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LB Foster PROTECTOR IV TOR Trackside Installation, Operation And Maintenance Manual

Trackside friction management system
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PROTECTOR® IV TRACKSIDE
FRICTION MANAGEMENT SYSTEM
Installation,
Operation and
Maintenance Manual
for
TOP OF RAIL
TOP OF RAIL
www.lbfoster.com

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  • Page 1 PROTECTOR® IV TRACKSIDE FRICTION MANAGEMENT SYSTEM Installation, Operation and Maintenance Manual TOP OF RAIL TOP OF RAIL www.lbfoster.com...
  • Page 3 For customer service contact the appropriate office listed below: United States: 415 Holiday Drive  Pittsburgh, PA 15220 USA 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 ...
  • Page 4 WELCOME Thank you for purchasing the noise and limit the initiation of rolling PROTECTOR Trackside contact fatigue (RCF) and gauge Friction Management System. The corner cracking (GCC). This is achieved PROTECTOR IV TOR system is part by distributing a friction modifier, of L.B.

  • Page 5: Safety First

    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.

  • Page 6: Tools Required

    INTRODUCTION 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.
  • Page 7 BASIC SYSTEMS AND COMPONENTS 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 friction modifier that is pumped from the tank to the bars.
  • Page 8 BASIC SYSTEMS AND COMPONENTS 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.
  • Page 9 BASIC SYSTEMS AND COMPONENTS 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 magnet connected to the control circuitry.

  • Page 10: Site Selection

    SITE SELECTION 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: INSTALLATION AND MAINTENANCE OF THE PROTECTOR IV SYSTEM REQUIRES PERSONNEL TO BE ON-TRACK, INCLUDING BETWEEN THE...
  • Page 11 SITE SELECTION Install the tank far enough from the track to safely clear the operation of ballast regulators, snow plows, and other track equipment, but close enough to allow the supply hose to be shortened for maximum efficiency. 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.

  • Page 12: 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 13 ELECTRICAL POWER (SOLAR PANEL) 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 upon the latitude of the location.
  • Page 14 ELECTRICAL POWER (SOLAR PANEL) Solar Panel – Tank Mounted Assembly Instruction Before beginning the assembly ensure the side of the tank hangs over the tie. 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 3/8"...
  • Page 15 ELECTRICAL POWER (SOLAR PANEL) Gauge on the Solar Panel Mounting Bracket used to Adjust the Angle Solar Panel Wiring 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. The 35 ft.
  • Page 16 ELECTRICAL POWER (SOLAR PANEL) 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. 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.
  • Page 17 ELECTRICAL POWER (AC POWER) AC Electrical Power and Battery Charger Connections Remove the bolts on the battery terminals using a 10mm socket or wrench. Look at battery and charger safety precautions. Be careful not to short the battery terminals with a tool. 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...

  • Page 18: Tor Installation

    TOR INSTALLATION Configuration at Track 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 configuration at track for PROTECTOR IV units is on both rails of a single track with uni-directional traffic.
  • Page 19 TOR INSTALLATION Install the MC-4TR® wiping bars as follows: Ensure selected tank location is such that the friction modifier supply hose(s) can be routed from tank and where rail is in good condition. To confirm clamp locations mate with existing cribs, lay out wiping bars on field-side of rail.
  • Page 20 TOR INSTALLATION MC-4TR Wiping Bar Installation 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.
  • Page 21 TOR INSTALLATION TOR -ML Wiping Bar Installation Distribution Hose Installation Install one main supply hose and four TOR distribution bar hoses as follows: Run main supply hose from tank, underneath the rail, to a position central to the top of rail distribution bars assemblies. Layout the “H”...

  • Page 22: Smart Wheel Sensor Installation

    SMART WHEEL SENSOR INSTALLATION The smart wheel sensor should be placed as far away from the distribution bars as possible using the supplied cable. Dig out the ballast from underneath the rail where the sensor will be placed. Place the J-bolt underneath the rail and fix to the bracket with the full nut and Nyloc nut.

  • Page 23: Operation & Start Up

    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 storage of the friction modifier and a clean hands compartment for all the electrical components, such as, the digital control box (DCB), motor, pump, battery and other mechanisms.
  • Page 24 OPERATION & START UP 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.
  • Page 25 OPERATION & START UP 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. Note: The LCD display will not display characters at temperatures below -20°C.
  • Page 26 OPERATION & START UP 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 set duration and the display will then turn off.
  • Page 27 OPERATION & START UP Press the test button to ensure the DCB correctly displays and activates according to the desired wheel frequency and pump duration settings. 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 Ensure clean hands section of tank is closed and tank outlet paddle is installed with screened section down in front of pump inlet.
  • Page 28 OPERATION & START UP 10. Priming is now complete. Return DCB toggle switch to normal to shut down system. 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. b) Verify material has at least filled hose inside track.
  • Page 29 OPERATION & START UP » Frequency of train traffic » Distribution arrangement » Adjustments to the DCB that controls the amount of material provided Your specific requirements must be determined by monitoring the unit’s consumption over time according to 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.

  • Page 30: Servicing And Maintenance

    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: If the unit is solar powered, check to see which voltage regulator lights are illuminated.
  • Page 31 SERVICING & MAINTENANCE 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 32 SERVICING & MAINTENANCE 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. Check the condition of the seal to see that it is staying tight to the railhead, is still supple and has good “snap”...

  • Page 33: Troubleshooting

    TROUBLESHOOTING Distribution Hoses and Wiping Bar System Problems with the distribution hoses and TOR 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 friction modifier flows freely. If problems are experienced with a blocked or uneven flow of friction modifier refer to the following table.
  • Page 34 TROUBLESHOOTING 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 Charge battery DCB has no readout in the LCD display and at same time Defective battery Replace battery...
  • Page 35 TROUBLESHOOTING Temperature is below Read display once -20°C temperature is above -20°C No readout Defective DCB Replace DCB High level of electrical Verify grounding of cabinet noise Unclear LCD Defective DCB Replace DCB Charge Controller The PROTECTOR IV’s charge controller has lights indicating battery conditions as well as charging condition.
  • Page 36 TROUBLESHOOTING 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 Sun is blocked from Change location of solar panel by a solar panel or remove physical obstruction obstruction...
  • Page 37 TROUBLESHOOTING 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 38: Wiring Diagrams

    WIRING DIAGRAMS AC Wiring Diagram for 200/25 Unit ® L.B. FOSTER Section 10.1...
  • Page 39 WIRING DIAGRAMS DC Wiring Diagram for 200/25 Unit ® L.B. FOSTER Section 10.2...
  • Page 40 WIRING DIAGRAMS AC Wiring Diagram for 800/100 Unit Section 10.3...
  • Page 41 WIRING DIAGRAMS DC Wiring for 800/100 Unit Section 10.4...
  • Page 42 200/25 AC AND DC TANK DRAWING & MATERIALS Section 11.1...
  • Page 43 200/25 AC AND DC TANK DRAWING & MATERIALS Part Number Quantity Material Description AC P-IV 200# Tank and Pump 788-30031-84 Assembly (single pump) DC P-IV 200# Tank and Pump 788-30031-80 Assembly (single pump) DC P-IV 200# Tank and Pump 788-30034-80 Assembly (double pump) AC P-IV 200# Tank and Pump 788-30034-84...
  • Page 44 200/25 AC AND DC STAINLESS STEEL TANK W/ BRONZE DOUBLE PUMP AND TWIN HOSE DRAWING & MATERIALS Section 12.1...
  • Page 45 200/25 AC AND DC STAINLESS STEEL TANK W/ BRONZE DOUBLE PUMP AND TWIN HOSE DRAWING & MATERIALS Part Number Quantity Quantity Material Description DC Double Pump Stainless Steel 788-30033-80 Tank and Pump Assembly AC Double Pump Stainless Steel 788-30033-94 Tank and Pump Assembly RPM- GPRS 502-927-082 Hose- Bottom...
  • Page 46 800/100 AC AND DC TANK DRAWING & MATERIALS Section 13.1...
  • Page 47 800/100 AC AND DC TANK DRAWING & MATERIALS Part Number Quantity Material Description AC P-IV 800# Tank and Pump 788-30081-81 Assembly (single pump) DC P-IV 800# Tank and Pump 788-30081-80 Assembly (single pump) DC P-IV 800# Tank and Pump 788-30085-00 Assembly (double pump) AC P-IV 800# Tank and Pump 788-30086-80...
  • Page 48 SOLAR PANEL AND POLE KIT DRAWING & MATERIALS Item Part Number Quantity Material Description 788-80001-00 Solar Panel Pole Kit 788-30001-02 Solar Panel 788-30007-95 Voltage Regulator with Bracket Section 14.1...
  • Page 49 PUMP MOTOR ASSEMBLY DRAWING & MATERIALS Item Part Number Quantity Material Description 788-30007-04SS Double Pump/Motor Assembly-Bronze 3M-3005 Coupler between Motor and Pump Motor Mount between Motor and 3M-3006 Pump 788-51054-00 Bronze Double Pump 713-506-0165 SHCS M6 x 1mm x 16mm GR.12.9 SS 713-40600-0Z M6 Elastic Locknut 713-50604-0S...

  • Page 50: Distribution System Piping Summary

    DISTRIBUTION SYSTEM PIPING SUMMARY Tank Configuration TOR 800# TOR 800# TOR 200# TOR 200# Single Pump Double Pump Single Pump 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 758-51255-40 788-41022-20 758-51255-40 788-41022-20 Near Track Supply Hose Far 788-41022-21 788-41022-21...
  • Page 51 QUICK HOSE COUPLING DRAWING & MATERIALS Item Part Number Quantity Material Description 788-00045-50 Quick Hose Coupling Kit 503-576-001 ¾" Brass Female Cam Lock 503-576-002 ¾" Brass Male Cam Lock 701-520-010 ½" NPT x ½" JIC Hose Adapter 2021-8-8 701-519-007 ¾" NPT x ½" JIC Adapter 503-668-000 Lock Ring 503-577-002...
  • Page 52 MC-4TR DISTRIBUTION BAR DRAWING & MATERIALS Item Part Number Quantity Material Description 788-07044-50 MC-4TR Bar Assembly 788-01152-00 Manifold 788-01169-00 Gasket 788-01172-00 TOR ML Port Plate- Bent 78801173-00 TOR ML Porting Plate 788-01164-00 Clip-on Seal 788-07045-00 Distribution Blade Assembly 788-07048-00 Seal Retaining Bar / Anti-Skid Assembly 713-001-008 8 mm Plated Lockwasher Standard M8 UNC Hex HD CPS Zinc Plated GR.10.9...
  • Page 53 TOR XL-BAR DRAWING & MATERIALS Item Part Number Quantity Material Description 788-07053-50 TOR XL-Bar Assembly 788-01154-00 Manifold 788-01155-01 Porting Plate 788-01164-00 Clip-on Seal 788-01156-00 Distribution Plate 788-01123-00 Angle Seal 788-01157-00 Seal Retaining Bar 713-408-000Z M8 Class 10 Elastic Lock Nut- Zinc Yellow M8 SHCS Zinc Yellow w/Loctite Band 788-01192-45 GR.12.9 X 45 mm...
  • Page 54 TOR ML-BAR DRAWING & MATERIALS Item Part Number Quantity Material Description 788-07066-50 TOR ML-Bar Assembly 788-01217-00 Manifold 788-01218-00 Cover Plate 788-01219-00 Top Seal #1 788-01220-00 Top Seal #2 (undercut front) 503-526-000 M10 SS Shoulder Bolt (hex style head) 503-525-000 SS Belleville Springs 788-01200-00 Clip-on Back Seal Exploded View of TOR ML-Bar Assembly...

  • Page 55: Intentionally Blank

    INTENTIONALLY BLANK...
  • Page 56 TOR FOAM BAR 24" DRAWING & MATERIALS Part Number Quantity Material Description 788-07139-24 TOR Foam Bar (24 in.) 701-520-010 Aeroquip 2021-8-8 Section 21.1...
  • Page 57 TOR FOAM BAR 36" DRAWING & MATERIALS Part Number Quantity Material Description 788-07139-36 TOR Foam Bar (36 in.) 701-520-010 Aeroquip 2021-8-8 Section 21.2...
  • Page 58 MOUNTING CLAMP DRAWING & MATERIALS Exploded View of Mounting Clamp Section 22.1...
  • Page 59 MOUNTING CLAMP DRAWING & MATERIALS Item Part Number Quantity Quantity Material Description TOR Bar Clamp Assembly 788-07055-50 (Standard) TOR Bar Clamp Assembly 788-07055-51 (Small) 788-01160-50 TOR Bar Rail Clamp Body J-Bolt ¾" x 10-½" Zinc 900-031-272 Plated Lock Washer Standard 700-675-077 ¾"...
  • Page 60 QUICK MOUNTING CLAMP DRAWING & MATERIALS Exploded View of Quick Mounting Clamp Section 23.1...
  • Page 61 QUICK MOUNTING CLAMP DRAWING & MATERIALS Item Part Number Quantity Quantity Material Description Quick Clamp Sub-Assembly 788-07092-50 (Standard) Quick Clamp Sub-Assembly 788-07092-51 (Small) 788-07079-50 Quick Cam Assembly TOR XL Rail Clamp Body 788-01179-00 (Small) 788-01161-00 Dual Keyed Hardened Washer 788-01081-00 3/8”...
  • Page 62 INTENTIONALLY BLANK...
  • Page 63 TOR BAR & CLAMP ASSEMBLY OPTIONS BY RAIL SIZE TOR ML + XL + FOAM Color 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...
  • Page 64 SMART WHEEL SENSOR DRAWING & MATERIALS Smart Wheel Sensor Assembly Exploded View of Section 25.1...
  • Page 65 SMART WHEEL SENSOR DRAWING & MATERIALS Item Part Number Quantity Quantity Material Description Smart Wheel Sensor 788-30009-05-P Head w/Pigtail 788-3000909-35DM Sensor Cable -50DM 788-50005-50 Smart Wheel Sensor (includes items 1 - 7 Package Kit (Standard listed below) 112+ lb.) 788-50006-50 Smart Wheel Sensor (includes items 1 - 7 Package Kit (Small <112...
  • Page 66 SMART WHEEL SENSOR W/QUICK CLAMP DRAWING & MATERIALS Smart Wheel Sensor with Quick Clamp Assembly Exploded View of Section 26.1...
  • Page 67 SMART WHEEL SENSOR W/QUICK CLAMP DRAWING & MATERIALS Item Part Number Quantity Quantity Material Description 788-50005-52 Smart Wheel Sensor (includes items Package Kit w/Quick 1 - 9 listed below) Clamp (Standard 112+ lb.) 788-50006-52 Smart Wheel Sensor (includes items Package Kit w/Quick 1 - 9 listed below) Clamp (Small <112 lb.) Smart Wheel Sensor...

  • Page 68: Glossary Of Terms

    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, Pump and Battery. Opposite to that section of tank containing friction modifier material.
  • Page 69 GLOSSARY OF TERMS » 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.
  • Page 72 www.lbfoster.com 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 Sheffield S9 2TX United Kingdom Telephone: +44(0) 114 2562225 Facsimile: +44(0) 114 2617826...

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