PROTECTOR IV TRACKSIDE FRICTION MANAGEMENT SYSTEM QUICK START GUIDE Installation, Operation, Maintenance and Troubleshooting
Contents Welcome 3 Tool List 3 Common Tools for All Systems 3 For Imperial Systems (North America) 3 For Metric Systems (Global) 3 Installation 4 Site Selection 4 Tank Installation 4 DC Powered Systems with Solar Panels 5 AC Powered Systems with Batteries 5 AC Powered Systems without Batteries 5 Bar Installation (General) 6 Gauge Face Bars 6 Top of Rail Bars 6 Smart Wheel Sensor 7 Operation 8 Start Up 8 Digital Control Box Overview 8 LED Status 8 Check Output Settings, Battery Voltage, and Product Level 9 Adjust Application Rate and Pump Settings 9 Priming 9 Check Wheel Counts 10 Reset Pump Time Out (PTO) 10 Warnings 10 Troubleshooting 11 Product 11 Power 11 Wheel Counting 11 Motor / Pump Assembly 11 Product Distribution 11 Contact Information 12 2
Welcome This Quick Start Guide is intended to provide an overview of the required activities necessary to properly install, operate and troubleshoot your PROTECTOR IV wayside friction management system. This document is intended for users who are already familiar with the PROTECTOR IV equipment, and is not intended as an in-depth user manual or for new operators. Please refer to the L.B. Foster Friction Management website or contact an L.B. Foster representative for a full selection of user manuals and training material. Americas: Europe: www.lbfoster-railtechnologies.com www.lbfoster.eu This Quick Start Guide is intended for use with both Gauge Face (GF) and Top of Rail (TOR) wayside friction management systems. Tool List Common Tools for All Systems > > Track shovel > > Pick axe > > Cordless impact wrench with 1/2 drive > > 1/2 drive swivel joint > > 1/2 drive ratcheting socket wrench (short handle) > > 1/2 drive ratcheting socket wrench (long handle) > > 6 (150 mm) extension for 1/2 drive ratchet > > 10 mm hex key (Allen) wrench (or 10 mm hex bit for 1/2 drive ratcheting wrench) > > Channel-lock pliers > > Locking pliers (vise-grips) > > Crescent wrench with 1-5/8 (42 mm) span > > Pipe wrench > > Phillips screwdriver > > Flat head screwdriver For Imperial Systems (North America) > > 1/2 drive deep well impact sockets: Sizes: 1-1/8, 15/16, 3/4, 9/16, 1/2, 7/16, 10 mm > > Combination wrenches: Sizes: 1-1/2, 1-3/8 (x2), 1-1/8, 1-1/16 (x2), 7/8, 9/16, 1/2, 7/16, 10 mm > > 7/16 nut driver > > Cable cutters > > 2-5 lb hammer > > 2 (50 mm) putty scraper > > Wire brush > > Utility knife > > Pail lid opener > > Caulking gun > > Industrial grade caulk > > Magnetic torpedo level > > Hand-held compass > > 25 foot (8 m) tape measure > > Digital multi-meter > > Combination square > > Torque wrench up to 150 ft.lbf (200 N.m) For Metric Systems (Global) > > 1/2 drive deep well impact sockets: Sizes: 24 mm, 19 mm, 17 mm, 15 mm, 13 mm, 10 mm, 8 mm > > Combination spanners: Sizes: 30 mm, 24 mm, 17 mm, 15 mm, 13 mm, 10 mm 8 mm, 9/16 > > 4 mm hex key > > 5 mm hex key 3
Installation Site Selection > > Select a site that provides access to the unit for regular maintenance. > > Select a site where railhead is in excellent condition and there is no pronounced railhead wear. > > Avoid selecting a site where trains routinely slow down or come to a complete stop. > > It is not recommended to install a unit in a curve which can cause premature wear on the wiping bars. DO NOT install bars closer than 200 ft (60 m) to an insulated joint or spiral of a curve. > > If both TOR and GF systems are being installed, install the TOR a minimum of 200 ft (60 m) before the GF. > > Verify the maximum allowable install distance from rail based on length of supply hose(s) supplied. Verify the minimum allowable install distance from the rail based on safety regulations and clearance for track equipment. > > For solar powered units, the location should receive a minimum of four hours of southern sunlight per day in the Northern Hemisphere. > > For Remote Performance Monitoring (RPM) systems using cell communication ensure adequate cell coverage available. Tank Installation > > Position tank on level stable ballast using a concrete pad or railroad ties (or sleepers). > > Position the tank so that the hoses exit the tank parallel to the track. > > For units equipped with a solar panel: Position the tank so the solar panel is away from the track General track layout (gauge face installation shown) NOTE: A passing train can damage improperly installed components. Allow sufficient track time to fully complete the installation and clear the track. Dual track PROTECTOR system with solar panel 4
DC Power Systems with Solar Panels > > The preferred method is to mount the solar panel to the PROTECTOR tank. If necessary, the panel can be positioned remotely to allow better access to sunlight. > > Assemble the pole into one piece and loosely assemble the solar panel to the pole with the two U-bolt clamps. > > Loosely attach the support arm to the solar panel and the pole with the pipe clamp. > > Angle of panel equals latitude +10. > > Tighten all bolts and zip tie cable to pole. > > If applicable, peel away the protective sheet on the panel and raise the assembled pole and solar panel into the vertical position against the tank and into the clamp block halves. > > Rotate the solar panel pole so that the solar panel is facing due south in the Northern Hemisphere (north in the Southern Hemisphere). > > Tighten solar panel clamp block halves with a 10 mm Allen wrench. > > Feed the panel cable through the tank wall fitting and tighten the wall fitting nut to ensure a weather tight seal. > > Connect the solar panel red wire to the PV+ terminal of the voltage regulator and the black wire to the COMterminal. > > Connect the ring terminals of the red wire [BAT+] from the voltage regulator and the controller power harness wires (one for single or two for a dual track) to the positive [+] terminal on the battery and the black wires [COM-] to the negative [-] terminal on the battery. AC Power Systems with Batteries > > Feed the AC power cable through the tank wall fitting and tighten the wall fitting nut to ensure a weather tight seal. > > Wire the AC power cable to the Ground Fault Circuit Interrupter (GFCI) as per the wiring diagram located in the Clean Hands Compartment. Note this may be labeled as GFCI or On/Off Switch. > > Connect the ring terminals of the red wire [BAT+] from the battery charger and the controller power harness wires (one for single or two for a dual track) to the positive [+] terminal on the battery and the black wires [COM-] to the negative [-] terminal on the battery. AC Power Systems without Batteries For 200 lb Transit Systems Only > > Feed the AC power cable through the tank wall fitting and tighten the wall fitting nut to ensure a weather tight seal. > > Wire the AC power cable to the Ground Fault Circuit Interrupter (GFCI) as per the wiring diagram located in the Clean Hands Compartment. Note this may be labeled as GFCI or On/Off Switch. PROTECTOR system with solar panel mounted to tank 5
Bar Installation (General) > > To confirm bar and clamps fit with existing tie (or sleeper) spacing, loosely assemble wiping bars to rail clamps and lay bars next to the rail. > > Ensure inlet elbows clear rail hardware. > > Ensure mounting clamps are square to rail and fasten them to the base of rail. As the J-bolt nuts are being tightened, occasionally tap clamp blocks to drive the V slot onto the rail base. > > Secure the mounting bolts to the clamp blocks tightening the bolt on the right hand side first. > > Use included rail clamp spacers to adjust the height. Do not store extra spacers below the head of the mounting bolts. Gauge Face Bars > > Thin blade must be at least 1/8 (3 mm) below any wheel flange contact marks observed along the rail gauge face. > > Thin blade must overlap gauge face by a minimum of 1/8 (3 mm) to ensure bar cannot be pushed under rail head. > > Final positioning of the bar must ensure the thin metal blade is tightly positioned against the rail gauge face for the entire bar length with no gaps or warping present. > > For MC4-XL bars a center clamp is required. > > Gauge face bar height should be set from the top of rail surface to the exit ports of the gauge face bar assembly as per the following: For bars with GreaseGuides: 1-3/8 ± 1/8 35 mm ± 3 mm For bars without GreaseGuides: 1-1/8 ± 1/8 29 mm ± 3 mm Top of Rail Bars > > For TOR-ML bars mount the bar such that the tip of the seal is LEVEL but no higher than the top of the railhead. > > Ensure the TOR- ML bar seal is tightly and completely seated against the rail for the entire bar length. Gauge side TOR level with tip of seal Field side Gauge side 1-3/8 ± 1/8 (35 mm ± 3 mm) TOR to bar exit ports Field side TOR-ML bar shown installed level with top of rail > > For TOR foam bars the top front edge of the foam should be LEVEL with the top of the railhead. > > Ensure the bar is positioned so that the foam is slightly pressed against the field face of the rail and that the exit slit clears the field face and opens into the field corner. TOR level with front edge of foam Gauge side Field side Gauge Face bar with GreaseGuide height from top of rail surface NOTE: Incorrect application bar height may result in wheel impact and bar damage if set too high, or poor product distribution if set too low. TOR foam bar shown installed level with top of rail 6
Smart Wheel Sensor (Standard) > > Secure the cable at the tank wall and connect the sensor cable to the control box. > > Position the sensor before the bars based on traffic and locate a space between two ties (sleepers) to mount the sensor near the end of the cable. > > Place the J-bolt underneath the rail and secure the bracket with the two (2) nuts and washers. The bracket for the sensor must be placed on the gauge side of the rail. > > The top of the sensor should be set to 2 ± 1/8 (50 mm ± 3 mm) below the top of the rail. Use the included spacers to adjust the heights of the sensor. > > Pass the cable through the body of the mounting bracket. > > Use cable ties to secure the cable to the supply hose(s). > > Correct system operation can be tested by swiping a solid metal object over the Smart Wheel Sensor. When a wheel passes the counter will increase and the LED number 3 will turn green or red for each wheel passage (depending on directional settings). > > For bi-directional systems with two Smart Wheel Sensors, the sensors must be placed a minimum of 10 ft (3 m) apart. 2 (± 1/8 ) 50 mm ± 3 mm Gauge side Smart Wheel Sensor height correctly set Field side High-Immunity Smart Wheel Sensor For use only in an area of overhead catenary wires or other strong background electromagnetic fields > > For the High-Immunity Smart Wheel Sensor variant used in a transit environment, the top of the sensor should be set to 1-3/4 ± 1/8 (44 mm ± 3 mm) below the top of the rail. > > If possible, observe the passing of one train and verify the correct operation of the Smart Wheel Sensor by noting both the actual number of wheels passed on the train and the wheels counted on the Digital Control Box. If the counted number of wheels is less than 90% of the actual wheels, move Smart Wheel Sensor to the opposite rail. Smart Wheel Sensor height checked using combination square NOTE: Setting the Smart Wheel Sensor too low may prevent it from counting wheels correctly, setting it too high may result in wheel strikes and damage to the sensor. 7
Operation Start Up > > Press the ON/OFF button to ensure the unit turns on and off and check for the green LED light on the control box. > > Ensure battery is charged to a minimum of 12 V DC. The voltage can be viewed on the screen after the unit is turned on. > > Ensure the pump inlet paddle is installed with screened section down in front of pump. > > Add enough consumable to the product reservoir of the tank to cover the inlet of the pump to prevent air intake. > > If supplied, ensure all ball valves in the piping at the center of the track are open. > > Prime the system as detailed in the Priming section on page 9. > > As the system pumps, ensure material appears from the port(s) of the bars and exits evenly. > > Priming is now complete and the unit is ready for operation. > > For RPM equipped units, note the Division and Milepost of the installed unit and relay this information to L.B. Foster. Digital Control Box Overview POWER Button Push to power ON Hold 2 seconds to Power OFF ESCAPE / BACK Button Can also be used as CANCEL POWER LED Green ON when powered UP Move up in menus or increase values OK Enter / Confirm / Select STATUS LEDs See LED Status Table DOWN Move down in menus or decrease values LED Status LED Color Mode Meaning POWER NONE OFF Power disconnected / system powered off GREEN ON System powered on GREEN ON Auto Prime, PTO Test or PTO Reset running LED 1 RED ON System warnings present (e.g. low voltage) ORANGE ON Simultaneous GREEN and RED LED conditions LED 2 ORANGE FLASHING On while pump running LED 3 GREEN FLASHING On if wheel counted by A sensor RED FLASHING On if wheel counted by B sensor 8
Check Output Settings, Battery Voltage, and Product Level From Start Up Screen: From Main Menu: > > Battery voltage > > Product level > > Output setting (AB) > > Output setting (BA) > > Go to Priming > > Product level > > Battery boltage > > Go to Main Menu Adjust Application Rate and Pump Settings Set directional programming, pump time, pump wheel count: > > Set Mode [AB only / BA only / A,B Same / A, B Different] > > Set pump time for specified direction [0.05-2.00 sec] > > Set number of wheels required to trigger pump activation [1-300] > > Calculated output flow rate based on settings > > Set additional Settings (see below) > > Shown if A,B Different setting selected. Go to BA setting page. Note: If using Full Compensation or Weight Calibration modes ensure correct output settings are used Set locomotive skip wheel count, system boost wheel count, maximum wheels per train: > > Set Locomotive Skip wheel count > > Set System Boost wheel count > > Set Maximum Wheels per Train > > Select Wheel Setting Counter mode Note: Only AB Information shown above. For BA Information select >Next Page on Settings (1/2) page. Priming Priming menu can also be accessed directly from Start Up screen > > Hold OK to run pump > > Set Auto Prime duration > > Run Auto Prime > > Run Test Mode A > B > > Run Test Mode B > A Note: Pushing any button during Auto Prime will stop pump 9
Check Wheel Counts For resettable wheel counts > > Total wheel counts since last reset > > Reset wheel counter > > Shown if A,B Different setting selected. Go to BA setting page. For non-resettable wheel counts > > Non-resettable wheel counts > > Total wheels skipped > > Total pump time > > Back to Information (AB) page Note: Only A B Information shown above. For B A Information select >Next Page on Information (1/2) page. Reset Pump Time Out (PTO) PTO is designed to cut power to pump if pump active for 30 seconds continuously. > > Test PTO if PTO not tripped. Reset PTO if PTO tripped. Note: Menu is context sensitive and will change depending on PTO status. Warnings View active warnings, clear warnings, view warnings report > > View all active warnings > > Clear all warnings > > View warnings report 10
Troubleshooting If product is not present at the application bars, the cause of the problem will be in one of five areas: Product > > Open product lid and check for low product. > > Add new product as needed. Power > > Using a voltmeter check voltage while priming pump, voltage must not drop under 12v DC. > > Disconnect the power source (voltage regulator or battery charger) from the battery (this is necessary in order to prevent a false reading). Check the battery voltage with a voltmeter or turn the control box off and on to display the voltage. Voltage must be between 12-14.5V DC (13.5 V DC is typical). > > Check voltage at output of voltage regulator. The voltage at the end of the voltage regulator wires should be between 12-14.5 V DC. Check voltage regulator fuses. > > For units equipped with a solar panel: Check solar panel voltage. The voltage at end of solar panel wire should be between 19-22 V DC when sunny or 15-17 V DC if cloudy. > > Replace battery, voltage regulator fuses, voltage regulator, or solar panel if required. Wheel Counting > > Verify the operation of the Smart Wheel Sensor (SWS) by passing a solid metal object over the sensor or by observing a train passage to ensure the wheel counter is increasing. Wheel counts can be viewed on the Digital Control Box. > > Verify the height of the SWS as per the instructions on page 7. > > Visually inspect the SWS for signs of a physical impact or damage. > > If the system is not counting, connect the SWS directly into the Digital Control Box to eliminate the possibility of a damaged cable. > > Replace the sensor or sensor cable if required. Motor / Pump Assembly > > Verify the operation of the pump and motor by either activating the Pump Priming or during a train passage and listening for motor / pump rotation. If no movement: > > Reset PTO using Reset PTO instructions on page 10. > > Check 20 amp slow blow fuse on bottom of Digital Control Box. > > Check connections to motor for voltage. > > Check contact brushes at the top of the motor. > > Use the blank end (i.e. non-screened) of the pump inlet paddle to block the pump inlet. Remove the motor / pump assembly and check for debris in pump inlet. > > Rotate the pump manually and verify that no debris is lodged in the pump gears or that any gears are broken. > > Replace motor or pump if required. Product Distribution > > Disconnect main supply hose at the tank wall and check for product while priming (see page 9 for Priming instructions). > > Disconnect the main supply hose at the valve assembly in the center of the track and check for product while priming. > > Disconnect the distribution hoses at each applicator bar and check for product while priming. > > Connect the hoses at each applicator bar and check for product while priming. Check applicator bars for leaks or seal damage impacting product output. Check applicator bars for any clogged ports. If any of the applicator bars and top seals are damaged or clogged, repair or replace them. 11
Need more help? Please refer to the L.B. Foster Friction Management website or contact an L.B. Foster representative for a full selection of user manuals and training material. Americas: Europe: www.lbfoster-railtechnologies.com www.lbfoster.eu L.B. Foster s Friction Management products are backed by market-leading experience in wheel / rail interface issues. Our team of professionals can provide the service and technical expertise necessary to achieve the optimum performance of your equipment throughout its life cycle, including: > > Site surveys and inspection > > Installation and commissioning technical support > > Scheduled maintenance and bulk filling operations > > Performance verification For customer service, contact the appropriate office listed below: Americas 415 Holiday Drive Pittsburgh, PA 15220 USA United Kingdom Stamford Street Sheffield S9 2TX United Kingdom Europe Westring 295 44629 Herne Germany +1.866.523.7245 TotalFrictionManagement@lbfoster.com www.lbfoster.com +44 (0) 114 256 2225 UKSales@lbfoster.com www.lbfoster.eu +49 23231761920 Info.de@lbfoster.com www.lbfoster.eu Data provided in this bulletin is to be considered as representative of current production generally and not as specifications. While all the data presented in this bulletin is believed to be reliable and because conditions of use are beyond our control, L.B. Foster makes no representations, guarantees or warranties, expressed or implied, including but not limited to any implied warranty or fitness for a particular purpose or as to the correctness or sufficiency of data herein presented. Each user should conduct a sufficient investigation to establish the fitness of any product for its intended purpose. No agent, representative or employee of this company is authorized to vary any of the terms of this notice. L.B. Foster, KELTRACK, and GreaseGuide are trademarks of the L.B. Foster Company Doc No: GLB-MAN-PRT-003 Rev: 3 Rev Date: 2018/08/15 Part No: 7880906800 12