LB Foster PROTECTOR IV Maintenance Manual

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Page 1

PROTECTOR® IV TRACKSIDE

RICTION MANAGEMENT SYSTEM

Installation, Operation &

Maintenance Manual

for TOP OF RAIL

www.lbfoster.com

Page 2

TABLE OF CONTENTS

Welcome ..........................................................................................................................................................................................................3

Introduction ...................................................................................................................................................................................................3

!"#$%&'(#)*+#&,&-./0123")$./ ..............................................................................................................................................................4

Site Selection .................................................................................................................................................................................................6

Electrical Power (Solar Panel) ..................................................................................................................................................................7

Electrical Power (AC Power) ..................................................................................................................................................................10

TOR Installation ..........................................................................................................................................................................................10

Smart Wheel Sensor Installation .........................................................................................................................................................13

Operation & Start Up ..............................................................................................................................................................................13

Servicing & Maintenance .......................................................................................................................................................................18

Troubleshooting ........................................................................................................................................................................................20

AC Wiring Diagram for 200/25 Unit ..................................................................................................................................................24

DC Wiring Diagram for 200/25 Unit ..................................................................................................................................................25

AC Wiring Diagram for 800/100 Unit ................................................................................................................................................26

DC Wiring Diagram for 800/100 Unit ...............................................................................................................................................27

200/25 AC and DC Tank Part Numbers ............................................................................................................................................28

200/25 AC and DC Stainless Steel Tank W/ Bronze Double Pump and

Twin Hose Part Numbers........................................................................................................................................................................29

800/100 AC and DC Tank Part Numbers ..........................................................................................................................................30

Solar Panel and Pole Kit Part Numbers ............................................................................................................................................31

Double Pump Motor Assembly Part Numbers ..............................................................................................................................31

Distribution System Piping Summary ............................................................................................................................................... 32

Quick Hose Coupling Part Numbers .................................................................................................................................................32

MC-4TR Distribution Bar Part Numbers ...........................................................................................................................................33

TOR XL-Bar Part Numbers .....................................................................................................................................................................34

TOR ML-Bar Part Numbers ....................................................................................................................................................................35

TOR Foam Bar 24” Part Numbers ........................................................................................................................................................36

TOR Foam Bar 36” Part Numbers ........................................................................................................................................................36

Mounting Clamp Part Numbers ..........................................................................................................................................................37

Quick Mounting Clamp Part Numbers .............................................................................................................................................38

Top of Rail Bar & Clamp Assembly Options ...................................................................................................................................39

Smart Wheel Sensor Part Numbers ...................................................................................................................................................40

Smart Wheel Sensor w/Quick Clamp Part Numbers ...................................................................................................................41

Glossary of Terms ......................................................................................................................................................................................42

Customer Service Contact Information ............................................................................................................................................43

Page 2PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

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WELCOME

Thank you for purchasing the PROTECTOR IV TOR Trackside Friction Management System. The PROTECTOR IV TOR system is part of L.B. Foster’s family of friction management products designed to improve conditions at

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the level of product quality, innovative engineering and customer support that you have come to expect from us.

The purpose of the PROTECTOR IV TOR trackside friction management system is to control friction to an intermediate level on the railhead in order to reduce rail wear and the onset of corrugations, reduce wheel noise and limit the initiation of rolling contact fatigue (RCF) and gauge corner cracking (GCC). This is achieved

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the top of the rail and distributed along the rail by the wheels. When the water in the liquid solution evaporates,

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INTRODUCTION

Safety First

There are no special hazards or potential risks regarding this equipment that cannot be made safe by good working practice.

Lifting

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equipment beneath the tank or chains secured to the four lifting handles. The tanks are equipped with a single-point lifting strap. Ensure that the tank doors are fastened and locked in place during moving. Never lift a partially full or full tank using the handles.

NEVER VENTURE BENEATH A TANK BEING LIFTED.

Note: Tank handles are provided for a minimum of four people to manually manoeuvre the tank with the hopper empty. Ensure the tank handles are not used in any other circumstances.

Live Rail Working

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for installation and removal. Only appropriate insulated tools should be used.

AC Power Supply

Ensure AC power source is isolated before connecting line to the power switch in the tank. Turn power switch to OFF before touching any electrical connections or working in the tank.

Batteries

Ensure batteries are DISCONNECTED before touching electrical connections or working in the tank. Do not cause shorting between the battery terminals. For operator safety, the batteries are sealed with no free acid

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SHORTING BATTERY TERMINALS WILL CAUSE SPARKS AND CAN RESULT IN BURNS.

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Digital Control Box

Ensure digital control box is switched OFF before working in tank.

Tools Required

The PROTECTOR IV unit comes equipped with an Allen wrench tool (for use on the pump mounting bolts). This tool is required for installation and maintenance of the pump.

Along with the supplied tool, the PROTECTOR IV unit can be installed and maintained with a minimum number of other tools. Ensure the following list of tools are available during the installation process (tools for the metric equivalents are in brackets):

1. Pick and ballast fork

2. Large and medium size adjustable wrench

3. Medium pipe wrench

4. ½” drive reversible ratchet

5. 1” open-end wrench for sensor cable wall connector

6. 10 mm open-end wrench or socket for battery terminal

7. &YZ[\]&L^Q&++R&#.%T*)&.3&.<*/G*/;&53*/%4&).&+.2/)&#*/#.3&).&>3"%T*)

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 » ^G_]&LPO&++R&53*/%4&.3&#.%T*) » Hammer (minimum weight 3 lb. (1 kg.))

BASIC SYSTEMS & CONFIGURATION

The following section is intended to provide a general overview of the operation of the PROTECTOR IV with a brief description of key components.

Digital Control Box

The Digital Control Box (DCB) is the heart of PROTECTOR IV’s control system. It provides excellent adjustability of the amount of grease that is pumped from the tank to the bars. It also provides integrity checks for verifying the electronic controls and motor(s) are working properly. The LCD screen at the top of the box displays all of the information for the operator.

Pump

A double gear pump is coupled to the electric motor. The pump/motor assembly distributes the grease to the rails.

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Motor

The 12v DC electric motor receives power from the DCB to activate the pump.

Power Requirements

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also be powered by AC if ordered with an AC/DC voltage convertor.

A BATTERY IS AN EXPLOSION HAZARD — BATTERIES CONTAIN CORROSIVE MATERIALS AND PRESENT A SAFETY HAZARD.

DC Powered Units

DC PROTECTOR IVs are powered using the provided solar panel. Supply requirements are 12v DC nominal. Voltages in excess of 14.5v DC can cause permanent damage to electronic controls. The solar panel charge controller ensures the batteries are not over charged.

AC Powered Units

Units operating with AC power are equipped with an AC/DC converter to produce DC power to maintain the battery condition. The power supply requires 95-135v AC or 200-250v AC, 50-60Hz, single phase AC. Power is to be supplied by the customer. The trickle charge to the battery is typically 13.8v DC.

Solar Panel

Every new PROTECTOR IV shipped with a solar package contains the following basic components:

• Solar panel with Lexan Vandal Guard and the voltage regulator mounted inside the clean 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

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to the DCB.

The sensor primarily consists of a small but very strong magnet connected to the control circuitry. When a

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control circuit. The magnet itself is encased within the body of the sensor block, surrounded by a protective plastic casing.

There is a short length of cable attached to the sensor with a pigtail connection. This mates to a length of cable feeding directly to the DCB. The wheel sensor is delivered with a bracket designed for mounting to the rail, and shims to adjust the sensor height.

Tank

The tank is designed with two separate sections; the materials section that contains the grease and the components section. The tank body should be secured to a base to ensure its stability and for drainage. Typically, tanks are mounted to wooden ties or sleepers or a concrete pad.

Distribution Hoses

The distribution hoses are used to distribute the grease from the tank to the rails. The hoses can be installed once the tank and the distribution bars are in place on the rails.

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Bars

The bars are designed to distribute grease to the gauge face of the rail. When applied properly, this reduces

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and wheel life, reduce noise and improve tracking through curves.

SITE SELECTION

INSTALLATION AND MAINTENANCE OF THE PROTECTOR IV SYSTEM REQUIRES PERSONNEL TO BE ON-TRACK, INCLUDING BETWEEN THE RAILS. PRECAUTIONS MUST BE TAKEN TO ENSURE THAT THERE WILL BE NO TRAFFIC WHILE DOING THIS WORK.

Proper site selection for the PROTECTOR IV is one of the most important considerations associated with

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performance of the unit depends upon attaining as many of the following general considerations as possible:

1. It should be positioned on level stable ballast. The base can be made from either cut wooden sleepers

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screws are provided for a timber base.

2. Locate the unit as close to the curve in the track as possible. Avoid locating the unit inside a curve. This is

particularly important if noise reduction is the primary goal.

IT IS NOT RECOMMENDED TO INSTALL A UNIT IN A CURVE. THE EFFECT OF HAVING THE WHEELS HUGGING THE HIGH RAIL CAUSES PREMATURE WEAR AND TEAR ON THE WIPING BARS. WIPING BARS LOCATED ON THE LOW RAIL ARE LESS EFFECTIVE IN DEPOSITING GREASE. DO NOT 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 and railhead is in excellent condition. If transposed

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before attempting to install the wiping bars.

5. Select a site where the tie conditions are good and install the unit as close to zero grade as possible.

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6. '*6*%)&"&#$)*&)4")&<3.?$;*#&"%%*##&).&)4*&2/$)&8.3&3*126"3&+"$/)*/"/%*&"/;&3*066$/19

7. Install the tank far enough from the track to safely clear the operation of ballast regulators, snow plows, and

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8. Select a site where power source can be easily routed to the unit. Be sure the length and size of the power

cable does not cause an unacceptable line loss. In remote locations with no AC power availability, the solar panel option is recommended.

Note: Outside AC electrical currents from overhead power wires, third rail power or signal system power sources can interfere with the wheel sensor detection capabilities.

9. Avoid selecting a site where trains routinely slow down or come to a complete stop.

10. Site selection should be in an area which will discourage acts of vandalism.

11. The grease works best where both the rails and wheels are clean.

Page 6PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

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ELECTRICAL POWER (SOLAR PANEL

)

Solar Panel Location and Installation

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Southern exposure in the Northern Hemisphere and Northern exposure in the Southern Hemisphere. This will ensure the most consistent exposure to sunlight through the course of a day. The panel should be unobstructed, so that it receives direct sunlight during daylight hours all year long.

The standard units are DC powered and charged by a solar panel. This supplies power to either one or two 12v batteries depending on the number of pumps. Brackets can be supplied so the solar panel can be mounted 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 Mounted to Tank Solar Panel Mounted Away from Tank

Solar Panel Adjustment – NORTH AMERICA

The pivot arrangement included with the solar panel’s mounting bracket provides an adjustment for the angle

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latitude of the location. Panels should always face south (see Figure 1).

Using the table below you can determine the optimal angle for your solar panel. The panel tilt is the latitude +10º. This will optimize the panel’s ability to collect the sun’s energy. Use the angle gauge on the mounting bracket to set the desired angle (see table below) or alternatively, use the distance from the pole to the base of the panel, also included in this table.

Figure 1: Solar Panel Adjustment

Page 7PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

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Optimum Angle for Sunlight

Site Tilt Base

Latitude (degrees) Angle (degrees) Distance (inches) Distance (millimeters)

35 45 17-¾ 451 36 46 17-½ 444 37 47 17-³7[\ 437 38 48 16-157[\ 430 39 49 16-57f 423 40 50 16-³7f 416 41 51 16-¹7f 409 42 52 15-¹³7[\ 402 43 53 15-97[\ 395 44 54 15-¼ 388 45 55 15 381

Solar Panel – Tank Mounted Assembly Instruction

1. Before beginning the assembly ensure the side of the tank hangs over the tie.

2. Assemble the pole into one piece and mount the solar panel to the pole. Use four bolts to help position

the pole’s clamp blocks to the tank. These bolts must be 37f]&G^g&X-&d&^Gh]&)43*";#&"/;&>*&"<<3.d$+")*6(& 10” long.

3. Using the studs, position two of the clamp block halves at their mounting locations top and bottom. Screw

the four studs into the tapped holes in the tank body to properly locate the 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 Allen head bolts and lock washers. The solar panel pole kit includes an Allen wrench for tightening these four bolts.

Solar Panel – Away from Tank Assembly Instruction

Locate the panel so that the supplied cable (35 ft./10.7 meter long) will reach the tank. Do not use a longer cable than the one supplied, as longer lengths will result in a voltage drop which may not allow the system to operate properly. If longer lengths are necessary, please contact us.

EXERCISE EXTREME CARE WHEN HANDLING THE SOLAR PANEL AND WORKING WITH SOLAR PANEL WIRING. FAILURE TO DO SO MAY RESULT IN EQUIPMENT DAMAGE OR BODILY INJURY.

Gauge on Solar Panel Mounting Bracket (Used to adjust the angle.)

Page 8PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 9

Solar Panel Wiring

The 35 ft. (10.7 meter) long power cable is factory installed to the solar panel at the junction box with spade terminals. The wall connector nut of the junction box is tightened securely, causing the bushing to grip the

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Electrical Connections

Connect the solar panel to the PROTECTOR IV battery as follows:

1. Remove any cover you have placed over the panel and peel away the protective panel guard protection.

2. Perform the following tests before beginning installation:

a) Using a voltmeter capable of reading 25v DC, check the panel output between the battery (+) and (-) in

the junction box or at the end of the cable. If the panel output exceeds 15v DC, check regulator wiring for proper connections, as shown in troubleshooting. Replace 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 OF ASSEMBLY.

3. Attach ring terminals to the solar panel cable wires, connecting the red wire to the positive battery terminal

and the black wire to the negative battery terminal.

ENSURE RED WIRE IS CONNECTED TO THE POSITIVE (+) AND BLACK WIRE IS CONNECTED TO THE NEGATIVE (-) TERMINAL OF THE BATTERY. CROSSED WIRES WILL CAUSE EQUIPMENT DAMAGE.

Solar Charge Controller

Solar panel charge controller in use on the PROTECTOR IV, which is located inside the clean hands section of the tank.

The wires should be attached as follows:

PV+ Positive lead from solar panel BAT+ Positive lead from battery

Vset Not used

COM- Negative lead from battery or solar panel

Photovoltaic Charge Controller

Page 9PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

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ELECTRICAL POWER (AC POWER

)

AC Electrical Power and Battery Charger Connections

1. Remove the bolts on the battery terminals using a 10 mm socket or wrench. Look at battery and charger

safety precautions. Be careful not to short the battery terminals with a tool.

2. Through the terminal bolt, connect the ring terminals of red wire from the charger and from the control

box power harness to the positive battery terminal (+) and in the same manner connect the black wires to the negative battery terminal (-).

3. !" #$%&'()*" )&)+,-'+'%." /$0," 1'-)" ,2)" $.',0" ,2-3$42" ,2)" 5$.+,'3." 637" %.*" 3.,3" ,2)" 3.839" *'0+3..)+," 637"

according to local regulations.

ALL WIRING MUST COMPLY WITH LOCAL AND NATIONAL ELECTRICAL CODES. USE ONLY THE WIRE SIZES SPECIFIED IN THE INSTALLATION INSTRUCTIONS. WE RECOMMEND HAVING THE INSTALLATION WIRED BY A CERTIFIED ELECTRICIAN.

ENSURE POWER SUPPLY CABLE GAUGE IS PROPERLY SIZED TO ALLOW FOR REQUIRED POWER LEVELS GIVEN THE DISTANCE FROM THE ORIGINAL SOURCE.

TOR INSTALLATION

!"#$%&'()*"#+()+,'(-.

Top of rail distribution bars should be installed in a position that agrees with the site selection criteria mentioned previously in this manual. The common

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The set up described here is shown in Figure 2.

The top of rail wiping bars assembly can be installed

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installation time required depends on the installer’s familiarity with components and labor available to complete the task.

3*%&'1+45+678('+!"#$%&'()*"#

/)01'+!"#$%&'()*"#2

• Two bars with single pump with distribution in center.

• Two bars with double pump and supply hoses routed from tank to bars.

A PASSING TRAIN CAN DAMAGE IMPROPERLY INSTALLED COMPONENTS. ALLOW SUFFICIENT TRACK TIME TO FULLY COMPLETE INSTALLATION.

Page 10PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 11

Install the MC-4TR® wiping bars as follows:

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where rail is in good condition.

2. D.&%./03+&%6"+<&6.%")$./#&+")*&5$)4&*d$#)$/1&%3$>#@&6"(&.2)&5$<$/1&>"3#&./&0*6;G#$;*&.8&3"$69

3. Ensure bars mounted on the same rail are located at a distance of 56 ½” (143 cm) between centers.

Note: Based on a 36” (91 cm) wheel diameter, the 56 ½” (143 cm) spacing allows bars to distribute material uniformly over opposing sections of each wheel’s circumference. If track conditions do not permit a 56 ½” (143 cm) distance to be respected, install bars closer together but maintain at least one bar length in between.

4. Ensure inlet elbows clear rail hardware. On smaller rail sizes, it is best to attach the wiping bar supply hose

(and adapter where necessary) before assembling to rail. The piping adapter is used to gain additional clearance with track hardware.

5. Loosely assemble wiping bars to mounting clamps.

6. Clean dirt and scale from rail in appropriate areas.

7. With a pick and ballast fork, remove ballast from selected cribs for installation of rail clamps.

8. Lay wiping bar assemblies adjacent to selected mounting locations.

9. Ensure mounting clamps are square to rail and fasten them to the base of rail. As the “J” bolt nuts are being

tightened using a hammer, occasionally tap clamp blocks driving the “V” slot on to the rail base. Torque mounting bolts to approximately 200-250 ft-lbs (340 N-m).

10. When clamps are secured tighten the safety nuts.

11. Position wiping bar assemblies on top of rail clamp blocks and against rail.

12. Adjust the wiping bar height as follows:

a) Mount the TOR bar such that the tip of the seal is not

higher than the top of the railhead (shown in Figure 3 MC4TR Wiping Bar Installation). A simple level can be used to help establish this position.

DO NOT STORE EXTRA SPACERS UNDER THE HEAD OF MOUNTING BOLTS.

b) Remove or add spacers between TOR clamps and wiping

bar mounting feet.

c) Adjust blade height until the inner (thin) blade is just at

top of the side of railhead. Store excess spacers in clean

Figure 3: MC-4TR Wiping Bar Installation

hands section of the tank.

Note: With newer rail, or where the radius has been ground on the top of the railhead, the curvature of the

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3:":-'+,'3."/3*'()-":-3/",2)"6%-",3",2)"+3.,%+,"?%,+2"1',23$,"-'0A"3:"*%/%4)",3"A))?",2)"0)%&"6)&31",3?"3:"-%'&B"

the required lower bar mounting draws the seal end away from the contact patch.

Page 11PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 12

13. '*%23*&)4*&+.2/)$/1&>.6)#&).&)4*&%6"+<&>6.%T#&)$14)*/$/1&)4*&3$14)&>.6)&03#)&).&*/#23*&)4*&).<&.8&3"$6&5$<$/1&

bars is pushed securely against the rail.

14. Occasionally tap the outside edge of the mounting foot with a hammer during tightening to insure TOR

wiping bars remain tight to the rail.

15. Torque mounting bolts to approximately 200-250 ft-lbs (340 N-m).

ML Top of Rail Wiping Bars

The installation of ML TOR distribution bars should be carried out using the same instructions as the MC-4TR TOR distribution bars. Figure 4 illustrates how the installed bar should be assembled.

Figure 4: TOR -ML Wiping Bar Installation

Distribution Hose Installation

Install one main supply hose and four grease distribution unit hoses as follows:

1. Run main supply hose from tank, underneath the rail, to a position central to wiping bar assemblies.

2. C"(.2)&)4*&ij]&%./0123")$./&.8&?"6?*#&5$)4&+"$/&4.#*&"/;&;$#)3$>2)$./&4.#*#9&

3. D43*";&)4*&+"$/<<6(&4.#*&).&)4*&ij]&%./0123")$./&.8&?"6?*#&")&%*/)*3&)3"%T9&

4. D43*";&*"%4&4.#*&>*)5**/&ij]&%./0123")$./#&.8&?"6?*#&).&"/&$/;$?$;2"6&5$<$/1&>"39&

Note: Hoses supplied by the customer must be non-conducting, this ensures the hose system will not shunt signals.

All customer supplied hoses must be the same length as those supplied by L.B. Foster. If longer or shorter,

!"#$"%&#&$'(&!)(*+!(%,$#-.(#,.(#&$/(00$*#$."1,2#'3$1,'$!"(&$.%+0'$0#1'$!%$!%%$4+."$%)$!%%$0(!!0#$0+*)(.1,!$ *#(,2$1550(#'$!%$!"#$)1(06

Page 12PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 13

SMART WHEEL SENSOR INSTALLATION

The smart wheel sensor should be placed as far away from the distribution bars as possible using the supplied cable.

1. Dig out the ballast from underneath the rail where the

sensor will be placed.

2. `6"%*& )4*& kG>.6)& 2/;*3/*")4& )4*& 3"$6& "/;& 0d& ).& )4*&

bracket with the full nut and Nyloc nut. These require

"& ^^G_]& LPO& ++R& 53*/%4& .3& #.%T*)9& D4*& >3"%T*)& 8.3&

the sensor must be placed on the gauge side of the rail, preferably the rail adjacent to the tank. However, if installing in areas with a conductor rail the smart wheel sensor should be placed on the opposite rail.

3. Use the shims provided to set the height of the smart

Figure 5: Fully Fitted Sensor Bracket

wheel sensor. It should be set so that the top of the sensor is 2” below the top of the rail, any more than this

"/;&)4*&#+"3)&54**6&#*/#.3&+"(&8"$6&).&%.2/)&54**6#9&U/%*&)4*&%.33*%)&4*$14)&$#&#*)@&"Kd&)4*&#+"3)&54**6& #*/#.3&).&)4*&>3"%T*)&2#$/1&)4*&8.23&>.6)#&<3.?$;*;9&F&%.33*%)6(&0))*;&#*/#.3&$#.5/&$/&l$123*&Q9

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.

D4*&>"#$%&2/$)&%./#$#)#&.8&"&)"/T&8.3&#).3"1*&.8&)4*&83$%)$./&+.;$0*3&"/;&"&&%6*"/&4"/;#&%.+<"3)+*/)&8.3&"66&

the electrical components, such as, the digital control box (DCB), motor, pump, battery and other mechanisms. Electrical power is used to activate an electric motor that is directly coupled to the pump.

A rail-mounted wheel sensor senses the passage of each wheel on a moving train. As each wheel is detected

)4*&#*/#.3&#*/;#&"/&*6*%)3$%"6&<26#*&).&)4*&m-!9&D4*&m-!&)4*/&"%)$?")*#&)4*&<2+<@&54$%4&;3"5#&83$%)$./&+.;$0*3&

from the tank and forces it through the distribution hoses and wiping bars on to the rail. Wheels then pick up the material and deposit it along the rail in a continuous cycle. A diagram of the cycle can be seen below.

Page 13PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 14

Start Up

The following sections explain how to ensure the unit is functioning properly, setup the unit and how to use and control the various options. These options are controlled from the DCB.

When supplied with a PROTECTOR IV unit the leads are disconnected from the battery for transport purposes, ensure that these are re-connected. Red or brown wires are connected to the positive battery terminal, black or blue wires connect to the negative terminal.

Charge Controller (DC units only)

The solar panel charge controller is situated inside the clean hand compartment. There are three LED lights on the charge controller labeled: Charge, Low and High that refer to the battery status.

• The CHARGE LED is green and is lit when it is receiving ample sunlight.

» @%02'.4"4-)).&N&#.6"3&<"/*6&$#&3*%*$?$/1/6$14)&>2)&$#&/.)&%.//*%)*;&).&"&

battery

• LOW LED

» lit&N&?.6)"1*&;3.<#&>*6.5&)4*&?.6)"1*&3*H2$3*;&).&<.5*3&)4*&m-!

• HIGH LED

» lit&N&)4*&%4"31*&%./)3.66*3&<3*?*/)#&+.3*&%233*/)&83.+&1.$/1&).&)4*&>"))*3(&

even if the solar panel is receiving sunlight

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 distribution of grease. Both frequency of distribution (the number of wheels that pass before each pump activation) and duration of distribution (how long distribution pump cycle lasts) can be easily changed directly on the DCB.

LCD Display

The LCD display is located on the front panel of the DCB. It displays a digital read-out indicating the DCB’s current operating conditions.

ote: The LCD display will not display characters at temperatures below -20°C. The DCB will continue to function regardless of the status display. See that the ON light is green.

J8& )4*& 13**/& CBm& V"#4*#& %./)$/2.2#6(& 54*/& )4*& ./7.S& >2))./& $#&

pressed, then it is possible there is a low voltage condition. If the voltage is above 11.5 volts the LCD will still function and programming changes can be made, but the control

>.d&5$66&/.)&%.2/)&)4*&54**6#9&J8&)4*&?.6)"1*&$#&6.5&)4*&CBm&5$66&V"#4&3*;@&>2)&)4*&C-m&;$#<6"(&5$66&/.)&.<*3")*9&

Once the voltage is restored to above 12 volts the controller will resume normal operation. If the LCD shows

/.&;$#<6"(&54$6*&CBm&%./)$/2.2#6(&V"#4*#&13**/&"/;&)4*&>"))*3(&?.6)"1*&$#&13*")*3&)4"/&.3&*H2"6&).&^b&?.6)#@&

the LCD is defective.

Page 14PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 15

<.8<9"C$,,3.

`3*##$/1&)4*&./7.S&>2))./&5$66&%"2#*&)4*&)3$G%.6.3&CBm&).&)23/&13**/@&"/;&)4*&C-m&;$#<6"(&)..5&iE"$6&

Technologies” for several seconds. In addition to this, the control box revision is displayed (e.g. REV

6.3) and also the battery voltage. Next the LCD will display the controller’s state, including cumulative wheel count and number of wheels until next pump activation. This will display for ten seconds before

#5$)%4$/1& ).& )4*& /*d)&#%3**/& ;$#<6"($/1&<2+<& ;23")$./& "/;& 83*H2*/%(9&D4*&C-m&5$66&)4*/& )23/&.S9&

Pressing either the up or down arrow button, will toggle through wheel count, wheel frequency and pump duration.

Wheels Button

When pressing the wheels button it will display the number of wheels required to pass the wheel sensor to activate the pump. This number can range from 1 to 256. The number can be changed by using the up or down arrow buttons, with increments/decrements of one.

Pump Button

By pressing the pump button it will display pump duration; the length 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. When the counter reaches zero the LED will turn red, the pump and motor will run for the

#*)&;23")$./&"/;&)4*&;$#<6"(&5$66&)4*/&)23/&.S9

Counter Button

:4*/&<3*##$/1&)4*& %.2/)*3&>2))./&)4*&).)"6&54**6&%.2/)&5$66&>*&;$#<6"(*;@&)4$#&5$66&3*+"$/&8.3&0?*&

minutes. Pressing a second time will display total pump time for ten seconds before the display turns

.S9&`3*##$/1&"/;&4.6;$/1& )4*& %.2/)*3&>2))./& ;$#<6"(#&54$%4& ;$3*%)$./L#R&)4*&#+"3)&54**6& #*/#.3&$#& "%)$?*9&F&;$S*3*/)&.<)$./&$#&;$#<6"(*;&*"%4&)$+*&)4*&%.2/)*3&>2))./&$#&<3*##*;e&F&).&!@&!&).&F@&"/;&F&

or B. If set as A to B the axles will only be counted when the train passes over smart wheel sensor

F&03#)@&>2)&5$66&/.)&%.2/)&"d6*#&8.3&)3"$/#&<"##$/1&.?*3&#*/#.3&!&03#)9&!&).&F&;.*#&)4*&.<<.#$)*e&./6(& %.2/)$/1&"d6*#&$8&)4*&)3"$/&<"##*#&)4*&!&#*/#.3&03#)9&J8&)4*&m-!&$#&#*)&).&F&.3&!@&)4*&"d6*#&5$66&>*&%.2/)*;&

regardless of the direction of train travel.

Up Arrow Button

Pressing the up arrow button will increase the count of the current display.

Down Arrow Button

Pressing the down arrow button will decrease the count of the current display.

Page 15PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 16

DCB System Test

1. `3*##& )4*& ./7.S&>2))./& ).& */#23*& CBm& )23/#&13**/9& B/#23*&C-m& <"/*6.5#& )4*& #*H2*/%*& ;*#%3$>*;& $/&

">.?*&#*%)$./&2#$/1&)4*&;$1$)"6&%./)3.6&>.d&Lm-!R&U/7US&>2))./9&B/#23*&C-m&)23/#&.S&54*/&%.+<6*)*;9

2. Press the up arrow button to ensure LCD display replays status and setting screens. Once this has completed,

do the same with the down arrow button, it should display the same screens again.

3. Press the wheels button to ensure desired wheel frequency setting is displayed. Change with up and down

arrow buttons if necessary.

4. Press the pump button to ensure desired pump duration setting is displayed. Change with up and down

arrow buttons if necessary.

5. Press the test button to ensure the DCB correctly displays and activates according to the desired wheel

frequency and pump duration settings.

6. Press the counter button to ensure total wheel count is displayed. Press it again to ensure accumulated

pump frequency time is displayed.

Priming the System

1. Ensure clean hands section of tank is closed and tank outlet paddle is installed with screened section down

in front of pump inlet.

2. F;;&83$%)$./&+.;$0*3&).&#).3"1*&)"/T9&

3. D.&<3*?*/)&"$3&$/)"T*&";;&*/.214&83$%)$./&+.;$0*3&).&%.?*3&)4*&<2+<&$/6*)9&'6$;*&)"/T&.2)6*)&<2+<&#%3**/&

"3+&2<&"/;&;.5/&).&*/#23*&)4")&)4*&<2+<&$#&V..;*;&5$)4&+")*3$"69

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. B/#23*&>"))*3(&$#&%4"31*;&).&"&+$/$+2+&.8&^^9Q?&m-9&J8&>"))*3(&$#&)..&6.5&CBm&5$66&V"#4&3*;9

D3,)E"F-'/'.4",G?'+%&&G"-)#$'-)0"%??-37'/%,)&G",2-))",3"(H)"/'.$,)0",3"+3/?&),)>"I31)H)-B"*)?).*'.4"3."0G0,)/" +3.(4$-%,'3."%.*"%/6').,",)/?)-%,$-)B"?-'/'.4"/%G",%A)"$?",3"JK"/'.$,)0>

7. Position DCB toggle switch to prime. Verify motor starts and continues to run. Monitor the hoses and

connectors for leakage.

8. As the system continues to pump, verify and ensure material appears from ports of the wiping bars.

NEVER HAVE ALL BALL VALVES AT CENTER TRACK CLOSED AT THE SAME TIME WHILE THE PUMP IS ACTIVATED. THIS MAY CAUSE BODILY INJURY AND/OR HOSE, VALVE OR PUMP DAMAGE. DOES NOT APPLY TO SYSTEMS WITHOUT BALL VALVES AT CENTER TRACK.

D3,)E"L3.',3-"12'+2"1'?'.4"6%-0"%-)"(-0,",3"*'0,-'6$,)"4-)%0)>";2)"+3--)0?3.*'.4"6%&&"H%&H)0"+%.",2)."6)"+&30)*"

to speed up priming of the remaining bars.

9. When material does appear, verify and ensure material exits evenly from all ports.

10. Priming is now complete. Return DCB toggle switch to normal to shut down system.

Page 16PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 17

11. If pump is not supplying material, take the following steps after system shut down:

a) Disconnect main supply line connection at outside tank wall.

>R& a*3$8(&+")*3$"6&4"#&")&6*"#)&066*;&4.#*&$/#$;*&)3"%T9

c) Reconnect main supply line and repeat priming procedure.

!*5$0,'.4"<$,?$,"3:"M-'+,'3."L3*'()-

After the PROTECTOR IV has been installed and primed the system must be set up to pump the desired

H2"/)$)(&.8&83$%)$./&+.;$0*39&D4$#&;*<*/;#&./&)4*&"<<6$%")$./&"/;&6.%")$./&.8&)4*&2/$)9&-4"/1*&).&)4*&;*#$3*;&

setting as follows:

1. `3*##&./7.S&>2))./&).&)23/&)4*&m-!&./9

2. Press the wheels button.

3. Use the up and down arrow buttons to set the desired wheel count between pump activations.

4. Press the pump button.

5. Use up and down arrow buttons to set the desired pump duration.

6. `3*##&./7.S&>2))./&)5$%*&).&)23/&)4*&m-!&.S&"/;&)4*/&./&"1"$/9

7. Watch the LCD screen until it shows the number of wheels between activation and the duration of pump

activation to verify that the desired settings have been stored to memory.

Notes:

l3*H2*/)&>2).3)*3&6*/1)4&"%)$?")$./#&<3.?$;*&"&+.3*&%./)$/2.2#&V.5&.8&83$%)$./&+.;$0*39&C./1*3&"%)$?")$./#&

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 0.5 seconds. The control settings may need to be adjusted periodically to suit changes in material and temperature.

D4*&"+.2/)&.8&83$%)$./&+.;$0*3&"<<6$*;&>(&)4*&`EUDB-DUE&Ja&5$66&;*<*/;&2<./&+"/(&8"%).3#&$/%62;$/1n

• l3*H2*/%(&.8&)3"$/&)3"K%

• Distribution arrangement

• Adjustments to the DCB that controls the amount of material provided

o.23&#<*%$0%&3*H2$3*+*/)#&+2#)&>*&;*)*3+$/*;&>(&+./$).3$/1&)4*&2/$)=#&%./#2+<)$./&.?*3&)$+*&"%%.3;$/1&).&

the variables listed above.

Pump Time Out (PTO) Device Operation

The PTO device has been incorporated into the PROTECTOR IV unit as a fail safe. In the event of a DCB

+"682/%)$./&)4*&+.).3&+"(&>*&"%)$?")*;&%./)$/2.2#6(@&%"2#$/1&"/&*d%*##$?*&?.62+*&.8&83$%)$./&+.;$0*3&).&>*&

pumped on to the rail and also rapid discharge of the battery. If the battery is subjected to a deep discharge it will never fully re-charge. The pump time out device prevents this from occurring by automatically cutting the power to the motor if it operates continuously for 30 seconds.

Page 17PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 18

If the PTO has to cut the power it will need to be reset. This is performed by holding the toggle switch on the side of the DCB in prime mode, while simultaneously pressing the reset button on the PTO device. However, if the PTO device has been tripped it may mean there is a problem with either the smart wheel sensor or the DCB which may need further investigation to prevent the problem from recurring.

Reset Button

SERVICING & MAINTENANCE

Maintenance Routines

The following sections explain how to perform regular routine maintenance on the PROTECTOR IV unit. These routines are recommended to ensure the best performance of your unit.

Tank and Pump Unit

Maintain the tank and pump unit on a weekly basis as follows:

1. If the unit is solar powered, check to see which voltage regulator lights are illuminated. This will provide a

quick, initial insight into the condition of the battery. Using a voltmeter, check the voltage at the battery under load. Voltage below 12v DC under load may cause a problem.

2. Perform the “Control System Integrity Checks” as listed in the Start Up section of the manual. This will

%./03+&)4")&)4*&#*/#.3&"/;&)4*&%./)3.6&>.d&"3*&82/%)$./$/1&<3.<*36(9&!*&"5"3*&)4")&;23$/1&)4$#&)*#)@&)4*&

motor 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 procedure. Use a rag to wipe this excess material

on the gauge face of the rail in areas adjacent to the bars.

5. Open the material section of the tank and stir the grease. Check for excessive settling of the material and

ensure that there is no blockage at the pump inlet.

Battery Maintenance

he sealed battery and charger provided with the PROTECTOR IV are maintenance free. However, corrosion can build on the terminals, connectors and/or wires. During regular routine maintenance the battery should be checked for cracks or leaks. If the battery is cracked or leaking, it should be replaced immediately. If corrosion is present on the battery, connectors or wires, disconnect the negative and then the positive terminal. Clean the wires and ends with a wire brush, battery spray cleaner or a solution of baking soda and water. Let it dry and reconnect the positive then negative terminals. Di-electric grease or battery terminal spray sealer can be applied to the terminal ends and bolts. If there is severe corrosion it may be necessary to replace the wiring harness.

Page 18PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 19

Solar Panel Maintenance

The solar panel is designed for trouble-free use and unattended operation. At most sites, rain will keep the panel surface clean, thus preventing power output degradation. The lexan sheet is exceptionally resistant to weathering as it will remain clear and non-yellowing for many years with minimal deterioration. The dirt accumulation, which may be encountered in heavily populated areas, can be corrected by an occasional cleaning with mild detergent.

On a yearly basis, as a preventative maintenance procedure, all bolts which fasten the panel should be tightened to insure continued integrity of the system. All electrical connections in the junction box as well as the voltage regulator should be inspected for tightness and for corrosion, especially in harsh environments.

As a measure of preventative maintenance, appropriate lightning protection should be installed as part of the system in areas where lightning activity is a threat. This protection should follow standard railway procedures and must be installed by the customer. The voltage regulators are equipped with surge arrestors which protect their circuitry against induced voltages from lightning or other sources, *+!$,%!$121(,&!$1$ '()#.!$0(2"!,(,2$ strike.

Distribution Hoses and Wiping Bars

Maintain wiping bar hoses and wiping bars on a weekly basis as follows:

1. ')*<&./&"&5$<$/1&>"3&4.#*@&.>#*3?*&)4*&83$%)$./&+.;$0*3&"#&$)&*+*31*#&83.+&)4*&5$<$/1&>"39

2. C..T& ).& #**& )4")&)4*& V.5& $#& 2/$8.3+& 83.+& )4*& */)$3*& 6*/1)49& F)& "/(&<.$/)& 54*3*& )4*& +")*3$"6&;.*#& /.)&

emerge, there may be a clog.

3. Insert a screwdriver under one end of the wiping bar seal.

4. '6$;*&)4*&#%3*5;3$?*3&"6./1&)4*&3"$6@&#%3"<$/1&"5"(&"66&83$%)$./&+.;$0*3&)4")&4"#&"%%2+26")*;&./&)4*&3"$64*";9

5. Scrape both the area under the seal as well as the balance of the top of the railhead.

6. Lift the seal and use a putty knife to scrape excess material from the tip of the distribution blade and from

the “gutter” formed between the thin inner blade and the distribution blade.

7. Check the condition of the seal to see that it is staying tight to the railhead, is still supple and has good

“snap” to the rail.

8. -6*"/&"5"(&*d%*##&83$%)$./&+.;$0*3&$/&.3;*3&).&+"$/)"$/&)4*&%./;$)$./&.8&)4*&#*"69

9. Repeat the above steps at the other bars. If one bar does not produce material there may be:

a) A clog inside the passageways of the wiping bar. Ordinarily, this would be a rare circumstance. Disassemble

that bar and clean all passageways; or

b) A problem with the check valve, located at the center of track distribution piping, between the ball valve

and the distribution hose. Remove and check for clogging.

W#$/1&"&<2))(&T/$8*&.3&.)4*3&V")&>6";*@&%6*"/&"/(&*d%*##&83$%)$./&+.;$0*3&83.+&)4*&0*6;&#$;*&.8&)4*&3"$64*";@&c2#)&

downstream from the wiping bars.

l3$%)$./&+.;$0*3&+")*3$"6&5$66&%.66*%)&"#&"&#*+$G#.6$;@&%"26TG6$T*&+")*3$"6&)4")&%"/&>*&<6"%*;&./&).<&.8&)4*&3"$6&

8.3&*S*%)$?*&%"33(G;.5/9

Recapturing waste material and keeping the site clean will help monitor future wastage and other changes in the distribution and carry-down process.

Page 19PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 20

Preparing for Winter

J/&%6$+")*#&54*3*&)4*&5$/)*3&#*"#./&5$66&"S*%)&)4*&.<*3")$./&.8&)4*&`EUDB-DUE&Ja&"/;&)4*&2/$)&5$66&*d<*3$*/%*&

very low temperatures the following should be considered:

• Latches- Due to temperature changes, the latches must be adjusted to prevent improper closing of the lids.

Grease hinges and latches to prevent ceasing or breaking.

• C$;& '*"6#G& '*"6#& 5$66& >*& "S*%)*;& >(& )*+<*3")23*& %4"/1*9& J8& %6.#*;& ./& "& 5*)& #238"%*& )4*& #*"6#& +"(& 3$#T&

damage in winter and will have to be replaced.

TROUBLESHOOTING

Distribution Hoses and Wiping Bar System

Problems with the distribution hoses and TOR distribution units can generally be avoided if the system is

<3.<*36(&#*)& 2<@& <3$+*;& "/;& +"$/)"$/*;&./&"& 5**T6(& >"#$#9& D4$#& 5$66&*/#23*& )4")&)4*& 83$%)$./& +.;$0*3&V.5#& 83**6(9&J8&<3.>6*+#&"3*&*d<*3$*/%*;&5$)4&"&>6.%T*;&.3&2/*?*/&V.5&.8&83$%)$./&+.;$0*3&3*8*3&).&)4*&8.66.5$/1&

table.

Symptom Possible Causes Possible Solutions

F%%2+26")*;&83$%)$./&+.;$0*3&$#&>6.%T$/1&

wiping bars manifold

J/#*3)&V")&#%3*5;3$?*3&>*)5**/&5$<$/1&

bar blade and track - OR -

`..3&V.5&.8&83$%)$./&

+.;$0*3&83.+&

wiping bars to TOR

X.&V.5&.8&83$%)$./&

+.;$0*3&83.+&)"/T&

to TOR

Slide screwdriver along length of the TOR wiping bar to remove caulked material

Ball valve at center of track is clogged Disassemble and clean ball valve

TOR bar has clog inside Disassemble and clean TOR wiping bar

Wiping bar installed too low at track for proper distribution

Top of rail distribution bars damaged by train wheel (wiping bar was installed too high)

Hose damaged Replace hose

D*+<*3")23*&)..&6.5&8.3&83$%)$./&+.;$0*3& ).&V.5

Ball valve at center track is closed Open ball valve

Reinstall at proper level

Replace with new TOR bars and ensure installation at correct level

Use winter grade KELTRACK

Page 20PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 21

Digital Control Box

The DCB is the primary component of the electrical system. Troubleshooting will start at the component level.

Symptom Possible Causes Possible Solutions

Battery voltage is too low Charge battery

DCB has no readout in the LCD

display and at same time LED is

V"#4$/1&13**/

Train wheels are not being

counted by DCB (pass a steel

object over sensor to test, LED on

m-!.26;&V"#4&(*66.5R

Train wheels are only counted

sporadically by DCB

Defective battery Replace battery

Defective DCB Replace DCB

Sensor is defective Replace sensor

Sensor wiring at DCB connection is incorrect or broken

Verify wiring connections according to wiring diagram and replace if necessary

Sensor height is incorrect Adjust sensor height using shims

Rail has become magnetized Relocate sensor

Sensor or bracket has become

Tighten bolts

loose

Loose cable connection Push connectors in fully, place

yellow housing over connection

LCD does not turn green when

U/7US&$#&<3*##*;

Control buttons do not change

readings in LCD display

No readout

Unclear LCD

Defective DCB Replace DCB

Battery voltage is too low Charge battery

Defective Battery Replace battery

Defective DCB Replace DCB

Temperature is below -20°C Read display once temperature is

above -20°C

Defective DCB Replace DCB

High level of electrical noise Verify grounding of cabinet

Defective DCB Replace DCB

Page 21PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 22

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

No battery power Check battery and charge controller

connections

Indicator lights do not

turn on

Defective battery Replace battery

Too dark A solar panel will only work during daylight

hours

No voltage Check wiring connections

Green LED indicating

sunlight is not lit

Defective solar panel Replace solar panel

Battery voltage too low Charge battery

Defective charge controller Replace charge controller

Solar Panel

The solar panel has the job of ensuring that enough voltage reaches the charge controller, the table below indicates possible problems.

Symptom Possible Causes Possible Solutions

Battery is not charging

properly

Sun is blocked from solar panel by a physical obstruction

Solar panel face is dirty Clean solar panel with mild detergent

Loose or corroded wire terminals to battery

Defective solar panel Replace solar panel

Change location of solar panel or remove obstruction

Tighten or replace wire terminals

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

L$/;$%")*;&>(&V"#4$/1&13**/&CBmR

Defective battery Replace battery

Defective DCB Replace DCB

Charge battery

Motor will not start

when DCB is set to

Prime

l3$%)$./&+.;$0*3&5$66&

not pump from tank

into distribution hoses

Defective fuse Replace fuse

Brushes stuck in DC motor Check brushes Blockage at the pump inlet from

foreign object

Blockage at pump inlet due to

83$%)$./&+.;$0*3&#*))6$/1

Remove blockage

Clean tank if necessary

')$3&83$%)$./&+.;$0*3&$/&)4*&)"/T

Page 22PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 23

Lead Acid Battery Safety Precautions

BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. FOLLOW THESE PRECAUTIONS, AND THOSE PUBLISHED BY THE BATTERY MANUFACTURER, TO REDUCE THE RISK OF EXPLOSION.

• X*?*3&#+.T*&.3&"66.5&"&#<"3T&.3&V"+*&$/&)4*&?$%$/$)(&.8&"&>"))*3(9

• Wear eye protection and protective clothing.

• Do not charge a frozen battery.

• If battery acid or corrosive by-products contact skin or clothing, wash immediately with soap and water.

J/&)4*&*?*/)&.8&*(*&%./)"%)@&$++*;$")*6(&V2#4&5$)4&32//$/1&5")*3&8.3&bO&+$/2)*#&"/;&)4*/&#**T&<3.+<)&

medical attention.

• Always ensure someone is nearby to help you in the event of an emergency.

• Remove personal metal items such as rings, watches, bracelets etc. and be careful not to drop metal or

tools on the battery. Contact to the battery terminals may result in a short circuit, causing severe 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.

• '5$)%4&.S&F-&<.5*3&>*8.3*&%.//*%)$/1&.3&;$#%.//*%)$/1&m-&5$3$/1&.3&>"))*3(&%.//*%)$./#9

• Do not operate the control box without a battery. The battery charger or the control box will be damaged

without a battery connected.

• Although the battery charger (Xantrex TrueCharge 10TB only) is approved as an ignition-protected device;

nonetheless one should avoid using in a space containing gasoline or propane tanks, a gasoline engine or

"##.%$")*;&82*6&6$/*#&"/;&0))$/1#9

• Ensure existing wiring is in good electrical condition, and that AC wiring size is 14 AWG or larger and less

than 100 ft. long.

• Do not operate the charger if it has received a sharp blow or has been dropped or damaged in any way. A

;"+"1*;&%4"31*3&+2#)&>*&3*<6"%*;&.3&)"T*/&).&H2"6$0*;&#*3?$%*&<*3#.//*6&8.3&3*<"$39

Page 23PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 24

AC WIRING DIAGRAM FOR 200/25 UNIT

L.B. FOSTER

Page 24PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 25

DC WIRING DIAGRAM FOR 200/25 UNIT

L.B. FOSTER

Page 25PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 26

AC WIRING DIAGRAM FOR 800/100 UNIT

L.B. FOSTER

Page 26PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 27

DC WIRING DIAGRAM FOR 800/100 UNIT

L.B. FOSTE R

Page 27PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 28

200/25 AC AND DC TANK PART NUMBERS

Part Number Quantity Material Description

788-30021-84 1 AC P-IV 200# Tank and Pump Assembly (Single Pump) 788-30021-80 1 DC P-IV 200# Tank and Single Pump Assembly (Single Pump) 788-30025-80 1 DC P-IV 200# Tank and Pump Assembly (Double Pump) 788-30025-84 1 AC P-IV 200# Tank and Pump Assembly (Double Pump) 783-40040-00 1 1 1 1 Battery- 40 AMP HR 788-30004-67 1 1 1 1 AC/DC Power Harness P-IV 788-30007-10 1 1 Motor Pump Assembly (Single Pump) 788-30007-04 1 1 Motor Pump Assembly (Double Pump)

3U-1200 1 1 Replacement for 788-30007-10

788-30008-53 1 1 AC Wiring Diagram

788-30009-04-P 1 1 1 1 Digital Control Box

788-30012-66 1 1 Charger Assembly

788-30020-01RA 1 1 1 1 Tank Protector P-IV 200#

788-30007-53 1 1 1 1 Pump Time Out P-IV 200# Tank 788-30008-56 1 1 DC Wiring Diagram 788-30006-31 1 1 2 2 Hose- ¾” Tank Wall

Page 28PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 29

200/25 AC AND DC STAINLESS STEEL TANK W/ BRONZE DOUBLE PUMP AND TWIN HOSE PART NUMBERS

Part Number Quantity Quantity Material Description

788-30033-80 1 DC Double Pump Stainless Steel Tank and Pump Assembly

788-30033-94 1

502-927-082 1 1 Hose- Bottom

502-927-081 1 1 Hose- Top 788-30004-67 1 1 Wiring Harness 783-40040-00 1 1 Battery- 40 AMP HR

788-30007-04SS 1 1 Motor / Pump Assembly Double Pump Bronze

788-30008-24 1 150 Watt Power Supply 788-30004-82 1 Power Supply Mounting Plate 788-39990-18 1 GFCI 788-30006-81 1 RPM Control Box GPRS

AC Double Pump Stainless Steel Tank and Pump Assembly RPMGPRS

Page 29PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 30

800/100 AC AND DC TANK PART NUMBERS

Part Number Quantity Material Description

788-30081-81 1 AC P-IV 800# Tank and Pump (Single Pump) 788-30081-80 1 DC P-IV 800# Tank and Pump (Single Pump) 788-30085-00 1 DC P-IV 800# Tank and Pump (Double Pump) 788-30086-80 1 AC P-IV 800# Tank and Pump (Double Pump) 788-30004-67 1 1 1 1 AC/DC Power Harness P-IV 788-30007-10 1 1 Motor Pump Assembly (Single Pump) 788-30007-04 1 1 Motor Pump Assembly (Double Pump) 788-30008-44 1 1 1 1 Plate- MTG, Control Box 788-30008-52 2 2 2 2 Latch 788-30008-55 1 1 Wiring Schematic- P-IV 800# DC

788-30009-04-P 1 1 1 1 Digital Control Box

788-30080-01 1 1 1 1 Tank Body Protector 788-31046-01 1 2 2 1 Gasket Plate to Wall 788-31052-00 1 1 Outlet Plate Cover 788-30006-30 1 1 Hose, 1PC Pump- Tank Wall P-IV 800# 788-30007-58 1 1 1 1 PTO Assembly- 800# Tank 789-40041-00 1 1 Battery- 80 AMP/HR- AC 788-40080-00 1 1 Battery- 100 AMP/HR- DC 788-30008-58 1 1 Wiring Schematic P-IV 800# AC 788-30008-64 1 1 Power Conditioning Device

Page 30PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 31

SOLAR PANEL AND POLE KIT PART NUMBERS

Item Part Number Quantity Material Description

1 788-80001-00 1 Solar Panel Pole Kit 2 788-30001-02 1 Solar Panel

3 788-30007-95 1

Voltage Regulator with Bracket

DOUBLE PUMP MOTOR ASSEMBLY PART NUMBERS

Item Part Number Quantity Material Description

788-30007-04 1

1 3M-3005 1

2 3M-3006 1

3 788-51055-00 1 Double Pump Ductile Iron

4 713-506-016S 10

5 713-40600-0Z 4 M6 Elastic Locknut

6 713-50604-0S 4

7 788-51049-00 1 Gasket

8 788-30007-12 1

Double Pump Motor Assembly (Ductile)

Coupler between Motor and Pump

Motor Mount between Motor and Pump

SHCS M6 x 1mm x 16mm GR.12.9 SS

SHCS M6 x 1mm x 40mm GR.12.9 SS

DC Gear Motor with Connector (P-IV)

9 788-51053-00 1

Not

shown

788-31046-01

(must be ordered

separately)

Double Pump Mounting Plate

Tank Wall to Pump Plate Gasket

Page 31PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 32

DISTRIBUTION SYSTEM PIPING SUMMARY

D"/T&-./0123")$./

TOR 800#

Single Pump

TOR 800#

Double Pump

TOR 200#

Single Pump

TOR 200#

Double Pump Distribution 4-Bar 2-Bar 4-Bar 2-Bar Adapter at Tank 701-5420-41 701-5420-36 None 701-5420-36 Supply Hose Near Track 758-51255-40 788-41022-20 758-51255-40 788-41022-20 Supply Hose Far Track 788-41022-21 788-41022-21 N/A N/A Center of Track Manifold 788-07034-50 788-57006-50 788-07034-50 788-57006-50 Adapter at Center of Track

Manifold

70-15200-17 None 70-15200-17 None

Distribution Hose 788-01099-00 788-41022-19 788-01099-00 788-41022-19 Adapter at Bar None 701-5200-10 None 701-5200-10

QUICK HOSE COUPLING PART NUMBERS

Item Part Number Quantity Material Description

788-00045-50 1 Quick Hose Coupling Kit

1 503-576-001 1 ¾" Brass Female Cam Lock

2 503-576-002 1 ¾" Brass Male Cam Lock

3 701-520-010 1 ½" NPT x ½" JIC Hose Adapter 2021-8-8 4 701-519-007 1 ¾" NPT x ½" JIC Adapter 5 503-668-000 1 Lock Ring

6 503-577-002 1 ¾" Poly Male Plug 7 503-577-001 1 ¾" Poly Female Cap

8 700-747-050 1 Bow Tie Cotter Pin

9 701-520-014 1 ¾" NPT x ½" JIC Hose Adapter 2021-12-8

Note: Lock ring to be inserted during assembly.

LOCK RING

REMOVE INSERT

Note: 6 and 7 should be stored i n lubricator.

Locking Levers

Attaches to 2

Attaches to 1

Page 32PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 33

MC-4TR DISTRIBUTION BAR PART NUMBERS

Item Part Number Quantity Material Description

788-07044-50 1 MC-4TR Bar Assembly

1 788-01152-00 1 Manifold

2 788-01169-00 1 Gasket

3 788-01172-00 1 TOR ML Port Plate- Bent

4 78801173-00 1 TOR ML Porting Plate 5 788-01164-00 2' Clip-on Seal

6 788-07045-00 1 Distribution Blade Assembly

7 788-07048-00 1 Seal Retaining Bar / Anti-Skid Assembly

8 713-001-008 8 8 mm Plated Lockwasher Standard

9 713-308-030z 8 M8 UNC Hex HD CPS Zinc Plated GR.10.9 x 30mm

10 788-01123-00 2' Angle Seal

503-383-001 1 ½” NPT Plastic Plug (not shown)

Page 33PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 34

TOR XL-BAR PART NUMBERS

Item Part Number Quantity Material Description

788-07053-50 1 TOR XL-Bar Assembly 1 788-01154-00 1 Manifold 2 788-01155-01 1 Porting Plate 3 788-01164-00 1 Clip-on Seal 4 788-01156-00 1 Distribution Plate 5 788-01123-00 1 Angle Seal 6 788-01157-00 1 Seal Retaining Bar 7 713-408-000Z 16 M8 Class 10 Elastic Lock Nut- Zinc Yellow 8 788-01192-45 6 M8 SHCS Zinc Yellow w/Loctite Band GR.12.9 X 45 mm 9 788-01155-02 1 Port Plate- Bent

10 503-379-000 1 O-Ring Seal, Buna-In 11 713-001-008 16 8 mm Plated Lockwasher Standard 12 788-01192-40 10 M8 SHCS Zinc Yellow w/Loctite Band GR.12.9 x 40mm 13 700-684-032 16 Nord-Lock Washer- Zinc Plated

503-383-001 1 ½’’ NPT Plastic Plug (not shown)

Page 34PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 35

TOR ML-BAR PART NUMBERS

Item Part Number Quantity Material Description

788-07066-50 1 TOR ML-Bar Assembly

1 788-01217-00 1 Manifold

2 788-01218-00 1 Cover Plate

3 788-01219-00 1 Top Seal #1

4 788-01220-00 1 Top Seal #2 (undercut front)

5 503-526-000 8 M10 SS Shoulder Bolt (hex style head)

6 503-525-000 32 SS Belleville Springs

7 788-01200-00 3' Clip-on Back Seal

Page 35PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 36

TOR FOAM BAR 24” PART NUMBERS

Part Number Quantity Material Description

788-07139-24 1 TOR Foam Bar (24 in.)

701-520-010 1 Aeroquip 2021-8-8

TOR FOAM BAR 36” PART NUMBERS

Part Number Quantity Material Description

788-07139-36 1 TOR Foam Bar (36 in.)

701-520-010 1 Aeroquip 2021-8-8

Page 36PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 37

MOUNTING CL AMP PART NUMBERS

Item Part Number Quantity Quantity Material Description

788-07055-50 1 TOR Bar Clamp Assembly (Standard)

788-07055-51 1 TOR Bar Clamp Assembly (Small) 1 788-01160-50 1 TOR Bar Rail Clamp Body 2 900-031-272 1 1 J-Bolt ¾" x 10-½" Zinc Plated 3 700-675-077 2 2 Lock Washer Standard ¾" Medium Plated 4 700-845-075 2 2 Hex Nut UNC Zinc ¾" 5 700-836-300 1 1 HH CS GR.5 UNC ¾" x 3- Plated 6 788-01081-00 3 3 Spacer- Plated 7 700-694-075 4 4 ¾" USS HD FW GR.8 2" OD-.135" ZN 8 956-00025-81 2 1 Open End Spacer 9 788-01161-00 1 1 Dual Keyed Hardened Washer

10 788-01179-00 1 TOR Bar Rail Clamp (Small)

Page 37PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 38

QUICK MOUNTING CLAMP PART NUMBERS

Item Part Number Quantity Quantity Material Description

788-07092-50 1 Quick Clamp Sub-Assembly (Standard)

788-07092-51 1 Quick Clamp Sub-Assembly (Small) 1 788-07079-50 1 1 Quick Cam Assembly 2 788-01179-00 1 TOR XL Rail Clamp Body (Small) 3 788-01161-00 1 1 Dual Keyed Hardened Washer 4 788-01081-00 3 3 3/8” Spacer 5 700-836-300 1 1 Hex Head Screw ¾” UNC x 3” Zinc 6 700-675-077 1 1 ¾” Lockwasher Zinc Plated 7 788-01160-50 1 TOR XL Rail Clamp Body (Standard) 8 700-694-075 4 4 ¾” USS Hard Flat Washer Zinc 9 956-00025-81 2 1 Open End Spacer

Page 38PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 39

TOP OF RAIL BAR & CLAMP ASSEMBLY OPTIONS

Assembly No. Part No. Part Description

788-07066-50 TOR ML-Bar

788-07139-36 TOR 36" Foam Bar Assembly-Silicone

788-07139-24 TOR 24" Foam Bar Assembly-Silicone

788-07055-50 TOR XL-Bar Rail Clamp Assembly

788-07055-51 TOR XL-Bar Rail Clamp Assembly-Small

788-07012-50 Rail Clamp Sub Assembly

788-07022-50 Rail Clamp Sub Assembly-Small

788-07092-50 TOR XL Quick Clamp Sub Assembly

788-07092-51 TOR XL Quick Clamp Sub Assembly-Small

788-00045-50 Quick Hose Coupling Kit- TOR

788-07058-50 TOR ML-Bar Manifold w/Clamps (112-141)

788-07058-51 TOR ML-Bar Manifold w/Clamps-Small (under 112)

788-07098-50 TOR ML-Bar Quick Clamps-Quick Hose (112-141)

788-07098-51 TOR ML-Bar Quick Clamps-Quick Hose-Small (under 112)

788-00048-00 TOR 36" Foam Bar w/ Clamps (115-141)

788-00049-00 TOR 36" Foam Bar w/ Clamps-Small (under 115)

788-00050-00 TOR 24" Foam Bar w/ Clamps (115-141)

788-00051-00 TOR 24" Foam Bar w/ Clamps-Small (under 115)

Assembly No. Part No. Part Description

788-07044-50 MC-4TR Distribution Bar Assembly

788-07012-50 MC-4 Rail Clamp Sub Assembly

788-07022-50 MC-4 Rail Clamp Sub Assembly-Small

788-07033-50 MC-4 TR Manifold Assembly (JAPAN)-RH

788-07033-51 MC-4 TR Manifold Assembly (JAPAN)-LH

788-07049-50 MC-4 TR Bar Assembly w/Clamps

788-07049-51 MC-4 TR Bar Assembly w/Clamps-Small

788-07032-50 MC-4 TR Bar (JAPAN) (112-140)-RH

788-07032-51 MC-4 TR Bar (JAPAN) (112-140)-LH

788-07032-52 MC-4 TR Bar (JAPAN) (under 112)-RH

788-07032-53 MC-4 TR Bar (JAPAN) (under 112)-LH

TOR ML + XL + FOAM

Color

MC-4 TR Bar

Color

Page 39PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 40

SMART WHEEL SENSOR PART NUMBERS

Item Part Number Quantity Quantity Material Description

788-30009-05-P 1 1 Smart Wheel Sensor Head w/Pigtail

788-3000909-35DM

-50DM 788-50005-50

(includes items 1-7

listed below)

788-50006-50

(includes items 1 - 7

listed below)

1 700-675-039 4 4 C.%T&:"#4*3&p7f]&L')"/;"3;R 2 700-693-075 1 1 Hard Washer ¾” ASTM F-436 ZNC 3 700-845-075 2 2 Hex Nut UNC Zinc ¾” 4 700-893-125 4 jj-'&&`6")*;&p7f]G^g&X-&d&^Ghq 4 700-893-175 4 HHCS Plated p7f]-16 NC x 1-¾" 5 788-30002-14 1 Smart Wheel Sensor Bracket (Standard) 5 788-30002-13 1 Smart Wheel Sensor Bracket (Short) 6 788-300-0215-313 2 2 '+"3)&&:4**6&&'*/#.3&&'<"%*3&r7[\q&L`"$3R 7 900-031-272 1 1 J-Bolt ¾” x 10-½” Zinc Plated

1 1 Sensor Cable

1 Smart Wheel Sensor Package Kit (Standard 112+ lb.)

1 Smart Wheel Sensor Package Kit (Small <112 lb.)

Page 40PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 41

SMART WHEEL SENSOR W/QUICK CLAMP PART NUMBERS

Item Part Number Quantity Quantity Material Description

788-50005-52

(includes items

1 - 9 listed below)

788-50006-52

(includes items

1 - 9 listed below)

1 788-30002-14 1 Smart Wheel Sensor Bracket (112+ lb.) 1 788-30002-13 1 Smart Wheel Sensor Bracket (<112 lb.) 2 700-675-039 4 4 C.%T&:"#4*3&p7f]&L')"/;"3;R

3 700-893-125 4 4 jj-'&&`6")*;&p7f]G^g&X-&d&^Ghq 4 788-300-0215-313 1 1 '+"3)&&:4**6&&'*/#.3&&'<"%*3&r7[\q&L`"$3R

5 788-01257-00 1 1 ½" Diameter Clevis Pin 6 788-01256-02 1 1 ½" x 6" HHCS Full Thread Zinc Plated 7 788-01255-00 1 1 Die Spring 8 788-01254-00 1 1 Bronze Bushing

9 788-01251-00 1 1 Quick Clamp Retaining Block 10 788-01250-00 1 1 Rail Clamp Cam 11 788-01249-00 1 1 Threaded Rod 12 700-747-050 1 1 Bow Tie Cotter Pin

Smart Wheel Sensor Package Kit w/Quick Clamp (Standard 112+ lb.)

Smart Wheel Sensor Package Kit w/Quick Clamp (Small <112 lb.)

Page 41PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 42

GLOSSARY OF TERMS

• CAUTION. Title included wherever a particular procedure or step may cause equipment to be damaged if not done correctly.

• Clean Hands Section. Section of the PROTECTOR IV tank which contains the Digital Control Box, Motor,

`2+<&"/;&!"))*3(9&U<<.#$)*&).&)4")&#*%)$./&.8&)"/T&%./)"$/$/1&83$%)$./&+.;$0*3&+")*3$"69

• Crib. The ballast, or the open space, between two adjacent crossties.

• Digital Control Box (DCB). Used to control the operation of the PROTECTOR IV unit.

• l3$%)$./&s.;$0*39&F&+")*3$"6&54$%4&$#&#$+$6"3&$/&"<<*"3"/%*& ).&"& 5")*3& >"#*;&6")*d&<"$/)9&D4$#&+")*3$"6&$#&

;$#)3$>2)*;&).&)4*&).<&.8&3"$6&54*3*&$)&8.3+#&"&)4$/&;3(&06+&54$%4&*/#23*#&$+<3.?*;&)3"%T$/1&)43.214&%23?*#@&

reduced noise and control of wear on rails.

• Liquid Crystal Display (LCD). Shows system related information in an alpha-numeric format.

• Light Emitting Diode (LED).

• `2+<&m23")$./9&D4*&)$+*&$/&#*%./;#&)4")&83$%)$./&+.;$0*3&5$66&>*&<2+<*;&>(&)4*&`EUDB-DUE&Ja9

• Stage One. A display sequence on the LCD which is shown immediately after display of “L.B. Foster.” Stage

./*&03#).5#& )4*& ).)"6&"%%2+26")*;&54**6&%.2/)& "/;& 54**6#&3*+"$/$/1& >*8.3*&/*d)&"%)$?")$./&8.3&)*/&

seconds, then the wheel frequency and pump duration for ten seconds.

• Smart Wheel Sensor (SWS). Wheel sensor that recognizes the signature of a wheel passing and communicates with the DCB.

• W<#)3*"+9&'*%)$./&.8&)3"%T&54$%4&)3"$/&5$66&<"##&.?*3&03#)9

• WARNING. Title included wherever a particular procedure or step may cause bodily injury or harm if all safety precautions have not been administered.

• Wheel Count. Number of train wheels which have been recorded by the digital control box of a PROTECTOR IV as passing by its sensor unit.

• Wheel Frequency. The number of train wheels which must pass by an installed PROTECTOR IV sensor unit to activate the pump.

Page 42PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual

Page 43

CUSTOMER SERVICE CONTACT INFORMATION

United States

415 Holiday Drive Pittsburgh, PA 15220 USA Telephone: 412.928.3400 Facsimile: 412.920.3510 E-mail: [email protected]

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: [email protected]

Europe

Stamford Street

'4*K*6;&'t&bDu

United Kingdom Telephone: +44(0) 114 2562225 Facsimile: +44(0) 114 2617826 E-mail: [email protected]

Revision 3-March 2016

PROTECTOR® IV 200/25 Tank US Patent Number D495,974

Page 43PROTECTOR® IV Top of Rail Installation, Operation & Maintenance Manual