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Whitmore LUBRICURVE ELECTRO 5, Installation & Maintenance Manual

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Whitmore LUBRICURVE ELECTRO 5 Installation & Maintenance Manual Download Page 10

10 

 

 

8 

Installation Trackside Items 

8.1

 

Fitting the Trackside Cabinet to mounting tube 

8.1.1

 

The vertical tube is to be installed and the concrete is to be fully cured prior to the 
installation of the cabinet 

8.1.2

 

The Cabinet includes three clamps to hold the cabinet secure to the vertical tube. All 
clamps are to be tightened at final fix. 

8.1.3

 

The cabinet is positioned adjacent to the vertical tube and the three clamps are assembled 
loose around the tube. The cabinet is then lifted approximately 300mm and the clamps are 
tightened. Note if a solar panel is to be fixed to the rear of the cabinet, ensure the rear of 
the cabinet is facing south for northern hemisphere and north for southern hemisphere 
locations. 

8.2

 

Fitting the Trackside Cabinet to Support Frame 

8.2.1

 

The support frame is to be installed on a level firm base, either concrete or two full length 
sleepers 

8.2.2

 

The support frame is to be bolted to the concrete with M8 x 80 anchor bolts or M8 x 100 
coach bolts, if timber sleepers are used. 

8.2.3

 

The Electro 5P cabinet is bolted to the support frame with 4 No. M8 bolts fitted through 
the base of the cabinet. 

8.3

 

Earth Bond 

8.3.1

 

Subject to local regulation it may be required to bond the unit to the track.   A 16.5 mm 
diameter hole is to be drilled in the rear of the cabinet   for a 16mm diameter earth stud 
(Whitmore Rail part No. LCS105-11). 

8.3.2

 

The bond itself must be supplied and fitted directly by Rail owner authorised personnel 
and not by the lubricator installer. 

8.4

 

Fitting the Solar Panel 

8.4.1

 

The solar panel is fixed directly to the rear of the cabinet. There are four spacers that hold 
the solar panel away from the cabinet. Using the M8 security bolts attach the spacers to 
the rear of the cabinet. The solar panel are fixed to the spacers with M8 security bolts. 

8.4.2

 

The cable from the solar panel is routed through a 20mm gland to the inside of the cabinet 
and the ends of the cable are connected to the solar panel controller. 

8.5

 

Battery Charger Electrical Connection 

The majority of the electrical termination is completed in the Whitmore Rail factory prior to 
despatch, a maximum of three site connections (including one for the Wheel Sensor, Section 
10.1.4) are required, for battery charging: 

8.5.1

 

Solar Panel Cabinet Mounted – (see section 8.6) 

8.5.2

 

Mains Power – two pole MCB for incoming 110 or 220vac fused and earthed mains power 
(see section 8.7) 

Summary of Contents for LUBRICURVE ELECTRO 5

Page 1: ...LUBRICURVE ELECTRO 5 Installation Maintenance Manual TRACKSIDE ELECTRIC RAIL WHEEL LUBRICATOR SYSTEM Running Rail o 2 blades o 4 blades Top of Rail o 2 blades o 4 blades 35kg Capacity ...

Page 2: ...olyte may cause severe burns If the electrolyte contacts the skin wash with large quantities of clean water and seek medical advice DO NOT expose the battery to naked flames or cigarettes During the charging process hydrogen gasses are vented from the battery and these gasses when mixed with the air may explode if ignited Do not short circuit the battery terminals as this may cause a spark or expl...

Page 3: ... hoses Cabinet to blade 16 10 4 Fitting the Main Delivery Hoses 16 10 5 Fill the Hoses and Blade s 16 10 6 Top of Rail TOR EasiBlade Installation 17 11 Commissioning Setting 18 11 1 Filling the Reservoir 18 11 2 Wheel Sensor Heights and Operation 18 11 3 Pump Setting 18 12 Routine Maintenance 22 12 1 Control Panel 22 12 2 Pump Setting 22 12 3 Measuring the Reservoir 23 12 4 Cabinet Maintenance 23 ...

Page 4: ...an be used in these LubriCurve Electro systems Use of other greases or friction modifiers will invalidate warranty and could affect operation 2 Product Transport Storage Goods are packed and delivered to the requested address in a form that is suitable for the product given good practice in the off loading by the receiving company LubriCurve systems are delivered on the basis that they will be ins...

Page 5: ...heel Sensor The Wheel Sensor clamps to the running rail and provides non contact sensing of passing wheels Indicating lamps provide local indication of correct operation during test Sensor is connected to control box through armoured cable Solar Panel Depending on model a solar panel is supplied The unit fits onto the rear of the cabinet and is used to provide power to the battery by utilising sun...

Page 6: ...dered Ensure that battery is fully charged with reference to green indicator lamp on the charge controller or the voltmeter display Blade Ensure they are not bent or damaged and all ports are free from blockages Ensure that all bolts are present and are fitted securely Ensure that the hose inlet tails which the delivery hoses attach to are in place and are not damaged Clamps Ensure that both Senso...

Page 7: ...et should be kept vertical at all times take care to avoid damage to the paint finish as this forms a part of the corrosion resistance and general integrity of the unit 6 Typical Install Process There are several possible sequences that can be followed to efficiently install the lubricator this will largely depend on personnel available track access and general conditions the following is recommen...

Page 8: ...le v e l P o le fix e d in c o n c re te o r b o lte d to s le e p e rs b u rie d in th e b a lla st 1 2 0 0 3 5 0 T y p ic a l in s ta lla tio n P o le m o u n te d D C 3 1 T C o n tro l B lu e P o w e r 12 10 5 3 0 0 0 2 8 0 0 0 8 8 5 0 0 N o te F ro n t o p e n in g d o o r fo r m a in te n a n ce a c c e s s to co n tro l p a n e l X X Y Y D C 3 1 T M id la n d P um p B irm in g ham U K N o te...

Page 9: ...hovel or ballast fork whichever one is the most suitable o Orange pipe to protect delivery hose and sensor cable across 4 and 6 o Spirit level o Compass o Lubricator installation tool kit see Section 14 o Wiring termination tools o Cordless or portable drill and bits Note Other site specific mounting options may be used ...

Page 10: ...fitted through the base of the cabinet 8 3 Earth Bond 8 3 1 Subject to local regulation it may be required to bond the unit to the track A 16 5 mm diameter hole is to be drilled in the rear of the cabinet for a 16mm diameter earth stud Whitmore Rail part No LCS105 11 8 3 2 The bond itself must be supplied and fitted directly by Rail owner authorised personnel and not by the lubricator installer 8 ...

Page 11: ...t the LED will flash The second LED can change colour from Red via Yellow to Green Battery voltage is shown by the colour and legend on the controller Green full charge Red low battery charge When the battery voltage falls below approximately 11v the multi colour LED will start to flash FAST While the battery remains at a low charge the LED will continue to flash slowly Warning This lubricator use...

Page 12: ...al cabinet components 8 7 2 The cable incoming cable should be armoured and suitably routed and protected to avoid a hazard 8 7 3 Cable rating should be 220 110 volt at 5 amps 8 7 4 Connection should be made on the two pole MCBs to the left of the main Control Box All other power wiring will have been completed during product assembly 8 7 5 Connection should only be undertaken with the lubricator ...

Page 13: ...u p p lie d w ith C h a rg e r W A R N IN G T h is lu b ric a to r u s e s a 1 2 v 1 0 0 a h b a tte ry w h ic h c o n ta in s a n a c id b a s e d flu id th e e le c tro ly te C a re m u s t b e ta k e n to a v o id th e e le c tro ly te c o m in g in c o n ta c t w ith th e s k in o r c lo th in g a s th e e le c tro ly te m a y c a u s e s e v e re b u rn s If th e e le c tro ly te c o n ta c t...

Page 14: ...that the cable exits in the opposite direction 10 1 2 Run the cable from the sensor along the foot of the rail on the cess or field side fix to each rail clip using cable ties and into the trackside Cabinet through the lower mast pivot point and into the cabinet 10 1 3 The cable must route through protective pipe when running across the 4 or 6 in third rail applications the cable should pass throu...

Page 15: ...fits hose layouts 10 3 3 The blades are provided in left and right hand forms the difference being the direction the hose tail points the correct layout is shown in the adjacent picture outer pairs with hose tails pointing towards each other 10 3 4 Tilt the blade up so that the blade tip is towards the rail head and as high as possible lightly tighten the two pivot bolts 10 3 5 Decide the required...

Page 16: ...ngle hose from cabinet to a T piece centrally between the two blades Four blades have single hose from cabinet to a Y piece near each rail linked in turn to T piece centrally between each blade pair 10 3 14 Specific hose routing will depend on each site note to assist balanced flow Main delivery hose runs should be of the same length Individual hose lengths between each interconnection should be t...

Page 17: ...etighten the Nyloc nut Single Port EasiBlade above 10 6 2 Tilt the blade up so that the blade tip is towards the rail head and as high as possible lightly tighten the two pivot bolts 10 6 3 Decide the required blade height and tap the two steel lugs on the blade evenly down using a hammer to achieve the required height 10 6 4 There may be a slight gap between the tip of the blade and the rail To c...

Page 18: ...ured directly from the drum or storage bag into the reservoir Electro 5 reservoir will hold 25 kg Do not over fill the reservoir Once filled close the lid by closing the lid slightly then opening to release the lock and then the lid can be closed fully Press firmly shut and secure using the latches It is important that the lid is locked correctly if the lid is left open the grease modifier may bio...

Page 19: ...e control panel open the main door of the cabinet Ensure the control panel is switched on Power button 1 must be pressed on the I rather than the O The controls are now sitting in a neutral state with the battery power allowing basic function The Electro 5 Lubricators are activated by the Wheel Sensor seeing the first wheels of a train When this occurs the Wheel Detected lamp 9 will illuminate as ...

Page 20: ...f Pump Steps or pump seconds Note For Running Rail Applications This inhibited period function will reset after 45 seconds if the set number of wheels have not been counted This means the pump will be ready to go every time a new train passes over the Wheel Sensor For TOR Applications There is no resetting of the inhibited period therefore the TOR control box carries the wheel count settings from ...

Page 21: ...an be used to run the pump settings without the Wheel Sensor being activated These buttons are useful during initial Lubricator set up or maintenance periods 11 3 5 The Run Pump Button 8 can be pressed and held for continuous pump operation This button is useful during the initial priming of the pipes and Blade blades Speed Carriages Carriages Carriages 2 3 4 Speed mph Speed kph Wheel Count Pump S...

Page 22: ...zeroed by depressing the buttons adjacent to the readout but this should be recorded as a specific maintenance activity 12 2 Pump Setting 12 2 1 Record the settings shown on the display as per Section 12 1 12 2 2 Establish by visual inspection that grease modifier output is correct or requires adjustment plus or minus o If additional grease modifier output is required then o Increase Pump Steps or...

Page 23: ...peration 12 4 3 Any water from rain or condensation should be removed so the inside of the cabinet is dry In extreme environments where condensation forms then a suitable desiccant or dryer should be installed 12 5 Battery Maintenance 12 5 1 The battery is not maintenance free and standard practices should be employed to correctly maintain by trained operatives This test will include 12 5 2 Check ...

Page 24: ...t rear 12 7 3 The sensor is secured to the pump body with two M8 nuts 13mm open spanner needed Loosen the outer nut loosen the inner nut and then unscrew the sensor fully from the pump body 12 7 4 The new sensor is supplied with two loose nuts and one lock washer Discard the lock washer and spin both nuts along the sensor and over the grey cable 12 7 5 Wind the sensor into the pump body by hand un...

Page 25: ...ring Testing the Wheel Sensor 12 10 1 The sensor height to be measured is the vertical distance between the top of the green sensor body and the top of the crown of the rail 12 10 2 The sensor height should be set at 42 to 45mm below the top of the rail 12 10 3 If the lubricator has not used the amount of grease that is required for this lubricator since the last time that it was maintained Check ...

Page 26: ... 12 12Inspection of the Blade s 12 12 1 Visually check the Blade s for damage and or wear Record and report findings 12 12 2 Check that each port is clear and that there is a vertical stand of grease from each running rail Blade 12 12 3 Check Blade height with reference to initial installation height settings 12 12 4 Check that the fastenings are secure 12 12 5 Operate the pump from the Test butto...

Page 27: ...m items are replaced periodically exchange will be dependent on traffic frequency and should be monitored during maintenance visits but as a minimum should include the following Item Exchange Frequency Battery 2 years Control Box 5 years Fasteners 5 years Hose 2 years Wheel Sensor 3 years ...

Page 28: ...bit 4 1 Battery volts Volts n a Comment Comments on leakage 2 1 Pump 2 2 Reservoir 2 3 Hoses 2 4 Blades 3 Wheel sensor 4 Battery charger unit panel 4 3 Solar panel volts Volts n a Comment 6 Wind turbine operation 7 Mains charger 9 Pump 9 1 Operation Test PASS FAIL 8 2 Pump Steps 8 3 Total wheel count reading 8 4 Total pump steps reading If above test failed action taken If above test failed action...

Page 29: ...het Handle 1 2 Drive Combination Spanner 24mm Combination Spanner 19mm Combination Spanner 17mm Combination Spanner 13mm Combination Spanner 10mm Nut Spinner 7mm Socket 13mm 1 2 drive Socket 17mm 1 2 drive Socket 19mm 1 2 drive Socket 24mm 1 2 drive 1lb Ball Pein Hammer Sharp Knife Side Cutter Junior Hacksaw and Blades Screwdriver 6 x 1 4 flat blade flared tip Screwdriver Pozidrive No 0 1 2 Termin...

Page 30: ...30 ...

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