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Page 22

PROTECTOR® IV Gauge Face Installation, Operation & Maintenance Manual

Train wheels are not being

counted by DCB (pass a steel

object over sensor to test, LED on

DCB should flash yellow)

Sensor is defective

Replace sensor

Sensor wiring at DCB connection

is broken or incorrect

Verify wiring connections

according to wiring diagram and

replace if necessary

Train wheels are only counted

sporadically by DCB

Sensor height is incorrect

Adjust sensor height using shims

Rail has become magnetized

Relocate sensor

Sensor or bracket has become

loose

Tighten bolts

Loose cable connection

Push connectors in fully, place

yellow housing over connection

LCD does not turn green when

On/Off is pressed

Defective DCB

Replace DCB

Battery voltage is too low

Charge battery

Defective Battery

Replace battery

Control buttons do not change

readings in LCD display

Defective DCB

Replace DCB

No readout

Temperature is below -20°C

Read display once temperature is

above -20°C

Defective DCB

Replace DCB

Unclear LCD

High level of electrical noise

Verify grounding of tank

Defective DCB

Replace DCB

Charge Controller

The PROTECTOR IV’s charge controller has lights indicating battery conditions as well as charging condition.

These will help to determine causes of electrical problems; this applies to DC voltage units only.

Symptom

Possible Causes

Possible Solutions

Indicator lights do not turn on

No battery power

Check battery and charge

controller connections

Defective battery

Replace battery

Too dark

A solar panel will only work during

daylight hours

Содержание Protector IV

Страница 1: ...www lbfoster com PROTECTOR IV TRACKSIDE FRICTION MANAGEMENT SYSTEM Installation Operation Maintenance Manual for GAUGE FACE For systems built prior to 2017 ...

Страница 2: ...Solar Panel 7 Electrical Power AC Power 10 Wiping Bar Installation 10 Smart Wheel Sensor Installation 14 Operation Start Up 14 Servicing Maintenance 19 Troubleshooting 21 AC Wiring Diagram for 200 25 Unit 25 DC Wiring Diagram for 200 25 Unit 26 AC Wiring Diagram for 800 100 Unit 27 DC Wiring Diagram for 800 100 Unit 28 Glossary of Terms 29 Customer Service Contact Information 30 ...

Страница 3: ... curve lubricant storage section INTRODUCTION Safety First There are no special hazards or potential risks regarding this equipment that cannot be made safe by good working practice Lifting Only unload units onto flat and stable ground taking care to keeping the tank upright Use mechanical lifting equipment beneath the tank or chains secured to the four lifting handles The tanks are equipped with ...

Страница 4: ...socket for battery terminal 7 15 mm socket or open end wrench to mount sensor to bracket 8 Slot and Phillips screwdrivers 9 Wire strippers and crimpers 10 Pliers or channel locks 11 For wiping bar and sensor bracket 0 250 ft lbs 0 350 N m torque wrench 1 30 mm wrench or socket Hammer minimum weight 3 lb 1 kg BASIC SYSTEMS CONFIGURATION The following section is intended to provide a general overvie...

Страница 5: ...an hands section Solar panel cable wired to the panel at the factory Solar panel pole kit if ordered Smart Wheel Sensor PROTECTOR IV assemblies are equipped with a bi directional smart wheel sensor as standard This can be configured for one way operation if required The sensor detects the passage of each train and sends a signal to the DCB The sensor primarily consists of a small but very strong m...

Страница 6: ... INSTALL BARS CLOSER THAN 100 ft 30 5 m TO AN INSULATED JOINT THIS WILL MINIMIZE ANY POTENTIAL GREASE BUILD UP AT THE JOINT WHICH COULD AFFECT SIGNALING 3 In areas with multiple curves select a site in a short tangent section of track between curves At this location the grease material is carried in both directions and into adjacent curves 4 Select a site where there is no pronounced railhead wear...

Страница 7: ...nted to a pole attached to the tank or a pole can be supplied that will allow the panel to be erected away from the tank if this will provide better sunlight Solar Panel Adjustment NORTH AMERICA The pivot arrangement included with the solar panel s mounting bracket provides an adjustment for the angle of the panel To gain maximum efficiency and output from the solar panel the tilt angle is based u...

Страница 8: ...e clamp blocks and help hold their position during this assembly 4 Raise the assembled pole and solar panel into the vertical position against the tank and into the clamp block halves 5 Turn the solar panel so that it is facing south 6 Position the second pair of clamp block halves sliding them over the studs and against the back halves Remove one stud at a time replacing them with the provided Al...

Страница 9: ...ace the regulator if defective b Check the battery s voltage If the voltage is below 11 5v DC the PROTECTOR IV will not function properly and the battery will need to be charged Note Charge battery through solar panel output until battery voltage exceeds 12v DC BEFORE PROCEEDING MAKE SURE THE SOLAR PANEL IS COVERED TO ELIMINATE ELECTRICAL POTENTIAL AND TO AVOID SHOCK HAZARD DURING THE NEXT PHASE O...

Страница 10: ...g bars should be installed in a position that agrees with the site selection criteria mentioned previously in this manual The common configuration at track for PROTECTOR IV units is on both rails of a single track with uni or bi directional traffic This is advantageous when lubrication of both rails is required when the track has curves in both directions The set up described here is shown in Figu...

Страница 11: ...wiping bar assemblies adjacent to selected mounting locations Take note that at the factory all lubricant inlet elbows are installed pointing in the same direction Thus half of the hose installed in the field will need tightened 180 degrees before piping Do this after installing on to rail 9 Ensure mounting clamps are square to rail and fasten them to the base of rail As the J bolt nuts are being ...

Страница 12: ...gement MC 4XL bars can only be installed on tangent track In a two bar arrangement MC 4XL bars can be installed early in the transition when two bars are to be installed on one or both rails they should be positioned end to end or as close as possible This insures lubrication of the entire wheel for maximum grease coverage Install these bars using the same instructions as provided on the configura...

Страница 13: ...cent to selected mounting locations 6 Slide the clamp blocks onto the gage side of the restraining rail and hook the J bolt on the field side of the running rail as shown in the picture below 7 As the J bolt nuts are being tightened using a hammer occasionally tap the clamp blocks driving the V slot onto the rail base 8 When clamps are secured tighten the safety nuts 9 With the clamp blocks secure...

Страница 14: ...is set affix the smart wheel sensor to the bracket using the four bolts provided A correctly fitted sensor is shown in Figure 4 OPERATION START UP General Operation Once the PROTECTOR IV is installed it is important to understand how it works in order to take full advantage of all its capabilities Below is a general theory of operation for the PROTECTOR IV The basic unit consists of a tank for sto...

Страница 15: ...nlight System Integrity Checks When the LED on the DCB is green the system is ready for priming perform the following integrity checks to ensure all is functioning Motor Integrity Test 1 Hold the toggle switch in prime 2 Verify motor is functioning properly Using the Digital Control Box DCB One of the most important advantages of the PROTECTOR IV unit is its ability to provide precise controlled d...

Страница 16: ...gth of time the pump operates per activation This duration can range from 0 05 to 1 95 seconds The number can be changed in 0 05 second increments using the up or down arrow buttons Test Button When pressing the test button wheel frequency and pump duration will be displayed This display will last for six seconds before beginning a countdown of remaining wheels left to pass before pump activation ...

Страница 17: ...nlet 2 Add grease to storage tank 3 To prevent air intake add enough grease to cover the pump inlet Slide tank outlet pump screen arm up and down to ensure that the pump is flooded with material 4 If ball valves are in the piping at the center of the track ensure they are in the open position 5 Open lid to clean hands section of the tank 6 Ensure battery is charged to a minimum of 11 5v DC If batt...

Страница 18: ...rify that the desired settings have been stored to memory Notes Frequent but shorter length activations provide a more continuous flow of grease Longer activations can produce puddles that tend to be splashed in various directions by the train wheels For normal operating conditions the pump duration should not exceed 0 8 seconds The control settings may need to be adjusted periodically to suit cha...

Страница 19: ...tor will be pumping material for the amount of time on the pump duration setting 3 Simulate the passing of a train wheel by waving a wrench or other steel object over the top of the sensor Check to see that the counter has recorded the simulation If the control system reaches the selected wheel frequency setting material will be distributed 4 Clean away any grease that was distributed during this ...

Страница 20: ...ges from lightning or other sources but not against a direct lightning strike Distribution Hoses and Wiping Bars Maintain wiping bar hoses and wiping bars on a weekly basis as follows 1 Step on the hose observe the grease as it emerges from the wiping bar 2 Look to see that the flow is uniform from the entire length At any point where the material does not emerge there may be a clog 3 Repeat the a...

Страница 21: ... valve at center of track clogged Disassemble and clean ball valve Wiping bar has clog inside Disassemble and clean wiping bar Wiping bar installed too low at track for proper distribution Reinstall wiping bar at proper level Wiping bar damaged by train wheel wiping bar was installed too high Replace with new wiping bar and ensure installation at correct level Hose damaged Replace hose Temperature...

Страница 22: ...en when On Off is pressed Defective DCB Replace DCB Battery voltage is too low Charge battery Defective Battery Replace battery Control buttons do not change readings in LCD display Defective DCB Replace DCB No readout Temperature is below 20 C Read display once temperature is above 20 C Defective DCB Replace DCB Unclear LCD High level of electrical noise Verify grounding of tank Defective DCB Rep...

Страница 23: ...Solar panel face is dirty Clean solar panel with mild detergent Loose or corroded wire terminals to battery Tighten or replace wire terminals Defective solar panel Replace solar panel Pump and Motor The pump and motor are considered one system when troubleshooting Symptom Possible Causes Possible Solutions Motor operates erratically when DCB is set to prime Battery charge is below 11 5v DC indicat...

Страница 24: ...evere burns or triggering an explosion Battery Charger Safety Precautions THE BATTERY CHARGER CONTAINS SHOCK AND ENERGY HAZARDS DO NOT DISASSEMBLE THERE ARE NO USER SERVICEABLE PARTS INSIDE Disconnect all AC and DC power at its source prior to cleaning or removing the wiring cover to access wiring terminals or the internal fuse Switch off AC power before connecting or disconnecting DC wiring or ba...

Страница 25: ...Page 25 PROTECTOR IV Gauge Face Installation Operation Maintenance Manual AC WIRING DIAGRAM FOR 200 25 UNIT L B FOSTER ...

Страница 26: ...Page 26 PROTECTOR IV Gauge Face Installation Operation Maintenance Manual DC WIRING DIAGRAM FOR 200 25 UNIT L B FOSTER ...

Страница 27: ...Page 27 PROTECTOR IV Gauge Face Installation Operation Maintenance Manual AC WIRING DIAGRAM FOR 800 100 UNIT L B FOSTER ...

Страница 28: ...Page 28 PROTECTOR IV Gauge Face Installation Operation Maintenance Manual DC WIRING DIAGRAM FOR 800 100 UNIT L B FOSTER ...

Страница 29: ...e time in seconds that grease will be pumped by the PROTECTOR IV Stage One A display sequence on the LCD which is shown immediately after display of L B Foster Stage one first shows the total accumulated wheel count and wheels remaining before next activation for ten seconds then the wheel frequency and pump duration for ten seconds Smart Wheel Sensor SWS Wheel sensor that recognizes the signature...

Страница 30: ...il FrictionMgmtSales lbfoster com Canada 172 Boul Brunswick Pointe Claire Quebec H9R 5P9 Canada Tél Phone 1 514 695 8500 x236 Téléc Fax 1 514 695 8110 E mail CanadaSales lbfoster com Europe Stamford Street Sheffield S9 2TX United Kingdom Telephone 44 0 114 2562225 Facsimile 44 0 114 2617826 E mail UKsales lbfoster com PROTECTOR IV 200 25 Tank US Patent Number D495 974 Doc No GLB MAN PRT 001 Rev 4 ...

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