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LUBRICURVE ELECTRO 15

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

•

120kg Capacity

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2
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Summary of Contents for LUBRICURVE ELECTRO 15

Page 1: ...LUBRICURVE ELECTRO 15 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 120kg Capacity ...

Page 2: ...e severe burns If the electrolyte is in contact with the skin then 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 exp...

Page 3: ...10 8 5 Solar Systems 11 8 6 Mains Powered Systems 11 9 System Wiring Diagram 12 10 Installation of Track Items 13 10 1 Wheel Sensor 13 10 2 Blade System 14 10 3 EasiBlade Installation 14 Routing of delivery hoses Cabinet to blade 15 10 4 Fitting the Main Delivery Hoses 15 10 5 Fill the Hoses and Blade s 15 10 6 TOR EasiBlade Installation Top of Rail 16 11 Commissioning Setting 17 11 1 Filling the ...

Page 4: ...tor and Surrounding Site 24 12 9 Checking for Leaks 24 12 10 Measuring Testing the Wheel Sensor 24 12 11 Checking for Airlocks 25 12 12 Inspection of the Blade s 25 12 13 Filling the Reservoir 26 12 14 Periodic Replacement of Components 26 Maintenance Log Sheet Example 27 13 Parts List 28 14 Basic Installation Tool Kit 28 ...

Page 5: ...an be used in these LubriCurve Electro 15 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 ...

Page 6: ... The wheel sensor clamps to the running rail and provides non contact sensing of the passing wheels Indicating lamps provide local indication of correct operation during the test The sensor is connected to the control box through armoured cable Solar Panel Depending on the model of the solar panel supplied optional The unit fits onto the rear of the cabinet and is required to provide power to the ...

Page 7: ...ordered Ensure that the battery is fully charged with reference to the 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 ...

Page 8: ...ld 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 recommended as ...

Page 9: ... ensure stability sleepers should be level in both planes As soon as the unit is manoeuvred onto the base it should be securely bolted down The equipment needed for the installation work includes o All relevant P P E needed to carry out the works safely o Shovel or ballast fork whichever one is the most suitable o Orange pipe to protect delivery hose and sensor cable across the 4 and 6 o Spirit le...

Page 10: ... panel is fixed directly to the rear and or side of the cabinet Using the M8 security bolts attach the spacers to the rear or side of the cabinet 8 3 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 4 Battery Charger Electrical Connection The majority of the electrical termination is...

Page 11: ...LED will start to flash FAST While the battery remains at a low charge the LED will continue to flash slowly 8 6 Mains Powered Systems If solar charging is not possible an alternative system that utilises local mains power to maintain battery charge may be used Cable routing and connection should be undertaken by trained and authorised personnel only The procedure is as follows 8 6 1 A suitable ca...

Page 12: ...a 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 tr o ly te c o n ta c ts th e s k in w a s h w ith la r g e q u a n titie s o f c le a n w a te r a n d s e e k m e d ic a l a d v is e D O N O T e x p o s e t h e b a t te ry t o n a k e d fla m e s o r c ig a r e t te s D u rin g th e c h a r g in g p ro c e s s h y d r o g e n g...

Page 13: ...such 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 ...

Page 14: ... 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 blade height and...

Page 15: ...0 3 13 Top of Rail Systems Two blades have single hose from the cabinet to each blade Four blades have single hose from the cabinet to a 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 the same length 10 4 ...

Page 16: ...nut 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 close this gap tap the corner of the lug as nece...

Page 17: ...directly from the drum or storage bag into the reservoir An Electro 15 reservoir will hold 100 kg Do not over fill the reservoir Once filled close the lid by opening it slightly then release the stay from its 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 biode...

Page 18: ... Ensure the control panel is switched on The 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 15 lubricators are activated by the Wheel Sensor seeing the first wheels of a train step control option When this occurs the Wheel Detected lamp 9 will illuminate as the sensor registers a p...

Page 19: ...ted The Wheel Count function controls this length of the inhibited period To adjust the Wheel Count press buttons 2 for More wheels to count or 3 for Less wheels to count As a train passes over the Wheel Sensor the number of wheels will be counted When the number of wheels reaches the set amount the pump will be activated for the set number of Pump Steps Note This inhibit function will reset after...

Page 20: ...equired pump settings will vary for each site and depends on such items such as train type and speed For guidance the table above should be followed and then adjustments made to suit local conditions during subsequent visits Note Settings for TOR applications are determined by site conditions 11 3 3 For maintenance log purposes the display screen also records the total wheel count and also the tot...

Page 21: ... 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 friction modifier output is required then o Increase Pum...

Page 22: ... chips and general trackside activity in the vicinity 12 4 2 It is important that both door locks are lubricated at each visit to ensure effective long term operation 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 ...

Page 23: ...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 until it cannot be turned further turn the sensor back one revolution Holding the sensor in that position fit the first nut tight to the pump body and then tighten the locknut 12 7 6 Route the cable behind the drum plate and to the...

Page 24: ...rease output that you have noted 12 9 2 Leaks on the primary side i e within the cabinet of the lubricator will cause an increase in grease output that is not due to the settings of the lubricator 12 9 3 Tighten any hose clips or nuts bolts screws that maybe the cause of the leak and or replace the faulty part that is causing the leak 12 10Measuring Testing the Wheel Sensor 12 10 1 The sensor heig...

Page 25: ... the lubricator will give you certain information into why the lubricator has not had a sufficient grease output If the lubricator has not used any grease but no air locks are present other corrective actions should be undertaken 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 i...

Page 26: ...nts 12 14 1 It is recommended that various system 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 Blade and pump Hose 2 years Wheel Sensor 3 years ...

Page 27: ...attery 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 taken 9 ...

Page 28: ...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...

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