LBFoster Protector IV Installation, Operation & Maintenance Manual

For gauge face (for systems built prior to 2017)

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PROTECTOR® IV TRACKSIDE

FRICTION MANAGEMENT SYSTEM

Installation, Operation &

Maintenance Manual

for GAUGE FACE

(For systems built prior to 2017)

www.lbfoster.com

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Summary of Contents for LBFoster Protector IV

Page 1 PROTECTOR® IV TRACKSIDE FRICTION MANAGEMENT SYSTEM Installation, Operation & Maintenance Manual for GAUGE FACE (For systems built prior to 2017) www.lbfoster.com...
Page 2: Table Of Contents
TABLE OF CONTENTS Welcome ..........................................3 Introduction ........................................3 Basic Systems & Configuration ................................4 Site Selection .........................................6 Electrical Power (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...
Page 3: Welcome
The PROTECTOR IV system is configured to run from a 12 volt DC battery charged by solar power, but can also be run from an AC supply.
Page 4: Basic Systems & Configuration
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.
Page 5 • 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.
Page 6: Site Selection
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 achieving effective friction management material distribution. When selecting a site for installation, optimal performance of the unit depends upon attaining as many of the following general considerations as possible: 1.
Page 7: Electrical Power (Solar Panel)
ELECTRICAL POWER (SOLAR PANEL) Solar Panel Location and Installation As you consider solar panel mounting options, be sure that the final configuration positions the panel to a 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.
Page 8 Optimum Angle for Sunlight Site Tilt Base Latitude (degrees) Angle (degrees) Distance (inches) Distance (millimeters) 17-¾ 17-½ 17-3/₁₆ /₁₆ /₈ 16-3/₈ 16-1/₈ 15-13/₁₆ /₁₆ 15-¼ Solar Panel – Tank Mounted Assembly Instruction 1. Before beginning the assembly ensure the side of the tank hangs over the tie. 2.
Page 9 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:...
Page 10: Electrical Power (Ac Power)
Wiping 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.
Page 11 A PASSING TRAIN CAN DAMAGE IMPROPERLY INSTALLED COMPONENTS. ALLOW SUFFICIENT TRACK TIME TO FULLY COMPLETE INSTALLATION. MC-4 Wiping Bar Installation 1. Ensure tank unit is located such that the lubricant supply hose can be routed from the cabinet to where the rail is in good condition.
Page 12 13. Secure the mounting bolts to the clamp blocks tightening the right bolt first to ensure the wiping bar is pushed securely against the rail. 14. Occasionally tap the assembly as you are tightening to insure wiping bar remains tight to the rail. 15.
Page 13 All customer supplied hoses must be the same length as those supplied by L.B. Foster. If longer or shorter, the hoses distribution efficiencies will be changed, and this could lead to too much or too little lubricant being applied to the rail. Restraining Bar Installation 1.
Page 14: Smart Wheel Sensor Installation
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.
Page 15 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.
Page 16 Once the voltage is restored to above 12 volts the controller will resume normal operation. If the LCD shows no display while LED continuously flashes green and the battery voltage is greater than or equal to 12 volts, the LCD is defective. On/Off Button Pressing the on/off button will cause the tri-color LED to turn green, and the LCD display to show “Rail Technologies”...
Page 17 DCB System Test 1. Press the on/off button to ensure LED turns green. Ensure LCD panel shows the sequence described in above section using the digital control box (DCB) On/Off button. Ensure LCD turns off when completed. 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.
Page 18 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 malfunction the motor may be activated continuously, causing an excessive volume of grease to be pumped on to the rail and also rapid discharge of the battery.
Page 19: Servicing & Maintenance
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.
Page 20 Recapturing waste material and keeping the site clean will help monitor future wastage and other changes in the distribution and carry-down process. Preparing for Winter In climates where the winter season will affect the operation of the PROTECTOR IV and the unit will experience very low temperatures the following should be considered. •...
Page 21: Troubleshooting
TROUBLESHOOTING Distribution Hoses and Wiping Bar System Problems with the distribution hoses and grease wiping bar system distribution units can generally be avoided if the system is properly set up, primed and maintained on a weekly basis. This will ensure that the lubricant flows freely.
Page 22 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...
Page 23 No voltage Check wiring connections Defective solar panel Replace solar panel Green LED indicating sunlight is not lit 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.
Page 24 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. • Never smoke or allow a spark or flame in the vicinity of a battery. •...
Page 25: Ac Wiring Diagram For 200/25 Unit
AC WIRING DIAGRAM FOR 200/25 UNIT ® L.B. FOSTER PROTECTOR® IV Gauge Face Installation, Operation & Maintenance Manual Page 25...
Page 26: Dc Wiring Diagram For 200/25 Unit
DC WIRING DIAGRAM FOR 200/25 UNIT ® L.B. FOSTER PROTECTOR® IV Gauge Face Installation, Operation & Maintenance Manual Page 26...
Page 27: Ac Wiring Diagram For 800/100 Unit
AC WIRING DIAGRAM FOR 800/100 UNIT PROTECTOR® IV Gauge Face Installation, Operation & Maintenance Manual Page 27...
Page 28: Dc Wiring Diagram For 800/100 Unit
DC WIRING DIAGRAM FOR 800/100 UNIT PROTECTOR® IV Gauge Face Installation, Operation & Maintenance Manual Page 28...
Page 29: Glossary Of Terms
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. PROTECTOR® IV Gauge Face Installation, Operation & Maintenance Manual...
Page 30: Customer Service Contact Information
CUSTOMER SERVICE CONTACT INFORMATION United States 415 Holiday Drive Pittsburgh, PA 15220 Telephone: 412.928.3400 Facsimile: 412.920.3510 E-mail: 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...