4

Section

INSTALLATION PROCESS
Section 4 contains the following subsections:
A. Travel Cable Installation
B. CPU/Distribution Amplifier Mounting
C. e*Display Wiring
D. Firsting Instructions
E. Top-of-Car Enclosure Mounting
F. Start-Up and Adjusting
G. LCD Display Mounting

Section 4 INSTALLATION PROCESS 37

38 INSTALLATION PROCESS Section 4
 Subsection

4A
Installing Traveling Cable
A new traveling cable needs to be installed when an existing travel cable does not
contain 4-shielded pair spares. For new traveling cable a straight run to the
Distribution Amplifier Enclosure is required. If new traveling cable is not
required, a butt splice connection to existing spare pairs in controller is required.
(See e*Display Wiring Section in this manual)

Suspension of Traveling Cables

Traveling cables shall be so suspended at the car and hoistways’ ends as to reduce
the strain on the individual copper conductors to a minimum. Refer to TIP 5.1-3
Traveling Cables for the proper method of installing traveling cables and the
various means of suspension.
1. By its steel supporting fillers (Cable Hanger).

2. By looping the cables around supports for unsupported lengths less

than 100 ft./30.48 meters.

3. By suspending from the supports by a means that automatically

tightens around the cable when tension is increased (Kellems Grip).

Tracking of Traveling Cable

When hanging a smaller or thinner traveling cable along with an existing cable, it is
recommended to maintain the natural loop for the cable, which is about 30 times
the diameter. The thinner cable loop should be 6-8 in./152.4-203.2 mm lower
than the existing heavier traveling cable. The lower loop will help keep the thinner
cable from trying to climb over the other cable. It is also recommended to allow
new cable to hang a period of time (at most 24 hours) before attaching it to the car
to allow the twists that is inherent in the spooling process to get out of the cable.
A lighter cable would require less time since it has fewer layers.

Subsection 4A Installing Traveling Cable 39

A simple rule to determine the length of the T/C for attachment under the car is
as follows:
Run the T/C down the pit wall and cross the pit floor to just under the center line
of the hitch. This point becomes the top of the hitch point.

For more information on the traveling cable and support clamps, see drawing
A__25500Z.
Typical Traveling Cable Procedure:

1. Install traveling cable reel in pit on rollers.

2. Pull enough cable to top of car. (Enough to go from top hanger to

distribution amplifier enclosure in machine room.)

3. Tie cable off to car top.

4. Run car on inspection to the top floor.

5. Hang cable with typical mounting brackets. Refer to proper cable

suspension device, typical car mounting and typical machine room and
hoistway mounting figures in this section.

6. Pull cable from hoistway through trough/conduit in machine room to

distribution amplifier enclosure location.

7. Run car to the bottom floor and hang travel cable from bottom of car
with typical mounting brackets. (Refer to proper cable suspension
device, etc.)

8. Pull cable to car top where top-of-car enclosure is to be mounted.

9. Leave enough spare cable to allow top-of-car enclosure to be moved (if

required).

10. Install travel cable in conduit alongside of the car if local code requires
(low voltage, 24 volts).

40 Installing Traveling Cable Subsection 4A

 Figure 1: Kellems Grip
Round Cable Suspension Device

Old Cable M Kellems E Breaking Figure

Part No. Part No. Dia. Range in./mm Part No. in./mm Strength
lbs./kg
336HT1 2-336AW1 0.750-0.990 13/330.2 024-20-1284 4/ 3100/
101.6 1404.3
336HT2 2-336AW2 1.000-1.240 14/355.6 024-20-1285 5/ 4000/
127 1812
336HT3 2-336AW3 1.250-1.490 15/380.1 024-20-1286 5/ 4000/
127 1812 1
336HT4 2-336AW4 1.500-1.740 16/406.4 024-20-1287 5/ 4000/
127 1812
336HT7 --- 0.750-0.990 10.5/266.7 022-03-015 8/ 1020/
or 203.2 462
REP-022-03-015
336HT12 --- 0.750-0.990 10.5/266.7 024-03-015 8 2050/
or 203.2 928.6
REP-024-03-015

Subsection 4A Installing Traveling Cable 41

 Arrangement Steel Core Size Max. Safe Siecor Figure
Load Per Cable Lbs./Kg Catalog No.
REP-5/32-1 SBKT 5/32 700/317.1 5/32-1 SBKT
REP-1/4-1 SBKT 1/4 1250/566.3 ¼-1 SBKT
2
AAA336MG5
or 1/8 500/226.5 1/8-1 SBKT
REP-1/8-1 SBKT

Figure 2: Cable Hanger

Round Cable Suspension Device

Part Vendor A B D Figure Remarks

mm/in. mm/in. in.
AAA336NQ1 40/1.57 73/2.83 6.35/0.250 3 Material: Nylon
Maximum Capacity: 3 Cables
15 mm/0.60 in. Thick X
76mm/3 in. Wide
AAA336NQ2 133/5.25 127/5.00 7/0.281 4 Material: Formed Sheet Steel
w/Aluminum Clamping Wedge
Draka Maximum Capacity: 3 Cables
Elevator 14 mm/0.55 in. Thick X
Products 101 mm/4 in. Wide
Maximum Load: 227 kg/500 lbs
AAA336NQ3 152/6.0 102/4.0 13/0.5 5 Material: Formed Sheet Steel
Maximum Capacity: 3 Cables
16 mm/0.625 in. Thick X
101 mm/4 in. Wide
Maximum Load: 681kg/1500
lbs

42 Installing Traveling Cable Subsection 4A

Note: If multiple
cables are being
supported, the
narrowest width
cable must not be
less than 70 % of
the width of the
widest cable.

Figure 3: Flat Cable Suspension Device A__336NQ1

Figure 4: Flat Cable Suspension Device A__336NQ2

Subsection 4A Installing Traveling Cable 43

 Figure 5: Flat Cable Suspension Device A__336NQ3

Mounting Pattern for A__336NQ1–3

44 Installing Traveling Cable Subsection 4A

 Typical Car Mounting
(For Round Traveling Cable)

Typical Machine Room and Hoistway Mounting (Concrete Wall)

(For Round Traveling Cable)

Subsection 4A Installing Traveling Cable 45

 Typical Car Mounting
(For Flat Traveling Cable)

46 Installing Traveling Cable Subsection 4A

 Typical Machine Room and Hoistway Mounting
(Concrete Wall)
(For Flat Traveling Cable)

Subsection 4A Installing Traveling Cable 47

 Typical Car Mounting
(For Flat Traveling Cable)

48 Installing Traveling Cable Subsection 4A

 Typical Machine Room and Hoistway Mounting
(Concrete Wall)
(For Flat Traveling Cable)

Subsection 4A Installing Traveling Cable 49

50 Installing Traveling Cable Subsection 4A
Traveling Cable Jacket Stripper
When installing or replacing traveling cable, it has been common practice to use
utility or pocket knives to strip off the insulation jacket at the ends of the cable.
Use of these knives has resulted in many cuts to hands and fingers. In order to
provide a safe and effective tool for this job, OSC now offers some different
traveling cable jacket strippers.

For more information, refer to TIP 41.1-62 Traveling Cable Jacket Stripper.

The jacket stripper comes with two replacement blades that can be stored in the
handle. See the table below for part numbers.
Part No. Description
MT-115002-3 Cable Stripper (RCW/Siecor #36-135)
MT-115002-4 Replacement Blades (RCW/Siecor #36-138)
MT-115002-5 Replacement Tip (RCW/Siecor #36-139)

Subsection 4A Installing Traveling Cable 51

52 Installing Traveling Cable Subsection 4A
 Subsection

4B
CPU/Distribution
Enclosure Mounting
The CPU/Distribution Enclosures can be mounted on the machine room wall or
on the existing controller. These units should be mounted as near the controller
as possible to reduce wiring. e*Display can be used in both a single car, multi car
single group and a multi car multi group configuration. For single car, multi car
single group and a multi-car multi-group installation procedures, refer to the
appropriate sections in this manual.

Warning: 120/240
Volt switch in
back of PC in PC
enclosure must be
set to appropriate
voltage.

Subsection 4B CPU/Distribution Enclosure Mounting 53

Tools and Material Required
Name Resource Have
PPE Equipment Buy locally
½ Drill Motor Buy locally
½ Wrench Buy locally
½ Socket Buy locally
Hilti Gun Buy locally
3/8 Bit for Hilti Gun Buy locally
Hammer Buy locally
Screw Driver Buy locally
Blowout Bulb Buy locally
½ Drill Bit Buy locally
½ Knockout Punch Buy locally
3/8 Drill Bit Buy locally

CPU Material Sundries Kit (Conduit, Connectors, Troughing) as Specified

A__27076V2:
Consists of: Quantity Have
¾ in. EMT Tubing 10 ft. Sections As required
¾ in. Zinc Set Screw Connector (Straight) 6
¾ in. 90° Type LB, LR or LL Set Screw 6
Access Fitting
1 ½ in. EMT Tubing 10 ft. Sections As required
1 ½ in. Zinc Set Screw Connector 2
(Straight)
1 ½ in. 90° Type LB, LR, or LL Set Screw 1
Access Fitting
1 ½ in. Cover for Access Fitting 1

54 CPU/Distribution Enclosure Mounting Subsection 4B

Distribution Material Sundries Kit (Conduit, Connectors, Troughing) as Specified
A__27076V3
Consists of: Quantity Have
¾ in. EMT Tubing 10 ft. Sections As required
¾ in. Zinc Set Screw Connector (Straight) 6
¾ in. 90° Type LB, LR, or LL Set Screw 6
Access Fitting
Wiring Trough 10 ft. Sections (Size as As required
Required)
Panel Connector Wiring Trough As required
Connector (Size as Required)

Single Car Installation Procedures

CPU/Distribution Enclosure Mounting
1. Position the CPU Enclosure on the machine room wall as near the
controller as possible to reduce wiring. Make sure unit is level. ____

2. Mark the centers of the holes in the four external angles at the base as
guides for drilling. ____

3. Drill and mount the CPU Enclosure to the machine room wall. (See
figures and procedures for anchoring CPU/Distribution Enclosure to
concrete, wallboard/hollow block, or existing controller.) ____

4. Install 1 ½ in. EMT Conduit Tubing and fittings from existing wiring
trough to the CPU Enclosure. (Used for traveling cable from CPU to
car.) ____

5. Install ¾ in. EMT Conduit Tubing and fittings from phone line feed
to CPU Enclosure (Supplied by others). ____

6. Install ¾ in. EMT Conduit Tubing and fittings from existing power
supply to CPU Enclosure (Power feed to CPU). ____

Multi Car Single Group and Multi Car Multi Group

Installation Procedures
CPU/Distribution Enclosure Mounting

Subsection 4B CPU/Distribution Enclosure Mounting 55

 1. Position the CPU Enclosure on the machine room wall as near the
controller as possible to reduce wiring. Make sure unit is level. ____

2. Position the Distribution Amplifier on the machine room wall as near

the controller and CPU Enclosure as possible to reduce wiring. Make
sure unit is level. ____

3. Mark the centers of the holes in the four external angles at the base as
guides for drilling. ____

4. Drill and mount the CPU Enclosure to the machine room wall. (See
figures and procedures for anchoring CPU/Distribution Enclosure to
concrete, wallboard/hollow block, or existing controller.) ____

5. Install ¾ in. EMT Conduit Tubing and fittings from phone line feed
to CPU Enclosure. (Supplied by others.) ____

6. Install ¾ in. EMT Conduit Tubing and fittings from existing power
supply to CPU Enclosure (Power feed to CPU). ____

7. Install ¾ in. EMT Conduit Tubing and fittings from CPU Enclosure
to the Distribution Amplifier. (For VGA line from CPU to
Distribution Amplifier.) ____

8. Install ¾ in. EMT Conduit Tubing and fittings from existing power
supply to Distribution Amplifier. ____

9. Install 2 x 4 or 4 x 4 wiring duct from existing wiring duct to

Distribution Amplifier. (Used for traveling cable.) ____

10. Install ¾ in. EMT Conduit Tubing and fittings from one Distribution
Amplifier to the next Distribution Amplifier in series. (For VGA
Cable from one Distribution Enclosure to the next Distribution
Amplifier. Multiple units are wired in series.) ____

Procedures: Anchoring CPU/Distribution Enclosure to concrete

1. Drill holes for anchor bolts (see Figure 1). The anchoring holes for the
Hilti Bolts are the same diameter as the Hilti Bolts (3/8) and should be
a minimum of 1¾ Deep. (Hardware supplied with CPU/Distribution
Enclosure.) ____

56 CPU/Distribution Enclosure Mounting Subsection 4B

 Figure 1

2. Clean out the holes for the Hilti Bolts with a blowout bulb
(See Figure 2). Remove as much dust as possible because the dust acts
as a lubricant on the bolt and makes it virtually useless. ____

Figure 2

3. Rotate the nuts onto the bolts until the top bolt is exposed
(See Figure 3). ____

Figure 3

Subsection 4B CPU/Distribution Enclosure Mounting 57

 4. Drive the bolts into the holes until the nut strikes the base angle.
____

5. Before anchoring the CPU/Distribution Enclosure remove the nuts

and washers and install the enclosure over the bolts (make sure not to
strip the threads). ____

6. Tighten nuts to 25 ft lbs with Torque Wrench. If a torque wrench is

unavailable, two turns from finger-tight position will achieve proper
setting. (See Figure 4). ____

Figure 4

7. Refer back to appropriate Car Installation Instructions (Single or Multi

Car Installation Procedures). ____

Procedures: Anchoring the CPU/Distribution Enclosure on

Wallboard/Hollow block
1. Drill holes for the Toggle Bolts (See Figure 1). The holes for the 3/8
toggle bolts should be 1 in. diameter. (Hardware supplied with
CPU/Distribution Enclosure). ____

58 CPU/Distribution Enclosure Mounting Subsection 4B

 Figure 1

2. Install toggle bolt through mounting angle and install toggle wings
(See Figure 2). ____

Figure 2

3. Fold toggle wings back and insert into wallboard (See Figure 3). ____

Figure 3

4. Tighten toggle to secure enclosure in place (See Figure 4). ____

Subsection 4B CPU/Distribution Enclosure Mounting 59

 Figure 4

5. Refer back to appropriate car installation instructions. (Single or Multi

Car Installation Procedures). ____

Procedures: Anchoring the CPU/Distribution Enclosure on the

Existing Controller
1. Position the CPU/Distribution Enclosure on the existing controller.
Make sure unit is level. ____

2. Mark the center of the holes in the four external angles at the base as
guides for drilling. ____

3. Drill ½ in. thru holes in controller cabinet. ____

4. Mount the CPU Enclosure to the existing controller cabinet with the
3/8 in. hardware supplied with CPU Enclosure. ____

5. Refer back to appropriate car installation instructions. (Single or Multi

Car Installation Procedures). ____

60 CPU/Distribution Enclosure Mounting Subsection 4B

 Subsection

4C
e*Display Wiring Machine
Room & Hoistway

⌧
The diagram on the following page illustrates the wiring in a typical. e*Display
configuration in most simplex installations, all wiring branches out through
conduits from one or two wireways. The wireway(s) and conduit protect the
wiring for the following items:
• Traveling Cable

• Power Cables
Caution: The
diagrams and
• VGA Signal Cables
other specific
wiring data
provided in this
• Phone Line (Comes with RJ11 connector. Any country specific
section are
adapter must be field-supplied)
samples. DO NOT
use this data to • Ground Wires
wire an actual
hoistway. The wiring plan (and subsequent installation) must conform to the National
electrical Code (NEC) and all applicable local codes. Make sure that you observe
all current revisions of the code when planning.
1. Travel Cable

• If new Traveling Cable, run cable uninterrupted from the

Top-of-Car Enclosure to the Distribution Amplifier Enclosure in
the machine room (If multi car single group or multi car multi
group) or the CPU enclosure (If single car). See Figure 1 for
typical travel cable wiring.

• If existing travel cable contains 4 Twisted Pair spares then butt

Note: Do not use splice traveling cable (Draka # 18-102-41 or 18-202-43) from
power from controller to Distribution Amplifier Box (If multi car single group
Emergency Power or multi car multi group) or CPU (If single car) and from car
Circuit.

Subsection 4C e*Display Wiring Machine Room & Hoistway 61

 junction box to Top-of-Car Enclosure. See Figure 1 for typical
travel cable wiring.

• When preparing the ends of the travel cable (four twisted shielded
pair) for termination, the length of the wires must be within
±6 inches./152.4 mm.

• The shield from each twisted pair of the traveling cable must be
connected to the ground lug in the distribution amplifier enclosure
or CPU enclosure depending on application (See Figure 1).
(There are 4 shields per cable with 2 cables [8 shields] connected
to ground lug).

• The shields from the travel cable in the top-of-car enclosure must
also be connected to ground in the terminal block. Note: When
preparing the
• Refer to Table 1 or Table 2 and Figure 1 Traveling Cable Wiring ends of travel
for e*Display traveling cable wiring. cable (twisted,
shielded pairs) for
termination, the
2. Run VGA Cat5 cable from CPU to Distribution Amplifier Enclosure
length of wire
through conduit. (See Figure 5 and 6)
must be within +-
6 in./152.4 mm.
3. Run dedicated phone line (supplied by others) to CPU Enclosure
through Conduit (See Figure 5).

4. Run 110 AC or 220 AC volt cable (power Source) to CPU and

Distribution Amplifier Enclosure through conduit. (See Figures 6, 7,
8, & 9)

5. Make sure power button on the power supply in the distribution

amplifier is in the on position (See Figure 10).

6. Run 110 AC or 220 AC volt (Power Source) to the Top-of-Car

Enclosure. Run through ½ in. flexible conduit (See Figure 4).
Warning: 120/240
7. Run VGA Cat5 Cable from Top-of-Car Enclosure to LCD Display Volt switch in
through Conduit. back of PC in PC
enclosure must be
8. Install Groud Cable (A__174ZU6 supplied with Top-of-Car set to appropriate
Enclosure) from Top-of-Car Enclosure to car frame. Remove paint voltage.
on car frame to ensure proper ground.

62 e*Display Wiring Machine Room & Hoistway Subsection 4C

 Table 1: e*Display Table 2: e*Display Traveling
Traveling Cable Cable Wiring
Wiring
Alternative 1 Alternative 2
Traveling Cable Traveling Cable
Terminal Terminal
Pair Wire Block Pair Wire Block

Black Red 1 1 1 3
White 2 2 6
Red Red 3 2 1 1
White 6 2 2
Orange Red 4 3 1 4
White 5 2 5
Yellow Red 7 4 1 7
White 8 2 8

Figure 1: Typical Traveling Cable Wiring

Distribution Enclosure A__25300D1

Subsection 4C e*Display Wiring Machine Room & Hoistway 63

 CPU Enclosure A__25300C1
Top-of-Car Enclosure A__25300E1

64 e*Display Wiring Machine Room & Hoistway Subsection 4C

 Figure 2: A__25300D Distribution Enclosure Typical Power Feed Wiring

Figure 3: A__25300C CPU Enclosure Typical Power Feed Wiring

Figure 4: A__25300E Top-of-Car Enclosure Typical Power Feed Wiring

Subsection 4C e*Display Wiring Machine Room & Hoistway 65

 Figure 5: Typical Machine Room Installation

66 e*Display Wiring Machine Room & Hoistway Subsection 4C

Note: Cat5 and
power must be
run separately.

Figure 6: CPU Enclosure

Subsection 4C e*Display Wiring Machine Room & Hoistway 67

 Figure 7: Typical Wiring Distribution Amplifier Enclosure

68 e*Display Wiring Machine Room & Hoistway Subsection 4C

 Figure 8: Distribution Amplifier Enclosure
(4-Car Wiring Shown)

Subsection 4C e*Display Wiring Machine Room & Hoistway 69

 Figure 9: Bottom View of CPU/Distribution Amplifier in Machine Room

70 e*Display Wiring Machine Room & Hoistway Subsection 4C

 Figure 10: Distribution Amplifier

Subsection 4C e*Display Wiring Machine Room & Hoistway 71

 Wireways and Conduit
The National Electrical Code requires that elevator wiring (with some exceptions)
be... “Installed in rigid conduit, intermediate metal conduit, electrical metallic
tubing, rigid nonmetallic conduit, wireways, or be Type MC cable or Type M1
cable...”

Wiring
Pulling wires through the conduit should not be difficult. If required, insert a pull
wire (AWG No. 14 or 18) into the conduit and use it to pull the wires through.
Wire supplied as multi-cables are insulated with a colored, PVC jacket and are
individually marked with an identifying number. If the wire has not been
predetermined in the field wiring diagram (e.g., AWG No. 18, or ORG, Wire No.
3), then pull sheets must be prepared listing the wire size, color, and wire number
used for each connection. Individual wires, supplied on reels, must be tagged.

Rules
• Work carefully and neatly to avoid mistakes.
• Be careful when stripping off insulation that you don’t nick the wire.
• Make sure you attach the wire to solderless lugs correctly and that the
connection is electrically sound. This is particularly important when
preparing the termination for wires that must carry heavy currents
since even small resistances generate heat.
• Label each wire as specified.
• Make sure you connect the right wire to the right place.

Wireways
Wireways are sheet-metal troughs with hinged or removable covers for housing
and protecting electrical wires and cable. Wireways are used in the hoistway as a
main trunk from which separate conduit runs are made. Strain sections are
installed in the hoistway to relieve the strain on the enclosed wires. They are
typically placed every 100 ft.
Conduit
Unlike wireways, conduit is only open at the ends. Wires must be “pulled” through
from either end. Conduit comes in three major types:
• Rigid (thick-walled, threaded ends)
• Electrical Metallic Tubing, also known as EMT (thin-walled, unthreaded)
• Flexible (Greenfield or flex)

72 e*Display Wiring Machine Room & Hoistway Subsection 4C

Otis standard wiring uses thin wall conduit or EMT. A special EMT conduit
bender is required. The use of EMT is regulated by code.
Flexible conduit is used primarily where the wiring must accommodate vibration
or movement and to make complex bends. Local codes may limit the length of
this conduit.

Fittings
Fittings are used to connect:
• Conduit to conduit
• Conduit to boxes and wireways
• Fittings to fittings

Conduit can be connected by set-screw or compression-fit couplings. Special

fittings—called pull ells—have removable cover plates to simplify the pulling of
wires.

Subsection 4C e*Display Wiring Machine Room & Hoistway 73

74 e*Display Wiring Machine Room & Hoistway Subsection 4C
Subsection 4C e*Display Wiring Machine Room & Hoistway 75
76 e*Display Wiring Machine Room & Hoistway Subsection 4C
 Subsection

Firsting the e*Display

4D
System
Once the machine room components have been installed and wired, the e*Display
system should be tested and the software downloaded from NGN (Firsting
process) (See NAA or International Procedures). This ensures that the system is
running properly prior to installation. Firsting is the process in which the building
specific software is downloaded to the computer. Prior to initiating the firsting
process the following tasks should be completed:
• Phone line installed

• CPU and Distribution Amplifier Enclosure installed and wired

• Phone line and CPU checked by calling e*Display phone number and
listening for CPU to pickup

• Temporarily connect e*Display test unit (if available) or LCD screen and
power supply to VGA connector on transmitter located in either the CPU
enclosure or the distribution enclosure

NAA Procedure for Firsting the e*Display System:

To initiate Firsting process, call Otisline at 1-800-458-6847 and ask for a team
leader or supervisor. Have the following information available:
• Building name and address

• Machine numbers in group

• PC serial number

• e*Display phone number

• Phone number where mechanic can be reached at job site

Subsection 4D Firsting the e*Display System 77

International Procedure for Firsting the e*Display System:

To initiate firsting process, notify the supervisor and have him call (952) 563-4400
and have the following information available:

• Building name and address

• PC serial number

• e*Display phone number

• Phone number where mechanic can be reached on the job site

Firsting Verification

• Site-specific loop will download in 15 min. to 2 hours depending on

content.

• Once firsting process is initiated, installer can continue with installation of

car components.

• Verify building template has been downloaded.

• If any issues occur with firsting process, NGN will contact the installer
directly at phone number supplied to Otis Line.

• Once firsting has been verified, call Otis Line and let them know it has
been completed.

78 Firsting the e*Display System Subsection 4D

 Subsection

4E
Top-of-Car Enclosure
VGA Receiver

Tools and Materials

Name Resource Have
PPE Buy locally
3/8 Drill Motor Buy locally
5/16 Drill Bit Buy locally
7/16 Wrench Buy locally
7/16 Socket Buy locally
½ in. Knockout Punch Buy locally
3/8 Drill Bit Buy locally

Material List Sundries (Conduit, Connectors) AAA27076V1

Consists of: p/n Qty Have
½ in. Greenfield (72 in. Length) 342AP88 2
Power
Cable ½ in. Straight Connector A__00440AAA002 4
½ in. 90° Connector 440G1 4

Traveling 1 in. Greenfield (72 in. Length) 342AP70 1

Cable 1 in. Straight Connector A__00440AAA004 2
1 in. 90° Connector 440G3 2

1 ½ in. Greenfield (72 in. Length) 342AP109 1

VGA
Cable 1 ½ in. Straight Connector A__00440AAA005 2
1 ½ in. 90° Connector 440G7 2

Subsection 4E Top-of-Car Enclosure VGA Receiver 79

Procedures: VGA Receiver Enclosure
1. Locate VGA receiver enclosure on car top in a place that is accessible
because there is some adjustments to be made later.

2. Install with hardware provided:

(4) ¼-20 x 1 ½ Bolts

(4) ¼-20 Nuts
(4) ¼ in. Flat Washers
(4) ¼ in. Lock Washers

(A) Mark holes and drill with 5/16 drill bits

(B) Install enclosure

3. If required, install ½ in. flexible conduit and fittings from Top-of-Car

Enclosure to Power Supply. Needed only when power is not supplied
in travel cable. (Power feed when required.)

4. Install 1 in. flex conduit and fittings from existing wiring duet to Top-
of-Car Enclosure. (Travel Cable)

5. Install ½ in. flex conduit and fittings from COP to Top-of-Car

Enclosure. (Power to display in car)

6. Install 1 ½ in. flex conduit and fittings from COP to Top-of-Car

Enclosure (VGA CAT5 to Display in Car).

80 Top-of-Car Enclosure VGA Receiver Subsection 4E

 Subsection

4F
Start-Up and Adjusting
e*Display Calibration Instructions

⌧
e*Display requires calibration to the LCD Display located in the COP and
Magenta Research box located in the Top-of-Car Enclosure. Prior to adjusting
the LCD display, verify that the red LED, when lit on the bottom of the
electronics enclosure, signifies that power is to the unit, and the green LED, when
lit, signifies the video signal is present.
NOTE: CPUs cannot be swapped out. Each CPU has a phone number
Caution: CPUs
cannot be
designated to that CPU through NGN. Swapping PCs that have already
swapped out.
been firsted will corrupt the updating process.
Magenta Research Adjustments
There are two adjustments that can be made to the Magenta Research Box:
• Picture Quality Adjustment—for picture quality (objects on LCD
screen appear grainy and fuzzy). Adjust external pot on end of
Magenta Research Box.

• Distance Adjustment—for horizontal tearing (horizontal lines on

the LCD screens or intermittent signal dropout or blockout).
Adjust internal pot located inside the Magenta Research Box.

These adjustments are factory set and only require adjustment if horizontal lines or
picture quality is not acceptable on the LCD screen.
1. Let system run 5 min. prior to making any adjustments.

2. Picture Quality Adjustments (if required). Locate knob on outside of

Magenta Research Box (see Figure 1). Adjust knob in clockwise or
counter-clockwise direction as required obtaining a clear picture.

Subsection 4F Start-Up and Adjusting 81

 Figure 1: Magenta Receiver Box

3. Distance adjustments (if required, normally not required). Locate

adjustment pot inside magenta research box (see Figure 2). Adjust pot
in clockwise or counter-clockwise direction as required eliminating
horizontal lines, tear, or intermittent signal.

NOTE: Adjustment Pot is delicate. Do not apply pressure because pot

will bend over and lie down on board.

Figure 2: Magenta Receiver Box

NOTE: End cover must be removed from VGA connector end to adjust pot.
Board shown removed for picture purpose only. Make adjustment with
board in housing.

82 Start-Up and Adjusting Subsection 4F

LCD Display Adjustments

There are several calibration adjustments that can be made to the LCD Display.
Auto setup should be the initial set-up with brightness and contrast to follow. (see
Figure 3)

• Brightness—controls back light brightness

• Menu button—turns OSD menu on or off (it will auto-time off)

• Select down—moves the selector to the next function (down)

• Select up—moves the selector to the previous function (up)

• + increase the setting/confirm the selection

• – decrease setting

Figure 3: LCD Display

Subsection 4F Start-Up and Adjusting 83

 Figure 4: View A Adjustment Buttons

Adjustment Procedure
1. Allow system to run 5 min. prior to making any adjustments.

2. Select menu button (see View A).

3. Press up or down arrow to select auto set-up.

4. Select +

5. Screen will jump and stretch for proper setting.

6. If quality is acceptable, no additional adjustment is required.

7. If quality is not acceptable, then adjust brightness or contrast buttons

within the on screen menu (see View A).

• Press up or down arrow to select brightness.

• Select + or – button to adjust picture quality to desired level.

• Press up or down arrow to select contrast.

• Select + or – button to adjust picture quality to desired level.

84 Start-Up and Adjusting Subsection 4F

 Subsection

LCD Display
4G
Mounting
The LCD Display can be either Applied Mount or Flush Mount. The flush
mounting requires a new COP Panel with mounting studs. See the following
procedures for applied and flush mounting. The power supply A__25300F2 that
is supplied with the LCD display needs to be mounted in the Top-of-Car VGA
Receiver enclosure (Refer to Top-of-Car Enclosure section).

Tools and Materials Required

Name Resource Have
Drill Motor Buy locally
#7 Drill Bit Buy locally
¼ in. Drill Bit Buy locally
1 ½ in. Hole Saw or Knockout Tool Buy locally
Phillips Screw Driver Buy locally
Center Punch Buy locally
11/32 in. Wrench or Spinet Buy locally
PPE Equipment Buy locally

Subsection 4G LCD Display Mounting 85

Procedures: LCD Display Mounting—Applied Mount
1. Locate LCD Display on existing COP Panel. Make sure unit is level
and plum. Use pattern template for cutout and hole location. Apply
mounting pattern: General Digital Part # 600-126-15. ____

2. Mark mounting holes and cable hole (If required). ____

3. Prior to drilling COP, make sure existing COP electrical components

(buttons, switches, etc.) are covered or shielded from fillings created
when drilling.

4. Drill mounting holes with ¼ in. drill bit. Use #7 drill bit as pilot (if
required). ____

5. Drill 1 ½ in. cable hole (If required). ____

6. Pass LCD Signal Cable through 1 ½ in. hole. ____

7. Install LCD Display and mounting plate to COP with (2) 10-32 x 5/8
Pan Head Screws and (2) 10-32 Nuts with panel thickness of 1/8 to ¼
in. Use (2) 10-32 x 1 5/8 Pan Head Screws with (2) 10-32 Nuts when
mounting to COP with 1 in. thick plywood backing. Hardware is
supplied with LCD Display. (See Figure 1). ____

8. Connect LCD signal cables (5 connector, black wire) to terminations

in the electronic enclosure (See Figure below). ____

86 LCD Display Mounting Subsection 4G

 9. Secure electronic enclosure to back of mounting plate using
(6) 6-32 x 5/16 Nylock Hex Nuts. ____

10. Calibrate LCD. See calibration instructions in Start-Up and Adjusting

Section. ____

11. Install Bezel using (4) 10-32 Screws. ____

Subsection 4G LCD Display Mounting 87

88 LCD Display Mounting Subsection 4G
Procedures: LCD Display mounting—Flush Mount
1. A new COP Panel with a factory cutout and studs is required for a flush
mount installation. Use pattern template for cutout and stud location.
General Digital Part # 600-126-16. ____

2. Install new COP Panel. ____

3. Install LCD Display to COP Panel (See Figure 2). Use (4)10-32 x 5/8 Pan
Head Screws and female spacer with panel thickness of 1/8 to ¼ in. Use
(4) 10-32 x 1 5/8 Pan Head Screws with female spacer when mounting to
COP with 1 in. thick plywood backing. (Hardware is supplied with LCD
Display) (See Figure 2). ____

Subsection 4G LCD Display Mounting 89

90 LCD Display Mounting Subsection 4G