100365-010 AB0 - HW Subsystem & SFTW Manual

Hot Wheel Detector Sub-System and Software Manual
For use with Micro Hot Box Detector

Operation, Maintenance, and Software Manual 100365-010 AB0
8 Copyright 2012 Progress Rail Services. All rights reserved. This copyrighted document may be reproduced free of charge by Progress Rail Services customers, if such reproduction is used exclusively in that customer=s internal operation. These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user=s purposes, the matter should be referred to Progress Rail Services. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material Progress Rail Services has no obligation to keep the material up to date after the original publication. THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
Reproduction and Use Restrictions Agreement

The information contained in this Technical Manual (the document) is the property Progress Rail Services and is protected by copyright and other intellectual property laws. Any unauthorized use or reproduction of this Document without the prior written consent of Progress Rail Services, whether in hard copy or in an electronic form, is strictly prohibited [except as otherwise set forth below]. Notwithstanding the foregoing, Progress Rail Services hereby grants to the purchaser of the Progress Rail Services equipment, or licensee of the Progress Rail Services software (such purchaser of licensee referred to herein as You), to which the Document pertains, the following limited reproduction rights. By reproducing any portion of the Document, You expressly agree to the following terms and conditions. You may make additional copies of the Document solely for use in connection with the Progress Rail Services equipment or Progress Rail Services software to which it pertains, provided that each copy is a complete copy and does not alter the content or meaning of the Document in any way, and provided further that each such copy preserves unaltered all trademark, copyright, patent designations and proprietary or confidentiality notices contained therein, including this Reproduction and Use Restrictions Agreement. Any other use or reproduction of any portion of the Document without the prior written authorization of Progress Rail Services is expressly prohibited. Without limiting any other rights or remedies of Progress Rail Services, in the event that You or any of Your employees, agents or contractors copies any portion of the Document in violation of this Reproduction and Use Restrictions Agreement, You agree to indemnify, defend and hold harmless Progress Rail Services from and against any and all claims, damages, losses, liabilities and expenses (including reasonable attorney=s fees) that may be incurred or awarded by reason thereof.
Revision History
This document supersedes all previously issued versions, providing new or revised information. The most recent publication can be determined by comparing the last three characters at the end of the part number and the date issued.
Hot Wheel Detector Sub-System

Part Number: 100365-010 AB0 Revision Level AA0 AB0 Date General Description of Changes Issued 01/30/04 02/27/12 Original release Re-brand Manual
Important Information
Conventions
Safety Alert Symbols
The symbol indicates that important personal safety information follows. Carefully read this text for the warnings information it contains. The signal word next to each safety alert symbol is defined as: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
WARNING
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This signal word may also be used to identify unsafe practices.
Static Sensitive Symbols for Equipment Handling Instructions
The and symbols indicate important handling guidelines established by the AREMA (American Railway Engineering and Maintenance-of-Way Association) for proper handling of electronic equipment modules and sensitive components for the prevention of potential damage that could be caused by ESD (electrostatic discharge) during routine maintenance, handling and transportation.
ESD NOTICE
To protect against ESD damage to electronic equipment containing modules, follow the field procedures in AREMA C&S MP-11.4.5. Failure to use protective measures could result in permanent equipment damage, either immediate or latent, when handling modules. To protect against ESD damage to electronic equipment containing components, follow the field procedures in AREMA C&S MP-11.4.5. Failure to use recommended protective measures could result in permanent equipment damage, either immediate or latent, when handling components.
ESD NOTICE
100365-010 AB0
Progress Rail Services
Hot Wheel Detector Sub-System Important/Notable Information Important: Indicates an operating procedure, practice, or condition which, if not strictly followed, may cause equipment damage. Note: Indicates additional information or emphasizes a topic related to the subject being discussed.
Personal Safety Instructions

Only qualified personnel should work on or around this equipment. To ensure the highest degree of personal safety, all who use this equipment are required to become thoroughly familiar with all safety instructions contained in this document. Successful and safe operation of this equipment depends upon proper handling, operation, maintenance, and application of associated railroad equipment.
WARNING
No information in this manual supersedes or replaces your railroad=s operating rules. If there is a difference in instructions between this manual and the railroad=s operating rules, follow the most restrictive instruction. The Progress Rail Services, Hot Wheel Detector Sub System is not a vital or fail safe device and must not be used for vital applications. If the Hot Wheel Detector Sub System is used as part of a vital application, it will make that application non-vital. Deliberate misuse or abuse of electronic components may cause personal injury or death.
Foreword
Technical Support Progress Rail Services will accept telephone calls between 8:00 AM and 5:00 PM CT. Call TOLL FREE (888) 701-3479 regarding installation, maintenance, calibration, adjustment, or repair of any components. Emergency after hours technical support is available 7 days / week via an answering service at this same number. Scope Progress Rail Services, Technical Information Department under the direction of the designated equipment Product Manager, issues this document. The manual introduces you to the Hot Wheel Detector Sub-System by providing the following sections: Overview, Controls and Indicator/Operating Instructions, Theory of Operation, Maintenance, Drawings, Installation, Troubleshooting, Software Introduction, Display Mode, Maintenance Mode, Configuration Mode, Supervisor Mode, and Setup Program. Please read carefully and thoroughly understand the instructions and processes before making any adjustments or modifications to the equipment. Carelessness may result in loss of life or property damage. ii
Progress Rail Services 100365-010 AB0
Important Information How to Order an Additional Copy or a Revised Printing Additional copies of this document may be ordered by directing all correspondence to:
Progress Rail Services Signal Division Inspection and Information Systems 3801 South Selsa RD STE 1 Independence, MO 64057-1713 Phone: 816.503.3780 or 888.701.3479 Fax: 816.817.7963
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Contents
Section 1 B Overview............................................................................................................................... 1-1 Section 2 B Micro HBD/HWD System Interconnect Diagram............................................................... 2-1 Section 3 B Theory of Operation ............................................................................................................ 3-1 Section 4 B Maintenance......................................................................................................................... 4-1 Section 5 B Drawings .............................................................................................................................. 5-1 Section 6 B Installation............................................................................................................................ 6-1 Section 7 B Troubleshooting .................................................................................................................. 7-1
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Overview
Section 1 Overview
Contents
Overview of SECTION I - Overview ...................................................................................... 1-1 Overview of SECTION II - Micro HBD/HWD System Interconnect Diagram ....................... 1-1 Overview of SECTION III - Theory of Operation................................................................... 1-2 Overview of SECTION IV - Preventive Maintenance Procedures........................................ 1-2 Overview of SECTION V - Drawings..................................................................................... 1-2 Overview of SECTION VI - Installation ................................................................................. 1-2 Overview of SECTION VII - Troubleshooting........................................................................ 1-2 Purpose of the System............................................................................................................. 1-2 System Overview ..................................................................................................................... 1-3 Pyro-HWD Detector Baseline Equipment Groups ................................................................ 1-3 Trackside................................................................................................................................ 1-3 Wayside Equipment Enclosure ............................................................................................. 1-4 List of Materials Supplied ......................................................................................................... 1-5 System Specifications .............................................................................................................. 1-5
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Overview
Section 1 Overview
Introduction
This manual describes operation and maintenance of a Micro Hot Wheel Detector manufactured by Progress Rail Services for use on railroads. Throughout this manual the Pyrometer Hot Wheel Detector is referred to as the Hot Wheel Detector Sub-System. The Hot Wheel Detector Sub-System is designed to operate as an integral part of a Micro Hot Box/Hot Wheel Detector System. The Micro HBD/HWD (Figure 1-2) includes the circuitry with which to process signals it receives directly from a Hot Wheel Detector Sub-System.
Technical Manual Overview

This manual is divided into thirteen sections; subsequent paragraphs in this section provide an overview of each section: 1. 2. 3. 4. 5. 6. 7. Overview Micro HBD/HWD System Interconnect Diagram Theory of Operation Preventive Maintenance Procedures Drawings Installation Troubleshooting
Overview of SECTION I - Overview This section defines the purpose of a Hot Wheel Detector Sub-System, and describes the equipment that comprises it. Included in the section are an overview, a list of equipment supplied, and specifications
Overview of SECTION II - Micro HBD/HWD System Interconnect Diagram This section displays the Micro HBD/HWD System Interconnect Diagram to demonstrate the interrelationship of the components in the Micro HBD/HWD system.
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Hot Wheel Detector Sub-System Overview of SECTION III - Theory of Operation This top-assembly-level theory presentation describes the signal path through the Hot Wheel Detector SubSystem circuitry and the characteristics of the heat signals.
Overview of SECTION IV - Preventive Maintenance Procedures The tables in this section describe the maintenance tasks and the interval at which each must be performed. Forms are provided for recording task-performance information such as the date performed, by whom, and related comments and observations.
Overview of SECTION V - Drawings The system site plans and top assembly drawings comprise the contents of this section; a drawing-location reference table lists the name and number of each drawing.
Overview of SECTION VI - Installation This section provides comprehensive, illustrated instructions for installing the Hot Wheel Detector Sub-System in a MICRO HBD/HWD system. The section begins with a brief description of its purpose, contents, and organization. The remainder of the section is divided into the following subsections: Overview of the Detector/assembly/subassembly nomenclature, and a review of safety/caution/warning/hazard information List of equipment required Installation procedures Adjustment procedures Operational checkout procedures
Overview of SECTION VII - Troubleshooting This section provides fully illustrated, comprehensive instructions for troubleshooting the Hot Wheel Detector Sub-System in a MICRO HBD/HWD system. After a brief description of its purpose, contents, and organization, the remaining subsections describe the following: Review of safety/caution/warning/hazard information List of the equipment required Troubleshooting procedure
Purpose of the System

Research has shown that the wheels of all rolling stock emit characteristic thermal 'signatures' that are the direct result of one or more of the following: Dragging brakes. Wear and deterioration of the wheel caused by wheel/rail interface factors such as axle alignment, load, rail condition. Heat conducted into the body of the wheel from the corresponding bearing.
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Overview The Hot Wheel Detector Sub-System is designed to detect these emissions; the MICRO processes these signals and provides appropriate alarm messages to the train crew and/or a remote monitoring station.
System Overview
The Hot Wheel Detector Sub-System enhances the heat-detection capability of the MICRO HBD/HWD System; both the Hot Wheel Detector Sub-System and the HBD systems together detect virtually every heat-related alarm produced by wheels and bearings passing these detectors. The following paragraphs describe the components that comprise the Hot Wheel Detector Sub-System.
Pyro-HWD Detector Baseline Equipment Groups A dual Hot Wheel Detector Sub-System Assembly is the typical configuration of a MICRO HBD/HWD system (Figure 1-1). The hot-wheel signal processing circuitry is an integral part of the MICRO HBD/HWD. The following paragraphs describe the equipment in each group.
TRACKSIDE EQUIPMENT WAYSIDE EQUIPMENT ENCLOSURE
PYRO-HWD SCANNER ASSEMBLY
PYRO-HWD SCANNER ASSEMBLY
Micro HWD
COM 2
Micro HBD
COM 2
CHANNEL 1 CHANNEL 2
CHANNEL 1CHANNEL 2
365-0002
Figure 1-1. Hot Wheel Detector Sub-System Baseline Equipment Groups
Trackside The Hot Wheel Detector Sub-System (Figure 1-2) consists of two pedestal-mounted Scanner Assemblies, and a Micro Hot Wheel Detector. Detecting wheel-heat is accomplished by a device that utilizes a pyrometer to sense the infrared radiation emitted by each wheel. The sensor is located within the scanner assembly, and is protected from the environment by a transparent vinyl window. Polyethylene is used because of its low IR absorption characteristics. The dual scanner assemblies are positioned so that the 'line of sight' is 2.5 inches (6.4 cm) above the heads of the rails, and at angle of 90 to the rail. Even at train speeds of 120 miles per hour (which translates to a viewing
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Hot Wheel Detector Sub-System 'window' of about 10 milliseconds duration), the sensor is capable of detecting the infrared heat emitted by each wheel. Signals from the Scanner Assembly are routed via buried cable to the Hot Wheel Detector Subsystem. A thermostatically-controlled heater within the scanner housing prevents the accumulation of snow, ice and moisture on the scanner's window.
365-0003
Figure 1-2, Pyro-HWD Trackside Equipment
Wayside Equipment Enclosure The cables from the Hot Wheel Detector Sub-System scanners located trackside is routed to the MICRO HBD/HWD Assembly.
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Overview
List of Materials Supplied

Table 1-1 describes the nomenclature, part numbers, and quantities of the kits, assemblies and components supplied with a Hot Wheel Detector Sub-System. Table 1-1. Materials Supplied with a Hot Wheel Detector Sub-System Dual Scanner Nomenclature
Foundation Kit Scanner Assembly Cable Assembly Base
Quantity
2 2 2 2
Part Number
200099-16 400041-44-2 400042-92 400080-45
System Specifications
Tables 1-2 and 1-3 describe the specifications for each item/parameter of the scanner, and cable assemblies that comprise the Hot Wheel Detector Sub-System. Table 1-2. Specifications for the Pyro-HWD Scanner Assembly Item/Parameter
Pyrometer Preamp Input Power Dimensions Weight Scanner Assembly Pedestal Assembly Base Assembly Case Material Thermostat Outer Ring Assembly Heaters (2) 37.5 lbs. (17 kg) 70 lbs. (31.8 kg) 30.5 lbs. (13.9 kg) Cast Aluminum ally Opens at 100 F 5; 38 C 3 Closes at 80 F 7; 27 C 4 100 Watts each, 105 to 125 Vac 50 to 60 Hz, 0.75 Ampere
Specification
+12V; regulated and filtered 13 1/8 (333 mm) wide 8 (210 mm) high 13 (330 mm) deep
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Table 1-3. Specifications for Hot Wheel Detector Sub-System Interconnect Cable 400082-97 Assembly Item/Parameter
Length Weight Construction * other lengths available: Length 65 ft 85 ft 100 ft 125 ft Part Number 400082-97 400082-97-01 400082-97-02 400082-97-03
Specification
65 ft. (19.1 meters)* 20 lbs (9.1 kg) 6 shielded pairs, ruggedized and shielded outer casing
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Micro HBD / HWD System Interconnect Diagram
Section 2 Micro HBD/HWD System Interconnect Diagram

Contents
Micro HBD/HWD System Interconnect Diagram..................................................................... 2-1
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Micro HBD/HWD System Interconnect Diagram
Section 2 Micro HBD/HWD System Interconnect Diagram

Micro HBD/HWD System Interconnect Diagram
365-0085
Figure 2-1, System Interconnect Diagram.
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Theory of Operation
Section 3 Theory of Operation

Contents
Introduction ................................................................................................................................................3-1 Pyro-HWD Scanner Assembly..................................................................................................................3-2 Heater and Thermostat Assemblies Circuit Operation.......................................................................... 3-2 Sensor Assembly Circuit Description..................................................................................................... 3-2 Two-Scanner Wheel-Scan Profiles ........................................................................................................ 3-4 Processing the Hot Wheel Signals............................................................................................................3-5 Hot Wheel Signal Processing................................................................................................................. 3-5
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Theory of Operation
Section 3 Theory of Operation
Introduction
A Pyro-HWD scanner operates as an integral part of a Micro HBD/HWD Detector System. The purpose of a Pyro-HWD scanner in an HBD system (Figure 3-1) is to detect potentially dangerous temperatures existing in the wheels of a passing train. To accomplish its purpose, the Pyro-HWD scanner: Detects the infrared heat emitted by each wheel of a passing train, and produces an analog-voltageequivalent of the heat emitted by each wheel. The signal produced by the scanner is routed via buried cables that connect the scanner(s) to the (HSIB) Hot Wheel Scanner Interface Board in the Hot Wheel Detector Sub-System located in a wayside equipment enclosure.
MICRO HWD
CHANNEL 1
CHANNEL 2
365-0005
Figure 3-1, Pyro-HWD Equipment Block Diagram
Note:
Refer to Section 2 Micro HBD/HWD System Interconnect Diagram for a block diagram of the system.
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Pyro-HWD Scanner Assembly

The scanner assembly includes the sensor assembly, two heater assemblies, and a thermostat assembly. The heaters and thermostat assembly function together to prevent the accumulation of snow, ice, and moisture on the vinyl window (Figure 3-2). The sensor assembly includes a pyrometer assembly, a preamp assembly, components that provide filtering and protection, and a terminal board. These components function together (Figure 3-2) to: detect the infrared radiation emitted by each wheel of a passing train; produce an analog voltage equivalent of the relative heat; and, amplify the voltage. The signal is routed via a buried interconnect cable to the HSIB.
HEATERS THERMOSTAT INFRARED RADIATION PYROMETER POWER PYROMETER ASSEMBLY HEAT SIGNAL
SCANNER HEATER POWER CHANNEL 1/ CHANNEL2 OPERATING VOLTAGE CONNECTOR MICRO HWD AMPLIFIED SIGNAL
PYROMETER PREAMPLIFIER CIRCUIT
POLYETHELENE WINDOW
GRILL ASSEMBLY 365-0006
Figure 3-2, Pyrometer Preamp Circuitry Block Diagram
Heater and Thermostat Assemblies Circuit Operation The thermostat assembly is connected in series between the two heater assemblies (Figure 3-3). Line voltage is applied to the heater assemblies via connections at the HWD. When the temperature of the grill assembly (reference Figure 3-2) falls below 80 oF +7 oF (27 oC +4 oC) the thermostat closes, thus completing the electrical path through the two, 100 Watt heaters. When the temperature reaches 100 oF +5 oF (38 oC +3 oC) the thermostat opens. Capacitor C17 and resistor R41 function as a contact-spike suppression circuit that eliminates transient voltages from occurring when the thermostat contacts open and close.
Sensor Assembly Circuit Description The components within the HWD Scanner Assembly (Figure 3-3) are connected to ground and DC and AC operating voltages on the Hot Wheel Detector Sub-System via shielded interconnect cable 400082-97, which connects to Channel 1/Channel 2 located on the Hot Wheel Detector Sub-System. DC Power Supply U17 on the Hot Wheel Detector Sub-Systems HSIB (Hot Wheel Scanner Interface Board) provides +Vdc for the pyrometer and its preamp via Channel 1/Channel 2; the ground path for the pyrometer and the preamp is via Channel 1 pin 5, Channel 2 pin 5. Channel 1 pins 6 & 7 and Channel 2 pins 6 & 7 provide 115 Vac (BX) and AC neutral (NX), respectively, for the thermostatically-controlled scanner heaters. Channel 1 pin 8 and Channel 2 pin 8 provide earth ground for the HWD chassis. The pyrometer sensor assembly and the components that comprise the preamp assembly are extremely sensitive to voltage fluctuations and noise. This sensitivity, combined with the low level of the signal generated by the pyrometer preamp, requires devices that shield, filter and trap unwanted noise and transients.
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Theory of Operation
Devices such as filter capacitor C14 filters the +Vdc as it enters the preamp; a varistor (RV1) protects the preamp from transient voltages on the +Vdc; resistor R41 and capacitor C17 form an RC filter network that dissipates transients created when the thermostat opens. A Hot Wheel Detector Sub-System baseline configuration includes two Pyro-HWD scanners. Operation is identical for all HWD scanners.
Figure 3-3, Sensor Assembly Circuit Diagram
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Two-Scanner Wheel-Scan Profiles Figure 3-4 illustrates what each scanner in a two-scanner installation actually 'sees' as the wheels on the near- and far-rails pass the scan line. The scan line indicates the area viewed as the wheel passes the scanner's 2" (50.8 mm) diameter spot-size field of view. The scanners are aligned on a common line of scan, therefore regardless of train direction each scanner 'sees' a portion of only the outside surface of each wheel. The resulting heatpulse profile has a characteristic dip, as shown in the figure: the high portions correspond to the flange; the dip represents the heat on the outside surface of the wheel.
Figure 3-4, Two-Scanner Wheel Scans and Corresponding Heat Profiles
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Theory of Operation
Processing the Hot Wheel Signals

At the HSIB Assembly, the scanner cable terminates at connectors Channel 1 and Channel 2. From these points forward, the hot-wheel signals undergo processing that is unique to the circuitry of the Hot Wheel Detector SubSystem. Hot Wheel Signal Processing Processing hot- wheel signal data in a Micro HBD/HWD system is accomplished simultaneously with the heat data from the systems bearing detectors. For a complete circuit description, refer to the Micro HBD manual P/N 100608-010.
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Maintenance
Section 4 Maintenance
Contents
Introduction............................................................................................................................... 4-1 Maintenance Tasks and Intervals ............................................................................................ 4-1 Cleaning/Inspecting the Scanner Assembly Visor ................................................................ 4-2 Cleaning the Scanner Assembly Lens Cover ....................................................................... 4-2 Verifying the Scanner Assembly Vertical Alignment (Plumb) ............................................... 4-3 Cleaning the Pyrometer Assembly Lens............................................................................... 4-3 Cleaning/Inspecting the Exterior of the Scanner Assembly.................................................. 4-3 Inspecting the Scanner Assembly for Chips and Rust.......................................................... 4-3 Verifying the Scanner Assembly/Target Alignment .............................................................. 4-3 Inspecting the Quality/Condition of the Ballast...................................................................... 4-3 Calibration................................................................................ Error! Bookmark not defined. Pyro Hot Wheel Detective Maintenance Record..................................................................... 4-4 Using the Maintenance Record............................................................................................. 4-4
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Maintenance
Section 4 Maintenance
Introduction
This section describes procedures that include inspection, cleaning, calibration and alignment which, when performed at the recommended intervals, will ensure optimum operation of the components comprising a PyroHWD.
Maintenance Tasks and Intervals

Periodic inspection, cleaning and adjustment of the Pyro-HWD components will in most cases identify potentially troublesome components/areas before they have an adverse effect on the Micro HBD/HWD system. Table 4-1 lists each task by location, description, and recommended interval, and includes references to procedures describing how to perform each task. The intervals are monthly (M), and quarterly (Q).
Task Scanner Assembly
Task Description Clean/Inspect Visor Clean/Inspect Lens Cover Verify Scanner Assembly Vertical Alignment (plumb) Clean Lens Verify Visor Securely Fastened Verify Scanner Securely Fastened to Pedestal Clean Exterior of Scanner Inspect Exterior of Scanner for Dents and Scratches Inspect Scanner Paint for Chips and Rust Clean/Inspect Exterior of Pedestal Inspect Pedestal Paint for Chips and Rust Verify Scanner & Target Alignment Verify Pedestal Securely Fastened to Base Inspect Quality and Condition of Ballast
Interval Monthly Quarterly X X X X X X X X X X X X X X X
Procedure page # 4-2 4-2 4-3 4-3 None None 4-3 4-3 4-3 4-3 4-3 4-3 6-3 4-3 6-14
Micro HBD/HWD Circuitry
Calibrate System
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Hot Wheel Detector Sub-System Cleaning/Inspecting the Scanner Assembly Visor Using a clean, narrow paint brush, carefully remove debris such as grass clippings, cobwebs, etc., from the interior of the visor. In the case of insect nests such as mud wasps, carefully remove the nests with a small screw driver, then use a soft sponge soaked in a mild detergent solution to remove the remaining mud/residue. If necessary, clean the scanner assembly lens cover. Inspect the visor for indications of damage; replace if necessary.
Cleaning the Scanner Assembly Lens Cover Note: 1. 2. Exercise care to avoid scratching the lens cover. Using a clean, narrow paint brush, carefully remove dust and dirt accumulated on the surface of the lens cover. Inspect the lens cover for scratches. If the severity or density of the scratches have reduced visibility through the cover, replace the cover: a. b. Remove power to the Scanner Assembly. Using an Allen Key, remove the two screws securing the Scanner Assembly Cover. Store the cover and hardware in a safe place. c. d. Remove the Scanner Assembly Visor. Using an Allen Key, remove the three cap screws securing the Outer Ring Assembly; carefully pull the Outer Ring straight off the front of the Scanner Assembly. Store the hardware in a safe place. e. f. g. h. Remove the Grill Assembly from the Outer Ring; store the Ring in a safe place. Unscrew the Load Ring from the Grill Assembly. Discard the vinyl sheet. Place a new piece of vinyl sheet over the Load Ring. Carefully screw the Load Ring into the Grill Assembly; ensure that the vinyl sheet remains taut to prevent wrinkles from forming. i. j. k. l. Using a razor or scissors, trim the excess sheet from the Outer Ring. Install the Outer Ring Assembly: carefully align the assembly to the two heaters and the thermostat. Install and tighten the hardware that secures the Outer Ring. Install the Visor; tighten the hardware.
m. Install the Scanner Assembly Cover; tighten the hardware. n. Apply power to the Scanner Assembly.
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Maintenance
Verifying the Scanner Assembly Vertical Alignment (Plumb) Using a carpenter's level, verify that the Scanner Assembly/Pedestal Assembly is plumb; measure plumb at two points that are 90o apart. If it is found to be severely out of plumb, the Scanner Assembly/Pedestal Assembly may have to be reinstalled at this or another location.
Cleaning the Pyrometer Assembly Lens 1. 2. 3. 4. Using an Allen key, remove the two screws securing the Scanner Assembly top cover. Store the cover and hardware in a safe place. Using a clean, soft-bristle paint brush, carefully brush the surface of the lens to remove loose dust and dirt. Using isopropyl (rubbing) alcohol and soft cotton or a cloth, carefully clean the lens; wipe dry with a soft, lint-free tissue. Install the Scanner Assembly top cover; secure it with the screws.
Cleaning/Inspecting the Exterior of the Scanner Assembly Using a stiff-bristle brush, remove accumulations of dirt and foreign matter from the exterior of the Scanner Assembly. In the case of insect nests such as mud wasps, carefully remove the nests with a small screw driver, then use a soft sponge soaked in a mild detergent solution to remove the remaining mud/residue. Inspect the exterior for signs of damage; replace if required. If necessary, verify the scanner assembly/target alignment.
Inspecting the Scanner Assembly for Chips and Rust 1. 2. Clean and inspect the scanner exterior. Inspect the exterior of the Scanner Assembly for paint chipping and areas of rust. If painting is necessary, use a wire brush and/or abrasive paper to thoroughly clean the area to be painted. Use an EPA-approved silver paint, such as Water Reducible Silver Gloss by Hartin Corporation. Read and follow the paint manufacturer's instructions regarding weather/temperature restrictions.
Note:
Verifying the Scanner Assembly/Target Alignment There are two procedures for performing scanner assembly/target Alignment: one involves the use of a Mirror Lens Cap & Target Kit (PN 200099-81-6), the other is a direct-sight method that utilizes a rigid metal tube. The tube should have an inside diameter of approximately 1/4 inch, and is 12" to 14" in length. Alignment of the Scanner Assembly/Target requires two people, and is applicable for any HWD system that utilizes transducers.
Inspecting the Quality/Condition of the Ballast Verify that the ballast is free of weeds, branches, and any foreign matter that could prevent proper drainage of the ballast. Inspect the grade in the area of the scanner assembly; if necessary, add ballast and re-grade.
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Pyro Hot Wheel Detective Maintenance Record

The PYRO HOT WHEEL DETECTIVE MAINTENANCE RECORD (page 4-1) lists all the tasks; their recommended intervals; applicable page and paragraph references; and spaces for recording the date each task was performed and the maintainer's initials. There are two versions of the RECORD; one for each configuration (single- and two-scanner).
Using the Maintenance Record References to page numbers are provided, where applicable, for each task. Some tasks, such as those performed quarterly, may not readily be remembered, the page reference makes finding the required information easier. Maintaining accurate records of the maintenance performed is critical to ensuring trouble-free operation of the Pyro-HWD.
YEAR________
MAINTAINERS (INITIAL) AND NAME _________________________________________

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HOT WHEEL DETECTIVE MAINTENANCE RECORD (DUAL SCANNERS)

TASK INTERVAL ONCE EACH MONTH ONCE EACH MONTH ONCE EACH MONTH ONCE EACH MONTH ONCE EACH MONTH ONCE EACH MONTH
RECORD OF MAINTENANCE PERFORMED (DAY OF MONTH/INITIAL)

DESCRIPTION CLEAN AND INSPECT VISOR CLEAN AND INSPECT LENS COVER VERIFY SCAN ASSY VERT ALIGN VERIFY SCAN TARGET ALIGN CLEAN SCANNER LENS VERIFY VISOR TIGHNESS PAGE JAN 4-2 FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
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Maintenance
YEAR:______
MAINTAINERS (INITIAL) AND NAME: (_____) / _________________________________________________ Page 1 of 2 HOT WHEEL DETECTIVE MAINTENANCE RECORD (TWO SCANNERS)
TASK INTERVAL
ONCE EACH MONTH ONCE EACH MONTH ONCE EACH MONTH ONCE EACH QUARTER ONCE EACH MONTH ONCE EACH MONTH ONCE EACH MONTH ONCE EACH MONTH
DESCRIPTION
REF. PAGE
JAN
RECORD OF MAINTENANCE PERFORMED

FEB MAR APR MAY JUN JUL
(DAY OF MONTH/INITIAL)
AUG SEP OCT NOV DEC
CLEAN AND INSPECT VISORS CLEAN AND INSPECT LENS COVERS VERIFY ALIGNMENT OF SCANNERS CLEAN SCANNER LENS VERIFY TIGHTNESS OF VISORS VERIFY SCAN ASSY/PEDESTAL TIGHTNESS CLEAN EXT OF SCANNER ASSEMBLIES INSPECT EXT CONDITION OF SCANNERS
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NONE
NONE
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YEAR:______
MAINTAINERS (INITIAL) AND NAME: (_____) / _________________________________________________ Page 2 of 2 HOT WHEEL DETECTIVE MAINTENANCE RECORD (TWO SCANNERS)
TASK INTERVAL
ONCE EACH MONTH ONCE EACH MONTH ONCE EACH QUARTER ONCE EACH QUARTER ONCE EACH QUARTER ONCE EACH QUARTER ONCE EACH QUARTER ONCE EACH QUARTER
DESCRIPTION
CLEAN EXT OF PEDESTALS INSPECT PED EXTERIORS FOR DAMAGE VERIFY CABLES CONDITION AND TIGHTNESS INSPECT PAINT CONDITION OF SCANNERS VERIFY ALIGNMENT OF SCANNERS VERIFY PED/BASE TIGHTNESS INSPECT BALST QUALITY AND CONDITION CALIBTRATE
REF. PAGE
RECORD OF MAINTENANCE PERFORMED

JAN FEB MAR APR MAY JUN JUL
(DAY OF MONTH/INITIAL)
AUG SEP OCT NOV DEC
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NONE
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NONE
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Drawings
Section 5 Drawings
Contents
Introduction ................................................................................................................................................5-1 Organization of the Drawings....................................................................................................................5-1
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Drawings
Section 5 Drawings
Introduction
This section contains drawings and parts lists of the components that comprise a Pyro-HWD. The contents of this section, together with the information in other sections of this manual will enable an operator to properly maintain, troubleshoot, adjust and repair the components that comprise a Pyro-HWD installed in a Micro HBD/HWD. Figure 5-1 provides the nomenclature and location of the components comprising a Pyro-HWD installed in a Micro HBD/HWD System.
Organization of the Drawings

Drawings and parts lists are provided for the Pyro-HWD Assembly, generic components associated with the Pyro-HWD, components associated with the Pyro-HWD in a Micro Hot Wheel Detector Sub-System. Table 5-1 lists the Tables that correspond to each list of drawings and parts. Table 5-1. Tables Provided in this Section Table
5-2 5-3 5-4 5-5
Title
Parts List for Drawing 400041-44-2, Pyro-HWD Assembly Generic Drawings and Parts Lists Associated with Pyro-HWD Drawing and Parts List Associated with Pyro-HWD Micro Hot Wheel Detector Sub-System Parts List for Drawing 400073-44, Tube Housing Assembly
Page
5-3 5-7 5-7 5-9
100365-010 AB0
5-1

NEAR-SIDE OF TRACK
COVER
FAR-SIDE OF TRACK
SCANNER ASSEMBLY
TUBE HOUSING
BASE ASSEMBLY
STEEL FOUNDATION
TO Micro HBD/HWD VIA BURIED CONDUIT
MICRO HWD
CHANNEL 1 CONCRETE FOOTING (OPTIONAL)
CHANNEL 2
365-0010
Figure 5-1, Pyro-HWD Component Nomenclature and Location Diagram Micro HBD/HWD
5-2
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Drawings Table 5-2, Parts List for Drawing 400041-44-2, Pyro HWD Assembly Ref No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18, 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 300090-19-1 300070-71 300071-90 100242-01 060001032 013492-3412 060006002 060012002 060011002 061162006 061250002 060006010 300068-70 300068-72 060066035 060066027 005035-1001 400045-54 400042-82 060112002 400042-77 061200033 060014009 013030-006 060001045 060006004 060140003
Part Number
400073-44 251356-000 400044-98 300066-98 013492-3408
Title
Tube-Housing Subassembly (HWD) Sensor, Pyro HWD Outer Ring, Detector Assy, HWD Gasket, HWD Scanner Screw, Mach Panhead, 4-40 X Not Used Grill Assembly (HWD) Spacer, 8-32 X 13/16 Screw, Mach Panhead, 10-32 X Washer, Lock, Split, Hel, Cres #6 Screw, 8-32 X Panhead Wshr, Lk, Split, Hel, Cres #8 Screw, Cap, Hex, -13 X 1 , But Not Used Thermostat Assembly (HWD) Scanner Cover Assembly Load Ring Not Used Clamp, Cable Washer, Lock, Split, Hel, Cres # Angle Bracket, HWD Visor, HWD, Complete Screw, 6-32 X 9/16 Cres Screw, 8-32 X Cres Cable Clamp Not Used Screw, Mach Panhead, 4-40 X 3/8 Washer, Lock, Split, Hel, Cres # 4 Nut, Plain, Hex, Mach Screw, 4-40 Washer, Flat, Round, Cres # 4 Clamp, Cable, 9/16 Dia. Not Used Screw, Mach, Panhead, 6-32 X Not Used Protective Film Label, Revision Level Cover, High Voltage, HWD NPL
Manufactures P/N
MS51957-13
P1379-M06F13832 MS51958-59 MS35338-136 MS51957-45 MS35338-137
8T010304-2.730 KKC-4 MS35338-143
F4NY-093-0 MS51957-15 MS35338-135 MS35649-244 MS15795-803 C3046-9S MS51957-32
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5-3
Hot Wheel Detector Sub-System Table 5-2, Parts List for Drawing 400041-44-2, Pyro HWD Assembly, Continued Ref No.
40 41 42 43 44 45 46 47 48-50 029312-001 061071033 400071-20-1 400071-20-2
Part Number
060001042 060004004
Title
Screw, 8-32 X 5/16, Panhead Washer, Lock, Internal Tooth, Cres Not Used Spacer, 6 X 3/8 LG Heater Assembly, HWD Heater Assembly, HWD Not Used Compound Thermal Bulk Type 120 4 Not Used
Manufactures P/N
MS51957-42 MS35333-72 9226-A-140-17
Drawing 400041-44-2, Pyro HWD Assembly, Sheet 1 of 2
5-4
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Drawings
Drawing 400041-44-2, Pyro HWD Assembly, Sheet 2 of 2
100365-010 AB0
5-5
Table 5-3, Generic Parts Associated with Pryo HWD

Part Name Signal Foundation (Steel) Foundation Kit, HWD, Parts List Hot Wheel Detective Alignment Kit, Parts List Mirror Cap Assembly (2.5) Mirror Cap Assembly (2.5) Parts List HWD Alignment Fixture Assembly HWD Alignment Fixture Assembly Parts List Tube-Housing Subassembly (HWD) HWD Kit Basic with Scan Foundation, Parts List Pedestal Casting, HWD Assembly Part Number 061310001 PL200099-16 PL200099-81-6 A400052-78 PL400052-78 B400071-96 PL400071-96 C400073-44 PL400073-50-08 C400080-45
Table 5-4, Parts Associated with Pyro HWD in a Micro HWD

Part Name Cable Assembly, Pyro HWD - 65ft Optional Cable Assembly, Pyro HWD 85ft Optional Cable Assembly, Pyro HWD 100ft Optional Cable Assembly, Pyro HWD 125ft Part Number 400082-97 400082-97-01 400082-97-02 400082-97-03
5-6
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Drawings
Drawing 400073-44, Tube Housing Subassembly Table 5-5, Parts List for Drawing 400073-44, Tube Housing Subassembly
Ref. No. 1 2 3 4 5 6 Part Number 800002-12 300092-19 300087-93 060034038 060022058 060095005 060041001 Title Terminal Housing Tube, pedestal Spacer 3/8 Diameter, 4 Long Spring Pin 5/16-18, 1 Long Oval Point Set Screw (ST sTL) Self-locking Nut, 5/16-18 (Flexloc) Drive Screw 3/16 21FKF-518 50-375-4.000 Manufactures P/N
100365-010 AB0
5-7
The steel signal foundation is constructed of 2-1/2 X 2-1/2 X steel angle and steel plate welded together. Bolts furnished are 3/4 10 with 2-3/4 inch projection. This foundation will accommodate all the following bolt spacings:
8 X 8 6 X 8 6-3/4 X 6-3/4 Entire assembly is finished with ZRC compound, hotdip galvanized or other equivalent anti-corrosion process
365-0044
Drawing 061310001, Signal Foundation (Steel) Table 5-6, Parts List for Drawing 200099-16, Foundation Kit, HWD
Ref. No. 1 2 3 4 Part Number 061310001 100250-17 060083001 060006014 Title Foundation Threaded Rod, -10 X 9 Long Nut, -10 Lockwasher, Manufactures P/N
5-8
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Drawings
Table 5-7, Part List for Drawing 200099-81, HWD Alignment Kit
Ref. No. Part Number Title Manufactures P/N
1 2
400071-96 400052-78
HWD Alignment Fixture Mirror Cap Assembly
100365-010 AB0
5-9
4 2
Apply 404 around inside of cap at point shown. Insert mirror, red facing aperture and press firmly against the lip of cap. Use 404 sparingly.
365-0045
Drawing 400052-78, Mirror Cap Assembly (2.5)
Table 5-8, Part List for Drawing 200099-81, HWD Alignment Kit
1 2 3 4
300088-82 800003-48-1 061192001 061014028
Cap, 2.5 Mirror Mirror, Modified (2.5) Adhesive Protective Cap 404 Loctite #682 RobRoy Industries
5-10
100365-010 AB0
Drawings
365-0046
Drawing 400071-96, HWD Alignment Fixture Assembly
Table 5-9, Part List for Drawing 400071-96, HWD Alignment Fixture Assembly
1 2 3
400071-95 300086-14 060191001
Bracket, Detail Assembly Target Plate Nut, Wing 10-32 WC-02 ESNS
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5-11

8
6
BLU BLK
RED BLK
PIN 1
WHT BLK
GRN K BL
400082-97
L YE
LOCKING TAB HWD SCANNER END
HW1 or HW2 SCANNER TERMINAL NUMBERS 1 4 6 6 6 7 8 9 GND
WIRE COLOR BLK of WHT/BLK WHT of WHT/BLK BLK of BLU/BLK BLK of RED/BLK BLK of GRN/BLK GRN of GRN/BLK BLU of BLU/BLK RED of RED/BLK YEL of YEL/BLK
MICRO HSIB INTERCONNE HW1 or HW2 PIN NUMBER 7 6
4 2 3 1 8 SHIELDS ORN 5
365-0047
Cable Assembly 400082-97, Pyro HWD Scanner/Micro HSIB Interconnect Table 5-10, Part List for Drawing 400073-50-08, HWD Kit, Basic with Scanner Foundation
1 2 3 4 5 6 7 8 9 10
400041-44
HWD Scanner Assembly
400074-49-2 400042-84
Cable Assembly, W3001-2 Function Simulator Support Assembly
800002-01
Split Base Modified
200099-16
Foundation Kit, Hot Wheel Detector
5-12
100365-010 AB0
Installation
Section 6 Installation
Contents
Introduction ................................................................................................................................................6-1 Installation Sequence ................................................................................................................................6-1 Scanner Installation Procedure .................................................................................................................6-1 Two-Scanner Installation Procedure...................................................................................................... 6-1 Calibration Procedure..............................................................................................................................6-13 Micro Hot Wheel Calibration....................................................................................................................6-14 Function Simulator set up..................................................................................................................... 6-15 Installation Checklist Two Scanners ....................................................................................................6-17 One Scanner Installation .........................................................................................................................6-18
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6-i
6-ii
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Installation
Section 6 Installation
Introduction
This section describes how to install the components comprising a Pyro-HWD in a Micro HBD/HWD system.
Installation Sequence
The installation procedures are divided into three topics: a. b. c. Scanner Assembly (Single and Double), Cabling connections in the wayside enclosure, Calibration.
The Scanner Assembly can be installed in a timely manner by referring to the Installation Checklist located at the end of this section.
Scanner Installation Procedure

Although a fully assembled scanner stands approximately 5 feet (1.5 meters) high, most of it is buried when the scanner is installed. When properly installed, the line-of-view of the scanner's lens will be 2.5 inches (64 mm) above the heads of the rails. When two scanners are located at an HBD site, they are installed directly opposite each other. Two-Scanner Installation Procedure
1.
Using the site plan as a guide, stake out the areas to be excavated for the scanners. Footings may be required: the one depicted in Figure 6-1 is approximately 43 inches (10.9 cm) on each side and 8.5 inches (216 mm) high.
Note:
100365-004 AB0
6-1
NEAR-SIDE OF TRACK
COVER
FAR-SIDE OF TRACK
SCANNER ASSEMBLY
TUBE HOUSING
BASE ASSEMBLY
STEEL FOUNDATION
MICRO HWD
CHANNEL 2
365-0010
Figure 6-1, Two-Scanner Pyro HWD System Installation Diagram
6-2
100365-010 AB0
Installation 2. 3. Excavate both areas to the required depth; install footings if required. Trench from each excavated area to the wayside equipment enclosure; this is for the cable assemblies that interconnect each scanner to the Micro HWD in the enclosure. Exercise extreme care while assembling the scanners to avoid damaging the viewing lenses.
Note: 4.
For your convenience, locate the two cables labeled 400082-97 and place them inside the wayside equipment enclosure (these cables will be routed from the enclosure to the foundations later in this procedure). Locate one of the signal foundations (Figure 6-1), the 3/4 inch lock and flat washers, and 3/4-10 x 9" threaded rods supplied. Install a flat washer, lock washer, and a nut on one end of each rod. Insert each rod up through the bottom of each slotted hole in the foundation's mounting plate (Figure 6-2). Install a flat and lock washer and a nut on each rod; run the nuts down to the plate but do not tighten them at this time.
5.
365-0048
Figure 6-2, Foundation Plate Threaded Rod Installation
6. 7. 8.
Install a nut on each of the rods; leave about 1.5 inches (38 mm) of rod exposed (Figure 6-2). Install the Base Assembly (400080-45) onto the rods. Install a flat and lock washer and nut on each rod; do not tighten the nuts at this time.
100365-004 AB0
6-3
365-0049
Figure 6-3, Installing the Base 9. Adjust the position of the rods such that they are centered in the slotted holes of the base and the plate. Carefully tighten the nuts that secure the rods to the foundation base.
10. Insert the Tube Housing Assembly into the base; ensure that the tube is flush with the bottom of the base. Tighten the bolt that secures the Tube Housing to the Base Assembly. 11. Position the base such that it is centered on the four rods that secure the base to the plate; carefully tighten the nuts. 12. Loosen the two screws that secure the scanner cover (Figure 6-1) to the scanner base. Remove the cover; store it in a safe place. 13. Install one of the cable PVC conduits between the wayside equipment enclosure and the scanner location. 14. Locate one of the cables labeled 400082-97 inside the wayside equipment enclosure. 15. Locate the nine leads on cable 400082-97. Snake this end of the cable through the PVC to the steel foundation. 16. At the steel foundation, insert the end of cable 400082-97 between two of the foundation's legs and then up through the tubing assembly. Allow approximately 12 inches (305 mm) of cable to protrude out of the scanner base. 17. Stand the signal foundation in the excavated area (or on the footing, if one is installed). 18. Repeat steps 5 through 17 for the other scanner 19. At the rail on which the transducers are mounted, locate the magnetic center of transducer A; mark both rails. Repeat this step for transducer B. 20. At the rail on which the transducers are mounted, locate and mark the center between the two marks made in step 19; mark the other rail. Note: Dimensions in Figure 6-3 are: A = 52" (1321 mm); A' = 72" (1829 mm).
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Installation 21. Using Figure 6-4 as a guide, determine the location for one of the scanners: both scanners must be located the same distance (+ 0.5" [12.5 mm]) from the respective rail. Note: Care must be exercised to ensure exact positioning of the scanner assembly throughout its installation. Progress Rail Services engineering recommends performing frequent verifications of the scanner's position, plumb, and distance from the rail during the installation procedure.
22. Using a carpenter's level, a tape measure, and the dimensions for A or A' derived from Figure 6-4, position the signal foundations such that three measurements are simultaneously achieved for each: the center of the tube assembly is the correct distance from the rail and is in the center of the gate, and the signal foundation is plumb.
A'
(MAXIMUM)
(MINIMUM)
(MINIMUM)
LINE - OF - SCA
A'
(MAXIMUM)
365-0026
Figure 6-4, Positioning the Signal Foundations
23. While maintaining the position of the signal foundation, back-fill the excavation to half the height of the foundation (Figure 6-5); this will support the foundation during the installation of the scanner assembly.
100365-004 AB0
6-5
365-0027
Figure 6-5, Partially Back-Filled Excavation
Note:
If necessary, remove excess slack in the cable at the tube housing assembly by carefully pulling the exposed portion of cable in the wayside equipment enclosure: exercise extreme care to avoid moving the signal foundation.
24. Using Figure 6-6 as a guide, connect the numbered leads to the terminal block; connect the large, numberless lead to the ground lug on the housing.
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Installation
Figure 6-6, Connecting the Cable Leads to the Terminal Block 25. Backfill the excavation to approximately grade level (final grading will be accomplished later). 26. Repeat steps 19 through 25 for the other scanner. Note: Alignment of the scanner assembly can be accomplished via two methods: the mirror cap assembly and alignment fixture method, and the direct-sighting method.
27. Align the scanner assembly: the mirror cap assembly and alignment fixture method begins at step 28; the direct-sighting method begins at step 42. 28. Install the HWD Alignment Fixture (Figure 6-7) on the rail opposite the scanner to be aligned. Ensure that the fixture's index mark is directly over the centerline mark (on the rail) between the two transducers. Ensure that the alignment fixture is fully seated on the rail head. 29. Ensure that the target faces the scanner to be aligned, and that the scanner's index mark aligns with the 0o mark (as shown in Figure 6-7): if necessary, loosen the wing nut and reposition the target, then tighten the wing nut.
100365-004 AB0
6-7
Figure 6-7, Installing the HWD Alignment Fixture 30. Remove the visor and the outer ring assembly from the scanner to be aligned. Note: To avoid alignment errors, ensure that the mirror lens cap is fully seated on the end of the scanner lens.
31. Install the mirror cap assembly onto the scanner lens (Figure 6-8).
6-8
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Installation
Figure 6-8, Installing the Mirror Cap Assembly onto the Lens
32. Loosen the two vertical positioning coarse-adjustment screws (Figure 6-9). 33. Loosen the locking nut for each vertical positioning fine-adjustment setscrew (Figure 6-10), but do not loosen the setscrews at this time. Note: Scanner/target alignment may require two people.
34. Point the scanner in the direction of the target.
100365-004 AB0
6-9
Figure 6-9, Vertical Positioning: Coarse-Adjustment Screws
SETSCREW LOCKING NUT
SETSCREW
SPRING PIN
365-0020
Figure 6-10, Vertical Positioning: Fine-Adjustment Setscrews
35. At the back of the target, look through the hole in the target toward the scanner: adjust the vertical and horizontal position of the scanner until the red dot on the mirror lens cap is in the center of the viewing hole on the target. Tighten the vertical positioning coarse-adjustment screws (Figure 6-9).
Note:
The base casting pivots about the spring pin that secures the base to the tube housing. To perform step 36 (fine-adjustment of the scanner), first back out one set and note how many turns, then turn in the opposite setscrew the same number of turns.
6-10
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Installation
36. Using the two fine-adjustment setscrews (Figure 6-10), make final adjustment to the vertical alignment of the scanner. If necessary, use the previous step as a reference to readjust the coarse adjustment of the scanner. 37. Repeat steps 28 through 36 for the other scanner. 38. When alignment is achieved, remove and store the alignment fixture and the mirror cap assembly. 39. Install the outer ring assembly. 40. Install the visor. 41. Grade the area around the scanner assembly. Note: Steps 42 through 54 are a continuation of step 27, and pertain using the direct-sighting method to align the scanner assembly.
42. Prepare a wood stake 1" x 6" x 30" (25 mm x 152 mm x 762 mm) for use as a sighting target (Figure 6-11). 43. On one side of the stake, draw a dark centerline down the entire length (Figure 6-11). 44. On the far side of the rail opposite the scanner to be aligned, excavate approximately 12" (305 mm) of ballast from the area near the center line of the wheel gate.
Figure 6-11, Preparing the Wood Stake Target 45. Position the stake vertically against the far side of the rail, such that the centerline of the stake is aligned with the wheel gate centerline mark on the rail, and is plumb; backfill to hold the stake in position (Figure 6-12).
100365-004 AB0
6-11
Figure 6-12, Installing a Stake 46. On the stake, mark a horizontal line that is level with the head of the rail (Figure 6-13).
Figure 6-13, Marking the Target on the Stake 47. Measure 4.75" (121 mm) up from the line drawn in the previous step; draw a horizontal line (Figure 6-13). The point at which these two lines cross is the center of the target for aligning the scanner; mark a solid, 1/4" circle at this point to make it easier to see when aligning the scanner. 48. Obtain a length of tubing that is approximately 14" long and 1/4" in diameter (356 mm x 6.4 mm). Place the tubing across the "V" cuts in the tops of both ends of the housing assembly (Figure 6-14). 49. Simultaneously look through the tubing and adjust the position of the housing assembly; when the tubing is centered on the crossed lines of the target, tighten the vertical positioning coarse-adjustment screws. 50. Using the two fine-adjustment setscrews (Figure 6-10), make final adjustment to the vertical alignment of the scanner. If necessary, use the previous step as a reference to readjust the coarse adjustment of the scanner. 51. Install the outer ring assembly and the visor. 52. Repeat steps 44 through 50 for the other scanner. 53. Remove and store the stake. 54. Backfill the conduit trench; grade to surrounding level.
6-12
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Installation
TUBING ON "V" CUTS
365-0028
Figure 6-14, Aligning the Housing Assembly to the Target
Calibration Procedure
The following equipment should be available while performing the calibration procedure:

CA200DV Calibration Assistant (251347-000) Function Simulator Mounting Bracket (400042-84) Function Simulator Cable (400018-67-XX) Wrenches: 3/16" open end, 1/4" open end Screwdrivers: 1/4" blade, 1/8" blade, cross-tip Allen key set
100365-004 AB0
6-13
Micro Hot Wheel Calibration

To Calibrate the Hot wheel detector subsystem, you will need the following items:

CA200 DV Calibration Assistant PN: 251347-000 Computer with Com program such as hyper terminal or procom. Serial cable to connect computer to hot wheel detector subsystem. Function Simulator Mounting Bracket Function Simulator Cable. Wrenches: 3/16 open end, open end. Screwdrivers: blade, 1/8 blade, cross-tip. Allen key set. Soft paintbrush
Turn on the calibration device to start warming up if not a Function Simulator. If the calibration device is a Function Simulator place in the shade with the power off until ready to use.
Cleaning/Inspecting the Scanner Assembly Visor Using a clean, narrow paintbrush, carefully remove debris such as grass clippings, cobwebs, etc., from the interior of the visor. In the case of insect nests such as mud wasps, carefully remove the nests with a small screwdriver, then use a soft sponge soaked in a mild detergent solution to remove the remaining mud/residue. If necessary, perform the following section (cleaning the scanner assembly lens cover. Inspect the visor for indications of damage; replace if necessary.
Cleaning the Scanner Assembly Lens Cover Note: 1. 2. 3. Exercise care to avoid scratching the lens cover. Using a clean, narrow paint brush, carefully remove dust and dirt accumulated on the surface of the lens cover. Inspect the lens cover for scratches. If the cover is in good condition, replace the cover and skip to Calibration Steps. If the severity or density of the scratches have reduced visibility through the cover, replace the cover: a. b. c. d. e. Remove power to the Scanner Assembly. Using an Allen Key, remove the two screws securing the Scanner Assembly Cover. Store the cover and hardware in a safe place. Remove the Scanner Assembly Visor. Using an Allen Key, remove the three cap screws securing the Outer Ring Assembly; carefully pull the Outer Ring straight off the front of the Scanner Assembly. Store the hardware in a safe place. Remove the Grill Assembly from the Outer Ring; store the Ring in a safe place.
6-14
100365-010 AB0
Installation f. g. h. i. j. k. l. Unscrew the Load Ring from the Grill Assembly. Discard the vinyl sheet. Place a new piece of vinyl sheet over the Load Ring. Carefully screw the Load Ring into the Grill Assembly; ensure that the vinyl sheet remains taut to prevent wrinkles from forming. Using a razor or scissors, trim the excess sheet from the Outer Ring. Install the Outer Ring Assembly: carefully align the assembly to the two heaters and the thermostat. Install and tighten the hardware that secures the Outer Ring. Install the Visor; tighten the hardware.
m. Install the Scanner Assembly Cover; tighten the hardware. n. Apply power to the Scanner Assembly.
Calibration Steps Place the Function simulator-mounting Bracket on the scanner to be calibrated, use a screwdriver to tighten the bracket to the scanner. Place the calibrator on the bracket; observe the bracket to make sure deflection of the bracket is at a minimum. Center the calibrator on the bracket. Make sure the ready light is on and has been on for at least 5 minutes. Establish serial communication between a computer and the Micro Hot Wheel Detector. Type mm <enter>, if prompted enter the password. This places you in the maintenance menu. Type C <enter> to start the calibration program. The following menu should appear:
SIB Board ID: 1 - Channel 1 2 - Channel 2 3 - Exit Hot Wheel (227294-010)
Note:
If the SIB Board ID is not 227294-010 the calibration software will not work correctly.
Enter the number of the channel to calibrate or 3 to exit calibration. A message will appear to enter the ambient temperature, or accept the ambient temperature displayed. Enter the ambient temperature. The temperature to set the Function Simulator to will be displayed. If using the Function Simulator as the calibration device perform the following steps:
Function Simulator set up 1. 2. 3. 4. When the hot wheel detector sub system gives the temperature to set the calibrator to, set the function simulator to 20 degrees less and turn on the function simulator. When the light goes out on the function simulator turn the temperature to the correct temperature. This prevents a temperature overshoot problem. Then place the function on the bracket and center the function simulator. When the message Press <Enter> to begin calibration.. appears wait at least 10 seconds to press <Enter>.
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6-15
The following is a typical calibration run from a defaulted system; the actual calibration messages may vary.
Calibrating...Please Wait...(Press <Enter> to exit)200 204 201 204 204 200 203 202 204 200 202 203 201 204 200 203 204 200 204 202 203 201 202 203 201 204 200 202 203 201 203 201 204 205 200 204 201 204 199 204 203 200 204 201 205 202 202 204 201 202 200 204 201 202 203 199 205 200 203 204 201 203 201 203 201 203 203 202 204 201 204 205 200 204 201 204 201 201 204 200 204 201 205 206 201 204 200 204 203 201 204 201 205 201 202 204 200 203 201 202 204 Adjusting Gain... Existing Absolute Nov Pot Steps = 27 New Absolute Nov Pot Steps =6 Checking Gain...108 107 110 108 111 112 111 112 111 112 111 112 114 112 113 111 114 112 113 114 112 114 113 114 114 112 114 112 115 113 114 114 112 114 113 115 114 113 114 112 114 113 114 115 112 115 113 114 115 113 115 113 114 112 114 115 113 114 113 114 114 113 114 114 114 113 113 114 113 114 113 114 115 112 114 113 115 115 113 114 113 113 113 113 114 113 114 113 114 115 113 115 112 114 113 113 115 113 115 113 115 Adjusting Gain... Existing Absolute Nov Pot Steps = 6 New Absolute Nov Pot Steps =7 Checking Gain...119 120 118 121 118 120 120 119 120 117 120 118 119 120 118 119 118 120 121 118 120 118 120 120 118 120 119 120 118 120 120 118 120 118 120 119 118 120 118 119 119 118 120 118 120 118 119 120 118 119 117 119 120 118 120 117 119 120 117 120 117 120 117 118 119 118 120 117 118 120 118 120 118 119 120 118 120 118 119 118 119 119 118 120 118 120 119 119 120 119 119 121 117 119 118 120 120 118 120 117 120 Average ADC Reading = 118 Hardware Gain Factor = 103 Absolute Hardware Gain = 1.19
Validating...Software Gain Please Wait...(Press <Enter> to exit)117 115 117 115 116 117 115 117 115 117 115 116 116 114 117 115 116 116 115 117 115 117 118 115 116 114 117 115 115 118 114 117 115 116 117 114 117 114 116 117 116 116 114 117 114 116 117 115 116 115 116 116 115 117 115 117 117 115 117 115 116 117 115 117 115 117 115 115 117 115 116 114 117 117 114 117 114 117 117 116 117 115 117 115 116 116 115 117 115 117 117 115 117 114 117 116 115 117 115 116 117
Repeat the above procedures for the second scanner.
6-16
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Installation
Installation Checklist Two Scanners
Item Check
Activity Establish Locations Locations Excavated Cable Trenches Footings (optional) Signal Foundations Mounting Bases Cable Assemblies Check Plumb of each Foundation Final Positions Established Back Fill Ballast at Both Foundations Verify Positions and Plumb of Both Foundations Install Scanner Assemblies onto the Foundation Alignment of Both Scanners Calibrate Micro HWD/HBD
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6-17
One Scanner Installation

Note: 1. This scan method only inspects one side of the train. It is highly recommended that the scanners be mounted on alternating sides of the trains for the best inspection.
Using the site plan as a guide, stake out the areas to be excavated for the scanner. A footing may be required: the one depicted in Figure 6-15 is approximately 43 inches (10.9 cm) on each side and 8.5 inches (216 mm) high.
Note: 2.
Cut a tie to an appropriate length and install in the ballast with 6 inches above the top of the rail. Clean one side of the tie. Prime, then paint the primed side white.
NEAR-SIDE OF TRACK
COVER
FAR-SIDE OF TRACK
SCANNER ASSEMBLY
TUBE HOUSING
RAILROAD TIE
BASE ASSEMBLY
STEEL FOUNDATION
PAINT WHITE
MICRO HWD
CHANNEL 2
365-0012
Figure 6-15, One Scanner/One Side Pyro-HWD System Installation Diagram
6-18
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Installation 3. 4. 5. Excavate the scanner area to the required depth; install footing if required. Excavate target area (tie) to required depth. Trench from the excavated area to the wayside equipment enclosure; this is for the cable assemby that interconnect the scanner to the Micro HWD in the enclosure. Exercise extreme care while assembling the scanner to avoid damaging the viewing lenses.
Note: 6. 7.
For your convenience, locate the cable labeled 400082-97 and place them inside the wayside equipment enclosure (the cable will be routed from the enclosure to the foundation later in this procedure). Locate the signal foundation (Figure 6-15), the 3/4 inch lock and flat washers, and 3/4-10 x 9" threaded rods supplied. Install a flat washer, lock washer, and a nut on one end of each rod. Insert each rod up through the bottom of each slotted hole in the foundation's mounting plate (Figure 6-16). Install a flat and lock washer and a nut on each rod; run the nuts down to the plate but do not tighten them at this time.
365-0048
Figure 6-16, Foundation Plate Threaded Rod Installation 8. 9. Install a nut on each of the rods; leave about 1.5 inches (38 mm) of rod exposed (Figure 6-16). Install the Base Assembly (400080-45) onto the rods.
10. Install a flat and lock washer and nut on each rod; do not tighten the nuts at this time.
100365-004 AB0
6-19
365-0049
Figure 6-17, Installing the Base 11. Adjust the position of the rods such that they are centered in the slotted holes of the base and the plate. Carefully tighten the nuts that secure the rods to the foundation base. 12. Insert the Tube Housing Assembly into the base; ensure that the tube is flush with the bottom of the base. Tighten the bolt that secures the Tube Housing to the Base Assembly. 13. Position the base such that it is centered on the four rods that secure the base to the plate; carefully tighten the nuts. 14. Loosen the two screws that secure the scanner cover (Figure 6-1) to the scanner base. Remove the cover; store it in a safe place. 15. Install the cable PVC conduits between the wayside equipment enclosure and the scanner location. 16. Locate the cable labeled 400082-97 inside the wayside equipment enclosure. 17. Locate the nine leads on cable 400082-97. Snake this end of the cable through the PVC to the steel foundation. 18. At the steel foundation, insert the end of cable 400082-97 between two of the foundation's legs and then up through the tubing assembly. Allow approximately 12 inches (305 mm) of cable to protrude out of the scanner base. 19. Stand the signal foundation in the excavated area (or on the footing, if one is installed). 20. At the rail on which the transducers are mounted, locate the magnetic center of transducer A; mark both rails. Repeat this step for transducer B. 21. At the rail on which the transducers are mounted, locate and mark the center between the two marks made in step 20; mark the other rail. Note: Dimensions in Figure 6-17 are: A = 52" (1321 mm); A' = 72" (1829 mm).
22. Using Figure 6-18 as a guide, determine the location for the scanner. The scanner and the tie must be located the same distance (+ 0.5" [12.5 mm]) from the respective rail.
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Installation
Note:
Care must be exercised to ensure exact positioning of the scanner assembly throughout its installation. Progress Rail Services engineering recommends performing frequent verifications of the scanner's position, plumb, and distance from the rail during the installation procedure.
23. Using a carpenter's level, a tape measure, and the dimensions for A or A' derived from Figure 6-18, position the signal foundation such that three measurements are simultaneously achieved for each: the center of the tube assembly is the correct distance from the rail and is in the center of the gate, and the signal foundation is plumb.
TIE
A'
(MAXIMUM)
WHITE SIDE TIE
(MINIMUM)
WHITE SIDE
(MINIMUM)
LINE - OF - SCA
A'
(MAXIMUM)
365-0S26
Figure 6-18, Positioning the Signal Foundations
24. While maintaining the position of the signal foundation, back-fill the excavation to half the height of the foundation (Figure 6-19); this will support the foundation during the installation of the scanner assembly. 25. Verify that the tie is vertical with a level and that the white face is facing the track. The top of the tie should be at least 6 inches above the top of the rail. The tie height must meet the railroads clearance requirements.
100365-004 AB0
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365-0027
Figure 6-19, Partially Back-Filled Excavation
Note:
If necessary, remove excess slack in the cable at the tube housing assembly by carefully pulling the exposed portion of cable in the wayside equipment enclosure: exercise extreme care to avoid moving the signal foundation.
26. Using Figure 6-20 as a guide, connect the numbered leads to the terminal block; connect the large, numberless lead to the ground lug on the housing.
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Installation
Figure 6-20, Connecting the Cable Leads to the Terminal Block 27. Backfill the excavation to approximately grade level (final grading will be accomplished later). Note: Alignment of the scanner assembly can be accomplished via two methods: the mirror cap assembly and alignment fixture method, and the direct-sighting method.
28. Align the scanner assembly: the mirror cap assembly and alignment fixture method begins at step 29; the direct-sighting method begins at step 42. 29. Install the HWD Alignment Fixture (Figure 6-21) on the rail opposite the scanner to be aligned. Ensure that the fixture's index mark is directly over the centerline mark (on the rail) between the two transducers. Ensure that the alignment fixture is fully seated on the rail head. 30. Ensure that the target faces the scanner to be aligned, and that the scanner's index mark aligns with the 0o mark (as shown in Figure 6-21): if necessary, loosen the wing nut and reposition the target, then tighten the wing nut.
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Figure 6-21, Installing the HWD Alignment Fixture 31. Remove the visor and the outer ring assembly from the scanner to be aligned. Note: To avoid alignment errors, ensure that the mirror lens cap is fully seated on the end of the scanner lens. 32. Install the mirror cap assembly onto the scanner lens (Figure 6-22).
Figure 6-22, Installing the Mirror Cap Assembly onto the Lens
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Installation
33. Loosen the two vertical positioning coarse-adjustment screws (Figure 6-23). 34. Loosen the locking nut for each vertical positioning fine-adjustment setscrew (Figure 6-24), but do not loosen the setscrews at this time. Note: Scanner/target alignment may require two people.
35. Point the scanner in the direction of the target.
Figure 6-23, Vertical Positioning: Coarse-Adjustment Screws
SETSCREW LOCKING NUT
SETSCREW
SPRING PIN
365-0020
Figure 6-24, Vertical Positioning: Fine-Adjustment Setscrews
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36. At the back of the target, look through the hole in the target toward the scanner: adjust the vertical and horizontal position of the scanner until the red dot on the mirror lens cap is in the center of the viewing hole on the target. Tighten the vertical positioning coarse-adjustment screws (Figure 6-23). Note: The base casting pivots about the spring pin that secures the base to the tube housing. To perform step 37 (fine-adjustment of the scanner), first back out one set and note how many turns, then turn in the opposite setscrew the same number of turns.
37. Using the two fine-adjustment setscrews (Figure 6-24), make final adjustment to the vertical alignment of the scanner. If necessary, use the previous step as a reference to readjust the coarse adjustment of the scanner. 38. When alignment is achieved, remove and store the alignment fixture and the mirror cap assembly. 39. Install the outer ring assembly. 40. Install the visor. 41. Grade the area around the scanner assembly. Note: Steps 42 through 53 are a continuation of step 28, and pertain using the direct-sighting method to align the scanner assembly.
42. Prepare a wood stake 1" x 6" x 30" (25 mm x 152 mm x 762 mm) for use as a sighting target (Figure 6-25). 43. On one side of the stake, draw a dark centerline down the entire length (Figure 6-25). 44. On the far side of the rail opposite the scanner to be aligned, excavate approximately 12" (305 mm) of ballast from the area near the center line of the wheel gate.
Figure 6-25, Preparing the Wood Stake Target 45. Position the stake vertically against the far side of the rail, such that the centerline of the stake is aligned with the wheel gate centerline mark on the rail, and is plumb; backfill to hold the stake in position (Figure 6-26).
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Installation
Figure 6-26, Installing a Stake 46. On the stake, mark a horizontal line that is level with the head of the rail (Figure 6-27).
Figure 6-27, Marking the Target on the Stake 47. Measure 4.75" (121 mm) up from the line drawn in the previous step; draw a horizontal line (Figure 6-27). The point at which these two lines cross is the center of the target for aligning the scanner; mark a solid, 1/4" circle at this point to make it easier to see when aligning the scanner. 48. Obtain a length of tubing that is approximately 14" long and 1/4" in diameter (356 mm x 6.4 mm). Place the tubing across the "V" cuts in the tops of both ends of the housing assembly (Figure 6-28). 49. Simultaneously look through the tubing and adjust the position of the housing assembly; when the tubing is centered on the crossed lines of the target, tighten the vertical positioning coarse-adjustment screws. 50. Using the two fine-adjustment setscrews (Figure 6-24), make final adjustment to the vertical alignment of the scanner. If necessary, use the previous step as a reference to readjust the coarse adjustment of the scanner. 51. Install the outer ring assembly and the visor. 52. Remove and store the stake. 53. Backfill the conduit trench; grade to surrounding level.
100365-004 AB0
6-27
TUBING ON "V" CUTS
365-0028
Figure 6-28, Aligning the Housing Assembly to the Target
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Troubleshooting
Section 7 Troubleshooting
Contents
Introduction ................................................................................................................................................7-1 Repair/Replacement/Return of Failed Equipment....................................................................................7-1 Interrelationship Diagrams ........................................................................................................................7-1 Connector Pinouts .....................................................................................................................................7-2 Sensor Assembly Circuit Diagram and Cable Assembly Connector Pinouts....................................... 7-2 Troubleshooting Guidelines Table ............................................................................................................7-4
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Troubleshooting
Section 7 Troubleshooting
Introduction
This section describes how to troubleshoot the components of a Pyro-HWD installed in a Micro HBD/HWD System. Included are diagrams that illustrate equipment interrelationships and connector pinouts, and tables that present information in a symptom/cause/action format. The tables define problems that can arise within the Pyro-HWD system as well as those that originate in the HBD system but manifest themselves as symptoms of an Pyro-HWD malfunction. Not all problems can be anticipated and/or documented, therefore only the most commonly occurring problems are included in the tables; as in any system, troubleshooting relies heavily on an individual's knowledge and understanding of how the system functions. It should be noted that the timely performance of the tasks in a comprehensive preventive maintenance program can prevent the occurrence of problems associated with equipment alignment, cleanliness, cabling and connections, and weather ingress.
Repair/Replacement/Return of Failed Equipment

Many problems can be corrected or repaired on site using basic tools and materials at hand; others will require replacement with parts obtained either locally or directly from Progress Rail Services. A complete listing of field-replaceable parts for the Pyro-HWD system is provided in Section 5 of this manual. Note: Before returning any material to Progress Rail Services for credit or replacement, refer to the WARRANTY statement located in the front of this manual.
Interrelationship Diagrams
The first step in troubleshooting is to remember the importance of the 'big picture', that is, the fact that the problem exists within a system of interconnected, interrelated equipment: it is even possible that site-related factors such as location, track orientation and electrification can be the cause of a problem. Focusing too quickly on a specific symptom or indication could result in overlooking the real cause of a problem: many problems exhibit more than one symptom. The purpose of an interrelationship diagram is to present that 'big picture' as a starting point. By relating the symptom(s) to the respective area(s) on the appropriate diagram, it is possible to identify a common-cause location before setting up any test equipment. Figure 7-1 is an example of the diagrams that pertain to troubleshooting a Pyro-HWD. It is intended to illustrate how a typical Pyro-HWD is interconnected in a Micro HBD/HWD system; it is not representative of a specific system, consequently the documentation that describes the Micro HBD site/system in which a problem exists must be available.
100365-010 AB0
7-1
Figure 7-1, Pyro-HWD/Micro HWD Interrelationship Diagram
Connector Pinouts
The following information describes the connector pinouts and scanner signal path of a Pyro-HWD. Sensor Assembly Circuit Diagram and Cable Assembly Connector Pinouts Figure 7-2 is the Sensor Assembly circuit diagram and Figure 7-3 illustrates Cable Assembly 400082-97 Connector Pinouts.
7-2
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Troubleshooting
Figure 7-2, Sensor Assembly Circuit Diagram
Figure 7-3, Cable Assembly 400082-97 Connector Pinouts
100365-010 AB0
7-3
Troubleshooting Guidelines Table

Figure 7-4 is an example of the troubleshooting guidelines table. The table presents the information in a symptom/cause/action format. The SYMPTOM column lists three basic symptoms that have been known to occur: no alarms; continuous alarms; missed alarms. For each symptom, the first entries in the CAUSE column are those most likely to cause the symptom, or are the easiest to verify or observe. However, each symptom can have more than one cause and, consequently, more than one ACTION for each cause. Some of the actions include references to additional information in this section and in other manuals. By carefully reviewing all of the causes and actions for a given symptom, it may be easier to identify a logical, related area to begin troubleshooting. The troubleshooting guidelines table may not include problems that are experienced at a specific site. However, Electro Pneumatic Corporation welcomes contributions to this section, and has provided a self-addressed postage paid Documentation Comment Report (located inside the back cover of this manual) for this purpose. Changes to this section will be made concurrent with technical changes in other sections. Symptom No Alarms Cause HWD Present software switch incorrectly set Scanner lens/polyethylene sheet blocked/dirty two (scanner installations) Scanner misaligned (single scanner installations) Action Interconnect a PC or terminal; verify settings of relevant software switches (refer to software sections in this manual) 2. Inspect visor for foreign matter. 3. Inspect polyethylene sheet; clean if required. 4. Inspect scanner lens; clean if required. Verify Alignment 5. Quick Check a. Remove scanner cover b. Lay 14 (356mm) tube in V cuts c. Verify alignment to spot in target; if required go to step b. 2. Perform Scanner Alignment Refer to Scanner Alignment Step 25 in Section 6 of this manual. Perform Scanner Alignment: Refer to Scanner Alignment in Section 6 of this manual. Inspect cable connections at Micro HWD assembly: clean/tighten/repair as required Inspect exposed portions of cable for rodent/weather damage; replace as required. Measure signal levels on terminal block - Verify 12 volts pin 8 to pin 6 - Verify 6 volts pint 9 to pin 6 and pin 7 to pin 6 - BX 110 pin 4 - NX 110 pin 1 Calibrate alarm circuits
Scanner misaligned (two scanner installations) Scanner interconnect cable 400082-97: loose connections, frayed or broken leads Incorrect voltage or levels on the Pyro HWD terminal block on scanner
Pyro HWD alarm circuits require calibration
7-4
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Troubleshooting
Symptom Continuous Alarms
Cause Alarm threshold values set too low for normal or reverse direction Scanner misaligned
Action Refer to Micro How Wheel Detector Software Users Manual (PN: 100092-008) to adjust the alarm levels. Verify Alignment 1. Quick Check b. Remove scanner cover b. Lay 14 (356mm) tube in V cuts c. Verify alignment to spot in target; if required go to step b. 2. Perform Scanner Alignment Refer to Scanner Alignment Step 25 in Section 6 of this manual. Perform scanner alignment (refer to step 27 in section 6 of this manual) 1. Connect a DVM between TB1-1 and TB1-4 on the terminal block HWD scanner 2. While observing the DVM, induce a train present signal at the Micro HWD: if line voltage does not drop to zero, replace the SIB Board. 1. Inspect visor for foreign matter 2. Inspect polyethylene sheet; clean if required 3. Inspect scanner lens; clean if required Refer to Micro How Wheel Detector Software Users Manual (PN: 100092-008) to adjust the alarm levels. Verify Alignment 1. Quick Check c. Remove scanner cover b. Lay 14 (356mm) tube in V cuts c. Verify alignment to spot in target; if required go to step b. 2. Perform Scanner Alignment
Scanner misaligned (two scanner installations) Scanner heater(s) not switching off when a train is present
Missed Alarms
Scanner lens/polyethylene sheet blocked/dirty Alarm threshold values too high in normal or reverse direction Scanner misaligned (singlescanner installations)
Refer to Scanner Alignment Step 27 in Section 6 of this manual. Scanner misaligned (twoPerform scanner alignment (refer to step 27 in scanner installations) section 6 of this manual) Fogging or build-up of moisture 1. Remove the scanner cover. on the lens cover caused by 2. Inspect for broken/loose heater wires; repair as one or both heater not required. Install cover. operating or not producing sufficient heat Figure 7-4, Troubleshooting Guidelines Table
100365-010 AB0
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100365-010 AB0

100365-010 AB0 - HW Subsystem & SFTW Manual

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100365-010 AB0 - HW Subsystem & SFTW Manual

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Hot Wheel Detector Sub-System and Software Manual

For use with Micro Hot Box Detector

Reproduction and Use Restrictions Agreement

Hot Wheel Detector Sub-System

Static Sensitive Symbols for Equipment Handling Instructions

Progress Rail Services

Personal Safety Instructions

Progress Rail Services

Hot Wheel Detector Sub-System

Progress Rail Services

Progress Rail Services

Hot Wheel Detector Sub-System

Progress Rail Services

Progress Rail Services

Hot Wheel Detector Sub-System

Progress Rail Services

Technical Manual Overview

Progress Rail Services

Purpose of the System

Progress Rail Services

PYRO-HWD SCANNER ASSEMBLY

PYRO-HWD SCANNER ASSEMBLY

Figure 1-1. Hot Wheel Detector Sub-System Baseline Equipment Groups

Progress Rail Services

Figure 1-2, Pyro-HWD Trackside Equipment

Progress Rail Services

List of Materials Supplied

Progress Rail Services

Hot Wheel Detector Sub-System

Progress Rail Services

Micro HBD / HWD System Interconnect Diagram

Section 2 Micro HBD/HWD System Interconnect Diagram

Micro HBD/HWD System Interconnect Diagram..................................................................... 2-1

Progress Rail Services

Hot Wheel Detector Sub-System

Progress Rail Services

Micro HBD/HWD System Interconnect Diagram

Section 2 Micro HBD/HWD System Interconnect Diagram

Figure 2-1, System Interconnect Diagram.

Progress Rail Services

Hot Wheel Detector Sub-System

Progress Rail Services

Section 3 Theory of Operation

Progress Rail Services

Hot Wheel Detector Sub-System

Progress Rail Services

Section 3 Theory of Operation

Figure 3-1, Pyro-HWD Equipment Block Diagram

Progress Rail Services

Hot Wheel Detector Sub-System

Pyro-HWD Scanner Assembly

PYROMETER PREAMPLIFIER CIRCUIT

GRILL ASSEMBLY 365-0006

Figure 3-2, Pyrometer Preamp Circuitry Block Diagram

Progress Rail Services

Figure 3-3, Sensor Assembly Circuit Diagram

Progress Rail Services

Hot Wheel Detector Sub-System

Figure 3-4, Two-Scanner Wheel Scans and Corresponding Heat Profiles

Progress Rail Services

Processing the Hot Wheel Signals

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