PO Box 141 Bradford, PA 16701 (814) 362-6811 TRAIN CHIEF® II LOCOMOTIVE REMOTE CONTROL SYSTEM w/LIGHTWEIGHT OCU-BT OPERATOR'S MANUAL Document Number: Revision: Date: 95-00-0-062 08 8/26/05 Issued By: Checked By: Approved By: CWY 95-00-0-062, Rev 09 c-1 Control Chief Corporation
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL Revision History Revision 01 06 Release Date Mar 2005 May 2005 06.1 07 May 11 2005 5/13/05 7.1 08 09 09a 6/10/05 6/17/05 8/26/05 12/27/05 Comments Original Sec 6: added fig 6-1a1,6-1b, 6-1c. Added figs 8-1, 8-2, 8-3 and callouts. Sec 8 replacement parts aligned to figures and Eng’g dwgs SKT00123 & 00124. Modified figures 6-5, 8-3. Added watermark. Revised jpg images w/mushroom E-stop, added LED images Sect 7.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL TABLE OF CONTENTS CHAPTER 1 INTRODUCTION / SAFETY Introduction Common Acronyms Receiver / Controller Unit Installation Kit Lightweight OCU-BT Reference Drawings Safety 1-1 1-1 1-1 1-2 1-2 1-2 1-3 CHAPTER 2 SPECIFICATIONS General Specifications Lightweight OCU-BT Specifications Receiver / Controller Unit Specifications CHAPTER 3 2-1 2-1 2-1 PHYSICAL DESCRIPTION AND INSTALLATION The Lightweight OCU-BT The Receiver / Controller Unit The I
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 1 INTRODUCTION / SAFETY 1.1 Introduction This Owner’s Manual provides operating and troubleshooting information for the installer and end user of the Train Chief® II Locomotive Remote Control System (LRCS) with a Lightweight Operator Control Unit (OCU) Brake & Throttle variant (BT).
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 1.4 The Installation Kit In order to effectively and reliably interface to the locomotive controls / operations, various kitted items are provided to complete the installation. An antenna kit is provided to allow the radio antenna to be mounted on the locomotive cab. Surge suppressors are provided for installation on all inductive devices (i.e. solenoid coils, electrical contactor coils, etc.) to minimize Electro Magnetic Interference (EMI).
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 1.7 Safety The safety guidelines in this manual are not intended to replace any rules or regulations or any applicable local, state, or federal governing laws. The following information is to be used in conjunction with all other rules and/or regulations already in existence. It is important to read all safety information before operating any wireless radio remote control system.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL Strict procedures must be followed to ensure that there can only be one RCT in active control of the RCL at any one time. Prior to performing any function (as prescribed in 49 CFR 218.22.c.5) the RCO should apply threepoint protections; (1) fully apply the locomotive and train brakes, (2) center the reverser, and (3) place the generator field switch to the OFF position. Passenger trains should NOT be operated by use of a remote control device.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 2 SPECIFICATIONS 2.1 General Specifications Frequency Operating Range Temperature Range System Diagnostics System Address Capacity Encoding/Decoding Method Data Security Communication Security Modulation Response Time 2.2 Lightweight OCU Specifications Dimensions Weight Carrying Method Environmental Conditioning OCU Diagnostics Switches Supply Voltage Battery Life RF Power Output Frequency Stability Channel Spacing Antenna Type 2.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL ! WARNING: CHANGES OR MODIFICATIONS NOT EXPRESSLY APPROVED BY CONTROL CHIEF® CORPORATION COULD VOID THE USER’S AUTHORITY TO OPERATE THE EQUIPMENT. RF Exposure Warning! This device uses RF energy for communications and is limited to use in a controlled occupational environment. The device must be used only in a manner as described in this operators manual.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3 PHYSICAL DESCRIPTION AND INSTALLATION 3.1 The Lightweight OCU-BT Train Chief® II equipped locomotives are controlled by using one or two Lightweight OCU’s (Operator Control Unit). Each OCU is a small 3.9 lb hand operated device that gives an operator complete speed and braking control of the locomotive up to approximately ½ mile away.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL Throttle Selector: Ten-position selector represents the throttle position available in the cab. However, one additional feature of the OCU throttle is the HALT function. • HALT: commands the throttle to idle, removes the generator field, and also gradually applies independent brakes. • IDLE: commands throttle to idle and removes generator field but does not apply brakes.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.2.2 Misc. Locomotive Controls Bell / Horn Alert Reset & Sand Reset & Bail Headlight Bright/Dim Figure 3-2: Lightweight OCU Misc. Locomotive Controls (Manual Brake/Throttle model shown) Bell / Horn switch: This is a 3-positon switch. It is latched at the rear (OFF) position and at the center (BELL) position. The forward (HORN) position is spring loaded to return to BELL position when released.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.2.3 OCU Operation Controls and Associated Functions Transfer (Pitch) Power Tilt Time Extend (F1) Status (F4) Figure 3-3: Lightweight OCU-BT Controls Power Button: Push-On / Push-Off switch to apply power to the OCU. Power is supplied from the battery pack and the power bridge. Depending on the charge state of the power bridge, the OCU may activate for a short time without an installed battery.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.2.4 OCU Keypad, Indicators and Display The location of the LEDs, Character-display, and Intensity sensor are shown in the diagram below. All LEDs will illuminate during the power on sequence to allow detection of inoperative LEDs.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.2.6 OCU Harness The harness system is an integral part of the LRCS. With the many situations encountered in rail equipment operations it is imperative the OCU does not constantly occupy an operator’s hands. Control Chief has combined the OCU support harness with a high visibility safety vest to avoid the operating gear and safety gear conflicts that are sometimes present when having to don separate items.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.3 The Receiver / Controller Unit (RCU) The RCU consists of the control electronic and pneumatic components. The electronic components consist of the programmable logic controller (the SLC 500 PLC) with various I/O and specialty modules, the transfer switch and various DC relays. The pneumatic components consist of proportional valves, solenoids valves, pressure switches, and pressure regulator, all mounted on specifically designed manifolds.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL Programmable Logic Controller - SLC 500 System The SLC 500 is the control center for the Train Chief® II system. The SLC 500 incorporates the necessary I/O modules to control the various locomotive interfaces based on a ladder logic program, specifically, developed for locomotive remote control and tuned for your particular application.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL INPUT MODULE(S) The input module(s) provide a means to monitor critical functional states of the locomotive system. Typical system parameters monitored are the manual throttle, manual reverser, external E-Stop switches, pressure switches, and wheel slip. The module features input filtering, optical isolation, and built-in surge protection. All input modules provide LED indicators for each input point.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL WATCHDOG SYSTEM Remote control systems based on the SLC 500 controller with the Communicator® module will utilize a multiple feature watchdog safety system. The first watchdog circuit is built into the wireless Communicator® module and monitors the operation of the module CPU. Should this watchdog time out, then an automatic interrupt is generated which faults the SLC 500 CPU and clears all SLC output tables.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.3.2 Pneumatic Components The following pneumatic components comprise the pneumatic control and interface for the Train Chief® II system and are included in the RCU, mounted on the specifically designed enclosure back plate. PROPORTIONAL VALVES AND MANIFOLD Manifolds have been specifically designed to integrate the brake pneumatic components.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.4 The Installation Kit Each system is shipped with an installation kit which includes various materials required for the integration of the receiver / controller unit into the locomotive systems. The types of standard materials provided included: o Power Supply Input Filter and Surge Suppressor. The DC locomotive power is conditioned by an input filter and surge suppressor.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.5 Receiver / Controller Unit Mounting The RCU should be securely mounted inside the locomotive cab. The mounting location should allow for reasonable access for both the electrical and pneumatic interfaces, but also be picked to avoid interference with normal locomotive cab operations.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.6 Locomotive Interface Introduction The connection of the RCU to the locomotive is achieved through both electrical and pneumatic (air) interfaces. All locomotive interface connections are located on the bottom of the RCU. The RCU manages all necessary conversions for the specific locomotive functions.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.6.3 Dedicated Locomotive Hook-Ups Locomotive connections to the locomotive interface panel are accomplished through the bottom of the panel via dedicated locomotive hookups. These hookups consist of connector sockets based on system options to facilitate ease of installation. ¾ The pneumatic connections are located on the bottom left of the panel, and include quick connect ports for main air, locomotive brake, train brake, and bail.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.7 General Installation Practices WARNING: Before attempting to service any pneumatic components, ensure the air system has been vented to atmosphere (zero pressure in air lines). CAUTION: Contaminants in the air system can significantly reduce the component life and performance of the remote control pneumatics.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 3.7.2 Specific Installation Requirements ¾ During the installation you may have mark-up prints. Upon completion of the installation forward these prints to Control Chief Corporation Application Engineering so the mark-ups can be incorporated in our drawings and an updated copy provided. ¾ Locomotive Antenna Installation. Included with the locomotive antenna kit are detailed installation procedures (P/N 94-85-0-006).
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL ¾ J-1 Valve and Shuttles Valves. The J-1 valve must be installed with the correct orientation, as per the manufacturer. All brake shuttle valves must be installed with the mounting feet pointing up.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4 START UP AND OPERATING PROCEDURES 4.1 Locomotive Stops The locomotive remote control system can automatically initiate either of two (2) types of locomotive stops, depending on the specific situation. The two locomotive stops are defined below and are referenced in subsequent operational descriptions.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.2 Setup and Remote Control Operation 4.2.1 Initial Locomotive Setup It is essential for safe and efficient remote control operations that the locomotive is in proper working order in manual mode. Verify that all brake pipe hoses are connected and cutout valves are OPEN. Verify the transfer switch on RCU is in the MANUAL position. This switch is located on the left hand side of the unit.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.2.2 OCU Mode > > Locomotive Setup (Train Chief® II) HMI screen views are for example only. Note 1: Note 2: This screen is only available on systems configured with the Selective Dual Control feature. If your system does not have this feature, skip to section 4.2.3 OCU Assignment Procedure – Locomotive Setup. • The RCU is equipped with a Human Machine Interface (HMI) display panel.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.2.3 OCU Assignment Procedure – Locomotive Setup (Train Chief® II) F2 XM TR TO LOCO ASSI GM EN T OCU MODE >> LOCO SETUP BRAKE & M AI N RES. PRESSURES OCU ASSIGNMENT TROUBLESH OOTI N G OCU >> LOCO ASSMT STORED ERRORS 1-5 • Select the “OCU >> LOCO ASSIGNMENT” screen using the ENTER button.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.2.4 OCU Setup All switches and levers should be in their OFF positions. Set INDEPENDENT BRAKE Selector to fifth position for FULL service brake application Check AUTO BRAKE toggle in center position Place HORN/BELL switch in OFF position (toward operator) Place Reverser switch in NEUTRAL position. Throttle selector in HALT position. E-Stop pulled out. OCU not tilted. Note: The operator should be wearing the break-away vest by this time.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.2.5 OCU Assignment Procedure – Register OCU with Locomotive • The “COMMAND/STATUS” screen is used to initiate the assignment process. o Before initiating, align the IR ports of the OCU and receiver so they can see each other. The OCU should be held between 6” to 18” from the RCU. • Push “F1” button to start the assignment process. • During the data exchange, information will be displayed in the HMI “Status” field.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL configuration to be assigned. (The HMI display will provide a message to identify the nature of the error; “Invalid OCU Config” for example.) • The assignment process is complete when the OCU sounds a one (1) second beep and the HMI “Status” field displays “OK”. The OCU and controller are ready for Remote Control operation.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.3 Transfer to Remote Mode and Resetting Locomotive PCS Fault. To activate the communication link from OCU to locomotive, move the horn toggle to HORN. The locomotive should respond by sounding the locomotive horn. Note: If the locomotive bell begins to sound it is an indication that the main reservoir is below 60-psi. This could indicate that the isolation valve is in the wrong position.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.4 Air Brakes and Safety Features Test According to the FRA Safety Advisory 2001-01 it is recommended that the air brake and safety function of the OCU be tested at the beginning of any remote control activity. The following summary is provided in support of that practice. Locomotive Brake Test. Perform all required standard locomotive and trainline brake tests using the OCU to ensure all remote braking functionality. E-Stop Test.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.5 Normal Operation 4.5.1 Train Chief® II with Lightweight OCU Throttle/Brake Control Configuration As an operator, you can control movement with an OCU in several different ways.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.5.3 Starting (Train Handling) • Set Movement Direction (FWD or REV) • Press RESET (to reset reverser) • RELEASE the locomotive brakes: o Move the Independent Brake selector to RELEASE (rotation toward operator) as shown by all indicators off. o Pull the Auto Brake and hold for at least two (2) seconds to release train brakes (if equipped).
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.5.5 Stopping (using the Independent Brake and Throttle selectors) To stop the train manually using the Independent Brake selector: • Turn the Independent brake selector to apply the required braking power to bring the train to a manually controlled stop.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.5.9 Man Down Alarm When the tilt function has been active for more than 1 minute the locomotive horn will begin to cycle on and off or sound continuously depending on your site operating rules. The alarm will continue to be active until the receiver/controller is reset. If the OCU is returned to its normal operating position before the man down timer expires the alarm will be cleared. 4.5.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.5.12 Operating under winter conditions • During winter conditions, brake components may get covered with snow or ice and braking power may be reduced. Therefore, during these types of conditions, make regular brake applications to keep the braking components working properly. o With the locomotive moving at a speed of no greater than 4 mph (6 ft/sec), apply a small amount of brakes by moving the Independent Brake selector to Low position.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.6 Selective Dual Control 4.6.1 (also known as Pitch & Catch) Introduction Selective dual control enables a team of two operators to selectively control a locomotive during remote control operations, commonly referred to as “Pitch & Catch”. The operator currently in control of a locomotive can simply relinquish control status of the locomotive until the other operator acquires control status.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL d) Locomotive acknowledges the operator’s acquire command by activating the appropriate RED or BLUE strobe to designate which operator is the primary. i) The locomotive will only accept control commands from the primary operator. ii) Priority commands will be accepted by the locomotive from either operator. e) Primary operator commences with remote control tasks.
TRAIN CHIEF® II LRCS W/ Lightweight OCU-BT – OPERATORS MANUAL 4.7 Transferring from Remote to Manual ¾ Turn off the OCU. ¾ Go to the locomotive and place the independent brake handle into the FULL APPLY position and the automatic brake handle to the EMERGENCY position. ¾ Place the transfer switch on the receiver / controller unit in the MANUAL position. ¾ Place the air valve that feeds the receiver / controller unit in the OFF/MANUAL position.
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