AxleGen™

FUNCTIONAL
AND
TECHNICAL SPECIFICATION

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AxleGen™ THIS DOCUMENT CONTAINS INFORMATION THAT IS PROPRIETARY TO ZTR™

Table of Contents
FUNCTIONAL SPECIFICATION ..................................................................................... 3
1 System Overview ..................................................................................................... 3
2 Components ............................................................................................................. 3
3 AxleGen System Description.................................................................................... 3
3.1 Interface Module ................................................................................................ 3
3.1.1 Interface Module Wiring Harnesses ............................................................. 4
3.1.2 Interface Module Mounting .......................................................................... 4
3.1.3 Interface Module Inputs ............................................................................... 5
3.1.4 Interface Module Outputs ............................................................................ 5
3.2 Disc Assembly.................................................................................................... 6
3.2.1 Disc Assembly Wiring .................................................................................. 6
3.2.2 Disc Assembly Mounting ............................................................................. 7
4 Commissioning and Monitoring ................................................................................ 8
5 Technical specification ............................................................................................. 8
5.1 General .............................................................................................................. 8
5.2 Installation .......................................................................................................... 9
5.3 Wiring ................................................................................................................. 9
5.4 Environmental .................................................................................................... 9
ROLES AND RESPONSIBILITIES ................................................................................ 10
ZTR WARRANTY .......................................................................................................... 12
ZTR COPYRIGHT AGREEMENT ................................................................................. 13
REVISION HISTORY .................................................................................................... 15

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FUNCTIONAL SPECIFICATION

1 System Overview

The ZTR AxleGen will translate rotational movement of the locomotive axle into electrical
signals readable by most speed indicator displays, event recorders and cab electronics
in general.

Key benefits and features:

 3 isolated outputs groups

 Up to 8 output channels in total
 24V & 10V asymmetrical outputs and +/-10V symmetrical outputs
 Quadrature outputs available
 Resolutions from 20 to 512 PPR per group
 Manufactured to exceed the demands of tough Railroad environments
 No proprietary software necessary to configure AxleGen

2 Components

The ZTR AxleGen kit contains:

 Interface Module – Contains microprocessor, circuitry and power supply

 Disc Assembly – The locomotive axle encoder
 Input Harness – Connects the Disc assembly to the Interface Module
 Power Harness – Provides power to the Interface Module
 Output Harnesses – Connects to AxleGen to locomotive equipment
 Communication Cable (on a customer request basis) – Connects AxleGen to a
laptop running a modern browser
 AxleGen Mounting Hardware – Fasteners, gasket, tie-downs, etc.

3 AxleGen System Description

3.1 Interface Module

The Interface Module is the ‘brains’ of the AxleGen product. It contains a microprocessor
that samples the encoded locomotive axle motion and together with conversion circuitry,
outputs multiple frequencies of varying amplitudes and resolutions. Axle rotation direction
can also be read from the Interface Module.

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The Interface Module’s configurable outputs are programmed through an easy-to-use

web browser interface. No proprietary software is required. Some troubleshooting
information is also available through the browser.

3.1.1 Interface Module Wiring Harnesses

Wiring harnesses are included per the following:

 Input Harness
o Power to and signals from the Disc Assembly

 Power Harness
o Provides nominal 74VDC power to the Interface Module

 Output Harness
o Provides frequency signals to onboard equipment

3.1.2 Interface Module Mounting

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3.1.3 Interface Module Inputs

The Interface Module requires two input types, power and Disc Assembly signaling.

The Interface Module is powered by nominal 74VDC bus power from the locomotive.
Power is supplied by the included Power Harness.

The Disc Assembly is powered by a 24VDC converter located inside the Interface Module.

3.1.4 Interface Module Outputs

The Interface Module outputs are available in three electrically isolated groups. Each
group can be individually configured in both signal amplitude and pulses per revolution
(PPR). Detailed as follows:

 Each group can be independently configured with a PPR of 20 to 512 inclusively.

 All three groups support 24VDC and 10VDC asymmetrical outputs
 Group 3 can also support +/-10VDC symmetrical outputs
 Group 1 outputs support quadrature signaling; simply use outputs 1 & 2 together
and/or outputs 3 & 4 together (all group 1 outputs can be used independently)

Output Output PPR / Frequency

Group Signal T1 T2 T3
Signal 1

Signal 2
Group 1
Signal 3

Signal 4

Signal 5
Group 2
Signal 6

Signal 7
Group 3
Signal 8

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3.2 Disc Assembly

The Disc Assembly is mounted to the journal box and coupled to the axle splines with a
customer furnished driveshaft. The Disc Assembly operates on 24VDC power supplied
from the Interface Module.

The Disc Assembly outputs a noise resistant signal compatible with the ZTR Interface
Module. Connecting the device directly to locomotive equipment may result in damage to
the Disc Assembly and/or connected equipment. It will not provide useful signals without
the Interface Module.

The Disc Assembly is designed to meet IP67 ingress protection levels for dust and water
tightness.

3.2.1 Disc Assembly Wiring

A wiring harness is included per the following:

 Input Harness
o Power from and signals to the Interface Module

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3.2.2 Disc Assembly Mounting

The Disc Assembly is mounted to a standard 6” x 4.5” PCD pattern and accepts a
common 5/8” ID driveshaft (customer supplied).

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4 Commissioning and Monitoring

Commissioning and monitoring software is hosted in the Interface Module and is

accessible using a standard laptop running a modern, mainstream web browser
(Windows Explorer, FireFox or Chrome released after 2014). An RJ45 to M12 Ethernet
cable complying with the AAR MSRP connects the laptop with the Interface Module. Your
AxleGen kit may have included one of these cables.

The following information is available through the diagnostic port:

 Configuration
o Interface Module outputs information table
o Pulses per revolution (PPR) settings for each of the three groups
o Voltage output settings for each of the three groups
o Disc Assembly location setting; Driver’s side or Conductor’s Side
o Wheel diameter and units of measure settings

 Monitoring
o Real time locomotive speed with analog indicator

 Help & Information

o ZTR Technical Service contact information
o General system information

5 Technical specification

5.1 General

The ZTR AxleGen has been designed and tested to withstand the rigors of railroad
operating environments. As with all ZTR products, the system utilizes high reliability
components applicable to the railroad industry that are designed to maximize life in a
railroad environment.

The system includes installation instructions to guide installers in the application and
commissioning of the equipment.

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5.2 Installation

The ZTR AxleGen will be shipped with the Disc Assembly, Interface Module, and all
necessary harnesses and accessories to complete the basic installation. Refer to the
ZTR AxleGen Installation Manual for detailed instructions.

5.3 Wiring

All ZTR AxleGen conductors (wires and cables) are copper and meet or exceed ITT-
SURPRENANT Specification DAA-1069A - "Diesel - Electric Locomotive Control and
Power Cable".

5.4 Environmental

The system equipment has been designed to meet or exceed EN50155 standard for
Rail Mounted equipment.

Temperature EN50125-1:1999, -40°C to +70°C (-40°F to 158°F) storage

and operation

Vibration EN61373:1999, Interface Module Category 1/Class B (body

mounted equipment), Disc Assembly Category 3 (axle
mounted equipment)

Operating Voltage IEC 60571:2012, Nominal 72 VDC, Rated 82.8 VDC,

Maximum 90 VDC

Surge Immunity EN61000-4-5:2006, 2 kV

EFT Burst Immunity EN61000-4-4:2004, 2 kV (I/O), 2 kV (Power Supply)

Total Weight 18lbs (8kg) approx..

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ROLES AND RESPONSIBILITIES

Customer

a) The customer and/or installer acknowledge that ZTR will only be responsible for
the accuracy of the installation instructions as it pertains to its control system. This
documentation will only retain the accuracy of the electrical schematic and wire
running list furnished to ZTR and specifically would not include any updates made
to the locomotive and not included in the documentation furnished.

b) The customer and/or installer acknowledge that ZTR will only be responsible for
the electrical integrity of the installation instructions, as stated above. The scope
of work does not include removing or adding any functionality to or from the
locomotive control system, other than that specified in this document. The scope
of work also does not include specifying the type of contactors, switches, wire
gauges, etc., that are used in conjunction with our system.

c) The customer will provide and install a common 5/8” ID driveshaft.

d) The customer and/or installer will utilize personnel familiar and skilled with wiring
locomotives, and who have a good working knowledge of the operation of a
locomotive, while performing the installation of the ZTR AxleGen.

e) The customer and/or installer will wire the locomotive in accordance with standard
OEM wiring recommendations. If not ordered as an option, the customer will
furnish the necessary wiring to complete the installation.

f) The customer and/or installer acknowledge that ZTR will be entitled to

reimbursement for any on-site visits to the customer property in accordance with
ZTR’s technical service pricing for any time spent resolving locomotive
performance issues that are mutually agreed upon between the customer and ZTR
as not having been ZTR’ responsibility.

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ZTR

a) ZTR will provide a set of generic installation instructions depicting how the ZTR
AxleGen should be mounted and wired, to interface with the existing control
circuits. ZTR is not responsible for any changes in the design of the locomotives
that are outside the scope of the ZTR AxleGen. Installation Instructions are
supplied in English only.

b) One set of product support documents would be furnished to the customer in .pdf
format as part of the quotation. Additional paper copies are available at additional
charge. The training materials and documentation would be furnished in English
and reflect only a typical ZTR AxleGen operation without providing any specific
information related to this particular application.

c) ZTR can provide on-site commissioning of the ZTR AxleGen, at additional

charge. Pricing for this service would be dependent on location of installation and
duration.

d) ZTR’s warranty and support obligation is limited to defects in material and

workmanship of the ZTR AxleGen and not other parts of the electrical system or
locomotive. Please note attached warranty statement at end of this specification.

e) Once the specification is defined, any changes to it will be handled through change
orders. In cases where a change order results in a price change, the customer will
be furnished with that pricing information. The change would not be incorporated
until such time as approval for this pricing change has been submitted in writing.

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ZTR WARRANTY
a) LIMITED WARRANTY. ZTR (“Seller”) warrants that all equipment sold hereunder
has been inspected and tested and found to meet its published specifications when
shipped from Seller’s plant. Seller warrants that said equipment will be free from
defects in material and workmanship for a period of one year from the date of
shipment; provided, however, that this warranty does not apply to normal
deterioration of replaceable or renewable parts and components. EXCEPT FOR
THE WARRANTY EXPRESSLY SET FORTH IN THE PRECEDING
SENTENCES, SELLER MAKES NO WARRANTY (EXCEPT AS TO TITLE),
EXPRESS, IMPLIED, BY DESCRIPTION, BY SAMPLE OR OTHERWISE, AND
IN PARTICULAR AND WITHOUT LIMITATION MAKES NO IMPLIED
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PURPOSE. No
modifications are authorized in this warranty unless in writing and signed by the
President or any Vice President of Seller.

b) REPAIR OR REPLACEMENT EXCLUSIVE REMEDY. If any item of equipment

fails to conform with the provisions hereof, Buyer’s sole and exclusive remedy is
to return the non-conforming equipment for repair, replacement or, at Seller’s
option, refund, to Seller’s factory, transportation charges pre-paid. If Seller
confirms that such equipment is non-conforming, Seller will repair or replace the
same, free of charge f.o.b. the Seller’s plant, or at its option, Seller may refund or
credit the purchase price paid for the non-conforming equipment. Seller’s
obligation hereunder is subject to the other terms and provisions hereof, and shall
terminate no later than one year from the date of shipment of the equipment.

c) LIMITATION OF LIABILITY; NO CONSEQUENTIAL DAMAGES. Seller’s liability,

whether in contract, in tort, or otherwise arising in any way in connection with the
equipment sold hereunder, the non-delivery of said equipment or in any other
fashion in connection with the equipment or its sale (a) shall not include liability for
any incidental or consequential damages, loss or expense, such as, but not limited
to, loss of profits, loss from business interruption, loss of information, damage or
injury to, or death of, persons or property, or other monetary loss and (b) in any
event shall not exceed the amount paid for the equipment in connection with which
the liability arises.

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ZTR COPYRIGHT AGREEMENT

The Software, Software Materials, Documents, Product Design Information, Hardware
Components provided by ZTR Control Systems constitute proprietary intellectual property
of ZTR and include trade secrets and confidential information of ZTR.

Customer acknowledges that it acquires only the right to use these materials as permitted
hereinunder and does not acquire any ownership, right to title in or to the Intellectual
Property of ZTR Control Systems or any Third Party Intellectual Property.

No part of the above mentioned intellectual property may be reproduced in any form or
by any means, electronic or mechanical, including photocopying, without express written
permission of ZTR Control Systems.

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Policies, Terms & Conditions

1. General Terms & Conditions of Sale. ZTR Control Systems (“Seller”) standard
General Terms & Conditions of Sale that apply to this Statement Of Work are
located at the following location at the link titled “ZTR General Terms &
Conditions of Sale”.
https://www.ztr.com/policies-terms-and-conditions

2. Telematics Sales Terms & Conditions. ZTR Control Systems (“Seller”) standard
Telematics Sales Terms & Conditions that apply to this Statement Of Work are
located at the following location at the link titled “Telematics Sales Terms &
Conditions”.
https://www.ztr.com/policies-terms-and-conditions

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