GE Transportation Systems Global Signaling, LLC
Proprietary and Confidential
Document No. 5002866 Rev. C (DRAFT)
28 April 2003
SYSTEM OPERATIONS MANUAL
FOR
LOCOTROL
®
REMOTE CONTROL LOCOMOTIVE
(RCL)
P.O. Box 8900
Melbourne, Florida 32902-8900
GE Transportation Systems Global Signaling, LLC
Proprietary and Confidential
Document No. 5002866 Rev. C (DRAFT)
28 April 2003
SYSTEM OPERATIONS MANUAL
FOR
LOCOTROL
®
REMOTE CONTROL LOCOMOTIVE
(RCL)
Prepared by: Approved by:
G. Peltonen Date S. Kellner Date
G. Smith Date Date
GE Transportation Systems Global Signaling, LLC
Proprietary and Confidential
Document No. 5002866 Rev. C (DRAFT)
28 April 2003
Notice/Copyright
These instructions are not intended to cover all details or variations in equipment nor are
they intended to provide for every possible contingency to be met in connection with
installation, operation, or maintenance. Should further information be desired or should
particular problems arise which are not covered sufficiently for the user’s purposes, the
matter should be referred to GE Transportation Systems Global Signaling, LLC. Any
applicable Federal, State or local regulations or company safety or operating rules must take
precedence over any instructions given in this material. GE Transportation Systems Global
Signaling, LLC has no obligation to keep the material up to date after the original
publication. There are no warranties of accuracy, merchantability or fitness for particular
service.
This document contains confidential and proprietary information of GE Transportation
Systems Global Signaling, LLC, and is protected as an unpublished, copyrighted work.
Copyright 2002 GE Transportation Systems Global Signaling, LLC. All rights reserved.
Reproduction and Use Restrictions Agreement
The information contained in this Technical Manual (the “Document”) is the property of
GE Transportation Systems Global Signaling, LLC (“GETSGS”) and is protected by
copyright and other intellectual property laws. Any unauthorized use or reproduction of this
Document without the prior written consent of GETSGS, whether in hard copy or in an
electronic form, is strictly prohibited (except as otherwise set forth below).
GETSGS hereby grants to the purchaser of the GETSGS equipment, or licensee of the
GETSGS software (such purchaser or licensee, including, but not limited to all employees
and/or representatives, referred to herein as “You”), to which the Document pertains, the
following limited reproduction rights. This Document will remain the property of GETSGS,
will be used solely for its intended purpose and will not be used in any way directly or
indirectly that is detrimental to GETSGS or its affiliates, and such Document will be kept
strictly confidential by You and will not be disclosed to any person in any manner
whatsoever, except that You may disclose the Document or portions thereof to those of its
directors, officers, employees who need to know such information (it being agreed that
those individuals will be informed of the confidential nature of the Document and will
agree to be bound by this agreement and not to disclose the information to any other
person). You agree to be responsible for any breach of this agreement by its
Representatives. You may make additional copies of the Document solely for Your internal
use in connection with the GETSGS equipment or GETSGS software to which it pertains,
provided that each copy is a complete copy, is not placed into the public domain and does
not alter the content or meaning of the Document in any way, and provided further that
each such copy preserves unaltered all trademark, copyright, patent designations and
proprietary or confidentiality notices contained therein, including this Reproduction and
Use Restrictions Agreement. By reproducing the Document and/or any portion thereof, You
expressly agree to these terms and conditions. Any other use, distribution or reproduction of
any portion of the Document without the prior written authorization of GETSGS is
expressly prohibited. Without limiting any other rights or remedies of GETSGS, in the
event that You or any of Your employees, agents or contractors violate any terms or
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Document No. 5002866 Rev. C (DRAFT)
28 April 2003
conditions of this Agreement, You agree to indemnify, defend and hold harmless GETSGS
from and against any and all claims, damages, losses, liabilities and expenses (including
reasonable attorney’s fees) that can be incurred or awarded by reason thereof. You also
agree that GETSGS shall be entitled to equitable relief, including, without limitation,
injunction and specific performance, without proof of actual damages or exhausting other
remedies, in addition to all other remedies available to GETSGS at law or in equity.
DataTrain
®
is a registered trademark of General Railway Signal Corporation. Trademarks,
marked and not marked, are the property of their respective owners.
®
LOCOTROL
is a registered trademark for GE Transportation Systems Global Signaling,
L.L.C.
FCC Compliance
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at their own expense.
Compliance Statement (Part 15.19)
This device complies with Part 15 of the FCC Rules and with RSS-210 of Industry Canada.
Operation is subject to the following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may
cause undesired operation
Warning (Part 15.21)
Changes or modifications not expressly approved by the party responsible for compliance
could void the user’s authority to operate the equipment.
RF Exposure (OET Bulleting 65)
To comply with FCC RF exposure requirements for mobile transmitting devices, this
transmitter should only be used or installed at locations where there is at least 2m
separation distance between the antenna and all persons.
GE Transportation Systems Global Signaling, LLC
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Document No. 5002866 Rev. C (DRAFT)
28 April 2003
Safety Conventions
GE Transportation Systems Global Signaling, LLC, Technical Information Department
under the direction of the designated equipment Product Manager, issues this document.
The manual provides equipment setup instructions. Please read carefully and thoroughly
understand the instructions and processes before making any adjustments or modifications
to the equipment. Carelessness may result in loss of life or property damage.
The following table illustrates and describes the primary safety and static sensitive symbols
used throughout this document.
Through our Technical Support Hotline, 1-800-645-6245, you can directly reach a Product
Support Leader Monday through Friday, 8 a.m. to 5 p.m. or visit the GE Transportation
Systems Global Signaling website.
For after hours Locomotive Products technical support pertaining to RCL, call 1-800-8257090 and press 3.
Revision History
This document supersedes all previously issued versions, providing new or revised
information. The most recent publication can be determined by comparing the last three
characters at the end of the part number and the date issued.
GE Transportation Systems Global Signaling, LLC
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Document No. 5002866 Rev. C (DRAFT)
28 April 2003
REVISION RECORD
Revision Date Description
A 11/21/02 Initial Document/Revision
B 03/06/03 Incorporate Product Updates
C 04/28/03 Incorporate Product Updates
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1. INTRODUCTION
1.1 Document Overview
The following outlines the content of Remote Control Locomotive (RCL) Operations
Manual:
• Introduction – Describes the purpose and physical description (Chapter 1).
• Controls and Indicators – Lists and describes the controls and indicators (Chapter 2).
• Operation – Provides guidelines for operation as well as information on the various
modes used (Chapter 3).
• System Faults – Lists the system faults and actions (Appendix A)
This manual refers to the operator as the user of the RCL system; however, the term
operator and you are used interchangeably when outlining procedures or instructions.
1.2 Purpose of Equipment
The Remote Control Locomotive (RCL) system provides railroad yard crews the ability to
control one locomotive at a time through an Operator Control Unit (OCU) for switching
and general yard operations. The locomotive under control can be used in Multiple Unit
(MU) locomotive consists. The system provides control of the locomotive by command
signals transmitted over a radio link from the OCU. Operationally, several trains equipped
with the RCL system can operate on the same radio frequency and within radio range of
one another. Additionally, the RCL system allows two OCUs to operate the train in a pitch and catch method where only one OCU is in control of the train. The RCL system consists
of the portable OCU and a Locomotive Control Unit (LCU) located on the locomotive and
other support components. The support components are such items as an operator vest for
the OCU, an electronic fence for hump yard operations, and various safety and operational
attachments to the locomotive.
1.3 Physical Description of Equipment
The RCL system consists of On-board locomotive equipment and Off-board Operator
equipment. The Off-board equipment functions as the commanding unit and the On-board
equipment functions as the locomotive controlling unit (Figure 1.3-1).
The locomotive equipment is mechanically designed to withstand, the shock and vibration
encountered in locomotive operation. The system is sealed against dust, locomotive gasses
and oily fumes; however, it is not weatherproofed and must be sheltered from the elements.
The Operator Control Unit (OCU) is designed to meet NEMA 4 standards and to withstand
the rigors encountered in the railroad environment, however, the OCU is not waterproof
and must be sheltered from the elements.
Copyright 2002, 2003 GE Transportation Systems
Global Signaling, LLC
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Document No. 5002866 Rev. C (DRAFT)
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The major components of the RCL system are briefly described in the following table.
Table 1.3-1 Remote Control Locomotive Components
Component Description
Component Description
Operator Control Unit (OCU) Contains the switches and controls necessary to control the
RCL locomotive as well as the alarms and fault reporting
messages (see Figure 1.3-2).
Operator Vest Contains the D ring clips for attaching and securing the OCU
during RCL operation (see Figure 1.3-3).
Setup Control Unit (SCU) Contains the equipment on the RCL to allow for operator set-
up, system status display, and provides RCL system
interfaces to on and off train equipment (see Figure 1.3-4).
Voice Radio Contains a standard 35-watt Spectra locomotive radio. This
radio provides the capability for the SCU to send alerts and
status over the railroad voice radio network (customer
provided).
Headlight Control Module Contains the electronics used for controlling the Long and
short hood headlights. These control both Bright and Dim
operation (see Figure 1.3-5)
Locomotive Control Unit (LCU) Contains the electronics, which perform the functions
necessary to control the overall system operations. In
addition, it provides electrical isolation between the system’s
module circuitry and the locomotive’s train line signals (see
Figure 1.3-6).
Brake Control Unit (BCU) Contains the electronic and pneumatic devices to control the
locomotive Automatic, Emergency, and Independent brakes
(see Figure 1.3-7).
AEI Tag Reader Contains the necessary tag reader electronics for detecting
track bed mounted AAR/ISO AEI tags. These tags will be
placed at the defined boundaries of operation such as yard
containment or pullback, as well as at high traffic areas, such
as grade crossings within the boundaries (see Figure 1.3-8).
Radio Module Contains the low power radios. This radio provides the closed
loop radio based communications between the OCU and the
LCU (see Figure 1.3-9).
Axle Generator Contains the electronics to detect locomotive wheel rotation
rate and convert it to speed and direction signals (see Figure
1.3-10).
Traction Motor Current Module Contains the electronics necessary to interface to the
Locomotive traction motor shunt (see Figure 1.3-11).
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Component Description
Air Sensor Module (ASM) Contains the electronic and pneumatic devices used to detect
Brake Pipe airflow, Truck Brake Cylinder cut in, and Horn
activation (see Figure 1.3-12).
GPS Contains necessary equipment for Global Positioning
Satellite (GPS) location determination to supplement AEI
Tag Reader System.
Emergency Stop Buttons Two exterior and one interior mounted red mushroom
emergency stop buttons for RCL. (see Figure 1.3-13)
O
p
r
a
e
Display
LEDS
Speed
Speed Enable
Loco Brake
Loco Brake Enable
Direction
Train Brake
Pitch/Catch
Tilt Ovr-ride
Headlight
On/Off/Mode
Tilt
Power
Mngmt
RF Router (if needed)
ISM Band Radio
R
O
P
E
A
O
T
E
V
T
S
t
o
r
R
o
C
n
t
o
r
Interface
Actuator
Conditioning
Processor
ISM Band
Radio
Battery
AEI Tag
Reader
A
B
C
H
l
IRDA
T
A
RCL PTU
P
T
U
Event Downloader
Voice
n
U
t
i
Voice
Synth
IRDA
Interface
S
t
e
-
u
p
o
n
C
t
r
o
l
U
n
t
i
GPS
Receiver
Status
Control
Display
Buttons
LEDS
Radio
L
o
c
o
m
o
t
v
i
o
C
e
ISM Band
Radio
Processor
I/O
+
Drivers
I/O
Speed (2)
R
E
T
Y
R
E
G
R
Speed
Air Brake
I/O
n
t
r
o
U
l
n
t
i
Excitation
Amp
Axle
Generators
Brake
Control
Pneu.
Headlight F Brt
Headlight Dim
Headl i g h t R Brt
Alarm
A Valve
B Valve
C Valve
D Valve
Forward
Reverse
Gen Field
Manual Sand
Slow Speed Enable
Wheel Slip
PCS
Light
Pneu
Bell
Horn
Emr Stop
26-L
Power
Traction
Current
Figure 1.3-1 RCL Top Level Block Diagram
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Figure 1.3-2 Operator Control Unit (OCU)
Figure 1.3-3 Operator Vest
Figure 1.3-4 Setup Control Unit (SCU)
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Figure 1.3-5 Headlight Control Module
Figure 1.3-6 Locomotive Control Unit (LCU)
Figure 1.3-7 Brake Control Unit (BCU)
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Figure 1.3-8 AEI Tag Reader
Figure 1.3-9 Radio Module/Router
Figure 1.3-10 Axle Generator
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Figure 1.3-11 Traction Current Module
Figure 1.3-12 Air Sensor Module
Figure 1.3-13 Emergency Stop Button
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1.4 Operational Overview
In conventional railroad yard switching operations without an RCL system, all car and
locomotive movements require an operator on board the locomotive as well as personnel on
the ground to direct movements and set switches.
The RCL system provides the yard crews with the ability to control the locomotive from a
portable/handheld unit, thereby eliminating the need for an operator on board the
locomotive. The yard crew can then set switches and directly control the locomotive/train
movements from the ground. Additionally, the RCL system allows one operator to transfer
control to another operator in a pitch and catch method when control of the train is needed
from another position in the yard.
The yard crew uses the portable OCU to command locomotive movement. The OCU also
provides the operator the ability to control the direction, speed, and braking of the
locomotive/train. Additionally, the OCU provides the capability to control the headlights,
manual sand, bell, and horn. The OCU provides fault and alarm status data from the
locomotive.
The LCU on board the locomotive receives the commands from the OCU and activates the
appropriate control functions. Control relays or solenoid valves control each function on the
locomotive. Sensor circuits monitor the status of the controlled functions to ensure that the
control function has been properly activated. If the status does not match the commanded
function, a miscompare alarm is generated and appropriate action is taken to ensure the
locomotive is in a safe and appropriate state.
If communications are lost between the OCU and LCU for greater than 5 seconds the LCU
will go to the Park state where the locomotive is idled and a full service automatic and
independent brake application is made. The system remains linked and if communications
are restored the Park State can be recovered and normal operations resumed. If
communications is lost for longer than the comm. loss unlink time as set in the
Configuration File, the LCU will go to the Safe State where the emergency brakes are
applied, the locomotive is set to idle, and the system is unlinked.
1.5 OCU Commanded Functions
The OCU detects the operator inputs and transmits these commands to the LCU. The LCU
then activates the appropriate control signals to carry out the commanded control function.
Table 1.5-1 lists the normal command functions transmitted to the LCU.
Table 1.5-1 OCU Command Functions
Electrical Functions Pneumatic Functions
Electrical Functions Pneumatic Functions
Direction Automatic Brake Applications and Releases
Set Speed Independent Brake Applications and Releases
Bell Emergency Brake Applications and Releases
Horn
Sand
Headlight
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1.6 LCU Control and Status Functions
When the LCU receives commands from the OCU, it activates the appropriate locomotive
control lines needed to perform the commanded control function. Locomotive status lines
are monitored to ensure that the proper functions have been activated and to provide
feedback for function control loops. Table 1.6-1 and Table 1.6-2 lists the normal LCU
controlled and monitored functions.
Emergency Stop Buttons ER Pressure, BC Pressure, MR Pressure
Rear Headlight Switch Position BP Pressure
Wheel Slip Front and Rear Truck BC Pressure > 25 psi
PC Switch Bell
Traction Motor Current Horn
Axle Generator #1 Speed Feed (Brake)Valve (FV)
Axle Generator #1 Direction Penalty Pipe
Axle Generator #1 Speed Switch Pipe
Axle Generator #1 Direction BP Flow
Locomotive Alarm
Manual Sand
Governor Shutdown
Hot Engine
Ground Fault
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LR
SS RS RR
RI
28 April 2003
2. CONTROLS AND INDICATORS
This Chapter provides the operator with a comprehensive background for operation of all
controls and an understanding of the monitoring indications. Each control and indicator
located anywhere on the system is listed and described in one of the tables provided.
Refer to Figure 2.1-1 and 2.1-2, OCU layout, when reading Table 2.1-1 and Table 2.1-2;
Figure 2.2-1, SCU Assembly, when reading Table 2.2-1 and 2.2-2; and Figure 2.3-1 and
2.3-2, LCU Assembly, when reading Table 2.3-2.
No attempt is made to describe any circuitry in detail. Only functional descriptions are
provided. For detailed circuit descriptions, see the Service Manual.
2.1 Operator Control Unit (OCU)
The OCU contains controls, a display, a speaker and an Infra-Red Port (see Figure 2.1-1).
Table 2.1-1 lists and describes the Operator controls. Table 2.1-2 lists and describes the
OCU outputs. Commanded functions are indicated on the OCU display by a flashing LEDs
and the actual locomotive status is indicated by a solid LEDs. When the actual locomotive
status matches the commanded value the status LED is solid.
ABS
BHS
IR Port
TOR
IBS
ABI
IBI
BHI
Display
SI/TOI
SSI
Future use
(spare)
Future use
(spare)
PCC/LNK
BatterySonalertMHL
PWR
Figure 2.1-1 Operator Control Unit – Actuators
GE Transportation Systems Global Signaling, LLC
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that result in the OCU transmitting speed and
stop commands. Movement of the Speed
Selector also provides a signal to reset the
vigilance timer.
Speed Selector (SS) (Hump Yard OCU)
The Speed Selector provides eight positions
that result in the OCU transmitting speed and
stop commands. Movement of the Speed
Selector also provides a signal to reset the
vigilance timer.
Left Reset (LR)
Right Reset (RR)
These switches need to be pressed first to
allow the following OCU actions within 3
seconds:
• SS out of stop
• ABS from full to charge
Also these buttons:
• Command Manual sanding if pressed for
more than 5 seconds:
• Resets OCU vigilance.
• Approves linking of secondary OCU
• Commands sleep mode option
• LR:
i) unfreezes locomotive status screen
ii) lowers OCU LED brightness
• RR:
i) freezes locomotive status screen
ii) increases OCU LED brightness
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Function Description
Reverser Selector (RS)
The RS is a three-position toggle switch:
(a) FWD Position: Activates Locomotive
Forward trainline (TL8)
(b) N Position: Neutral, no direction
commanded
(c) Rev Position: Activates Locomotive
Reverse trainline (TL9)
Independent Brake Selector (IBS)
The IBS provides five positions that result in
the OCU transmitting the following
independent brake commands:
(a) emergency
(b) full
(c) medium
(d) low
(e) released
Actuation of the IBS also provides a signal to
reset the vigilance timer.
Automatic Brake Selector (ABS)
The ABS is a three-position toggle switch. The
Center position is a no change position. The
ABS toggle position away from operator’s
body is a momentary position that results in the
OCU transmitting a command to the next
sequential brake application in the following
sequence:
(a) Release
(b) Minimum (7 psi reduction)
(c) Light (15 psi reduction)
(d) Medium (20 psi reduction)
(e) Full (26 psi reduction)
(f) Charge
The ABS toggle position toward operator’s
body for at least 2 seconds results in the OCU
transmitting a direct release command.
ABS also resets OCU vigilance.
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Function Description
Bell and Horn Selector (BHS)
The BHS is a three-position toggle switch. The
BHS toggle position toward the operator is bell
and horn off. The BHS switch center position
results in locomotive bell on with horn off. The
BHS toggle position away from the operator is
a momentary position and results in a bell and
horn on.
BHS also resets the vigilance timer.
Manual Headlight (MHL)
The MHL is a push button that results in the
OCU transmitting a headlight command to
control the brightness level (Off, Dim, or
Bright) of the Locomotive consist’s front and
rear headlights. MHL resets the vigilance
timer.
Tilt Over-ride / Tilt Test Over-ride / Status
(TOR)
The TOR is a three-position toggle switch.
TOR toggle in the center position shall be in
the neutral position.
TOR toggle position toward the operator is a
momentary position and adjusts the OCU
display for status. Toggling the switch Multiple
times steps the Status display through the
following status displays:
• Loco Status
• OCU Status
• Link Status
TOR toggle position away from operator is a
momentary position for tilt timer extend and
tilt test. The Tilt Override feature will be
activated for up to 60 seconds when the switch
is toggled to this position. Changing any OCU
control will cancel the tilt override timer.
TOR also resets the vigilance timer.
Pitch Catch Control / Link (PCC/LNK)
The PCC/LNK is a momentary switch that:
• Starts OCU linking via infrared port to SCU
• Pitch and catch operation to move locomotive
control to a secondary OCU
• Resets OCU vigilance.
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Function Description
Power (PWR)
The PWR is a push button switch that performs
a soft power on/off of the OCU and must be
held for 5 seconds to power off the OCU.
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LR
SS RS RR
RI
28 April 2003
ABS
BHS
IR Port
TOR
IBS
ABI
IBI
BHI
Display
SI/TOI
SSI
Figure 2.1-2 Operator Control Unit - Indicators
Table 2.1-2 OCU Outputs/Indicators
Function Description
Display The display is used to report system events and
status and fault and alarm data. Toggling the
TOR actuator to the Status position selects the
following system status:
1. Loco Status
2. OCU Status
3. Link Status
Independent Brake Indicator (IBI)
The IBI is the status indicator for the
Independent Brake Selector (IBS). It indicates
the actual independent brake level (illuminated
indicator) and the commanded independent
brake level (flashing indicator) for the LCU.
The following braking levels are indicated:
(a) EMER
(b) FULL
(c) MED
(d) LOW
(e) REL
Automatic Brake Indicator (ABI)
The ABI is the status indicator for the
Automatic Brake Selector (ABS). It indicates
the actual automatic brake level (illuminated
indicator) and the commanded automatic brake
level (flashing indicator) for the LCU. The
following braking levels are indicated:
(a) CHARGE
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