TSG 07-012 Rev A Multiplexing Faults

TSG#: 07-012
REVISION: A
REVISION DATE: June 18, 2013
ISSUE DATE: July 26, 2007
AUTHOR: A. Ford
APPROVED BY: C. Harkness
Customer Engineering  Electro-Motive Diesel, Inc.  9301 W. 55th Street  LaGrange, IL 60525
TROUBLESHOOTING GUIDE - Multiplexing Faults
Table of Contents
Table of Contents ............................................................................................................................................ 1

Introduction ..................................................................................................................................................... 1
Locomotives Affected:.................................................................................................................................... 1
Documents Referenced: .................................................................................................................................. 1
Theory of Operation ........................................................................................................................................ 2
Multiplex Cycle ........................................................................................................................................... 2
Multiplex Circuit ......................................................................................................................................... 4
Standard Operating Description ...................................................................................................................... 6
Fault Code Troubleshooting ........................................................................................................................... 8
Troubleshooting Tips: .................................................................................................................................. 8
Troubleshooting Steps: .............................................................................................................................. 10
Help Desk Troubleshooting .......................................................................................................................... 14
Appendix A: Inspection Procedure for Grounds .......................................................................................... 15
Low Voltage Grounds: ............................................................................................................................... 15
AC Grounds: .............................................................................................................................................. 16
NOTE: The troubleshooting procedures contained in this guide are intended as general instructions.
If any specific step within this guide causes a violation of railroad or local safety rules, do not
perform that specific step and contact your local EMD rep for troubleshooting guidance.
Changes in revision A of this Troubleshooting Guide are indicated by the box (A) in the margin of
the affected text
Introduction
This Troubleshooting Guide (TSG) is issued to provide an overview and troubleshooting guidelines for
locomotive digital Multiplex system.
Locomotives Affected:
Any EM2000 equipped locomotive.
Documents Referenced:
 Service Advisory 05-050: Troubleshooting APC Low Voltage Grounds
Page 1
Copyright  Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
TSG#: 07-012
REVISION: A
AUTHOR: A. Ford
Theory of Operation
Multiplexing is a process through which several inputs can be monitored with the use of only one input
channel. Selective monitoring makes this possible. Not all inputs to the computer need to be monitored
constantly, just periodically. The inputs are gathered in groups of 5; the CPM looks at the first group for 10
milliseconds, the next group for 10 milliseconds, and so on until it has seen inputs from all five groups. A
sixth group of channels is used for verification of the multiplexing circuit.
Six DIO module output channels are used for completing paths to negative through the multiplexed input
channels. During each 10-millisecond portion of the cycle, a different output channel is energized thereby
allowing monitoring of the different sets of input channels.
Multiplex Cycle
The CPM completes the Multiplex cycle in 100 milliseconds. Each multiplex cycle consists of 10 portions,
each of which is monitored for a duration of 10 milliseconds. The first five portions are for reading system
feedbacks, which consist mainly of contactor interlock feedbacks (P1, B, SGC, MB, etc.) and switch
feedbacks (isolation, engine run, horn, etc.). During each of the first five portions, the CPM energizes a
different DIO output channel and thereby monitors a different set of feedbacks. Based on the operating
conditions of the locomotive, the CPM knows whether a specific feedback interlock should be active.
When the multiplexed output channel containing that specific feedback is energized, the computer is
expecting to see a specific result. For example, when under power, the computer expects to see the P1
interlock feedback closed. If during the multiplexing cycle, the P1 feedback interlock circuit is not
completed, the computer will log a “Failed To Pick Up” fault. The opposite is also true, whereby if the
computer sees a channel active that should not be, it will log a “Failed To Drop Out” fault.
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Figure 1: Multiplex Cycle
The 6th and 7th portions are Multiplex system diagnostic checks. During the 6th portion of the cycle, all
channels are turned ON to verify the circuit is completed on all channels. During the 7th portion of the
cycle, all channels are turned OFF to ensure none of the channels remain energized when they shouldn’t be.
The remaining three portions of the Multiplex cycle serve no purpose. If during the 6th portion, all
MUXON channels do not turn on, or during the 7th portion, all the MUXOFF channels do not turn off, the
computer will log one of the DIGITAL INPUT SYSTEM FAILURE faults show in the Fault Code
Troubleshooting Section.
Figure 1 illustrates the full 100-millisecond Multiplex cycle.
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Multiplex Circuit
Figure 2 illustrates a simplified multiplex circuit. The illustration uses only two output channels and three
input channels. The locomotive multiplex circuit has six output channels and up to 144 input channels. It
can be seen by tracing the circuit how energizing different output channels allows the computer to monitor
different feedbacks.
Figure 2: Example Two Channel Multiplex Circuit
When the DIO-1 (OUT) CH 23 turns ON for (10 ms) the DIO-1 (IN) CH 2, DIO-2 (IN) CH 6 and DIO-2
(IN) CH 8 provide an ON = (1) or OFF= (0) sample back to the CPM. The ON or OFF state of the device
is then compared to an internal lookup table compiled in the CPM’s software logic in order to determine if
the input should be active or not. For example DIO-1 (IN) CH 2 is sampling GFC interlock while DIO-2
(IN) CH 6 is providing a sample of FCF1 interlock. The exception is DIO-2 (IN) CH 8. This input is
connected directly to the DIO OUTPUT channels 21 through 25 with a solid wire connection. This DIO
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(IN) is used exclusively to test the ON state of the OUTPUTS. When DIO-1 (OUT) CH 23 is ON the DIO-
2 (IN) CH 8 will convey an ON state to the CPM, or what is called the MUXSEL-3 value.
The MUXSEL input provides a feedback to the CPM as to the turn ON state of each OUTPUT device that
is used to sample switches or interlocks. The feedback can be observed on the EM2000 fire screen as the
MUXSEL values 1 through 5. The MUXSEL 1 is testing the DIO-1 (OUT) CH 21, then MUXSEL 2 DIO-1
(OUT) CH 22 and so on through CH 25. The DIO-1 (OUT) CH 26 does not have a MUXSEL test.
Continuing, when the DIO-1(OUT) CH 24 turns ON for (10 ms), all the inputs DIO-1 (IN) CH 2, DIO-2
(IN) CH 6 & DIO-2 (IN) CH 8 provide a sample back to the CPM (CPU) to the state of the contact that are
in circuit. During this next sampling period of (10ms) the same inputs previously used are now sampling
the contacts or switches of different components. DIO-1 (IN) CH2 is checking GFD interlock while DIO-2
(IN) CH 6 is checking FCF2 interlock. DIO-2 (IN) CH 8 is now sampling the turn ON state of DIO-1
(OUT) CH 24 or MUXSEL-4 value which should be ON.
Below each INPUT channel is a CMU Plug. All Multiplexed inputs, contacts, interlocks and switches are
connected to the CMU Plug. The CMU base plug, to which the CMU Plug connects, acts as a shorting
connector so that up to Five (5) individual interlock of switches can be connected to One (1) input Channel.
Above each OUTPUT channel is a Diode Input Panel (DIP). The DIP panel diode assembly provides a
gated path for current to travel through the respective INPUTS and SWITCHES to the OUTPUT that is
active (ON). Having these DIP devices in circuit discrimination of the switches or contacts being sampled
is then possible. No cross channeling occurs with these diodes in the circuit, allowing the system to provide
accurate data back to the CPM regardless of the switch position.
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Standard Operating Description

Refer to Table 1 for standard normal operating of the Mulitplex system. The signals listed below can be
located in the Data Meters section of the EM2000 remote session.
Table 1: Multiplex Diagnostic Circuits

Signal Description Normal Operation
MxOf01< Multiplexer Off 1 (DIO 1, Channel 1) OFF
MxOf02< Multiplexer Off 2 (DIO 1, Channel 2 ) OFF
MxOn01< Multiplexer On 1 (DIO 1, Channel 1 ) ON
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Signal Description Normal Operation

MxOn16< Multiplexer On 16 (DIO 2 Channel 8 ) ON
MxOn20< Multiplexer On20 (DIO 3, Channel 4) ON
MxSel1< Multiplexer 1 Feedback ON
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TSG#: 07-012
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Fault Code Troubleshooting

The fault codes listed in Table 2 are addressed by the troubleshooting steps in Table 3.
Table 2: Fault Codes

Fault Code Description
2955 DIGITAL INPUT SYSTEM FAILURE
(CHECK MUX CIRCUIT)
3164 DIGITAL INPUT SYSTEM FAILURE
(CHECK MUX CIRCUIT)
3479 NO START
DIGITAL INPUT SYSTEM FAILURE
3937 AUTOMATIC ENGINE SHUTDOWN DELAYED -
ACTIVE MUX FAULT
4264 NO LOAD - DIGITAL INPUT SYSTEM FAILURE
CHECK MUX CIRCUIT OR BATTERY VOLTAGE
4533 NO LOAD - DIGITAL INPUT SYSTEM FAILURE
BATTERY VOLTAGE TOO LOW
CAUTION: Before following the procedure below, make sure the locomotive is properly locked out
and flagged per your local procedures. Ensure the proper job briefing, safety
procedures and Personal Protective Equipment required for the task were discussed.
Troubleshooting Tips:
Prior to troubleshooting a Multiplex Fault, read through the following tips and keep them in mind as the
troubleshooting steps in Table 3 are performed.
Fault Commonality
 Determine the operating condition of the locomotive at the time of fault. Doing so can help narrow
down the events occurring at the time of the fault and allow you to replicate the conditions at the
time of fault. Determining the operating state of the locomotive is especially useful if the MUX
faults are no longer active.
o Is the unit in power, dynamic brake, or transitioning from power to DB, etc.?
 Are P contactors picked up, B contactors picked up, etc.
o The specific contactors or relays logging faults can be an indicator of the operating
conditions at the time of fault. Attempt to replicate these conditions while troubleshooting.
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o Review the event recorder download in order to determine if there is an event (e.g. bell,
horn, etc.) that coincides with the faults. Any event that coincides is a clue to possible
grounds on the locomotive and helps narrow down the problem circuit.
 Examine the quantity and duration of the faults logged in the archive.
o A “failed to drop out” fault that is active once for a significant length of time is most likely a
hard ground.
o A “failed to drop out” fault that is logged a quantity of times for a shorter duration may be a
spike or short time event
 For example if the fault is logged 60 times and shows a duration of 10 minutes, you
should be looking for an event that has a duration of 10 seconds.
 Failed suppression diodes on magnet valves (horn, bell, sanding, radar blow down,
radiator shutters, etc.) can cause spikes into the circuit. Active all of these type of
valves during testing.
 Usually a number of “failed to drop out” faults are logged together. Look for commonality across
the faults
o Investigate the circuits these faults all share
 In addition to commonality across faults, look for an “odd man out” when it comes to a specific
channel. For example:
o Most P-contactors share the same channel. Is there one P-contactor that didn’t log a fault?
Investigate this contactor.
o Is there one fan that didn’t log a fault when a number of the others did? Investigate this
contactor and circuit.
Low Voltage Ground Investigation

 When investigating low voltage grounds, is the test light steady on or flashing/pulsing?
o A pulsing light indicates a ground in the MUX circuitry
o A steady light indicates a standard 74v circuit low voltage ground
 When isolating low voltage grounds, it is possible to isolate specific circuits by disconnect the plugs
from the DIP panel and even removing pins from the plugs in the DIP panels.
 A MUX fault always requires at least two paths to ground in order to create the fault. Be sure to
locate both grounded paths.
1. A ground in a circuit to provide current
2. A ground in the MUX circuit to allow that current into the MUX circuitry
o Correcting only 1 ground only fixes half of the problem
AC Ground Investigation
 Always run all self-tests (blower, cooling fan, excitation, etc.) and check for AC grounds during the
operation of the self-test.
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EMPATH Multiplex Self Test

A  If the unit has EMPATH then the Multiplex self-testis available. This test allows the user to
activate specific DIO output channels thereby allowing current flow through that entire MUX
circuit. In effect it is freezing the Multiplex Cycle (Figure 1) on a specific channel. This test is
particularly useful when troubleshooting “failed to pick up” faults or faults where the “MuxOn” or
“MuxSel” has failed and is showing off.
DIO Swapping
 Use caution when swapping DIO’s to cure a Multiplexing problem. Swapping DIO modules can
appear to cure a problem when it really has not.
o The input voltage required to “turn on” a channel can vary slightly between DIO’s. A 35v
ground may be enough voltage to activate a channel on one DIO, but may not be enough
voltage to activate a different DIO.
Troubleshooting Steps:
Table 3: Troubleshooting Steps
Step Action Results/Notes
1 Examine the EM2000 fault archive and look for If there are Multiplex faults and repetitive
multiple faults of different relays and/or relay/contactor faults for failing to drop out go
contactors that failed to drop out or pick up, plus to step 2.
the existence of any of the above listed
Multiplex faults. If there are repetitive relay/contactor faults for
failing to pick up go to step 5.
If there are only faults for one individual

contactor, troubleshoot that circuit specifically.
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REVISION: A
AUTHOR: A. Ford

2 Relay or contactor faults that indicate failed to Use a 15-watt test light to check for DC and AC
drop out are usually caused by grounds on the grounds as described in Appendix A: Inspection
locomotive. Procedure for Grounds in order to narrow down
the problem area.
NOTE: Review the Fault Commonality section
of the Troubleshooting Tips listed above in If the 15-watt test light does not light, it is
order to attempt to narrow down the operating acceptable to check with a lower wattage test
conditions of the locomotive at the time of fault. light (6-watt).
Any event that coincides is a clue to possible
grounds on the locomotive and helps narrow Clear any and all grounds and retest.
down the problem circuit.
3 Examine the Muliplexing screen in the EM2000 If any of the “MUXOFF” channels show “ON”,
Data Meters Menu. To locate this screen, select or are flickering from “OFF” to “ON”, this is an
the Locomotive Data button on the engineer’s indication of a ground. Note that it takes more
display screen. This will display the EM2000 than one DC ground to cause mux problems.
remote session box. Now select “Data Meters” Therefore, when checking for DC grounds, look
and then “Mulitplexing”. You may be required for multiple grounds on the locomotive.
to push the “Next” button to scroll to the second
page of the “Data Meters” menu. Check for DC and AC grounds as described in
Appendix A: Inspection Procedure for Grounds.
Examine the “MUXOFF” screens. All of the Clear any and all grounds and retest.
“MUXOFF” must be off. Look for any channels
flickering “ON” and “OFF”, or staying “ON”
constantly.
4 Using the information gained in the step above Replace this DIO module.
and the electrical schematic for the locomotive,
determine which DIO input channel is giving the A quick check can be made by swapping the bad
MUXOFF of “ON”. DIO with an adjacent DIO module, and the
problem should move with the bad module.
If the problem does clear, replace the offending

DIO in the original spot to ensure the problem
re-occurs in order to verify the module was truly
at fault.
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5 Multiple relay/contactor problems that indicate Use the electrical schematic to determine which
failed to pick up are usually caused by circuit has the problem. Inspect all plugs, pins,
intermittent connections. sockets, fastons and wires within that circuit for
loose connections or damage.
Correct any defects and retest.

6 View the “Multiplexing” screen as described in If you isolated a multiplexer with problem, go to
step 3. Normally all “MUXON” should be ON the next step. Otherwise go to step 9.
and all “MUXSEL” must be ON.
In EMPATH, select the “Simulate [F3]” tab and

use the multiplexer self-test. The test enables
you to lock open a DIO output channel, so the
mux inputs associated with that multiplexer will
be active while other inputs will not. Lock each
of the six multiplexer in order to isolate the
multiplexer with problem. Note: Make sure
you select “Normal Operation” after completing
the test.
Similar test can also be run using the EM2000

script in Crosstalk.
7 If there is only one MUXON showing “OFF”, If the problem is fixed, replace the bad DIO
the input channel or the connections to and from module otherwise the fault is in the wiring
it are failed. Use the locomotive schematic to connections. Check for wiring problems in the
determine the input channel that may be failed plugs and wires between the following points:
and swap out that DIO to test. 1. Between the Power Distribution plug and the
plug in the back of EM2000 chassis
2. Between the plug in the back of EM2000
chassis and CMU plug
3. Between the CMU plug and DIP panel
4. Verify positive voltage is present at the PA
wire for that input channel. This wire is
shown at the very top of the schematic on
the Multiplex pages.
5. Replace the computer chassis as a last resort.
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8 Multiple MUXON or MUXSEL channels 1. Verify positive voltage is present at the
showing “OFF” could be due to the loss of a “PA” wire for that input channel. This wire
“shared feed”. is shown at the very top of the schematic on
the Multiplex pages.
2. Verify continuity to negative of the “NA”
wire at the bottom of the Multiplex circuit.
3. Replace the computer chassis as a last resort.
9 Individual MUXSEL channel is reading “OFF” An open circuit exists in the offending
when they should all be reading “ON”. There is MUXSEL circuit. Therefore, qualify all the
a wiring connection problem. An open circuit connections and wiring in the circuit. Make sure
exists in the offending MUXSEL circuit. you trace the entire path from the Power
Distribution panel to the DIO output cannel.
In EMPATH, select the “Simulate [F3]” tab and Inspect all the connections, pins and wires.
use the multiplexer self-test. The test enables
you to lock open a DIO output channel, so the Replace the computer chassis as a last resort if
mux inputs associated with that multiplexer will an open patch is not found in the entire
be active while other inputs will not. Active the MUXSEL circuit.
MUX output channel containing the offending
MUXSEL signal. This will provide a
continuous path to negative in order to
troubleshoot the MUXSEL wiring.
Similar test can also be run using the EM2000

script in Crosstalk.
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Help Desk Troubleshooting
Table 4: Help Desk Troubleshooting Steps

1 Swap the DIO modules. It is recommended to
swap the modules individually with the far right
module.
2 Open any unnecessary circuit breakers. It is If neither of these steps fix the problem, it will
possible one of these circuits could be grounded. be necessary to shop the locomotive. Please
make a note of any troubleshooting performed in
the failure incident.
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Appendix A: Inspection Procedure for Grounds
Low Voltage Grounds:
1. Verify the test 15-Watt light illuminates when connected across battery knife switch.
2. Make sure the locomotive is completely isolated and is not connect to any other locomotive via the
MU cable.
3. Ensure all circuit breakers are closed, and turn on all the lights (cab lights, front and rear headlights,
engine room lights, ground and step lights).
4. Apply one of the test light leads to the positive side of the battery knife switch and the other lead to
anywhere convenient on the car body that is paint free and makes adequate contact. Note if the
light illuminates. If it illuminates, go to step 6 otherwise go to step 10.
5. Now apply one of the test light lead to negative side of the battery knife switch and other lead to car
body ground. Note if the light illuminates. If it illuminates, go to step 6 otherwise go to step 10.
6. If the light illuminates in step 4 or 5 above, it indicates that there is a low voltage ground present in
either the negative side or the positive side. Note that a pulsating light bulb indicates a ground in
the MUX circuit. If the light is steady and not pulsating, go to the next step otherwise go to step 11.
7. Now connect the test light to the side of the battery knife switch that lit the light above and the other
lead to the car body ground.
8. Open one (1) circuit breaker at a time until the test light extinguishes. If the ground clears when a
particular circuit breaker is opened, that circuit needs to be inspected in order to find and repair the
ground.
9. If ground is still present after opening all the circuit breakers, check all the battery connections for
problems.
10. With one lead connected to battery knife switch and the other to car body ground, perform each of
the following tests in order to identify and narrow down the source of the possible grounds:
a. Check the turbo lube pump circuit by shutting down the locomotive engine
b. Operate the horn, bell, sanders, heated windshield etc.
c. Perform the contactor/relay self test. During the test, keep an eye on the contactor/relay that
causes the light to illuminate.
d. Perform throttle 8 load test
e. Perform all the other EM2000 self tests
f. Perform throttle 1 stall test
11. View the MUXOFF data meter screens to determine which MUXOFF input is showing ON or
flickering between OFF and ON.
12. In the locomotive electrical schematic, identify the circuits that are associated with the affected
channel.
13. Once the circuits are identified, the ground can be isolated by disconnecting the D1 plug on the DIP
panels one by one until the ground goes away. As you go through the process of disconnecting the
D1 plugs that belongs to the affected channel, leave the plugs disconnected once the ground is
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isolated to a DIP panel. Leave that panel isolated and start reconnecting the removed plugs to
ensure that there are not additional grounds on the mux circuit.
14. After identifying the affected DIP panel, plug the D1 connector back in, ensure the ground is still
present. Follow the electrical schematic and start to isolate the ground by removing pins from the
D2 and D3 plugs on the DIP panel that was isolated in step 13.
15. After determine what mux channel has the ground, start isolating the components until the failed
component is identified.
AC Grounds:
1. Verify the 15-Watt test light illuminates when connected across battery knife switch.
2. Check for grounds with the test light connected between each of the six (1-6) Companion Alternator
test points and car body ground under following conditions:
a. Perform throttle 2 stall test
b. Perform throttle 1-8 load test. Throttle out slowly and stop at a throttle position at which the
light illuminates.
c. Perform all the blower self tests
d. Perform Cooling fan self test
3. On SD70ACe and SD70M-2 models, don’t use the test light to check for grounds on the APC
winding of the companion alternator. APC winding test points are 7, 8 and 9. Follow Service
Advisory 05-050: Troubleshooting APC Low Voltage Grounds to check for grounds across each of
the test points 7-9 and car body ground with the use of a megger.
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TROUBLESHOOTING GUIDE - Multiplexing Faults

Table of Contents ............................................................................................................................................ 1

TROUBLESHOOTING GUIDE - Multiplexing Faults

TROUBLESHOOTING GUIDE - Multiplexing Faults

Figure 1: Multiplex Cycle

Figure 1 illustrates the full 100-millisecond Multiplex cycle.

TROUBLESHOOTING GUIDE - Multiplexing Faults

Figure 2: Example Two Channel Multiplex Circuit

TROUBLESHOOTING GUIDE - Multiplexing Faults

TROUBLESHOOTING GUIDE - Multiplexing Faults

Standard Operating Description

Table 1: Multiplex Diagnostic Circuits

TROUBLESHOOTING GUIDE - Multiplexing Faults

Signal Description Normal Operation

TROUBLESHOOTING GUIDE - Multiplexing Faults

Fault Code Troubleshooting

Table 2: Fault Codes

TROUBLESHOOTING GUIDE - Multiplexing Faults

Low Voltage Ground Investigation

TROUBLESHOOTING GUIDE - Multiplexing Faults

EMPATH Multiplex Self Test

If there are only faults for one individual

TROUBLESHOOTING GUIDE - Multiplexing Faults

Step Action Results/Notes

If the problem does clear, replace the offending

TROUBLESHOOTING GUIDE - Multiplexing Faults

Step Action Results/Notes

Correct any defects and retest.

In EMPATH, select the “Simulate [F3]” tab and

Similar test can also be run using the EM2000

TROUBLESHOOTING GUIDE - Multiplexing Faults

Step Action Results/Notes

Similar test can also be run using the EM2000

TROUBLESHOOTING GUIDE - Multiplexing Faults

Help Desk Troubleshooting

Table 4: Help Desk Troubleshooting Steps

TROUBLESHOOTING GUIDE - Multiplexing Faults

Appendix A: Inspection Procedure for Grounds

Low Voltage Grounds:

TROUBLESHOOTING GUIDE - Multiplexing Faults

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