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LB Foster PROTECTOR IV User Manual

LB Foster PROTECTOR IV
43 pages
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www.lbfoster.com
PROTECTOR® IV TRACKSIDE
F
RICTION MANAGEMENT SYSTEM
Installation, Operation &
Maintenance Manual
for TOP OF RAIL
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LB Foster PROTECTOR IV Specifications

General IconGeneral
BrandLB Foster
ModelPROTECTOR IV
CategoryIndustrial Equipment
LanguageEnglish

Summary

WELCOME

INTRODUCTION

Safety First

General safety guidelines for operating the equipment.

Lifting Precautions

Proper procedures and warnings for lifting the unit.

Live Rail Working

Guidelines for working near live electrical rails.

AC Power Supply Safety

Safety measures for connecting to AC power sources.

Battery Safety

Precautions for handling and connecting batteries.

Tools Required

BASIC SYSTEMS & CONFIGURATION

Digital Control Box (DCB)

The central control unit for the PROTECTOR IV system.

Pump Assembly

Details of the pump and motor assembly for grease distribution.

Motor

Description of the 12v DC electric motor powering the pump.

Power Requirements

Details on power sources for DC and AC units.

DC Powered Units

Information specific to DC-powered units.

AC Powered Units

Information specific to AC-powered units.

Solar Panel

Components and function of the solar power package.

Smart Wheel Sensor

Description of the standard bi-directional smart wheel sensor.

Tank

Design and mounting considerations for the system tank.

Distribution Hoses

Function and installation of hoses for grease distribution.

SITE SELECTION

ELECTRICAL POWER (SOLAR PANEL)

Solar Panel Location and Installation

Guidance on positioning and mounting the solar panel for optimal sunlight.

Solar Panel Adjustment

Instructions for setting the optimal tilt angle for solar panel efficiency.

Solar Panel Wiring and Connections

Procedures for connecting the solar panel to the system.

ELECTRICAL POWER (AC POWER)

AC Electrical Power and Battery Charger Connections

How to connect AC power and the battery charger.

TOR INSTALLATION

Configuration at Track

Describes typical track configurations for distribution bars.

ML Top of Rail Wiping Bars Installation

Instructions for installing ML type top of rail wiping bars.

Distribution Hose Installation

Steps for connecting the distribution hoses from the tank to the bars.

OPERATION & START UP

Smart Wheel Sensor Installation

Procedures for installing the smart wheel sensor on the rail.

General Operation Theory

Explains how the PROTECTOR IV system functions.

System Start Up and Configuration

Steps for initial setup, including charge controller, integrity checks, and DCB operation.

Digital Control Box (DCB) Operation

Details on using the DCB buttons for configuration and monitoring.

DCB System Test and Priming

Procedures for testing the DCB and priming the system.

Adjusting Friction Modifier Output

How to set the desired amount of friction modifier applied.

SERVICING & MAINTENANCE

Maintenance Routines

Recommended weekly and yearly maintenance tasks.

Tank and Pump Unit Maintenance

Procedures for maintaining the tank and pump.

Battery Maintenance

Checks and cleaning procedures for the battery.

Solar Panel and Wiping Bar Maintenance

Maintenance tasks for solar panels and distribution hoses/bars.

Preparing for Winter

TROUBLESHOOTING

Distribution Hoses and Wiping Bar System Issues

Common problems and solutions for the distribution system.

Digital Control Box (DCB) Issues

Troubleshooting guide for DCB readouts and button functions.

Charge Controller, Solar Panel, and Pump/Motor Issues

Common electrical and mechanical problems and their solutions.

Wiring Diagrams

AC Wiring Diagram for 200/25 Unit

Electrical schematic for the AC powered 200/25 model.

DC Wiring Diagram for 200/25 Unit

Electrical schematic for the DC powered 200/25 model.

AC Wiring Diagram for 800/100 Unit

Electrical schematic for the AC powered 800/100 model.

DC Wiring Diagram for 800/100 Unit

Electrical schematic for the DC powered 800/100 model.

Part Numbers and Assemblies

200/25 AC and DC Tank Part Numbers

List of part numbers for 200/25 tank and pump assemblies.

200/25 Stainless Steel Tank Part Numbers

Part numbers for 200/25 stainless steel tank with double pump.

800/100 AC and DC Tank Part Numbers

List of part numbers for 800/100 tank and pump assemblies.

Solar Panel and Pole Kit Part Numbers

Part numbers for solar panel mounting kits.

Double Pump Motor Assembly Part Numbers

Part numbers for the double pump motor assembly.

Distribution System Piping Summary

Overview of piping components for different tank configurations.

Quick Hose Coupling Part Numbers

Part numbers for quick hose coupling components.

MC-4TR Distribution Bar Part Numbers

Part numbers for the MC-4TR distribution bar assembly.

TOR XL-Bar Part Numbers

Part numbers for the TOR XL-Bar assembly.

TOR ML-Bar Part Numbers

Part numbers for the TOR ML-Bar assembly.

TOR Foam Bar Part Numbers

Part numbers for TOR Foam Bars (24" and 36").

Mounting Clamp Part Numbers

Part numbers for TOR bar clamp assemblies.

Quick Mounting Clamp Part Numbers

Part numbers for quick clamp assemblies.

Top of Rail Bar & Clamp Assembly Options

Options for assembling TOR bars and clamps.

Smart Wheel Sensor Part Numbers

Part numbers for smart wheel sensor components.

Smart Wheel Sensor w/Quick Clamp Part Numbers

Part numbers for sensor kits with quick clamps.

GLOSSARY OF TERMS

CUSTOMER SERVICE CONTACT INFORMATION