This procedure is for upgrading the APU102E series unit currently running the 486 board to a Pentium motherboard with network communication capability

Required Materials and Tools

Upgrade Parts Required

LPM-TX-N Kit to upgrade APU102E series (486)
- - Pentium CPU Card with Compact Flash board, Ethernet board and SSD daughter-card (attached)
  - Compact Flash with application executable, support files and generic parameters.
24” CAT5 network patch cable
IRQ cable (2 connector, CBL-151-1124G)
RJ45 pass-through jack
“NIC” Label

Tools/supplies Required

Misc hand tools
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 Buss cards

Optional

APU-102 System Operations Manual
Communications program users guide
Compact Flash (CF) Recovery Quick Start Guide
COM4N modification document, 376-0029-05
UART Replacement document # 376-0018-00
TI UART

= Upgrade Procedure =

If your site has maintenance reporting, contact the appropriate department and notify them that you are about to perform the Pentium 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 message will be generated. Maintenance reporting should be disabled until the upgrade is completed. Verify you have all materials required for the upgrade. If possible, check 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 Pentium 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 LPM-TX Pentium card from its anti-static bag and verify the CMOS battery jumper is properly installed. The jumper may be shipped in the off position to conserve the CMOS battery. The jumper is located on the main board, under the PPM-10/100 network card (See Figure 2). 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, flag files, etc) using the ZSEND command. (Refer to APU-102 System Operations Manual, Section 4, and your communications program user guide as necessary)

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

6) Note last sequence number; the starting sequence (next sequence) 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 486SLC card in card cage.

11) Remove the 486SLC from the card cage.

12) Place removed 486SLC 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 (Solid State Disk card)

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

15) Connect the CAT5 cable to the RJ45 jack on the Network adapter board on the Pentium “stack”

16) Install new LPM-TX Pentium-N card combo in card cage slot formerly occupied by the 486SLC card. Note: the Pentium-N combo requires four slots. Refer to the following figure for recommended card placement.

Figure 1: APU-102 Recommended card placement in card cage

17) 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.

18) Affix the supplied “NIC” label over the “LINE 2” label if LINE 2 jack was replaced.

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

20) Remove the cables to the COM4 card and remove it from the card cage. The COM4 must be replaced with a network compatible COM4N or existing COM4 must be modified for network use. Refer to document 376-0029-05 to modify the COM4 for shared interrupt/network operation.

21) Examine the COM4N. The Hardware Watchdog MUST be enabled. Verify the jumper J18 is installed.

22) Install the replacement COM4N or reinstall the modified COM4N card.

23) Reinstall communication cables to COM4N card.

24) Install the new IRQ-N cable supplied (CBL-151-1124G) to the Pentium card, J4 and to the TDA 104-J3. There is no connection to the COM4N. (See Figure 6 for IRQ cable routing) Seat connectors completely.

25) Connect the 50-pin header of multi I/O cable to LPM-TX Pentium card.

Note: Use caution to connect correct cable to the LPM-TX. The 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.

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

27) Reinstall locking bar.

28) Connect external network as necessary.

29) Remove ESD wrist strap.

30) Power on the APU. The Pentium will take up to 5 minutes to boot up initially. A beep may be heard for a second boot-up (this is normal). (SYS LED on solid when ready)

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

32) Upload parameters dumped in step 1. Edit the following parameters that change for 5.0:

<span id="HTMLENTITY:1741260929830" style="font-family: courier new", courier;" class="mwt-preserveHtml">Acquisition.Operating.MaxWheelEvents=4096

<span id="HTMLENTITY:1741277207332" style="font-family: courier new", courier;" class="mwt-preserveHtml">DiskManager.MaxTrains=100

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

33) 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.

34) 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)

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

36) Log back into supervisory level and back up the current parameters with the “BP” command. (may take 2 hits on return key to run)

37) 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.

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

39) Verify site is operational. Notify your network/communications department and/or Comet Electronics that the APU-102 upgrade is complete. Re-enable maintenance reporting if disabled above. If calling Comet Electronics, please provide site #, location, phone number of site and s/n of APU-102.

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

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

Figure 6: IRQ Cable With Pentium CPU (TDA104 50-pin cable removed for clarity)