LX800 Upgrade Procedures with LX-COM for APU102

To provide the procedure to upgrade an APU102 unit to the latest LX800 processor card with the Comet Electronics LX-COM board.

ATTENTION!

The new LX-800 processor board in this kit comes with a compact flash preloaded with the Comet AEI application software, version 5.x. Comet Electronics is permitting the transfer of the license from an existing 5.x AEI licensed system. The applicable embedded Windows and RTX licenses are non-transferrable and new licenses are included with this upgrade. Please refer to the “Version 5.X Upgrade Credit Program” document 385-0014-00.

Scope

This procedure is for upgrading the APU102, regardless of current configuration, to the LX800 platform. Please refer to the Version 5.X Upgrade Credit Program document to insure you are in compliance with all software licensing before proceeding.

Required Materials and Tools

Upgrade Parts Required

• LX800 Upgrade Kit – Includes the following:
• LX800 CPU Card with LX-COM daughter-card (4-Port Serial Adapter)
• 2.7Ah External CMOS Battery
• Compact Flash with application executable, support files and generic parameters.
• IRQ cable (2 connector, CBL-151-1124H) (attached)
• 24” CAT5 network patch cable
• RJ45 Pass-through Jack
• “NIC” label

Tools/supplies Required

• Laptop computer with communication program such as ProComm, HyperTerminal, etc.
• Null modem cable or modem cable with null adapter (25-pin DB male on APU-102 end)
• Antistatic (ESD) wrist strap
• Individual antistatic bag to fit APU-102 STD Bus cards

Optional

• Comet AEI software license if not covered by the Version 5.X Upgrade Credit Program. Contact Comet Electronics for purchase.
• APU-102 System Operations Manual
• Communications program users guide
• Compact Flash (CF) Recovery Quick Start Guide

Upgrade Procedure

If your site has maintenance reporting, contact the appropriate department and notify them that you are about to perform the LX800 upgrade on the APU-102. If you are unable to do the parameter dump and load or file transfers, they can do that for you. During the upgrade process, maintenance messages will be generated. Maintenance reporting can be disabled until the upgrade is completed. Verify you have all materials required for the upgrade. If possible, check the train schedule by the site and schedule the upgrade accordingly to reduce the risk of missed trains.

Note: The parameter dump, file downloads, and preparation of the LX800 card procedures that follow can be done prior to the site visit.

Caution

Follow proper antistatic precautions when handling the boards.

1) Put ESD wrist strap on wrist and connect to ground lug on outside-bottom of APU.

2) Remove the LX800/LX-COM combo from its anti-static bag and connect the external CMOS battery on the LX-COM board, J9, located near the battery and holder. (See Figure 1). The battery may be shipped disconnected to conserve the CMOS battery. Place back into the bag until needed.

3) Connect a laptop to APU-102 via the local port and get a current parameter dump of the site. Refer to APU-102 System Operations Manual, Section 4, and your communications program user guide if necessary.

4) Download any site-specific files (VIO.CFG, header files, APUERROR.DAT, access scripts, flag files, etc) using the ZSEND command. (Refer to APU-102 System Operations Manual, Section 4, and your communications program user guide as necessary)

Figure 1: LX-COM (4-Port Serial Adapter)

5) Verify trains that have been recorded have reported to all active sessions.

6) Note last sequence number; the starting sequence (next) may need to be set on the upgraded processor card.

7) Open the APU enclosure.

8) Power off the APU.

9) Remove the locking bar. (Loosen the thumbscrew and slide the pin toward the center of the card cage to release)

10) Remove cables to the processor card in card cage.

11) Remove the processor card from the card cage.

12) Place removed processor card in individual antistatic bag and label so that it can be easily determined which site/APU-102 it came from.

13) Remove the USSD card (Universal Solid State Disk), if applicable, and place in individual antistatic bag and label so that it can be easily determined which site/APU-102 it came from..

14) Remove the cables to the COM4 card and remove it from the card cage. The COM4 will be replaced with the LX-COM board. If IRQ cable was connected, it will not be reused.

15) If APU doesn’t have a NIC connector on the bottom right side (near the telco jacks), remove the pass-through jack for LINE 2. Install the RJ45 pass-through in its place. The removed RJ11 jack and cable can be left loose inside the enclosure. Apply the supplied “NIC” label over the “LINE 2” label.

16) Connect the CAT5 patch cable to the RJ45 pass-through jack from inside the APU. (Labeled NIC or the one just installed)

17) Remove the DB9 and modular telco cables from the modem and move to the eighth slot from the left.

Note: Cards are not slot addressed so placement doesn’t matter. Recommendations are so existing cables reach and ease of service.

Refer to Figure 2 for recommended card placement.

18) Remove the 10-pin IRQ ribbon cable from the TDA-104. The IRQ cable will not be reused.

19) Remove the 50-pin ribbon from the TDA104. Move the TDA-104 to the third slot from the left. Reinsert the 50-pin ribbon cable to the TDA-104.

Note: Refer to Figure 2 for recommended card placement.

20) Re-secure the TDA-104 cable in the retaining clips.

Figure 2: APU-102 Recommended Card Placement in Card Cage

21) Install new LX800/LX-COM combo into the card cage in the sixth slot.

Note: Refer to Figure 2 for recommended card placement.

Seat cards and connectors completely.

22) Connect the cables formerly connected to the COM4 removed earlier (except IRQ) to the LX-COM board in the same orientation as on the COM4.

Note: Refer to Figure 3 for cable connections.

23) Connect the 50-pin header Multi I/O cable to LX800 card.

Note: Use caution to connect correct cable to the LX800. The LX800 Multi I/O cable has 3 smaller ribbon cables connected to a single 50-pin connector. One is DB9 to modem, one goes to external Local Port and one is AT style keyboard jack (not used). It is the same 50-pin connector as the cable to the TDA104. The TDA104 cable is a full 50-pin ribbon cable.

24) Reconnect the cables to the modem. Modular cable can connect to either jack.

25) Connect the IRQ cable (10-pin ribbon cable pre-attached to the LX800) to the TDA-104, J3 (bottom connector).

Note: Refer to Figure 3 for cable connections.

Figure 3: Cable Connections with LX800/LX-COM

26) Connect the CAT5 cable to the RJ45 jack on the LX-COM board.

27) Inspect/reset all other cable connections to make sure none have come loose during the upgrade process, especially the IRQ cable.

28) Reinstall locking bar.

29) Connect external network as necessary.

30) Remove ESD wrist strap.

31) Power on the APU. The LX800 will take a few minutes to boot up initially. (SYS LED on solid when ready)

32) Set the clock on the APU. (Refer to APU-102 System Operations Manual, Section 4).

33) Upload parameters dumped in step 1. Observe the parameter load to insure all parameters are accepted, especially if loading via the local port. Resend any portions that are rejected.

34) Edit the following parameters changes if upgrading from version 4.x:

Acquisition.Operating.MaxWheelEvents=4096

DiskManager.MaxTrains=100

Note: If serial Inter-track communications is used at the site, edit/verify the appropriate auxiliary data port for 9600 baud as follows: Ports.AUX1PORT.BaudRate=5 or Ports.AUX2PORT.BaudRate=5

35) Edit any other parameters required for testing (Save raw files, transaction logs, etc) or any new parameters (i.e., network settings). Refer to APU-102 System Operations Manual, Section 4, and your communications program user guide as necessary.

36) Upload any site-specific files downloaded earlier with ZREC. (Refer to APU-102 System Operations Manual, Section 4, and your communications program user guide as necessary)

37) Perform MR (Master Reset) with reboot option. Set starting sequence if necessary.

38) Log back into supervisory level and re-enable maintenance reporting if disabled above.

39) Reset the clock if necessary

40) Back up the current parameters with the “BP” command.

41) Use the “SHELL COMMIT” command to save timezone parameters to protected partition. (pre 5.2 software)

42) For proper operation of the CF recovery utility, a new backup image of the current configuration must be created. The CF is pre-imaged with factory defaults. Make an image of the AEI application directory with the “SHELL IBACKUP” command. Follow the instructions on the terminal screen. A reboot is required to initiate the backup. The APU-102 will reboot when the backup is complete. Refer to the CF recovery document for further details.

43) Inspect remainder of AEI site and correct as necessary.

44) Verify site is operational. Notify your network/communications department and/or Comet Electronics that the APU-102 upgrade is complete. If calling Comet Electronics, please provide site #, location, phone number of site and s/n of APU-102, LX800, and Pentium card removed.

Comet Electronics Service technicians are available M-F, 8:00 am to 4:00 pm Central Time if you require assistance or additional documentation.

(888) 700-4214 or (816) 245-5400