Automated Single Car Test Device Gen III User s Guide

Transcription

1 Automated Single Car Test Device Gen III User s Guide Home Introduction > Introduction Setup Specifications Parts List > View Parts List Parts and Accessories Daily Test > Daily Test Setup Troubleshooting s > Daily Test s Single Car Test s Test Sequence > 4 Port Test Sequence End of Car Test Sequence About SiteMap Page 1 of 23

2 Introduction The Wabtec Automated Single Car Test Device (ASCTD) Gen III was designed to perform freight car brake air tests in accordance with AAR Specification S It is capable of performing single car tests through the end of car hose or through Wabtec s 4-port receiver and provides a record of the test results. The purpose of this manual is to describe appropriate procedures for setting up the Wabtec Automated Single Car Test Device (ASCTD). It is important the operator observe all AAR requirements for air brake testing on a freight car. For this reason, copies of all applicable AAR standards should readily available to the operator at time of testing. Important: It is the responsibility of those receiving these instructions to ensure they are followed scrupulously during the operation of the Automated Single Car Test Device (ASCTD). The individuals receiving these instructions are responsible for properly informing other designated operators of the intended purpose of this device. Page 2 of 23

3 Setup General The Wabtec Automated Single Car Test Device (ASCTD) Gen III was developed to comply with AAR Specification S It is capable of performing single car tests through the end of car hose or through Wabtec s 4-port connector. Setup A. Unpack tester and verify that you have received Items #1 6. B. Install appropriate fitting to supply air inlet (⅜ NPT Connection) (9). C. Connect 110 Volt GFCI power supply to AC inlet (13). Allow battery to charge for 24 hours before first use. D. Connect keyboard (2) to keyboard cable connection on test device (11). E. Blow out air supply line and connect to fitting installed at supply inlet (9). Supply air pressure must not fall below 100 psi. F. Press ON button and hold for 3 seconds. Wait approximately 2 minutes for system to initialize and screen to display time and date. Confirm AC battery light (18) on tester is illuminated. G. Verify date and time screen. Push YES to accept and NO to change. H. The main menu will appear. Before performing single car testing, a successful daily test must be completed. (See Daily Test page) J. Once you have successfully passed a daily test press YES. The tester will reboot, returning to the time and date screen. K. Your Wabtec Automated Single Car Test Device is now ready to perform freight car air brake testing Select 1, Single Car Test from Main Menu. Select 1 for Access Plate/Receiver Test or Select 2 for End of Car Test. Follow on-screen prompts. Note: Some applications require a password. All new testers are shipped with the password set as WABCO. recommends training before running the single car test. Wabtec Page 3 of 23

4 Specifications Compliance Complies with AAR S Electrical Unit can be operated from 3 power sources. The power sources are internal battery, 110V AC line power (GFCI protected) or 12VDC vehicle system. A unit connected to ac power will not charge back into a vehicle system. Internal Battery The internal battery will power the unit for up to 4 hours under normal use conditions. For low temperature operations less than 32 F (0 C) battery life is reduced substantially due to the draw from internal heaters. 110VAC AC power source must be GFCI protected Units are designed for 110VAC operation. 12 VDC Power Supply Unit can be operated and charged from a 12 VDC power supply such as a vehicle system. The ASCTD unit has an automatic low voltage shut down at 10.5 volts. Therefore a unit left on while the vehicle is turned off will not drain the vehicle system completely but it is recommended that an additional deep cycle battery be installed with a battery isolator to keep from draining vehicle battery if unit is left on for an extended period of time. Auxiliary power port- this port is supplied directly from the battery and protected by a 7.5 Amp fuse under the main cover. Continuous draw from this port must be limited to less than 2 amps or battery power will drop resulting in an automatic power shutdown. Accessories run from this power port must be disconnected when the unit is not in use. Otherwise battery damage may occur if battery voltage drops below 10.5 V Supply Air The recommended minimum supply air pressure is 100 psi. Maximum supply air pressure should not exceed 120 psi. An internal pressure relief valve will release supply pressure if it exceeds approximately 140 psi. Regulator Regulator adjustments should only be made when necessary. Check for supply problems before adjusting. The regulator cannot compensate for low supply pressure. Page 4 of 23

5 Air Filtration The test device comes equipped with particulate (replacement element Parker P/N PS701P) and coalescing (replacement element Parker P/N PS724P) filters located on the left side of the tester. The particulate filter is located toward the front and the coalescing filter is located toward the rear. NOTE: The automatic drain valve on the coalescing filter is equipped with a drain cock that is to be left open for normal operation and closed manually for cold temperatures below 32 F. AC Line 115VAC 60 Hz 1.0Amp Internal Battery Type Dry cell Size 7 1/4 x 3 x 6 5/8 Voltage 12vdc Capacity 17AH 15A blade fuse type DC Power 12VDC nominal 2amp typical draw 10A Internal Resettable Fuse Protection Environnemental Operating temperature range of -10 F to +130 F (-23 C to +54 C). Page 5 of 23

6 Parts List Parts List: 6 1. ASCTD Gen III 2. Keyboard 3. 4 Port Access Hoses Brake Cylinder Hose with Fittings 5. Glad-hand Adapter 6. Dummy Coupling 7. 12V Power Connection 8. Hose Manifold 9. Cover Plate 10. Supply Air Inlet 11. Regulator Adjustment 12. Keyboard Cable Connections VAC Power Connection 14. USB/Data/Printer Ports 15. Cart (optional) 16. Brake Cylinder Hose/Hose Reel (optional) 17. ON and OFF Switch 18. Indicator Lights 19. Downstream/Brake Cylinder Pressure Tap 20. Auxiliary 12V Power Port 21. Particulate Filter (Manual Drain) 22. Coalescing Filter (Autodrain Manual Override) 23. Drain Cock (leave open for normal operation and close for cold temperature operation) 24. Truck Mounting Rails Kit Page 6 of 23

7 Parts and Accessories Replacement Parts: 2 Keyboard P/N Port Access Hoses 20 P/N Brake Cylinder Hose with Fittings P/N Glad-Hand Adapter with Dummy Coupling P/N Dummy Coupling P/N Daily Test Fitting Adapter P/N Not Shown Particulate Filter Replacement Element P/N Not Shown Coalescing Filter Replacement Element P/N Not Shown 10 Amp Fuse P/N Not Shown 7.5 Amp Fuse P/N Not Shown Double Gasket P/N Not Shown Double Gasket P/N Not Shown O-ring P/N Not Shown Battery P/N Not Shown Quick Disconnect Coupling P/N Options and Accessories: Cart P/N Truck Mounting Rails Kit P/N Brake Cylinder Hose/Hose Reel P/N Brake Cylinder Tubing with Fittings P/N V Power Harness P/N Keyboard Extension Cable P/N End of Car Hose P/N End of Car Hose P/N Page 7 of 23

8 Daily Test Setup Perform daily test to ensure test car does not fail as a result of a faulty test device. Before attaching supply air to test device, blow supply line clear of moisture and foreign particles. 1. Attach the Access Plate/Interface Connector Hose Assembly to the front of the test device. 2. Attached the Glad Hand Adapter with Dummy Coupling to the Access Plate/ Interface Connector Hose Assembly. 3. Connect the Daily Test Adapter Fitting to the Downstream Transducer on the front of the Test Device. 4. Connect the female fitting of the Brake Cylinder Hose to the Daily Test Adapter Fitting. 5. Connect the male fitting of the Brake Cylinder Hose to the female fitting on the Glad Hand Adapter. 6. Select 4, Daily Test from the Main Menu on the test device. Press YES to confirm daily test. Follow on-screen prompts. Downstream Pressure Transducer Brake Cylinder Hose Glad Hand Adapter with Dummy Connector Access Plate/Interface Connector Hose Assembly Page 8 of 23

9 Troubleshooting Before suspecting there is a problem with the test device: Ensure all steps have been followed as described in the set up procedure. Ensure air supply matches the requirements as stated in Item E. Ensure all connections are secure. Battery is sufficiently charged per Item C. Problem: Unit indicates low air supply, unable to test. Possible correction: Air supply must be maintained at 110 psi. Problem: Display on keyboard doesn't work. Possible correction: Wait approximately two minutes for display to appear or disconnect keyboard cable at unit and reconnect ensuring positive connection. Page 9 of 23

10 DAILY TEST ERROR CODES Indication 100 Quit key pressed. 50 ASCT hardware issue, system check failed. 37 Audible warning defective. 24 Interface pistons sticking or control line issue. 25 Interface pistons sticking. 1 Pressure transducer zero out of range. Check Calibration or pressure transducers. 2 Flow sensor zero out of range. Check calibration or flow sensor. 3 Regulator adjustment low or malfunction, pressure transducer calibration or malfunction, supply pressure or leakage issue. 4 Regulator adjustment high or malfunction, pressure transducer calibration or malfunction. 5 BP pressure rising over regulated level. Check regulator or supply leakage into brake pipe. 6 Leakage from BP line. Reservoir lines not increasing. Check interface connector and hose for external leakage. 7 Flow sensor span out of range. Flow sensor calibration or malfunctioning. 8 BC pressure rising from regulated setting. 9 Auxiliary leakage, decreasing. 10 Leakage detected into reservoir or cylinder lines. BP and Interface connector lines pressurized. Probable internal interface connector leakage. Possible B1, B2, BCC valve leakage. 11 BC rising. Check Interface connector leakage. 12 Emergency leakage, decreasing. 13 Pressure transducer zero issue. Check hardware and calibration. 15 BC leakage, decreasing. 18 Unable to drain brake pipe or brake cylinder. 19 Leakage from AUX to BP. 20 Leakage from EM to BP. 21 BP rising from zero. Possible interface connector leakage. 22 Unable to drain brake pipe during CBP test. 23 CBP valve leakage when closed. 38 Unable to charge BP to regulated pressure. Calibration, or supply problem. 39 Unable to charge BC to regulated pressure. Calibration, or supply problem. Indication 40 Pressure transducer zero out of range. Check calibration or transducer. 43 Aux decreasing. Possible interface connector. 44 EM decreasing. Possible interface connector. 45 Transducer voltage out of range. Check calibration. 46 Flow transducer output voltages out of range. Check calibration. 47 Transducer voltage out of range. Check calibration. 51 ASCT hardware fault. 26 Unable to reach regulated pressure. Check supply or regulator problem. 27 Unable to reach regulated pressure. Check supply or regulator problem. 28 Check supply or regulator. Unable to reach regulated pressure. Check supply or regulator problem. 29 Unable to reach regulated pressure. Check supply or regulator problem. 30 Unable to drain pressure. 31 Unable to control pressure. Check supply. 32 Unable to reach regulated pressure. Check supply or regulator problem. 33 Unable to reach regulated pressure. Check supply or regulator problem. 34 Unable to drain pressure. 35 Unable to drain pressure. 36 Open Valve cannot drop to set pressure. Possible matrix valve. 41 Unable to drain pressure. 48 Valve driver error. Possible matrix valve. 49 Open Valve cannot rise to set pressure. Possible matrix valve. Page 10 of 23

11 ERROR CODES [T5] No. General Inspection Message General inspection failed. [T7] Connect The Test Device To The Car Aborted. [T9] Flow Through Excessive BP buildup Failed flow through Unable to drain BP Excessive restriction detected BP line restricted. Insure that angle cocks open. [T11] Draining Reservoirs and BC Unable to vent system. Check transducer calibration Trans zero voltage fault Transducer zero failed. [T12] Charge BP to 20 PSI AUX reservoir charging too quickly. Probable defective service portion Unable to charge brake pipe to 20 psi Excessive retainer blow AUX not charging properly Emergency not charging properly Excessive system leakage or low supply. [T13] Retainer Test Defective retainer. Unable to exhaust brake cylinder pressure Unable build brake pipe to set brake for retainer test. BP< Excessive retainer blow Unable to charge BC to 30 psi. Probable excessive BC/retainer leakage Retainer/brake cylinder leakage. Apply valve to determine which Unable to drain BC to 16 psi Probable defective emergency portion Probable defective service portion Defective retainer or brake cylinder leakage Unable to set brake for retainer test. BC <17 psi [T14] [T15] No. Message Hand Brake Inspection Hand brake system must pass inspection. System Leakage Unable to charge BP to 90 psi Excessive system leakage Excessive system leakage Flow meter faulty or calibration incorrect Faulty flow meter or flow valve Regulator pressure incorrect Unable to recharge the car Unable to recharge the car Unable to charge BP to 95 psi Excessive BP line leakage detected BP line leakage detected Excessive system leakage detected System leakage detected Flow reading not valid. Check supply and rerun test. [T16] B-1 AAV Test Probable defective service portion Probable defective vent valve or emergency valve No-B1 activity detected. Probable defective B1 valve Unable to recharge BP to 92 psi. Check supply pressure Unable to recharge BP to 92 psi. Check supply pressure Unable to exhaust BP Emergency application detected. Probable defective vent valve Emergency application detected. Check that BPCC closed. [T17] VV Stability Test / 30 Psi Reduction (no VV) Unable to exhaust BP. Possible defective service portion Possibly defective emergency portion. Check that BPCC is open Likely EMERG. Portion AAV not shutting down. Check vent valve exhaust for flow Drop in emergency detected, first check service and emergency portions. Check separation plate in reservoir last Failed system no-go test. Page 11 of 23

12 No. Message Control valve stability test failure, emergency valve defective Unable to drop BP Unable to exhaust BP Venting too quickly for VV test Defective vent valve Check vent exhaust for flow Unable to exhaust BP. Possible defective service portion Check VV plug Check that VV plug is properly plugged and bleed stem pulled if equipped Unable to exhaust BP. Possible defective service portion Defective emergency portion Likely emergency portion AAV not shutting down. Check vent exhaust for flow. [T18] Check Piston Travel Adjust piston travel Slack adjuster needs attention Adjust piston travel or slack adjuster. [T20] Check Rigging Drain system and repair brake rigging Rigging system not ok Low BC pressure on full service likely BC leakage, bad service portion, or branch pipe cut-out cock not opened. [T22] Drain BP to 0 PSI Unable to vent BP. Possible defective service portion. [T23] Manual Release Test Defective service portion Defective service portion Defective service portion Defective service portion Defective brake cylinder or rigging Defective service portion. [T26] Vent Valve Test Setup Defective emergency portion or BPCC opened too fast Can t charge BP to 60 psi Can t drain BP. No. Message Probable defective service portion. [T27] Vent Valve Test Defective vent valve Probable defective service portion Defective vent valve Defective vent valve. [T28] Remove Dummies/Close BPCC Warning dangerous condition. Test aborted. [T29] Minimum Application Test Defective service portion Unable to charge BP Unable to charge BP to 95 psi Probable defective service portion Unintended release on min application. Possible defective service or emergency Leakage detected on min application Excessive BC leakage or unintended release Excessive BC increase detected Applied leakage diagnostic for BC increasing. No increase after full service Applied leakage diagnostic for BC increasing. Increase continues after full service Applied leakage diagnostic for BC increasing. Increase continues after full service Possible defective service portion. [T30] Applied Leakage Test Excessive auxiliary reservoir leakage Excessive BC pressure. Probable defective service or emergency portion Excessive applied leakage Brake cylinder leakage Unable to charge BC to 20 psi Regulator needs adjustment. [T31] AAV Test Defective emergency portion Unable to drop BP by 5 psi Run choke calibration test Unable to charge BC to 60 psi. Page 12 of 23

13 [T32] No. Limiting Valve Test Message Defective service portion Unable to drop BC < 2 psi. [T33] Service Release Test Release failure, suspect service portion Unable to charge BC to 20 psi. [T34] Service Stability Test Stability test failure. Defective emergency portion Defective emergency portion. AAV runs on Probable defective service, possible emergency Unable to drop BP 25 psi Unable to drain BP. [T35] Emergency Test Defective emergency portion BP must be > 40 psi for emergency test Probable defective emergency portion Unable to drop BP Unable to exhaust BC Probable defective emergency portion. [T36] High Pressure Movement Test Defective emergency portion Probable defective service portion. [T37] Leakage Into BP Test Emergency pressure not higher than full service Probable defective service, possible emergency. [T38] Emergency Accelerated Release Test Defective emergency portion Unable to charge BP to 28 psi Slack adjuster needs attention. [T39] Receiver Check Valve Leakage Test Leakage into test device. Check receiver check valves or run daily test Leakage into test device. Check receiver check valves or run daily test Unable to charge BP to 60 psi Unable to drain BP to 60 psi. No. Message Unable to drain BP to 50 psi Unable to charge BC to 57 psi Unable to drain the tester. [T40] Disconnect Procedure Defective receiver. [T41] Flow Through Diagnostics Likely blockage in brake pipe between branch pipe and restricted side Blockage between pipe bracket & BP tee Check tester supply pressure or tester requires maintenance Unable to drain BP and BC to 2 psi Test device requires maintenance. [T42] Unable To Charge Brake Pipe To 20 Psi Hold BP at 20 psi to find excessive brake pipe leakage. [T43] Excessive Retainer Blow Probable defective emergency portion Probable defective service portion. [T44] AUX Not Charging Properly Defective service portion Probable defective service portion AX RES piping leak or service portion gasket. Soap to determine. [T45] Emergency Not Charging Properly Probable defective service portion Probable defective service portion EM RES piping leak or service portion gasket. Soap to determine. [T46] Excessive Retainer Blow Probable defective emergency portion Probable defective service portion. [T47] Unable To Charge BC To 30 Psi Hold BC at 30 psi and soap BC to find leaks. [T48] Retainer/Brake Cylinder Leakage Maintain BC at 15 psi to soap retainer, BC and related piping for leakage BC pipe/cylinder/service portion leakage. Maintain BC at 15 psi to find leak Hold BC at 15 psi to soap retainer Page 13 of 23

14 No. Message and related piping to find leak Unable to charge BP to 90 psi Regulator pressure incorrect Unable to charge BP to 95 psi Unable to drop BP 3 psi to apply valve. [T49] Excessive System Leakage Car must pass leakage test Car must pass leakage test. [T50] Excessive System Leakage Car must pass leakage test. Heavy system leakage above range of flow meter Car must pass leakage test. Light system leakage. Over 225 limit. [T51] Failed System No-Go Test Diagnostics aborted! Check air supply Diagnostics aborted! Check air supply Defective emergency portion Probable defective vent valve. Possibly incorrect BP length Unable to drain BP Unable to drop BP 25 psi. [T52] Check Piston Travel Slack adjuster needs attention. [T53] Manual Release Diagnostics Defective service portion Defective service portion Defective brake cylinder or rigging Defective service portion. [T54] Applied Leakage Test In Progress Defective branch pipe cut-out cock Defective service portion Defective emergency portion Probable defective BPCC. Possible BP leakage at control valve BP was not charged sufficient for release Unable to drop BP by 5 psi. [T55] Brake Cylinder Leakage Soap BC and all associated BC piping to find leak Defective emergency portion Defective service portion. No. Message Unable to drop BP to 50 psi. [T56] Check Piston Travel Slack adjuster needs attention Adjust piston travel and re-test car Unable to charge BP to 70 psi Unable to charge system to 80 psi Unable to exhaust BC Unable to drop BP to 70 psi Unable to charge BC to 67 psi. [T57] Empty/Load Test Unable to charge the system Unable to charge BP Unable to drain BP E/l device defective or leakage E/l device defective or leakage E/l soap detected leakage Unable to drain BP Unable to recharge the car Unable to recharge the car Unable to vent BP. To recharge BP to 92 psi. Check supply pressure Unable to drain BP BC detected. Manual release failed. Defective service portion Manual release reset fail Bad BC pressure tap E/L device defective leakage or manual release portion defective E/L device defective or leakage E/L soap detected leakage UDE occurred on E/L [T58] Apply and Release Test Probable defective emergency portion Unable to charge BP. [T61] Charging Up System Unable to release brake. Possible bad service portion or tester Unable to release brake. Possible bad service portion or tester Can t maintain 70 psi. Possible supply or system leakage problem. Check supply or run SCT test. [T62] Setting Up For Alternate 4 Hour Test Unable to drain BP to 2 psi. Possible Page 14 of 23

15 No. Message calibration or exhaust valve problem. Failed because of excessive BC leakage (BC < 30 psi) hour test failed Leakage into BP Unexpected emergency application or excessive BP leakage. Test aborted. [T63] Receiver Check Valve Leakage Test Leakage into test device. Check receiver check valves or run daily test Leakage into test device. Check receiver check valves or run daily test Unable to charge BP to 60 psi Unable to drain BP to 60 psi Unable to drain BP to 50 psi Unable to charge BC to 57 psi Unable to drain the tester. [T64] Disconnect Procedure Defective receiver. [T66] Charging Up System Unable to release brake. Possible bad service portion or tester Unable to release brake. Possible bad service portion or tester Can't maintain 70 psi. Possible supply or system leakage problem. Check supply or run SCT test. [TTX] Miscellaneous (s found under multiple tests) XXX Unable to charge BP. XXX Unable to drop BP. XXX Defective service portion. XXX Probable defective emergency portion. XXX Aborted. XXX Probable defective emergency portion. XXX Possible defective service portion. XXX E/L soap detected leakage. XXX Excessive restriction detected. XXX Excessive system leakage or low supply. XXX Check for supply problem. XXX Check for supply problem. No. Message XXX Check for supply problem. XXX Can t maintain charge pressure. Possible supply or system leakage problem. XXX Can t maintain charge pressure. Possible supply or system leakage problem. XXX Check for supply problem. XXX Check for supply problem. XXX Check for supply problem. XXX Check for supply problem. XXX Check for supply problem. XXX Check for supply problem. XXX Check for supply problem. XXX System leakage failed possible supply pressure problem. XXX System leakage failed possible supply pressure problem. Page 15 of 23

16 4-PORT TEST SEQUENCE Test S4027 S486 Description [T5] General Inspection Walks operator through general car inspections [T7] Connect The Test Device To Connect to car The Car [T9] Train line Flow Through This test starts out with an automated restriction test that will automatically detect restrictions in the branch pipe and cut out cock. It is followed by a manual check for train line restrictions by having operator feel for blow of air from both glad hand. The device limits the air pressure from rising above 6 psi for this test. This allows glad hands to be installed. If the device cannot keep the pressure from building more than 20 psi, the device will stop and issue an error. [T11] Draining Reservoirs and BC Residual air in reservoirs is drained before the test can continue. If the bulk of the air is not drained when initially instructed this step will not be able to drain it all and the test may stop. [T12] Charge BP to 20 PSI This is a charging pretest. Brake pipe pressure is held at 20 psi and the charging rates of AUX and EM reservoirs are evaluated. If the reservoir pressure is not increasing in pressure that usually indicates reservoir piping leakage. If it is building to quickly that usually indicates internal leakage in the control valve. [T13] Retainer Test The retainer test is performed while the car system is charging. With the retainer set the first check detects air blowing into the retainer/brake cylinder line. This usually indicates that a control valve portion is leaking air into the cylinder line at a rate that will fail the system leakage test. If this test passes, the Brake cylinder pressure is built up to between 15 and 20 psi and the retainer/ cylinder leakage is noted as a pressure drop. This could be due to leakage at the retainer, retainer pipe or cylinder piping and packing cup. [T14] Hand Brake Inspection Directs operator to manually inspect and test. [T15] System Leakage 3.6, ,3.4.2 Train line and system leakage is combined. If system leakage fails then the diagnostics will direct operator to close cut out cock to diagnose leakage location. [T16] B-1 AAV Test The device will try to automatically detect the B-1 activity. If it cannot the operator will be directed to check manually. [T17] VV Stability Test / 30 Psi Reduction (no VV) The auxiliary vent valve stability test is performed with the system cut in. A 30 psi reduction is applied with position 5 rate. To diagnose a failure, plug the vent valve and repeat the stability test on the control valve only. Page 16 of 23

17 [T18] Check Piston Travel The device prompts the operator to check the piston travel and note that it is acceptable. The operator can enter the measurement for record purposes. [T20] Check Rigging Directs operator to manually inspect [T22] Drain BP to 0 PSI Sets up the car to test the manual release function and if equipped, the vent valve sensitivity (go) test. If there is a vent valve, the operator is instructed to close cut out cock. This traps air in the train line and vent valve for the stability test that will follow after the manual release check. [T23] Manual Release Test The operator is instructed to pull the release rod and manually check that the cylinder retracted. The device then does a quick evaluation of brake pipe, cylinder and reservoir leakage such would occur if the release rod was stuck open or air was leaking back into brake pipe or if the manual release did not fully lock up. [T26] Vent Valve Test Setup If there is a vent valve, the system is drained to set up for the vent valve sensitivity test. This effectively deactivates the control valve emergency venting so a valid sensitivity test can be performed on the auxiliary vent valve. [T27] Vent Valve Test The operator is instructed to slowly open the cutout cock. The device senses when the cutout cock is open and automatically runs the vent valve sensitivity (go) test on the pre-charged vent valve that was previously isolated. If the brake pipe had dropped below 40 psi due to unusual leakage or an extended time to evaluate the manual operations, the system will reset and attempt to rerun the test. [T28] Remove Dummies/Close BP Cutout Cock Sets up the car to run the control valve tests on the internal device volume [T29] Minimum Application Test The system is recharged to a slightly higher 95 psi and a minimum application is made to check the application sensitivity. The application is held at the 90 psi regulator setting and the brake cylinder is adjusted to the equivalent of a 10 psi brake pipe reduction for the applied leakage test. Page 17 of 23

18 [T30] Applied Leakage Test The applied leakage test is performed over an 80 second period. Therefore, 1.3 psi change in 80 seconds is equivalent to 1 psi change in 60 seconds. In addition to evaluating the brake cylinder leakage, the brake pipe flow is measured along with the AUX and EM pressure drops. [T31] AAV Test The device will try to automatically detect the AAV activity. If it cannot the operator will be directed to check manually. [T32] Limiting Valve Test The limiting valve function in the service portion should maintain a minimum amount of brake cylinder pressure if it is functioning correctly. The device drains brake cylinder pressure while it is in the applied condition and evaluates that the limiting valve can open and resupply the brake cylinder pressure. [T33] Service Release Test The brake cylinder is readjusted for the service slow release test. The brake pipe is built up at the position 2 rate and the release function is evaluated. In addition to meeting the specified release timing, the service release differential pressure is evaluated as well. [T34] Service Stability Test After the system recharges the service stability test is performed. [T35] Emergency Test The device performs the emergency stability test. The device automatically detects that the pressure is 5 psi higher than the full service and quickly goes into a venting routine that limits the pressure so that a 2nd piston travel check can be performed without excessive brake cylinder pressure affecting the travel measurements. [T36] High Pressure Movement Test After the emergency test, the brake cylinder, emergency and auxiliary should equalize. [T37] Leakage Into BP Test The device will measure the leakage into brake pipe after the emergency. Internal leakage in the control valve is usually the indication. [T38] Emergency Accelerated Release Test The device builds up the brake pipe pressure to 28 psi and detects that the brake pipe continues to rise on its own. Page 18 of 23

19 [T57] Empty/Load Test The device will recharge the system and make a brake application to evaluate the empty load equipment if equipped. [T39] Receiver Check Valve Leakage Test A quick check of the check valves in the 4 port receiver will be made before the operator is instructed to disconnect. [T40] Disconnect Procedure Page 19 of 23

20 End Of Car TEST SEQUENCE Test S4027 S486 Description [T5] General Inspection Walks operator through general car inspections [T7] Connect The Test Device To The Car Connect to car [T9] Train line Flow Through A manual check for train line restrictions by having operator feel for blow of air from the opposite glad hand. The device limits the air pressure from rising above 6 psi for this test. This allows glad hands to be installed. If the device cannot keep the pressure from building more than 20 psi, the device will stop and issue an error. [T15] Train line charge and flowrate Leakage from the train line only is evaluated with the cut out cock closed. [T16] B-1 AAV Test The device will try to automatically detect the B-1 activity. If it cannot the operator will be directed to check manually. [T17] VV Stability Test The auxiliary vent valve stability test is performed on the train line only. A 30 psi reduction is applied with position 5 rate. [T27] Vent Valve sensitivity Test The emergency rate is applied and the device notes that vent valve activated as noted by brake pipe pressure venting. [T13] Retainer Test The retainer test is performed while the car system is charging. With the retainer set the device first detects air blowing into the retainer/brake cylinder line. This usually indicates that a control valve portion is leaking air into the cylinder line at a rate that will fail the system leakage test. Next a quick Brake application is made before the system is fully charged. This will build cylinder pressure to between 15 and 20 psi and the retainer/ cylinder leakage is noted as a pressure drop. This could be due to leakage at the retainer, retainer pipe or cylinder piping and packing cup. If the quick application does not build any brake cylinder pressure, an error will be issued. This usually indicates that there is major issue with the system since a brake application cannot be made. [T14] Hand Brake Inspection Directs operator to manually inspect [T15] System Leakage The device evaluates system leakage using the flow sensor. The test will automatically end early if there is excessive leakage. Page 20 of 23

21 [T34] Service Stability Test After the system recharges the service stability test is performed. [T18] Check Piston Travel The device prompts the operator to check the piston travel and note that it is acceptable. The operator can enter the measurement for record purposes. [T20] Check Rigging Directs operator to manually inspect [T35] Emergency Test The device performs the emergency stability test. The device automatically detects that the pressure is 5 psi higher than the full service and quickly goes into a venting routine that limits the pressure so that a 2nd piston travel check can be performed without excessive brake cylinder pressure affecting the travel measurements. [T37] Leakage Into BP Test The device will measure the leakage into brake pipe after the emergency. Internal leakage in the control valve is usually the indication. [T38] Emergency Accelerated Release Test The device builds up the brake pipe pressure to 28 psi and detects that the brake pipe continues to rise on its own. [T29] Minimum Application Test The system is recharged and a position 4 minimum application is made to check the application sensitivity. [T30] Applied Leakage Test The applied leakage test checks for 1 psi change in brake cylinder pressure over 60 seconds. [T33] Service Release Test The brake pipe is built up at the position 2 rate and the release function is evaluated. Meeting the specified release time. [T31] AAV Test The device will try to automatically detect the AAV activity. If it cannot, the operator will be directed to check manually. [T18] Check Piston Travel 2nd The device prompts the operator to recheck the piston travel and note that it is acceptable. The operator can enter the measurement for record purposes. Page 21 of 23

22 [T23] Manual Release Test The operator is instructed to pull the release rod and manually check that the cylinder retracted. The device then does a quick evaluation of brake pipe, and brake cylinder pressure to confirm release. [T57] Empty/Load Test The device will recharge the system and make a brake application to evaluate the empty load equipment if equipped. [T40] Disconnect Procedure Page 22 of 23

23 About Important: It is the responsibility of those receiving these instructions to ensure they are followed scrupulously during the operation of the Automated Single Car Test Device (ASCTD). The individuals receiving these instructions are responsible for properly informing other designated operators of the intended purpose of this device. Disclaimer: The Wabtec Corporation accepts no responsibility for injury or damage to personnel or equipment resulting from either direct or indirect use of this manual. This includes liability for injury or property damage as a result of conditions on or around the car prior to or during car testing and the presence and/or actions of workers or bystanders causing incidental or consequential damages of any kind. Revision: C Copyright 2013 by Wabco Freight Car Products All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher, except in the case of brief quotations embodied in critical reviews and certain other noncommercial uses permitted by copyright law. Page 23 of 23