to the other test options. Then press
Select (F2) for the desired option.
3.3.6.Before pressing F3 from the “Self Test Pass” menu, note that the Shorts test will begin
automatically at 5 seconds after pressing F3. Press F3 now to continue to Shorts Test menu.
3.4. Shorts Test - Slave Unit with Cable
3.4.1. From the “Shorts Test” menu, press F2 to start the shorts test.
A. “Run Shorts Test” menu is displayed. Wait for test to complete
B. If “Shorts Test Fail” is displayed, press F2 to review the faults. Follow the displayed menu
options to review each fault or return to retest.
C. If “Shorts Test Pass” is displayed, press F3 to continue to “Slave Unit Ready.”
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3.4.2. Leave the designated slave unit in its current condition and go to the other end of the
locomotive consist to set up the master unit.
3.5. Setup - Master Unit
3.5.1.Set up a second MU Cable Tester unit to be used as the master.
A. Remove the cover.
B. Power switch is off.
C. Confirm emergency shut off switch to be in home position (button up).
D. Select power source: internal battery or apply AC adapter.
3.5.2.Locate the Chassis Test Lead from the storage pouch
A. Connect it to the threaded chassis post next to the MU receptacle. The forked terminal
must be securely sandwiched between the threaded nut and threaded post plate.
B. Clip the other end of the chassis test lead to the locomotive chassis.
3.6. Self test - Master Unit
3.6.1. Turn Power switch of master unit to ON position; wait for unit to completely boot up.
3.6.2. Display shows “MU Cable Tester.” Press F1 to set test unit to Master.
A. View the display to confirm “Master Unit” designation.
3.6.3. Press F1 to Start the Self-test sequence.
3.6.4. Wait for the designated master unit to complete self test.
A. When unit displays “Self Test Pass,” proceed to step 3.6.5.
B. If self test fails, resolve source of failure and retest. Indications found on the Display can
be used to help determine cause of failure.
3.6.5.Connect the Master unit to the locomotive consist by inserting an MU jumper cable into the
master MU cable receptacle and the other end into the open end of the consist MU receptacle.
3.6.6.If a specific test is required, press F2 Select
A. Use the Prev (F1) and Next (F3) buttons to navigate to the desired test.
B. Press Select (F2) to select the test.
3.6.7.The entire test or a subset of the selected test may be selected.
A. If the entire test is required, press Select (F2) for the All Tests selection.
B. Use the Prev (F1) and Next (F3) buttons to navigate to the other test options. Then press
Select (F2) for the desired option.
3.6.8. From the “Self Test Pass” menu, note that Shorts test will begin automatically at 5 seconds
after pressing F3. Press F3 now to continue to Shorts Test menu.
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3.7. Shorts Test - Master and Slave Units combined
3.7.1. From the “Shorts Test” menu, press F2 to start the shorts test.
A. “Run Shorts Test” menu is displayed. Wait for test to complete
B. If “Shorts Test Fail” is displayed, press F2 to review the faults. Follow the displayed menu
options to review each fault or return to retest.
C. When “Shorts Test Pass” is displayed, press F3 to continue to “Leakage test” menu.
3.8. Leakage Test
3.8.1.From the “Leakage Test” menu, press F2 to initiate leakage testing; allow test to finish.
A. If “Leakage Test Fail” is displayed, press F2 to review the faults. Follow the displayed
menu options to review each fault or return to retest.
B. When “Leakage Test Pass” is displayed, press F3 to continue to “Continuity Test.”
3.9. Continuity Test
3.9.1. From the “Continuity Test” menu, press F2 to start continuity testing; allow test to finish.
A. If “Continuity Test Fail” is displayed, press F2 to review the faults. Follow the displayed
menu options to review each fault or return to retest.
B. When “Continuity Test Pass” is displayed, press F3 to continue to “Test Complete” menu.
3.9.2. Press F3 to exit or F1 to continue to the Main menu.
4. Specifications
4.1. Physical
4.1.1.Size
The MU Cable Tester System in comprised of two tester units, each housed in a durable
plastic case that measures as follows:
Width: 20”
Depth: 16”
Height: 7.5”
The snap-on vinyl pouch attaches to the top of the case. The additional height of the storage
pouch is less than one inch when empty, and about 1.5 inches with the battery charger/power
adapter and chassis test lead are stored inside.
4.1.2.Weight
The weight of each MU cable tester unit with battery installed and accessory pouch with battery
charger/power adapter and chassis test lead is:
27.5 lbs.
4.2. Electrical
The following electrical parameters must not be exceeded. Operation in excess of these limits
may cause damage to the MU Cable Tester.
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4.2.1.Input Power
A. Battery Charger/Power Adapter Input Voltage 120 VAC 60Hz
B. Input Current 0.8 Amp
4.2.2.Battery Operating Time
A. 5 hours, with fully charged battery
4.3. Environmental
The MU Cable Tester meets the following environmental specifications.
4.3.1.Storage Temperature
A. Storage Temperature Range: -40°C to 85°C
4.3.2.Operating Temperature
A. Operating Temperature Range: 0°C to 70°C
16814-99 Rev. A