Sm-7001

Transcript

IUNION SWITCH & SIGNALl[m] A member of the ANSALOO Group 5800 Corporate Drive, Pittsburgh, PA 15237 SERVICE MANUAL 7001 Operator Guide DIGITAIR® End-of-Train Monitor System Model 6620 Series Sense and Transmit Unit 1987 Version August, 1987 A-2/93-2971-1 COPYRIGHT 1993, UNION SWITCH & SIGNAL INC. PRINTED IN USA AN SAL DO Trasporti NOTICE Effective July, 1992, this document became the property of Union Switch & Signal Inc. All references to "Dynamic Sciences Limited" and "DSL" apply to Union Switch & Signal Inc. For service on this Union Switch & Signal product, please contact: Union Switch & Signal Inc. The Service Shop 645 Russell St. Batesburg, SC 29006 Toll-Free Phone: 1-800-652-7276 Fax: 803-532-2940 Rear of Train Monitor DSL DIGITAIR® SENSE AND TRANSMIT UNIT . Users' Guide CAUTION This unit contains a sensitive motion detecting instrument. Rough handling will seriously damage this motion sensor. Handle with care when installing or removing from coupler. If possible, use original packing when shipping the unit. DO NOT DROP Copyright© 1986 DSL Dynamic Sciences Limited All Rights Reserved DIGITAIR® is a Registered Trademark of DSL Dynamic Sciences Limited PREFACE This manual is intended for use by operating personnel of the railroad who may be non-technical. It contains instructions in the installation and use of the Sense and Transmit Unit and associated batteries. DIGITAIR I PROPRIETARY INFORMATION This document contains commercial and technical data and designs which are the exclusive property of DSL DYNAMIC SCIENCES LIMITED (DSL) and may contain proprietary information of others, which shall not be used, copied or disclosed in any way to any third party without the prior written consent of the Manager of Contracts of DSL. The recipient of this document, by its retention and use, agrees to maintain it in confidence using the same safeguards as it uses to protect its own confidential information. PATENT INFORMATION Patents have this manual. The following granted: been granted or are pending on items described in patents have been applied for or have been Railway Brake Pressure Monitor, US Patent 4,487,060, CAN. Patent 1,214,810 Coupler Mount Assembly, US Patent 4,520,662 Railway Vehicle Motion Detector, US Pat. Pend., CAN. Pat. Pen. Rechargeable Battery Pack, US Patent 4,554,221, CAN. Pat. pen. Railway Emergency Brake System, US Patent 4,641,892, CAN. Pat. Pen. Railway Brake Pressure Monitor, Australia, Pat. Pen. REGISTERED TRADEMARK DIGITAIF: ® is a registered trademark of DSL DYNAMIC SCIENCES LIMITED (United States Trademark Registration No. 1,293,996; Canadian Trademark Registration No. 296,425, Australia Trademark Registration No. 402,337). Applications have been made in several other countries. Questions regarding the manual should be directed to: CLtstomer SLtpport - DIGITAIR@ DSL DYNAMIC SCIENCES LIMITED 4279 Canada Way B•-trnaby, B.C. Canada V5G 4P1 In Canada: In USA: (604) 437-1600 <800} 66'.:~-866 7 Copyright e) 1987 DSL DYNr~MIC SCIENCES LIMITED All rights reserved. SENSE ANO TRANSMIT UNIT (STU) USERS GUIDE INDEX ===== STU INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General Description .............................. Physical Installation............................ Connecting The Air Line.......................... Brief Test of Rear Unit.......................... HVM Light and Tilt Switch Test ..............•.... 1 1 3 3 4 BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 5 Telemetry Battery................................ Highly Visible Marker Light Batteries ............ 5 7 DESCRIPTION OF BATTERIES .............................. 9 Telemetry Battery................................ Marker Light Battery............................. 9 9 BATTERY CHARGING . . . . .. . . . . .. . . . . . . .. .. .. . . .. . . .. .. . .. . 10 CARE AND HANDLING OF BATTERIES........................ MAINTENANCE INSTRUCTIONS .............................. 11 12 STU (REAR UNIT) INSTALLATION General Description Ensure the Uni~ is operational and contains fully charged batteries. You need no special tools to install the Unit, except for the padlock supplied by the railroad. Physical Installation Refer to Figure 1 for each of the 5 steps below, illustrated by a photograph with the same letter. To install the Rear Unit: a) With the unit upright and the ID number si4e facing away from the coupler insert the right hand jaw into the rightmost pair of casting holes. b) Rotate the Rear Unit so that the left hand jaw fits into the leftmost pair of casting holes. Unscrew the clamping screw if necessary. c) With the unit in place hand tighten the clamping screw until the urethane spring washer in the shoulder of the screw is compressed. DO NOT OVER-TIGHTEN. Note: Ensure both feet are firmly seated on the coupler, equally spaced above and below the casting holes at the rear. d) Turn clamping screw to the vertical position and close latch. e) & f) Padlock if desired. REAR-UNIT - 1 - AUGUST 1987 (a) (b) (d) (c) (f) (e) Figure 1: REAR-UNIT Installing the Rear Unit - 2 - AUGUST 1987 Connecting the Air Line Connect the Glad Hand on the Rear Unit to the car air hose as in Figure 2. Attach the strainrelief between the glad-hand and lower mounting frame. Open the angle cock. If the brak~ pipe is pressurized above 7 psi ( 49 kPa), the unit will turn on and will beep each time a pressure measurement is made (every second). When a data transmission is made the unit gives a quick double beep. (In noisy environments it may be difficult to hear the beeps.) Figure 2: Connect1ng the Air Line Brief Test of Rear Unit Locate the TEST button on the outside of the unit. Look through the window on the upper left front of the unit. Press TEST, and observe the following display sequences: 1 a) If air pressure has not been applied and the unit is off, the display wi 11 show 11 6621 11 for a short time, then the software verion; eg. 11 F2 11 , 11 819 11 , and finally the air pressure. In this case 11 011 • The di sp 1ay wil 1 turn offi n 5 seconds. If the air pressure is higher than 5 psig, the display will read the applied air pressure for a short time, then shut off 1 b} With no air pressure (less than 5 psig) applied, the unit will shut off in 5 minutes, deactivating all operation including the HVM light. 1 c) If, in addition, the display shows a [W], an [F], or an [A], the battery is weak, about to fail, or failed respectively. The battery must be replaced before leaving the terminal if any of these letters appear. 2 a) If air pressure greater than 5 psig is applied, the unit turns on automatically, then follows the start-up sequence outlined in para 1 a) above. 2 b) Any time the test button is pressed when the unit is ON, only the air pressure and any battery warning message, if applicable, will appear. Note: REAR-UNIT When TEST is pressed, the unit also11 transmits a 11 report 11 to the 11 locomotive. You will hear a double transmit beep. Ensure that the displayed pressure agrees with the nominal brake pipe pressure expected. - 3 - AUGUST 1987 The beeper sounds for one minute after the power is turned on (by connecting the air, or by pressing the TEST button), and each The audible beeps are discontinued time TEST is pressed. automatically after one minute. HVM Light and Tilt Switch Test The HVM light will be activated and under photocell control, either by applying pressure or by pressing the Test Button, and can be deactivated either by tilting the STU on its side (if tilt switch fitted), or by removing the HVM batteries. To check cover the the light flashing. daylight, photocell. the light during daylight hours, ensure the unit is ON and then photocell (located at the bottom of the adapter housing on which is mounted) with your finger and observe the marker light At night, the light will commence flashing automatically. In the light will go out when the finger is removed from the Whenever the light is on, the Rear Unit will send a marker light "ON" signal to the front unit in the locomotive cab, on which light status is displayed in the second character position. If the STU is turned ON by air pressure (rather than by pressing the test button) the photocell continues to control the light even after air pressure is removed and the STU turns OFF. To stop the HVM from flashing, tilt the STU on its side. Turning the STU upright will turn the HVM on again so long as the STU is ON. To deactivate the HVM light, the STU must first shut down; this occurs automatically after 5 minutes of operation at pressure less than 5 psig. The STU can then be placed on its side causing the mercury tilt switch to deactivate the HVM. Turn the STU upright, the HVM will no longer turn on. Note: The 'tilt' must be done after the STU itself has shut off, otherwise the HVM will reactivate when stood upright. Photocell Test Button Figure 3: REAR-UNIT - 4 - AUGUST 1987 Note: In very bright sunlight, enough light may enter the photocell even with a finger covering it to prevent the HVM from flashing. Black PVC tape can be used in this case. This completes the marker light test. BATTERY REPLACEMENT The battery is specially manufactured to include locating holes ana recessed electrical sockets which mate directly with the contact pins in the Rear Unit. Telemetry Battery: Refer to figure 4 for each of the steps below illustrated by a photograph with the same letter. To remove the telemetry battery: a) Move the clamping screw to the horizontal position. b) Release the two retaining latches. c) Open the battery compartment lid. d) Lift the lid to the fully open position - it will stay in place. e) Remove the thumbscrew retainer. f &g) Gently remove the battery. Pull straight out of the unit. Install a fully charged battery in the reverse order of the steps above. REAR-UNIT - 5 - AUGUST 1987 (a) (b) • :,~~~~L.t.,. ,'. \~>» -~ (c) (e) ( f) (g) Figure 4: REAR-UNIT Telemetry Battery - 6 - AUGUST 1987 Highly Visible Marker (HVM) Light Batteries: Refer to Figure 5 for each of the steps below illustrated by a photograph with the same letter. To remove the marker light batteries: a) Open the telemetry battery lid slightly and pull back the interlocking latch. b) Release the two retaining latches on the hinged lid of the HVM. c &d) Fully open the HVM lid. Note, if the lid interferes with the top of the coupler it may be necessary to loosen or even remove the STU from the coupler. With the lid open the HVM batteries are fully accessable. e &f) Remove the tethered retaining nuts and remove the batteries. g &h) The HVM will operate with one or more batteries in any position. Maximum operating life is obtained with all 3 batteries installed. REAR-UNIT - 7- AUGUST 1987 ,_ (a) (b) (c) (d) (e) ( f) - I -iiiiii-._,llft....___ ,:#!Jiilii&" ,,i\';i " 0 (h) (g) Figure 5: REAR-UNIT Marker Light Batteries - 8 - AUGUST 1987 DESCRIPTION OF BATTERIES Telemetry Battery: The STU telemetry is operated by a single 4 Amp Hour (Ah) rechargeable nickel-cadmium (NiCd) battery. The battery is enclosed in a protective plastic case and is specially designed to include locating holes and recessed electrical sockets which mate directly with the guide pins and sockets of the charger. Figure 6: STU Battery Marker light Battery If the HVM light option is fitted, the light is powered by its own set·of three batteries. Each of these is identical to that for the STU (4 Ah NiCd). Figure 7: REAR-UNIT HVM light Battery Complement - 9 - AUGUST 1987 BATTERY CHARGING The charger will hold either 4 or 16 batteries at one time. The 4 battery charger is shown on Figure 8. Before using the charger, ensure that the amber "power on 11 indicator is illuminated on the charger. Install the battery. by pushing it down on the contact pins, using the guide pins for alignment. Charging begins automatically when the battery is installed, indicated by illumination of the red indicator. When charging is complete (approximately 15 hours) the green indicator is illuminated. Each charger position functions independently. Figure 8: Four-battery Charger Remove batteries from the charger when charging is complete. Do not store charged batteries by leaving them plugged onto a charger. The batteries will discharge at a rate of 5% a day if left in the charger when green light is on. Note: If batteries are difficult to remove from the charger apply a small amount of silicon grease to the electrical connections on the charger. Apply label to battery indicating date charged. Do not install recharging. batteries that have been stored more than 15 days without Check batteries with volt meter before installing in rear end device. If reading is less than 13 volts, return to nearest radio shop for evaluation. REAR-UNIT - 10 - AUGUST 1987 CARE AND HANDLING OF BATTERIES If handled properly, NiCd batteries have a lifetime of approximately 1000 charge-discharge cycles or more. If abused they will last only a short time. The following comments will assist in developing good handling practices for these· batteries. For optimal battery life and avoidance of problems resulting from improper charging, the charging current should be c/10 amps, where c is the capacity of the battery in ampere-hours. For the DIGITAIR battery, this gives 4/10 = .4 amps or 400 milliamps. This is the current delivered by the DSL charger. A battery may be subjected to this charging current indefinitely without damage. Therefore if in doubt about the state of charge of a battery, it should be charged. Some chargers use acceptable practice battery should not in a charged battery a higher current to reduce the charge time. This is but requires careful control, because a charged be subjected to the higher current. Gas is developed at high current which can cause damage. A phenomenon called 11 memory 11 has been associated with NiCd batteries, under which the battery is unable to deliver its full rated energy. 11 Memory 11 is presently much less a problem than with early NiCds, due to improvements in manufacturing. It is now associated with continuous cycling of a battery between a fixed discharge 1evel -and full charge, and can be corrected by a deep discharge procedure. "Memory" should never occur with DIGITAIR batteries because the discharge level varies randomly each time the battery is used·. Temperature is important in the battery charging process. Although the battery will operate down to -40°F (-40°C) it must not be charged at temperatures below 32°F (0°F). If the battery has been exposed to extreme cold allow time for the battery to warm up to a safe temperature before commencing charging. The shelf-life of NiCd batteries is limited. The battery loses approximately 10% of its capacity in the first 24 hours. Subsequent discharge is at a rate of approximately 10% per month. REAR-UNIT - 11 - AUGUST 1987 MAINTENANCE INSTRUCTIONS DSL 303-002! BATTERY NOTE: 12.0v I 4Ah Batteries are discharged when shipped by the manufacturer. They must be charged before use. FOR LONGEST LIFE & BEST PERFORMANCE 1. Charge the battery to full capacity, 14 hours at the standard C/10 rate (Capacity _x 11 0.10). For "rapid" chargers, allow aditional time (2-3 hours) for topping off 11 the charge after it switches from 11 11 11 chargeing to complete 11 • 2. Use the battery soon and use as much of the battery capacity as possible or practical. A battery that is charged and discharged completely will maintain the longest running time capacity. (Also, several charge/discharge cycles are recommended to bring a new battery up to its rated capacity). 3. Store and charge the batteries at room temperature 70~F +/-5°. Batteries that have been stored for over a month should be recharged before putting into service due to chemical self-discharge which occurs at a rate of approximately 1% per day (at room temperature). Do not charge cold batteries (40°F or below). 4. Reduced capacity or 11 memory effect" may result from repeated identical. shallow discharge/full recharge cycles. If such a cond1t1on ,s suspected, run the battery until the instrument loses all power, then fully recharge and discharge again. Repeat this cycle 3-4 times. Full usable capacity will be restored. REAR-UNIT - 12 - AUGUST 1987