To power off, press and hold the button for 2 seconds until the power light flashes rapidly.

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350-044-1 A23596 Polara Engineering, Inc. Page 1 of 9

EZ510 Security Box User’s Guide

The EZ510 Security Box is a specialized programming device used for transferring firmware, configuration data, and voice message/wave files to Polara’s EZ Communicator series of products. Typical application of the EZ510 is in a knockdown situation to copy the audio files and configuration program from a “good” EZ Communicator Push Button Station (EPBS) to the new replacement EPBS.

Powering the Security Box On/Off

All functions in the Security Box are controlled using the single button on the control panel of the Security Box. To turn on the Security Box, press the button. The blue light will light and the unit will perform a scan and self-test of all other lights.

To power off, press and hold the button for 2 seconds until the power light flashes rapidly. The Security Box will also power off after 30 seconds of inactivity.

Battery Use

The Security Box uses standard AAA batteries. Typical battery life is about 8 hours of use. It is recommended that multiple sets of extra batteries are kept in the technician’s kit with the Security Box. When batteries are low, the blue power light on the Security Box will flash slowly (1 flash per second) indicating that the batteries need to be changed. Once the light starts to flash, there may be less than 5 minutes of battery life remaining.

Due to the length of time necessary to program the CCU2EN .cip firmware, it is recommended that fresh batteries are installed before performing this update. If the batteries fail or programming becomes interrupted during the programming of the .cip firmware, it is possible (but not likely) that the CCU2EN will no longer be operational and will need to be sent to Polara with an RMA for repair.

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Getting the most out of your Security Box

In order to fully utilize all features of your Security Box and be prepared for any situation while in the field, the following setup is recommended. Every field kit which contains a Security Box should have at least one previously prepared flash drive, a USB A/B Cable, and fresh backup AAA batteries.

The flash drive would contain ONLY a knockdown file (see knockdown section for more information). Since the knockdown file contains a password, if more than one password is utilized in your inventory of intersection equipment, a separate flash drive will be required for each password. Note: Only one knockdown file is allowed per flash drive.

A second flash drive (not supplied) may be included in the field kit which would contain all current firmware files for each Polara EZ Communicator device. This includes any 2-Wire or 4-Wire EPBS firmware as well as CCU2EN firmware. Only these firmware files should be on this flash drive. No audio, configuration, or knockdown files should be included.

If you utilize custom audio messages in the EPBS’s, we recommend keeping these messages stored on flash drives in the traffic cabinet at the intersection. For example, at an intersection for Main at Broadway, there would be two flash drives prepared. One flash drive would contain Main at Broadway (Voice on Location and Walk audio files) while the second flash drive would contain Broadway at Main (Voice on Location and Walk audio files). See voice message section for instructions on creating Security Box Wave Files.

Creating the Security Box Kit and keeping the custom audio message flash drives inside the traffic cabinet at the intersection will ensure that the technician will have the tools necessary for nearly any situation.

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Creating Audio Security Box File

In order to store audio messages onto an EPBS using the Security Box, the messages must be prepared and stored onto a flash drive using a PC. Polara’s EPBS Audio Programmer software is used to generate the audio file in a similar manner as programming the EPBS using the software. Instead of programming the EPBS, the Security Box file is created and exported for storage onto the flash drive.

Polara EPBS Audio Programmer software Application Version 1.13, or newer, is required to create a Security Box file. If you do not have the software, contact your Distributor, or Polara, for more information.

Installing the EPBS Audio Programmer software:

Extract the software to a folder on your computer. In the folder called EPBS Audio Programmer, run the setup.exe file to install the software. If a previous version of the EPBS Audio Programmer was installed on your computer, it must be uninstalled using Add/Remove programs from the Control Panel prior to installing the new version.

Note: Microsoft .NET Framework v3.5 is a required component and will be installed as a part of the software installation if it is not detected. An internet connection is required to download this component if it is needed.

Creating Audio Security Box file:

Once the software is installed, open the program by clicking on the EPBS Audio Programmer icon. Follow the instructions in the help file to create your audio message set.

When all messages have been chosen and added, instead of clicking Next to program your EPBS, click on the File menu and choose “Export Security Box File”.

Enter the password used for the intersection in which these messages will be installed. All enabled messages will be exported and added to an .enwv file.

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Creating Configuration Security Box File

In order to store configuration parameters onto an EPBS using the Security Box, the configuration profile must be prepared and stored onto a flash drive using a PC. Polara’s 4 Wire EZ Communicator PBS USB Configurator software is used to generate the configuration profile and export it to a Security Box file. Instead of programming the EPBS directly with the PC connected to the EPBS using the USB cable, the exported file is stored on the flash drive and programmed using the Security Box.

Polara 4 Wire EZ Communicator PBS USB Configurator software version 3.04 or newer is required to save a Security Box file. If you do not have the software, contact your Distributor, or Polara, for more information.

Installing 4 Wire EZ Communicator PBS USB Configurator software:

Extract the software to a folder on your computer. In the folder called EZUSB Config, run the setup.exe file to install the software. If a previous version of the software was installed on your computer, it must be uninstalled using Add/Remove programs from the Control Panel prior to installing the new version. Note: Microsoft .NET Framework v4.0 is a required component and will be installed as a part of the software installation if it is not detected. An internet connection is required to download this component if it is needed.

Creating Configuration Security Box File:

Once the software is installed, open the program by clicking on the icon created during installation. Follow the instructions in the help file to create your configuration set.

When all configuration settings have been chosen, instead of clicking Update PBS to program your EPBS, click on the File menu and choose “Save Profile to Security Box File”.

Enter the password used for the intersection in which the configuration will be installed. Choose a location and a file name for the Security Box file.

Once the export process is complete, copy the file created to a flash drive. Note: There can only be one .en4c file per flash drive.

The current version of the 2-Wire EPBS does not have functionality which allows saving of configuration parameters via the Security Box or USB. Development is underway for software Service Pack 1 (SP-1) which will add this functionality to the 2-Wire units. Until this new software is released, only 4-Wire EPBS can utilize the configuration reading and saving features.

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Programming with the Security Box

Once a flash drive has been prepared for use with the Security Box, it can be used to program one or more units in the field.

Power on the Security Box unit by pressing the power button. Once the unit has powered on and the lights have flashed, insert the flash drive into the USB slot marked Flash Drive. The Flash Drive light should turn green if the flash drive is good and can be read. If the Flash Drive light turns red, then the flash drive may contain an invalid format, or may be malfunctioning.

Connect a USB A/B cable from the EZ Device to the USB slot in the Security Box marked EZ Device. The EZ Device must be powered up in order to be used with Security Box. The EPBS must be powered on and operating normally.

The EZ Device light will turn green if the EPBS or CCU2EN is powered on and functioning properly. If the light turns red, then the device may not be functioning correctly or the device may not be a valid EZ device.

Once an EZ Device has been connected and recognized, the Security Box will search the flash drive for files which are valid for the connected EZ Device (See diagram on pg. 9 for light to file chart). Lights corresponding to each file will turn green for each recognized file. If no files are located on the flash drive, the Flash Drive light will turn red. If any of the files found are corrupt, contain an incorrect password, or do not meet the minimum version prerequisites, then the Flash Drive light will turn red and the light corresponding to the file in error will turn red.

When both the EZ Device light and Flash Drive light are green and one or more file lights are green, then the unit is ready to begin programming.

Press the button to begin the programming process.

When programming begins, files will be programmed in order from 1 to 6. The light corresponding to the first available file will flash green while programming is in process. Once the file has been completed, the light will turn steady green and then next available file will flash green.

When all files have been programmed, all six file lights will turn green signifying that the programming process is complete and the USB cable can be removed from the EZ Device.

It is VERY IMPORTANT that the USB cable and flash drive are not disconnected while programming is in process. If the programming process is interrupted, it is possible (but not likely) the EZ Device may become unresponsive and may require an RMA to repair.

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Knockdown

The Security Box includes a knockdown feature which allows copying configuration parameters and audio files from one EPBS to a second EPBS. This will aid in situations where an EPBS was damaged and requires replacement. A technician can utilize the knockdown feature to copy the information from a working EPBS with the same parameters and write them to a new EPBS to replace the damaged EPBS. Note: The knockdown feature only works between EPBS’s of the same type. For example, settings from a 2-Wire EPBS can only be saved back to a 2-Wire EPBS and cannot be transferred to a 4-Wire EPBS. Additionally, the firmware versions stored in the destination EPBS must be the same or newer than the firmware versions of the source EPBS.

All configuration parameters are copied, but only audio messages which are enabled in configuration will be copied. For example, if the unit is configured to use Locate Tone 1, Clearance Tone 1, Custom Walk 1 and Custom Information Message, then only these four audio files will be copied. If countdown, direction messages, and 2nd language options are enabled, then all sounds associated with these

features will also be copied. Note that the time required to copy and write the files will increase with each sound which is enabled.

Note: Configuration parameters can be copied and written to all 4-Wire EPBS’s, but only to 2-Wire EPBS’s which have been upgraded to Service Pack 1 (v4.00 or greater). For 2-Wire units which have not been upgraded, the configuration parameters can only be read or written using the EConfigurator or via Ethernet in the CCU2EN. Since the configuration parameters cannot be determined on these units, audio messages to copy will not be chosen based on configuration parameters. Only sounds in Custom Walk 1 and Custom Information Message (Voice on Location) will be read and written for these 2-Wire units.

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Using the Knockdown Feature

Insert the knockdown flash drive into the Security Box.

Press the button on the Security Box to power the unit on. Verify that the Flash Drive light turns green. If the light is red, then the flash drive is improperly formatted, or is malfunctioning.

Connect the USB A/B Cable from the Security Box EZ Device USB slot to the source EPBS containing the information that will be copied. The EZ Device light should turn green if the device is powered up and functioning correctly. If the Flash Drive light turns red after inserting the EZ Device, then either the password stored in the knockdown file is incorrect, or the knockdown file is not present or corrupt. If both Flash Drive light and EZ Device light are green and all 6 file lights are off, then the Security Box is ready to read from the EPBS. Press the button to begin the reading process.

The Security Box will create files 3 and 4. The file lights for these files will flash while reading is in process and show steady when reading is complete. When all six file lights turn on, then the process is complete. Pressing the button again will reset the Security Box and you will see the file lights turn on for each file which was created. Do not press the button again at this stage or it will begin writing these files back to the device.

Remove the USB cable from the source EPBS device and connect the cable to the destination EPBS. When both Flash Drive light and EZ Device light are green and the file lights for 3 and/or 4 are lit, then the Security Box is ready to write the information to the EPBS.

Press the button to begin programming. When programming is complete, all six file lights will turn on. The files 3 and 4 which were written to the destination EPBS are deleted from the flash drive and the Security Box will be ready to read another set of data. Pressing the button again after programming is complete will reset the Security Box and only the Flash Drive light and EZ Device light will turn green. All six file lights will be off.

Remove the USB cable from the EPBS and verify that the settings and audio messages were copied as expected.

For non Service Pack 1 (v4.00 or greater) EZ Communicator 2-Wire EPBS’s and CCU2EN’s use the EConfigurator to set the proper configuration settings.

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Creating the Knockdown File

To utilize the knockdown feature, a flash drive must be prepared using a PC. This flash drive can be retained with the Security Box as part of a kit and does not need to be changed or modified once it has been prepared. The flash drive will contain a single “knockdown” file which contains the user password for the EZ Communicator units.

Obtain the EPBS Audio Programmer software from Polara (see page 3). Application Version 1.13 or greater is required for Security Box file creation.

After installation of the EPBS Audio Programmer software, open the application.

Insert a blank flash drive into a spare USB slot in your PC. Follow flash drive testing and formatting instructions if necessary.

From the File menu of the EPBS Audio Programmer software, choose “Create Knockdown File”.

Enter the password which is present in the Polara EZ Communicator units desired for use with the knockdown feature. Note: If more than one password is used for various installations, a separate flash drive and knockdown file is required for each password.

Browse to the flash drive desired for use and save the knockdown file. Any filename is acceptable; however, the file extension must be “.knck”.

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Flash Drives

File Types

The Security Box can program the following types of files:

File 1 File 2 File 3 File 4 File 5 File 6

EN2 (2 Wire EPBS) .en2a .en2m .en2c .enwv -- --

EN2 w/ Ext. Spkr .es2a .es2m .en2c .enwv -- --

EN4 (4 Wire EPBS) .en4a .en4m .en4c .enwv -- --

EN4 w/ Ext. Spkr .es4a .es4m .en4c .enwv -- --

CCU2EN .ccp .cip .cip .cip .cip --

Files are always programmed in order from File 1 to File 6. Each flash drive can contain only one file of each file type.

For EPBS:

File 1: Firmware file which controls the USB and Audio functions of the EPBS. File 2: Firmware file which controls the main operational functions of the EPBS. File 3: File which stores configuration parameters for the EPBS.

File 4: File for programming audio messages into the EPBS. For CCU2EN:

File 1: Firmware file for the central operating processor of the CCU2EN.

Files 2-5: Firmware file for the individual channel processors in the CCU2EN. The same .cip firmware file is used for each of the 4 channel processors.

Formatting a Flash Drive

Flash drive must be formatted in FAT (FAT16/FAT32) in order to be readable with the EZ510 Security Box. To determine if the flash drive is formatted correctly, insert the flash drive into the Flash Drive USB port on the EZ510. The Flash Drive light will turn green if the flash drive is formatted correctly and can be read by the Security Box. The light will turn red if the flash drive cannot be read.

To format your flash drive properly, insert the Flash Drive into your PC. Open My Computer and right click on the appropriate drive of your flash drive and choose “Format…”. Choose FAT from the File System dropdown and click Start. All data on the flash drive will be erased and the flash drive will be formatted with FAT file system. Once formatting is complete, remove the flash drive from your PC and re-test with the Security Box.

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