® Train Chief II LRCS w/Lightweight OCU (Brake &Throttle Industrial Version) Failure to return the Warranty Registration document (enclosed) to Control Chief within 30 days of purchase will void any warranty responsibilities on behalf of Control Chief Corporation Control Chief Corporation 200 Williams Street Bradford, PA 16701 814-362-6811 * 1-800-233-3016 * 814-368-4133 (fax) www.controlchief.
Control Chief Corporation, a world leader in wireless radio and infrared remote control products has developed and expanded upon this powerful technology. More than three decades of experience in designing, manufacturing and installing state-of-the-art remote communication systems emphasize Control Chief’s mission. Our systems are tailored to virtually any environment or application. Control Chief provides training, technical support, and comprehensive system design to maximize performance.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL TABLE OF CONTENTS CHAPTER 1 INTRODUCTION / SAFETY Introduction Common Acronyms Receiver / Controller Unit (RCU) Installation Kit Lightweight Operator Control Unit (OCU-BTIND) Reference Drawings Safety CHAPTER 2 SPECIFICATIONS General Specifications Lightweight OCU-DBT Specifications RCU Specifications CHAPTER 3 2-1 2-1 2-1 PHYSICAL DESCRIPTION AND INSTALLATION The Lightweight OCU-BTIND OCU-BTIND Control Groups The RCU RCU Mounting Locomotive I
TRAIN CHIEF® II LRCS w/Lightweight OCU CHAPTER 6 OWNER’S MANUAL DETAILED COMPONENT DESCRIPTIONS Lightweight OCU Features IR Registration Process OCU Controls OCU Keypad, Indicators, and Display Battery and Battery Charger Details Typical; Locomotive Pneumatic Interfaces 6-1 6-2 6-2 6-6 6-9 6-10 CHAPTER 7 TROUBLESHOOTING Lightweight OCU Troubleshooting Transmitter Diagnostics SLC 500™ Troubleshooting Control Chief Specific PLC Modules Troubleshooting Communications Faults Electrical and Pneumatic Sys
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 1 INTRODUCTION / SAFETY 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 for Industry (BTIND).
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 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 with the components necessary 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.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 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 OWNER’S 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 three-point 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 OWNER’S MANUAL 2 SPECIFICATIONS ! WARNING: CHANGES OR MODIFICATIONS NOT EXPRESSLY APPROVED BY CONTROL CHIEF® CORPORATION COULD VOID THE USER’S AUTHORITY TO OPERATE THE EQUIPMENT. FCC Part 15 and Industry Canada RSS Notice This device complies with Part 15 of the FCC Rules and Industry Canada licenseexempt RSS standard(s).
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Lightweight OCU Specifications Dimensions 6”(h) x 5”(d) x 10”(w) (15.2cm x 12.7cm x 25.4cm) Weight 3.9 lbs (1.8 Kg) with battery Carrying Method Four point vest-harness, break-away style Environmental Conditioning Weatherproof (IP-65) OCU Diagnostics 2-line 16 character display Switches Push buttons, toggle switches, knobs. Supply Voltage 7.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 3 PHYSICAL DESCRIPTION AND INSTALLATION The Lightweight OCU-BTIND Train Chief® II equipped locomotives are controlled by using one or two Lightweight OCU’s. Each OCU is a small 3.9 lb hand operated device that gives an operator complete throttle and braking control of the locomotive up to 2500 feet away. Control of the locomotive can be passed between two OCU’s when the optional Selective Dual Control feature is installed.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S 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 OWNER’S MANUAL Misc. Locomotive Controls Bell / Horn Reset & Sand Reset & Bail Optional Functions: Headlight or Tilt Extend Figure 3-2: Lightweight OCU-BTIND 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. Return the switch to the OFF position to silence the Bell. 1.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL OCU Operation Controls and Associated Functions Pitch IR Port Power Tilt Time Extend (F1) Status (F4) Figure 3-3: Lightweight OCU-BTIND 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. See page 6-2.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 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 OWNER’S MANUAL 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 OWNER’S MANUAL 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.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S 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 OWNER’S 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 OWNER’S 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 OWNER’S MANUAL 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 OWNER’S MANUAL 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. www.controlchief.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Figure 3-11 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 connections for the specific locomotive functions.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Manual/Remote Transfer Switch Selections and Functions Manual (CAB) Remote OUT IN Ignition Wire IN OUT Throttle Switch IN OUT Head Light IN OUT Reverser IN OUT Function Strobe Comments Strobe active ONLY in remote mode Disables engine start when in remote mode. Disables manual throttle lever in remote mode. Disables manual headlight switch in remote mode. Disables reverser lever in remote mode.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 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: ¾ 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 OWNER’S MANUAL 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 OWNER’S MANUAL Specific Installation Requirements ¾ During the installation you may have to 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.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 4 START UP AND OPERATING PROCEDURES 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. Full-Application Locomotive Stop - The full-application locomotive stop is automatically initiated in certain situations that are deemed non-emergency.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Brake Monitoring In order to monitor brake related component failure, the system monitors the independent brake pressure. If the air pressure does not exceed at least 30 PSI within 3 seconds of a commanded FULL INDEPENDENT brake, then an EMERGENCY STOP condition is activated. To reset this condition, cycle power to the receiver cabinet only.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL ¾ Turn on the Lightweight OCU by pressing the Power-On pushbutton at the lower right hand corner of the unit (see Figure 3-3). At power-on the OCU will perform a Power-OnSelf-Test (POST). When POST has completed successfully the unit is ready to be assigned to a Train Chief® II equipped locomotive. A successful POST is indicated by the flashing OCU indicators and display message (“OCU > LOCO ALIGN IR”).
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 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. Return the toggle to OFF. Note: If the locomotive bell begins to sound it is an indication that the main reservoir is below 75-psi. This could indicate that the isolation valve is in the wrong position.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 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 OWNER’S MANUAL Normal Operation Train Chief® II with Lightweight OCU Brake/Throttle Control Configuration As an operator, you can control movement with an OCU in several different ways.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Starting (Train Handling) ¾ Set Movement Direction (FWD or REV) ¾ RELEASE Automatic Brakes by pulling the toggle switch for 1-2 seconds (if equipped). ¾ RELEASE the locomotive brakes: o Move the Independent Brake selector to RELEASE (rotation toward operator) as shown by all indicators off. ¾ Press RESET (to reset brakes) o Throttle selector must be moved from the HALT position within 3 seconds of pressing the RESET.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Stopping and Changing Directions To stop the train manually using the Independent Brake selector: ¾ Rotate the Throttle selector to IDLE ¾ Rotate the Independent brake selector to apply the required braking power to bring the train to a manually controlled stop. ¾ Once the train is stopped a new direction can be selected using the reverser toggle switch.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Tilt Extend The tilt extend is provided to facilitate operator tasks requiring two hands. To extend the tilt timeout the independent brakes must be applied. ¾ Set the Throttle selector to HALT. ¾ Press the F1 push button on the keypad until the OCU acknowledges the request with a beep then release F1. ¾ The operator has 60 seconds to perform tasks while tilting the OCU.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Transferring from Remote to Manual 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. ¾ Place the brake pipe isolation valve in the MANUAL position.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 5 OPTIONS The following optional features are included in your Train Chief® II system. Special Features Supplied Independent Brake Bail Option The locomotive independent brakes are applied and released automatically by the locomotive brake distribution valve (if equipped), in a manner similar to that which is achieved when braking is controlled manually from the locomotive brake stand.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL OCU Two-Way Operational Messages OCU Status Messages (Solicited) Item OCU Message Description 1 BATT LVL OCU Battery Level Comments E░░░░░░F 2 MAIN RES Main Reservoir Pressure (PSI) XXX PSI 3 BRK PIPE XX PSI Brake Pipe Pressure (PSI) 4 BRKCLDNR XX PSI Brake Cylinder Pressure (PSI) OCU Operational Warning and Alarm Messages (Unsolicited) Item 1 2 3 4 5 6 7 OCU Message Low MR (Low MR Pressure) MAN DOWN OCU-A OCU E-STOP RCU E-STOP REVERSE
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 6 DETAILED EQUIPMENT DESCRIPTIONS Lightweight OCU Features The Train Chief® II LRCS receiver/controller unit and Lightweight OCU operate with the Advanced Universal Transmitter system that allows the assignment of a given OCU to a specific locomotive. The OCU assignment system will allow any OCU to be assigned to any locomotive, with identical controls and configuration.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Anytime the locomotive is returned to manual operation or the OCU power is switched OFF, the stored data will be lost requiring the assignment process to be repeated. The OCU will not lose its assignment data during a “hot battery swap” if the swap is accomplished promptly, within approximately 1 minute. ¾ IR Registration Process: At Receiver Power up: IR Indicating LED illuminated (RED) ¾ Power up Transmitter and wait for POST.
TRAIN CHIEF® II LRCS w/Lightweight OCU • • OWNER’S MANUAL Idle: commands the throttle to idle, removes generator field, but does not apply brakes. The remaining settings 1 – 8 command the same throttle settings as the control cab console settings of the same number. 2. Power Switch: Recessed Push-ON Push-OFF switch controls power to the OCU. Pressing the button applies power to the unit from the battery pack and power bridge. Pressing the button again removes power to the unit.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 7. Independent Brake Selector: Six position selector allows you to apply independent locomotive brakes to achieve the desired stopping power. Selectable positions are: • Release (0 psi): this is the normal operating position when operating in power mode (Throttle positions 1-8). (Note RELEASE selection is indicated when all Independent Brake LEDs are off.) • B1: Applies 1/5 of the available independent brake pressure to the brake cylinders.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 10. Automatic Brake Selector: This 3-position spring centered switch allows you to release or apply train brakes by reducing brake pipe by the following pressures: • Release 0-psi reduction • Minimum 6-8 psi reduction • Light 10 psi reduction • Medium 18 psi reduction • Full 26 psi reduction • The Charge position is used to charge the air brake system. The center switch position (LAP) maintains the last brake setting.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL OCU Keypad, Indicators and Display 11 12 10 9 1 8 2 3 4 6 5 7 Figure 6-3: OCU-BTIND Keypad Indicators 1 INDEPENDENT BRAKE INDICATORS: Displays selected locomotive brake setting. Green LEDs indicate the wearer’s control setting and Red LEDs indicate settings for the companion operator during Selective Dual Control operations.
TRAIN CHIEF® II LRCS w/Lightweight OCU 4 OWNER’S MANUAL LOW BATTERY INDICATOR: Blinking – Battery Low. This is an indication that OCU operational time is limited. The battery pack should be replaced with a freshly charged pack. The limited operational time during LOW battery condition will vary based on ambient temperature, battery service time, and usage. Operational run time in the LOW battery condition can range from 15 to 45 minutes. Steady – Battery Dead.
TRAIN CHIEF® II LRCS w/Lightweight OCU 9 OWNER’S MANUAL 2-LINE x 8-CHARACTER DISPLAY: LED Dot Matrix displays system status messages. Two intensity levels depending on ambient light sensor.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Battery and Battery Charger Details Battery Pack: The power source for the Lightweight OCU is a rechargeable 7.4 V Lithium-Ion battery pack specifically designed for the Lightweight OCU. The battery pack is designed to provide 12hours of continuous operation. The battery pack contains an internal capacity monitor. This monitor will be interrogated to report to the operator the remaining run time of the pack.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Typical Locomotive Pneumatic Interface 3 2>(5 $//(1 %5$'/(@ Figure 6-6 95-00-0-xxx Rev 000 6-10 Control Chief Corporation
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 7 TROUBLESHOOTING Lightweight OCU Troubleshooting General The following troubleshooting procedure is provided to assist in the identification of specific problems and/or abnormal operation. Control Chief recommends that you contact us before attempting any field repairs. Power-On-Self-Test If errors are detected during POST (Power-On-Self-Test) the display will show an error message and further operation will be inhibited.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL OCU Diagnostics The Lightweight OCU transmitter has a complete set of built-in diagnostic tests, to verify the functionality of all switches and levers. The tests are available by accessing the transmitter’s diagnostic mode and making a specific test selection using the function switches. CAUTION: Before performing any transmitter diagnostic test, transfer the locomotive to manual.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL The Switch Diagnostic Test If during the course of operations certain switch functions appear to be non-responsive or intermittent, use the transmitter diagnostic switch test for switch troubleshooting. The switch test provides a method to test transmitter switches without actually operating the locomotive. Press F1 and F4 simultaneously to enter the diagnostic switch test.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL KEYPAD Function Softkeys F1 F2 F3 F4 Display 08 04 02 01 Throttle Selector HALT IDLE 1 2 3 4 5 6 7 8 Display T0 T1 T2 T3 T4 T5 T6 T7 T8 T9 Front Right Switch Group RH RESET RH FRONT PB REVERSER – NEUTRAL REVERSER – FWD REVERSER – REV EMERG DEPRESSED EMERG PULLED OUT Display 40 20 00 04 08 00 03 Tilt Indicator Display (Upright) (Tilted) t T If the E-Stop switch is pushed in, the audible alarm will beep fast.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL SLC 500™ Troubleshooting This section provides a basic troubleshooting guide for the SLC 500™ power supply and processor modules. Please review the tables below for the fault condition your system is exhibiting. Additional SLC 500™ troubleshooting information is available in the Allen-Bradley publication 1746-6.2.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL SLC 500™ Error Conditions and Actions - Power Supply Source Power Supply POWER OFF Processor RUN OFF CPU FLT ON Error Cause Inadequate System Power Improper Line Power Voltage Selection Actions Verify proper input power supply voltage. SLC 500™ Error Conditions and Actions - Processor Not in RUN Mode Power Supply POWER ON ON ON Processor RUN OFF OFF OFF CPU FLT Error Cause 1. Verify selected processor mode.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL SLC 500™ Error Conditions and Actions - CPU Major Fault Power Supply Processor POWER RUN CPU FLT ON OFF ON ON OFF FL OFF= No Illumination Error CPU Fault CPU Major Fault Cause Actions CPU Memory Error Cycle power. If problem reoccurs, contact factory. Hardware / Software Major Error Detected (Erratic repetitive power cycling can cause a processor major hardware fault) ON=Continuous Illumination Cycle power.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL High Current Relay Module w/Watchdog LED Indicators Indicators Error Cause Action OFF Normal Operation Enable command has not been issued Send HORN command from OCU. ON ON Normal Operation Enable is commanded, watchdogs are satisfied, both outputs ON. Continue operation. OFF ON Slot Select Fault Possible watchdog “0” fault. Replace Watchdog module. Select pulse is not functioning or possibly a problem on the module.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Troubleshooting Communications Faults First rule of troubleshooting communication problems – check the antenna. Most communication problems are caused by a missing or damaged antenna, or damaged coaxial cable. If communication performance has degraded, always check to ensure the antenna is attached and the antenna coaxial cable has not been damaged.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Electrical and Pneumatic System Troubleshooting Refer to reference drawing E-XXXX-03-1 for component location and part numbers. (E-XXXX is your system number) WARNING: Before attempting to service any pneumatic components, insure 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 OWNER’S MANUAL Main Reservoir If main air supply goes low (below 75-psi) the low main air AMBER light will illuminate on the receiver / controller cabinet. To clear this alarm condition the main reservoir must be restored to 105-psi. Once the main reservoir is at 105-psi or greater the system can be reset. Main air reservoir pressure can be verified on the PLC module in slot #1, input #0 (I; 1.0).
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 8 PRODUCT SUPPORT, SPARE PARTS, AND ACCESSORIES Product Support When contacting Control Chief Product Service please have the following information ready ¾ ¾ ¾ System Number.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Recommended Spare Parts Part Description Part Number Ref Figure 30-00-0-018 6-2 50-20-0-009 50-20-0-008 90-20-0-017 90-20-0-019 9-1 9-1 3-8 3-8 Lightweight OCU Rotary Knob (see NOTE 1) Receiver / Controller Unit Replacement kit for Particulate Filter Element Replacement kit Coalescing Filter Element Control Chief Watchdog Module Control Chief 10 Amp Relay Module (see NOTE 2) NOTE 1: The only readily replaceable parts on the OCU are the Independ
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL 9 DETAILED MAINTENANCE PROCEDURE Locomotive Antenna System To insure optimum system performance the locomotive antenna system should be inspected on a daily basis. This inspection would simply consist of a visual inspection of the antenna and the external cable. The visual inspection of the antenna would be to check the antenna is in place and not damaged. (The antenna should not be deformed.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Filter bowls are fitted with automatic drains to drain accumulated liquids to minimize maintenance and insure optimum performance. Filter Installation and Maintenance Flush piping before installation. To maintain maximum efficiency of the filter and to avoid excessive pressure drop the filter must be kept clean. Removal (of filter assembly) from operation is not necessary to clean the filter. Disassembly is simple and can be performed inline.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL Control Chief Recommended Operator Training Outline Purpose The purpose of this outline is to provide a guideline to help ensure operators are provided with a working knowledge of the remote control system. This guideline is not intended to qualify anyone as a certified operator and should be adapted to meet the needs of the customer and to cover applicable system options.
TRAIN CHIEF® II LRCS w/Lightweight OCU OWNER’S MANUAL ¾ Receiver: Explain the operator accessible features of the receiver and associated devices. This should include: 1. Overview of Receiver: Provide an overview of the receiver cabinet with a brief description of the electronic and pneumatic components, filter pack, diverter valves and transfer switch. 2. Alarms: Explain the purpose of any cabinet mounted alarms, including low air pressure, high temperature, low oil pressure and others, as applicable. 3.
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Installation Questions? Technical assistance is available from Control Chief. Please call us at 814-362-6811 or email the Service Department at prodserv@controlchief.com Control Chief Corporation 200 Williams Street PO Box 141 Bradford, PA 16701 814-362-6811 * 1-800-233-3016 * 814-368-4133 (fax) www.controlchief.
