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automated single car test device user`s & set user`s & set

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1. 3 CAR EQUIPPED WITH BC PRESSURE TAP Y S _BP _ Az E BC _ Use buttons 1 3 to toggle between YES Y and NO N All answers have YES as the default when the ASCTD is turned on If the ASCTD is not turned off the answers to the previous test become the new defaults After answering questions 1 3 press YES to continue OPTIONS 1 3 TGLE YES END PG 2 1 BC PRESSURE TAP DOWNSTREAM OF E L Y S BP _ Az _ E BC __ Use buttons 1 to toggle between YES Y and NO N All answers have YES as the default when the ASCTD is turned on If the ASCTD is not turned off the answers to the previous test become the new defaults Page 49 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual After answering questions 1 press YES to continue The following screen appears if you selected Yes for car equipped E L Device IS THE EMPTY LOAD DEVICE AN ELX S SLOPE SHEET MOUNTED VALVE YES NO S _BP _ A _ Ez_ BC _ After selecting the appropriate answer the next screen will appear HAS THE GENERAL INSPECTION BEEN SUCCESSFULLY COMPLETED ALREADY YES NO S _BP _ Az _ E BC _ If the General Inspection has already been successfully completed you may press YES to continue NOTE If the general inspection has not been completed the operator will press the NO button The unit will instruct the operator to check all items listed in the preliminary procedures of AAR Standard S 486
2. If Import File is a valid ASCTD Test Results file the message box below will be displayed Importing CAASCTIASCT50 DAT Do you want to continue Lies Figure 10 You have selected an ASCT Results File e Click on Yes to Continue with the import NOTE If the file does not appear to be an ASCT Results file then the following message box will be displayed Click on the OK button to abort the import function ASCT Module Function frmMain Import_Test_File Invalid Import File Figure 11 Invalid Import File Message October 2005 Page 28 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company Start ASCT Result File Import into the database The menu will be disabled while a file is being imported e The status bar at the bottom of the main screen will display a file open AAA A icon with the import file name As the file is imported the status bar will Import File Hame CHASE TABCTOZOO DAT update a bar to indicate relative progress AAA ES e When the import process is complete the Display summary message o box appears Figure 12 Import File Summary Message Box Import Tesi File Arcade imported bom testtile 200 Invalid records ba hera Des Duplicate recsrde found 0 Fecssde rines de Ustia il e Duplicate records are automatically excluded from the database i Duplicate records are the result of not clearing test records from th
3. Setup cannot install system files or update shared files if they are in use Before proceeding we recommend that you close any applications you may be running e This is the second screen of installation procedure You have the option to change the destination directory Default is CAASCT ASCT Setup Begin the installation by clicking the button below Click this button to install ASCT software to the specified destination directory Directory C AASCTS Change Directory October 2005 Page 22 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company e Installation of ASCT application was completed successfully and the above message box appears ASC Sep wae completed succesetulhy 10 0 USING ASCT EXE ASCT EXE is a Windows program using typical Windows procedures to activate features If you are familiar with Windows using the ASCT database program will be very easy e To start ASCT EXE double click on the application icon Figure 1 in the program manager LOS The user must first logon to the application e The installation program automatically installs the icon and a program group for the ASCT EXE program Figure 1 ASCT EXE Application Icon 10 1 ASCT LOGON The logon screen See Figure 2 is the first screen the user sees after starting the ASCT EXE program The User must enter their User ID and password to acces
4. 01 19 01 42 37 2000 01 19 00 37 12 9 2000 01 18 22 13 14 20 2000 01 18 13 59 59 71 15843 11 2000 01 18 11 39 51 71 12427 43 2000 01 18 09 23 05 71 15842 22 2000 01 18 04 40 20 26 2000 01 18 01 17 00 10 2000 01 14 12 05 47 71 14407 21 2000 01 14 10 59 36 71 15842 16 2000 01 14 10 44 14 71 15842 16 2000 01 14 05 56 31 18 2000 01 14 04 20 20 17 2000 01 13 15 56 26 71 15843 7 2000 01 13 13 28 50 71 15842 15 2000 01 13 10 24 54 71 15842 13 2000 01 13 08 38 46 71 15842 12 2000 01 13 03 44 08 39 2000 01 12 14 06 58 71 15843 6 71 14407 71 15846 71 12427 ae lama ee am me em meee e e Passed none ft i 57 4 2000 06 29 19 18 11 Total of records 7 Time in 24 hour Status messages displayed here During file import a progress bar will be displayed here Date in format format hh mm ss yyyy mm dd in the filtered set m 7 y Selected Column Inactive Active Sort Order Icon Inactive Active Last Filter Icon Imported Records Filter Icon Import file name Figure 4 ASCT Main Screen with Progress Bar in cut out Page 25 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 10 3 1 RECORD DETAIL WINDOW e Double clicking on any record in any column in the grid while records are displayed on the grid brings up the Reco
5. 1 1 CONTROL BP 2 2 20 PSI REDUCT 3 3 FULL SERVICE 1 10 MIN BC LEAKAGE TEST 4 EMERGENCY 2 ALTERNATE 4 HR TEST 5 CHARGE BP 3 MANUAL OPERATIONS 6 MIN APP 7 BC PSI 8 S A 9 RETAINER 5 1 SENSOR CALIBRATION 1 1 XDCRS PAGE 1 6 1 CALIBRATION 2 SYSTEM LEAKAGE TEST 2 FLOW 91 P W USER 7 3 CHOKE TESTING 3 SUPPLY 5 REGULATOR 1 SET TIME 2 TIME amp DATE PW USER 2 SET DATE 1 XDCRS 2 FLOW 3 PASSWORDS 1 TESTING 3 SUPPLY P W USER 2 UTILITIES 3 RESERVED 1 SHOW CAL 4 FILE UTILITIES 2 LOAD BACKUP CAL 5 DOWNLOAD PROGRAM 3 SAVE BACKUP CAL 6 CHANGE PASSWORD 4 TOAD USER CAL 5 SAVEUSERCAL 4 RESULTS 1 SELECT amp DISPLAY RESULTS 2 TRANSFER RESULTS TO P C 5 PROGRAM 1 RESTART PROGRAM P W USER 2 DOWNLOAD PROGRAM P W USER 4 XMODEM RECEIVE 5 XMODEM TRANSMIT 6 DISK 1 FILES P W USER 2 FORMAT 1 CAR IDENTIFICATION PAGE 2 1 USER OPTIONS 2 CAR LEAKAGE LIMIT P W USER 60 CIM 2 SHOW CALIBRATION 3 RACK EXT OPTION 3 SHOW DAILY RESULTS 1 ENGLISH 4 MAG VALV DIAG 2 ESPANOL 5 LANGUAGE 3 FRANCAIS 6 UNITS P W USER 1 ENGLISH To restart turn off battery switch 2 METRIC wait 1 minute then turn switch or type RR3 from DOS prompt WABCO Freight Car Products www wabtec com 1001 Air Brake Avenue 475 Seaman Street Wilmerding Pennsylvania 15148 Stoney Creek Ontario L8E 2R2 412 825 1000 Fax 412 825 1019 905 561 8700 Fax 905 561 8705 October 2005 Page 74 of 74
6. 534 5 50 GENI 4 028 5 49 4 032 5 50 GENII EM 0 551 5 49 BC 0 401 0 40 GENI 4 489 5 50 4 053 0 40 GENII 30 Press 5 to adjust ADJUST PRESSURE YES CONTINUE PSI BP 5 51 BC 0 45 CHARGE 0 P1 CLOSED 9 BCC CLOSED EXHAUST 1 E2 CLOSED 2 BCE CLOSED Page 63 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 31 Press 0 then 9 The system will charge up please allow it to stabilize for 30 seconds at approx 90 psi 32 Press YES to continue TRANSDUCER MONITOR 5 ADJUST NO EXIT VOLTS PSI VOLTS PSI BP 9 092 90 71 AX 9 078 90 73 GENI 4 028 90 72 4 032 90 71 GEN II EM 9 095 90 73 BC 9 082 90 72 GENI 4 053 90 72 4 053 90 72 GEN II 33 Record the values MASTER and XDCRS on the ASCTD Pressure Calibration Fill In Sheet The values for GEN I and GEN II differ Nominal examples are provided for each XDCRS MUST BE 0 5 OF HEISE THE MASTER HEISE SHOULD BE 90 5 TO 91 0 IF VALUES ARE OFF PRESS NO TO EXIT AND REPEAT CALIBRATION PROCEDURE FROM STEP 1 34 Press 5 to adjust ADJUST PRESSURE YES CONTINUE PSI BP 90 71 BC 90 7 CHARGE 0 P1 CLOSED 9 BCC CLOSED EXHAUST 1 E2 CLOSED 2 BCE CLOSED 35 Press 1 then 2 The system will drain please allow it to stabilize for 30 seconds at approx 0 0 psi 36 Press YES TRANSDUCER MONITOR 5 ADJUST NO EXIT VOLTS PSI VOLTS PSI BP 0 008 0 01 AX 0 018 0 01 GENI 5 032 0 00
7. A E BC _ At this point the operator may choose which version of the Single Car Test they would like to run The following instructions will cover both options through performance of the General Inspection Operation of the ASCTD in ACCESS Plate SSPB with Receiver mode requires a receiver mounted on the pipe bracket or an access plate with the receiver located between the service portion and the standard AB pipe bracket The interface connector of the Automated Single Car Test Device mounts to the receiver The interface connector will connect to either of the following Single Sided Pipe Bracket This arrangement is furnished with the receiver mounted directly to the pipe bracket Wabtec SSPB only October 2005 Page 46 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company Access Plate This arrangementis mounted between the service portion and the pipe bracket There are three styles to choose from Front Access Top Access Bottom Access If the Access Plate needs to be installed refer to WABCO Kit Bulletin 6225 1 Installation Procedure for Access Plate Kits Operation in End of Car mode tests through the End Of Car test connector and requires no additional equipment Select desired test version now to move to the following screen TESTING REQUIRES A PASSWORD TYPE PASSWORD PRESS ENTER YES END BS DEL S BP _ Az _ E BC __ Once the operator has keyed in the desir
8. C to Rev C 1 0 Revised recording forms to reflect document revision April 5 2002 E RobertCarr Flow calibration procedure includes fixed points Wabco flying W removed from pic IN 3 changed to CIM July 15 2004 F Robert Carr Removed software revision reference October 2005 Page 68 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtee company Battery Replacement Guide Disclaimer Wabtec Corporation is not responsible for damage during the replacement of the batteries for the ASCTD There is always risk involved when servicing electrical components that damage may occur If the Battery Container is damaged the customer will have to purchase a new replacement from the Wabtec Service Center If you do not feel comfortable in performing this task please call a Wabtec Corporation Field Service Representative for assistance AN WARNING Batteries contain Lead Acid Make sure you dispose of the batteries properly Identification This procedure is to replace new style ASCTD batteries only The old type battery has smaller terminals and will not allow the new type to be installed If you have an older type battery please refer to page 73 of this document in order to change out the wire ends The older type battery was made by Panasonic and can be identified by having 4 cells instead of 2 See pictures below OLD Type NEW Type Parts and Tools Required Power
9. E Device serial number 89805 E Software version G 0 0 _ O mya a j a en _ Version A IA Last Daily Test AN 14 21 18 Operator a Stamp number 111 Lot number 1111 Test duration 01 12 54 Calibration time 2002 07 10 14 28 03 Error code 0 Error Description No Errors Test Description Setup Options ARA Re E p Car stamp and lot ID fields option Low system leakage for the car builder option 60 in min Control Valve Configuration Is emergency portion an ABD ABDS No Vent valve Yes Separate emergency portion No B 1 valve No Automatic slack adjuster s Yes Brake pipe length feet 75 General Inspection Results E P AO EA O y Has the general inspection been run Yes I Brake cylinders fail to retum No a Brake shoe problems No No Problems with levers and pins No Rigging binds or fouls No No Problem with brake hoses No Car equipped with E L device Yes 5 ADA Car empty Yes Car equipped with BC pre essure tap Yes BC Pressure tap downstream of E L Yes Connected to car and air Ange and cut out cocks open LS ne Couplings Dan connectors installed Yes Check that AUX and EM are charging with BP 20 psi o AX increase is OK for a 15 second wait with BP at 20 psi Passed 5 _ Range 1 00 8 00 psi Value 3 137 EM increase is OK for a 15 second wait with BP at 20 psi Passed Range 0 30 5 00 psi Value 1 129 Retainer Leakage Test No retainer blow if BC lt 1 5 for 10 seconds Passed R
10. File Utilities Reports Help gt none gt 2000 01 19 02 47 07 71 12427 Passed 2000 01 19 01 42 37 71 21427 Passed lt none gt 2000 01 19 00 37 12 71 15546 Passed lt none gt 2000 01 18 22 13 14 71 14407 Passed lt none gt 2000 01 18 13 59 59 71 15843 11 Passed lt none gt 2000 01 18 11 39 51 71 12427 43 Passed lt none gt 2000 01 16 09 23 05 71 15642 22 Passed lt none gt 2000 01 18 04 40 20 26 71 14407 Passed lt none gt 2000 01 18 01 17 00 10 71 15846 Passed lt none gt 2000 01 14 12 05 47 71 14407 21 Failed lt none gt 2000 01 14 10 59 36 71 15642 16 RE SCT Passed lt none gt 2000 01 14 10 44 14 71 15842 16 RE SCT Failed none 2000 01 14 05 56 31 18 71 15842 CL SCT Passed lt none gt 2000 01 14 04 20 20 17 71 15842 CL SCT Passed none 2000 01 13 15 56 26 71 15843 7 RE SCT Passed none gt 2000 01 13 13 28 50 71 15842 15 RE SCT Passed none 2000 01 13 10 24 54 71 15842 13 RE SCT Passed lt none gt 2000 01 13 08 38 46 71 15842 12 RE SCT Passed none 2000 01 13 03 44 08 39 71 12427 JEL SCT_ Passed lt none 2000 01 12 14 06 58 71 15843 6 SCT Passed lt none gt Me Ready Records 699 51 2000 06 29 10 07 27 October 2005 Page 20 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company 9 0 EXTERNAL DATABASE Wabtec
11. If the car is equipped with a separate vent valve change default to Y YES 3 If the car is equipped with a B 1 quick service valve change the default to Y YES After answering questions 1 3 press YES to continue October 2005 Page 48 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company OPTIONS 1 3 TGLE YES END PG 2 1 AUTOMATIC SLACK ADJUSTER S N S BP _ Az _ E BC __ Use button 1 to toggle between YES Y and NO N All answers have NO as the default Once question has been answered press YES to continue Ifthe operator indicated the car was over 75 feet and no vent valve the unit will show a message requiring confirmation or corrections by the operator WARNING The test device will display a warning screen to protectthe operator and anyone in the immediate vicinity of the car under test WARNING CHOCK THE CAR WHEELS TO PREVENT MOVEMENT AND COMPLETELY DRAIN CAR WITH MANUAL RELEASE ROD PRESS YES CONTINUE S BP _ A _ E BC __ In accordance with AAR Standard S 486 the ASCTD will provide a prompt to reference the application of a brake cylinder measurement tap PRESS YES CAR MAY REQUIRE APPLICATION OF BRAKE CYLINDER PRESSURE MEASUREMENT TAP REFER TO CURRENT AAR SPECIFICATIONS FOR REQUIREMENTS YES CONTINUE S __ BP __ A __ E _ BC _ Press YES to continue OPTIONS 1 3 TGLE YES END PG 1 1 CAR EQUIPPED E L DEVICE Y 2 CAR EMPTY Y
12. MAIN MENU select option 6 VENT SYSTEM READY TO VENT SYSTEM DO YOU WISH TO VENT THE SYSTEM YES NO 4 Press YES to vent system SYSTEM VENT UTILITY WHEN SYSTEM IS COMPLETELY VENTED HIT YES BP 0 0 AX 0 0 EM 0 0 BC 0 0 5 Press YES ASCTD will go to MAIN MENU Close the needle valve on the Flow Meter do not overtighten 6 From MAIN MENU select option 5 UTILITIES 7 From UTILITIES MENU select option 1 CALIBRATION 8 Type password and press ENTER 9 From CALIBRATION UTILITY select option 1 SENSOR CALIBRATION 10 From SENSOR CALIBRATION UTILITY select option 1 CALIBRATE 11 From SELECT SENSORS TO CALIBRATE select option 2 FLOW FLOWMETER CALIBRATION THE AMBIENT TEMPERATURE MUST BE WITHIN 60 TO 80 F 15 TO 26 C PRESS YES TO CONTINUE 12 Press YES FLOWMETER CALIBRATION SECURELY INSTALL BLANKING PLATE WITH MASTER FLOWMETER CLOSE NEEDLE VALVE PRESS YES TO CONTINUE 13 Press YES Page 65 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual ASCTD will automatically perform a 90 second stabilization prior to showing the next screen While waiting with a soapy mixture check all connections from the FLOW METER to the Interface Connector No leakage allowed in 30 seconds FLOWMETER CALIBRATION MASTER 0 00 CAL POINT 1 MAX 12 SET FLOW METER TO 0 CIM PRESS YES TO CONTINUE 14 After the flow meter has been set to zero by cl
13. NOTE At this point the two Single Car Test versions Access Receiver EOC are different The operator MUST follow the on screen prompts performing the actions and entering the information requested by the ASCTD If the actions are not performed or the information not entered correctly the test is defective and may result in a failure automatically ending the test 12 5 SPECIAL TESTS This section covers tests available forthe operator for special situations Tests covered here are 1 10 MINUTE BC LEAKAGE TEST 2 ALTERNATE FOUR HOUR TEST 8 Manual Operations To access these tests the operator must select 3 Special Tests from the MAIN MENU as shown below MAIN MENU hh mm ss 1 SINGLE CAR TEST 4 DAILY TEST 2 RESERVED 5 UTILITIES 3 SPECIAL TESTS 6 VENT SYSTEM S _BP _ A _ Ez BC _ To access the special menu the test device will require a password be entered by the operator TESTING REQUIRES A PASSWORD TYPE PASSWORD PRESS ENTER YES END B S DEL S BP _ Az _ E BC __ October 2005 Page 50 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company NOTE B S DEL Press backspace to delete Press ENTER YES after entering a password the test device will then move to the special tests menu screen SPECIAL TESTS MENU 1 10 MINUTE LEAKAGE TEST 2 ALTERNATE FOUR HOUR TEST 3 MANUAL OPERATIONS NO EXIT S BP _ A E BC _ 1 10MINUTE BC LEAKAGE TEST
14. Selecting this option will perform the 10 Minute BC Leakage Test as described in AAR S 401 22 1 Brake Cylinder Leakage Method 2 ALTERNATE FOUR HOUR TEST Selecting this option will perform the Alternate 4 Hour Test as described in AAR S 401 22 2 Alternate 4 Hour Test Method 3 MANUAL OPERATIONS Selecting this option will take you to the Manual Operations screen MANUAL OP SELECTION MENU hh mm ss 1 MANUAL CONTROL ACCESS PORTS 2 MANUAL CONTROL GLAD HAND ADAPTER NO EXIT a USING OPTION 1 MANUAL CONTROL ACCESS PORTS Select option 1 if you are using the ACCESS PLATE SSPB WITH RECEIVER MAKE SURE BRANCH PIPE CUT OUT COCK IS OPEN AND BOTH ANGLE COCKS ARE CLOSED YES CONTINUE S BP _ Az _E BC __ INSTALL INTERFACE CONNECTOR TO RECEIVER AND SUPPLY AIR TO TEST DEVICE IF NOT ALREADY DONE YES TO CONTINUE S BP _ Az E BC MANUAL OPERATIONS MENU NO EXIT 1 CONTROL BP 4 EMERGENCY 7 BC PSI 2 20 PSI REDUCT 5 CHARGE BP 8 S A 3 FULL SERVICE 6 MIN APP 9 RETAINER S BP _ Az _ E BC __ CAUTION Selecting 2 3 4 6 7 8 and 9 will automatically cause the test device to make a brake application All safety precautions must be adhered to at this time Page 51 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 1 Control Brake Pipe Pressure Press 1 in Manual Operations Menu The operator can control the brake pipe pressure in this
15. Sonic Battery PS 12120 Quantity of 2 e Allied Electronics Part 621 1212 Phone 1 800 433 5700 e Philips Screwdriver 2 end Page 69 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual Battery Replacement Procedure 1 2 8 9 10 If the ASCTD is ON turn it OFF If AC is plugged in unplug it Open and remove the ASCTD door and toggle the battery switch to the OFF position Disconnect the battery cable and remove the battery container from the tester Place the battery container on a clean work surface and unscrew the 10 screws which fasten the lid to the battery container Figure 1 Lift the lid straight up by pulling up on the box connector Figure 2 Remove the 4 pin connector red white black green wires from the battery charger module by squeezing the tab underneath the connector and pulling straight out Figures 3 and 4 Remove the lid and place off to the side Pull off the quick disconnect connectors on the battery tabs blue and Black wires Figure 5 Remove the jumper wire that connects the 2 batteries Figure 6 Tip the battery container vertically on the handle end and remove the batteries Figure 7 AN WARNING Make sure the batteries are to be disposed of properly 11 12 13 Install the new batteries remove safety tabs and follow the procedure in reverse order After the battery container has b
16. and hold for 3 seconds Answer this screen by pressing YES or NO as applicable Reinsert brake shoe s if removed for this test REMOVE BLOCK S FROM BETWEEN SHOE S AND WHEELS YES WHEN DONE BP AX __ EM BC S BP _ A Ez_ BC __ CHARGING UP SYSTEM BP AX EM BC S BP A _ E BC __ CHARGING UP SYSTEM CHARGE BP BP AX EM BC S BP _ A E BC _ AM Automated test device will cycle the brake system to activate the automatic slack adjuster Note as brakes will apply all safety procedures must be observed October 2005 Page 56 of 74 ASCTD User s amp Set up Manual 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company CYCLING BC BP AX _ EM BC S BP __ A Ez _ BC __ SETTING UP FOR PISTON TRAVEL BP AX EM _ BC S _BP __ A Ez _ BC __ CHECK PISTON TRAVEL NOW PRESS YES WHEN DONE NO EXIT S BP _ Az _ E BC _ IS PISTON TRAVEL NOMINALLY THE SAME AS PREVIOUSLY NOTED PRESS YES CONTINUE NO EXIT S BP _ Az _ E BC __ 9 Retainer Test To test the retainer valve function or to test a newly applied retainer valve press 9 in the Manual Operations Menu Test device will test the retainer valve by instructing the operator through on screen prompts through completion of the test sequence RETAINER TEST PASSED PRESS YES TO CONTINUE BP AX EM BC S BP _ Az _ E BC _ Vent System To vent the brake system exit the manual operation The test device will show the follo
17. at any time without warning if there is air in the car or system When inspecting or checking brake rigging or brake cylinder action workers must be extremely careful to keep all body parts clear of any moveable components PRE TEST INSTRUCTIONS The following inspections and services are to be performed in accordance with applicable AAR Interchange Rules When making tests of cars having two or more sets of brake equipment each set with the section of brake pipe it controls must be tested separately Refer to car maintenance instructions or car stenciling to determine where brake pipe should be separated for testing On cars having two sets of brake equipment controlling a common length of brake pipe each set of equipment must be tested separately with the branch pipe cut out cock closed to one set while the other set is being tested NOTE The Automated Single Car Test Device is programmed to test cars equipped with AAR approved Control Valve portions It is NOT designed for use on AB Control Valves NOTE Empty cars equipped with empty load equipment must be tested in the loaded condition for all tests except where noted in this section Cars with empty load devices that automatically reset to empty position must be manually reset to loaded condition for each test unless otherwise indicated Page 45 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 12 4 1
18. b Temperature To properly complete this specification the ambient temperature should be within 60 to 80 F 15 to 26 C Prior to performing this specification please ensure the ASCTD adequate time to reach proper ambient temperature If the temperature is out of this range you may proceed with calibration only if the unit is to be used at the calibrated temperature If the ambient operating temperature changes drastically the unit may have to be recalibrated at the new ambient temperature c NSafety Procedures and Warnings 1 General shop safety procedures must be followed at all times 2 Eye and ear protection must be worn while performing this specification 3 Warnings Ensure connections are tight When required to loosen connections loosen them slowly to ensure air has been depleted d Important Wabtec Corporation may revise this document at any time lt is the responsibility of the user of this product to ensure the latest issue of this specification is being used Also the Calibration Kit must be in calibration when performing ASCTD calibration Do not deviate from this specification Regulator October 2005 Page 60 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company 1 0 Pressure Calibration XDCRS NOTE Ensure the ASCTD has passed the daily test Run the daily test if necessary the Calibration Kit test plate can be used for the daily
19. drop the ASCTD will confirm that brake cylinder pressure increases This checks that a brake application is obtained with a minimum application BC DROP lt 0 5 During the applied leakage test the ASCTD will confirm the brake cylinder pressure does not decrease during a preset time This checks for leakage out of auxiliary reservoir BC gt 10 amp BC lt 35 The ASCTD will generate brake cylinder pressure for the applied leakage test BC CHANGE 1 3 TO 1 3 During the applied leakage test the ASCTD will confirm the brake cylinder pressure does not decrease or increase during a preset time This checks for leakage out of or into brake cylinder AX CHANGE lt 0 7 During the applied leakage test the ASCTD will confirm the monitored auxiliary reservoir pressure does not decrease during a preset time This checks for auxiliary reservoir leakage EM DROP lt 1 During the applied leakage test the ASCTD will confirm the monitored emergency reservoir pressure does not decrease during a preset time This checks for emergency reservoir leakage FLOW lt Limit During the applied leakage test the ASCTD will confirm that the system has flowrated to less than 275 cubic inches minute This checks the brake pipe and cut out cock leakage October 2005 Page 16 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company SLOPE CHANGE FOUND The ASCTD will confirm an increase in the reducti
20. is supplied directly through the glad hand to brake pipe and to brake cylinder through the brake cylinder access hose This operation performs the single car test in a conventional manner All tests performed by the Manual Single Car Test Device as per S 486 are performed by the ASCTD but not always in the same order The ASCTD uses pressure transducers in the brake cylinder auxiliary and emergency reservoirs and brake pipe It can also detect problems not recognized by the Manual Single Car Test Device The test results are recorded for displaying printing or downloading to a computer and can be viewed sorted and printed using an external database program Page 3 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual This manual is designed for use with any Wabtec Corporation ASCTD in service Screens shown in this booklet may differ slightly from the screens on the test device you are operating This booklet was designed from screens shown on the Generation II test device If the test device being used is not a Generation II please follow the screen directions All test devices were designed to perform proper air tests as laid out by the Association of American Railroads AAR and will direct the operator through the correct operation There is a Troubleshooting Guide at the back of this manual for the operator s use The control panel contains a display screen mod
21. passwords but cannot view or change a password The SuperUser must clear a password then let the user change from the default password from the Change Passwords screen Error Reference source not found All fields on the Grid can be edited You can select and change the text in any field When the grid is full a new line will be generated for the next user It is necessary to click on another field or line to have the changes saved to the file Figure 20 Add Users Screen SuperUser Only 11 1 THE SQL STATEMENT WINDOW SUPERUSER ACCESS ONLY The Filter Window sets the criteria for the application to write a SQL SuperUser statement that is used by the application to extract a set of records from the database This statement window is provided to confirm the statement The copy function allows advanced users to copy the query into Microsoft Access and extract the same data for custom reporting etc The SQL statement is also written to the log file for diagnostic and support functions ASCT SQL Statement xj SELECT TOENA gil 0203_Al_imported_Records car_number gota lASCT_0203_AS_Imported_Records car _stamg LASCT_0203_AI_mported_Records test duration _sec FROM ASCT_ 0203_Al_imported_Records WHERE 1 1 ORDER BY ASCT_0203_All_imported_Records test_time_sec DESC Figure 21 View Current SQL Statement Window Page 33 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company
22. select and display results RESULT SORT 1 6 TOGGLE YES GO NO END 1 OPERATOR 4 LAST n TEST 2 AFTER 5 CAR NUMBER 3 BEFORE 6 TEST TYPE SS _BPz A E BC _ NOTE Select the option or combination of options to sort test results Once information is entered the following screen will appear SEARCHING RESULTS TOTAL RESULTS xx MATCHES FOUND xx PRESS NO CHANGE YES ACCEPT S BP _ A E BC _ To access the results press YES to continue This will cause the test device to display the desired results RSLTS 1 3 SHOW 0 PRINT NO END lt gt 1 1 2 3 PRESS YES SEARCH 4 6 PRINT 1 2 3 Sz_ BP _ A _ E BC _ NOTE To print a summary of test results from this screen press 0 Press number of test 1 3 to be viewed or printed To advance to other pages of results press gt Page 13 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual Test Type NO EXIT YES PROCEED CAR NUMBER TIME CAR STAMP NUMBER DATE CAR LOT NUMBER S BP A E BC __ Press YES to continue through selected result Individual results can be printed from any screen that shows 0 PRT VIEW RESULT SCREEN SUMMARY a DUMMY CONNECT ALL CONNECTED Confirmation that the operator has attached the interface connector to the receiver and the supply pressure to the Automated Single Car Test Device ANGLE AND CUT OUT COCKS OPEN Confirmation that the
23. 0 AX 0 0 EM 0 0 BC 0 0 GEN I VALUES VOLTS BP 5 0 AX 5 0 EM 5 0 BC 5 0 GEN II VALUES YES ACCEPT VALUES NO REPEAT QUIT ABORT 14 Prior to pressing YES record the values MASTER 8 XDCRS on the ASCTD Pressure Calibration Fill In Sheet The values for GEN and GEN Il will be different Nominal examples are provided for each 15 Press YES ASCTD will automatically charge itself TRANSDUCER CALIBRATION ADJUST REGULATOR NOW IF NECESSARY MASTER MUST BE 90 5 TO 91 PSI PRESS YES TO CONTINUE NOTE COMPLETE STEP 17 AND REVIEW STEP 18 PRIOR TO PRESSING YES 17 With asoapy mixture check all connections from the HEISE do not get the HEISE wet to the interface connector No leakage allowed in 30 seconds 18 The pressure displayed on the MASTER HEISE is the regulator setting Should the regulator require adjustment the front cover can now be removed without tripping the door switch safety feature Please refer to the diagram on page 60 for the location of the regulator Loosen the jam nut and turn the regulator shaft clockwise to increase the pressure or counterclockwise to decrease the pressure Adjust the regulator until the HEISE reads 90 5 to 91 0 Tighten the jam nut ensuring the HEISE reading stays 90 5 to 91 0 ensure ground wire is reconnected and replace front cover 19 Press YES TRANSDUCER CALIBRATION MASTER CAL POINT 2 MAX 2 ENTER MASTER VALUE IN PSI PRESS YES CONTINUE NO REPEAT 20 Master HEISE should re
24. 3 PASSWORDS 6 DISK NO EXIT S _ BP _ A E BC _ a Accessing Passwords Press 3 to access the Password function CHANGE PASSWORD REQUIRES A PASSWORD TYPE PASSWORD PRESS ENTER YES END BS DEL S _ BP A E BC _ The password assigned to the supervisor during training will most likely be the same as above The operator must type the desired characters and press ENTER or YES PASSWORDS 1 3 EDIT NO EXIT PAGE1 1 WABCO 12456 2 3 Sz_ BP A E BC _ NOTE The first password should NOT be edited or deleted The password shown in line 2 will be the assigned password during training Select the first blank line by pressing the appropriate number Page 9 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual EDIT PASSWORD NEW PASSWORD PRESS ENTER YES END BS DEL S _ BP A E BC _ The selected password will be shown on the top line of this screen To change this password enter the new password by key punching it in the line indicated and press ENTER or YES 1 6 TOGGLE YES END NO DEL 0 PWD 1 TESTING 4 FILE UTILITIES 2 UTILITIES MENU 5 DOWNLOAD PROGRAM 3 RESERVED 6 CHANGE PASSWORD Sz_ BP _ A _ E BC _ NOTE The new password will be shown in the top left corner Assign an authority level by entering the appropriate number Most users only require level 1 for testing Repeat until all passwords are entered S
25. 4 995 0 02 GENII EM 0 002 0 01 BC 0 007 0 00 GENI 5 006 0 00 5 022 0 01 GEN l 37 Record the values MASTER AND XDCRS on the ASCTD Pressure Calibration Fill In Sheet The values for GEN I and GEN II differ Nominal examples are provided for each XDCRS MUST BE 0 5 OF HEISE THE MASTER HEISE SHOULD BE NOMINALLY 0 00 IF VALUES ARE OFF PRESS NO TO EXIT AND REPEAT CALIBRATION PROCEDURE FROM STEP 1 38 Press NO to exit SYSTEM VENT UTILITY System vents and automatically proceeds to the next screen This message flashes very quickly 39 From SENSOR CALIBRATION UTILITY select NO EXIT 40 From CALIBRATION UTILITY select NO EXIT October 2005 Page 64 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company 41 From UTILITIES MENU select NO EXIT ASCTD will go to MAIN MENU 42 Disconnect the HEISE pressure gauge Leave the calibration test plate and hose connected Turn off HEISE and return it to the Calibration Kit Proceed to Flow Calibration 2 0 FLOW CALIBRATION 1 Connect the Flow Meter to the hose assembly and calibration test plate open the needle valve The plate should already be installed from the Pressure Calibration procedure if not please install the calibration test plate at this time 2 Keep the Flow Meter within 15 vertical throughout this procedure Flow Meter readings are taken at eye level using the middle of the ball 3 From
26. 5039 4 S 6 REI DUCTS ASCTD User s amp Set up Manual AWabtec company AUTOMATED SINGLE CAR TEST DEVICE USER S SET UP MANUAL October 2005 Supersedes all previous issues of 5039 4 S 6 and 5039 4 S 7 1999 WABCO Freight Car Products A Wabtec Corporation All rights reserved 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual Table of Contents GENERAL INFORMATI N cstonicnicai dana a a aa aaa e a a aaia edea a aaa 3 W0 INTRODUC TION consistido its 3 2 0 WARNINGS esime neei aa e a aE a a a vines cai tvs E A a a aaa e A aaa aAa 4 3 0 SAFETY CONSIDERATIONS cciociooictaioal acicate da diia Ea aai 4 4 0 EQUIPMENT FEATURES 0000 pa 5 50 REQUIREMENTS cortada tt dat tei At di tddi aves 7 6 0 EQUIPMENT FUNCTION SUPERVISOR SETUP usines 7 TO EQUIPMENT SE FUP asma eE aA aaae a a E aa EE OR NE a E Eaa 8 8 0 RESULTS VIEWING PRINTING AND DOWNLOADING iii nono nnn nan nr rra nan nc rnnnn nana 12 9 0 EXTERNALDATABASE 0 A ete ee Se ee 21 9 1 PON DATA FOTA ss LR nn Mn ae dan O nn nn ne 22 9 2 ProgramunstallatiOn teo nee rame nn nn ne le ee ten 22 10 05 USING ASGTEXE she ta Re ale sau o Re aaa 23 10 1 A rater capeeed caaehecc E eee made de canetig dens stance die seangieees sat sn td etienne 23 10 1 1 Compact Database nn TN A AA 24 10 2 Welcome Clica rm reader gi ete nee ash er tree ee mette aaa 24 10 3 ETES TE ee ie 24 10 3 4 Record Detail WiIndOW 22552 s
27. 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company VERIFICATION OF CALIBRATION FLOW NOTE Close the FLOW METER needle valve 21 From CALIBRATION UTILITY select option 1 SENSOR CALIBRATION 22 From SENSOR CALIBRATION UTILITY select option 2 MONITOR 23 From SELECT SENSORS TO MONITOR select option 2 FLOW FLOWMETER MONITOR SECURELY INSTALL BLANKING PLATE WITH MASTER FLOWMETER CLOSE NEEDLE VALVE PRESS YES TO CONTINUE 24 Press YES FLOWMETER MONITOR FLOW IN CIM 10V 900 CIM 25 Allow 90 SECONDS FOR THE FLOW TO STABILIZE TO APPROXIMATELY ZERO FLOWMETER MONITOR FLOW CIM 0 00 V 0 00 CIM 26 Record the voltage and flow values for CAL POINT 1 under the VERIFICATION OF CALIBRATION columns of the ASCTD FLOW CALIBRATION FILL IN SHEET The CIM cubic inches per minute reading must be within 15 CIM of zero 27 The CIM reading for the remaining CAL POINTS must be within 20 CIM of the corresponding setting on the FLOW METER Dial the FLOW METER to the next CAL POINT which would be 50 CIM Let stabilize for 10 seconds and record the values for the second CAL POINT Repeat these steps for the remaining CAL POINTS After the last calibration point CAL POINT 12 is recorded press NO to exit SYSTEM VENT UTILITY System vents and automatically proceeds to the next screen This message flashes very quickly 28 From SENSOR CALIBRATION UTILITY select NO EXIT 29 From CALI
28. ASCTD User s Set up Manual 11 2 EXTERNAL DATABASE REPORTS The first release ofthe ASCT program prints two reports 1 Detail Report The Detail Report is a single page report listing the results for the current record when printed from the detail record window The report may be several pages with one page printed per result of the records displayed by the current filter This last option is selected from the menu 2 Summary Report The Summary Report prints the fields displayed on the grid Test date Car Number Lot Number Stamp Number Operator Name Test Type and Overall Pass Fail This report prints these details on one line for each record of the filtered set The summary report is printed from the menu option NOTE If no records are displayed on the grid the result of a filter or a new installation the menu options to print will be disabled Sample reports on following pages October 2005 Page 34 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtee company 11 2 1 DETAIL REPORT SAMPLE ASCT TEST PASSED 3 Car number 11 WABCO ASCT Detail Report Test date 2002 09 11 11 44 08 Freight Car Products 2002 10 01 20 56 31 Test result PASSED General Information
29. BP _ A E _ BC __ Connect Supply air and press YES to continue OPEN ASCTD DRAIN COCK FOR 5 SECONDS PRESS TO CONTINUE S BP _ A E _ BC __ Open drain cock located on the left side while facing the keyboard at the bottom of the test device Gen II only for five seconds to allow any moisture escape close it then press YES to continue Page 41 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual The test device will now run through Running System Check If this test is successful it will move to next test automatically If test fails the screen will show an error message See troubleshooting at the end of this manual for corrections to error messages Audible alarm test will show the following AUDIBLE ALARM TEST DO YOU HEAR A BEEP YES NO S __ BP _ Az _ E BC _ Press YES if audible alarm sounded test will continue Ifthe user presses NO the display will show an error message The daily test will abort Repairs must be made before test will continue The next test will check the interface pistons The interface connector pistons are located under the connector cover The operator must physically check the operation of the interface connector Pistons must be observed as instructed during this test INTERFACE PISTON CHECK FLIP OPEN INTERFACE CONNECTOR WARNING AVOID PINCH POINTS YES CONTINUE S _ BP _ A E BC __ After removing interfa
30. BRATION UTILITY select NO EXIT 30 From UTILITIES MENU select NO EXIT ASCTD will go to MAIN MENU 31 Disconnectthe FLOWMETER close the needle valve and remove the hose assembly Slowly remove the calibration test plate Return equipment to Calibration Kit 32 Fill out a new ASCTD calibration sticker located in kit and apply inside the lid cover 33 Run a daily test to verify ASCTD operation Page 67 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual Revisions Date Revision Changes November 11 1997 New Jeff Reid Original October 21 1999 A John Joyce Revised entire document calibration procedures are now performed first followed by verification Revised recording forms to reflect procedural changes April 27 2000 B John Joyce Added Wabtec Corporation Logo January 29 2001 C John Joyce Revised document to reflect changes made in the ASCTD software revisions GEN Rev F and GEN II Rev C ASCTD screen on regulator adjustment pg 4 item 16 now matches the calibration procedure Screen on flow cal points pg 9 item 14 now matches the calibration procedure Password entry levels were slightly changed updated document to reflect this Eliminated the number option for Save and Exit and Exit it is just YES or NO Revised recording forms to reflect document revision March 19 2001 D John Joyce Changed GEN Rev F to Rev F 1 0 and GEN II Rev
31. C NO EXIT NEW DESIRED PRESSURE BP __ AX EM BC YES CONTINUE S _BP _ Az E BC _ The operator must enter the pressure desired in the space provided and press YES to continue Brakes will apply and brake cylinder pressure will change and be indicated below Press NO to exit this operation CONTROL BC NO EXIT NEW DESIRED BC PRESSURE BP __ AX EM BC __ CURRENT DESIRED BC PRESSURE __ S BP _ A _E BC __ 8 Slack Adjuster Test To test the operation of an automatic slack adjuster press 8 in the Manual Operations Menu The test device will testthe automatic slack adjuster with input from the operator SETTING UP FOR SLACK ADJUSTER TEST PLEASE WAIT S _BP _ Az E BC _ October 2005 Page 54 of 74 ASCTD User s amp Set up Manual 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company CHARGING SYSTEM DROPPING B P BP AX __ EM gt BC S _ BP _ A _ Ez _ BC __ CHARGING SYSTEM CHARGE BP BP AX EM BC S __ BP _ Az _ Ez_ BC __ SETTING UP FOR PISTON TRAVEL CHECK BP AX __ EM BC S _ BP _ Az _E _ BC __ BP AX EM BC CHECK PISTON TRAVEL NOW PRESS YES WHEN DONE NO EXIT S __ BP _ Az _ Ez_ BC __ IS THE PISTON TRAVEL WITHIN LIMITS FOR THIS CAR PRESS YES TO CONTINUE NO EXIT S BP _ Az _ E BC __ DRAINING BP S _BP _ Az _ E BC _ PULL MANUAL RELEASE ROD FOR 3 SECONDS DID CYLINDER FULLY RETRACT YES NO S _BP _ A _ Ez_ BC _ Operator must pull brake cylinder release ro
32. CONTINUE S _ BP _ Az _ E BC _ Page 43 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual Gauge must read between 77 and 83 psi or it must be condemned as defective If gauge reads 77 to 83 psi press any key DO NOT PUSH QUIT to continue and the following screen will appear BC GAUGE LEAKAGE TEST CHARGING TO 90 PSI S BP _ A E BC The ASCTD will automatically charge the Brake pipe Brake Cylinder Gauge to 90 psi and perform a 1 minute leakage test If unit fails leakage test the daily test error screen will be shown indicating failure cause leaking gauge hose or coupling If unit passes the test the following screen will appear BC GAUGE LEAKAGE TEST BC GAUGE LEAKAGE __ PSI BC GAUGE LEAKAGE TEST PASSED PRESS ANY KEY TO CONTINUE S BP A E BC Press any key to continue The unit will charge for the emergency drain function If an error occurs charging during this test an error screen will be shown Refer to troubleshooting guide for corrections Once charging is complete the unit will show following screen PUSH EMERGENCY DRAIN BUTTON TO CHECK OPERATION S _ BP A E BC _ Push Emergency Drain button EMERGENCY DRAIN DETECTED WAITING 60 SEC TO DRAIN S _ BP _ A _ E BC _ The ASCTD will automatically perform a 60 second emergency drain Once the Emergency Drain test has completed the test device will display the followi
33. Corporation s external database program ASCT EXE permits users to store retrieve query and generate reports of tests performed by Wabtec Corporation s Automated Single Car Test Device ASCTD The PC based software is designed around the Microsoft Windows Operating System 3 1 or greater ASCT EXE was designed to handle a 300 Mb database approximately 10 years of ASCTD results System Hardware Requirements The following table lists the minimum level of computer hardware needed to effectively use the Wabtec Corporation ASCT Database program Device Minimum Required Processor Pentium P5 90 Processor Memory 16 MB RAM Central Storage Device 500 MB Hard Drive NOTE Normal database maintenance operations require hard drive storage at least twice the expected database size Disk Drive 3 5 1 44 MB Disk Drive Graphics 640 X 480 X 256 VGA Small Fonts Additional Requirements Mouse 1 available COM port LPT port for Printer Interface Microsoft Windows 3 1 e Using ASCT EXE the user will take a file of results taken from the Automated Single Car Test Device ASCTD and start an import process where the results will be validated and then stored in the database The stored results can be viewed on the main screen grid where a detailed view is possible by double clicking on any record The detailed view can be printed on a separate report The user can filter records by the main criteria which is displayed as headers on the grid columns Additio
34. ES ENTER CONTINUE NO ABORT Sz_ BP _ A _ E BC _ Key in the correct time and press YES or ENTER NOTE Time is set in Military format 24 hour clock TYPE DATE AS MM DD YYYY CURRENT DATE _ PRESS lt DEL gt BLANK PRESS YES ENTER CONTINUE NO ABORT S _ BP A E BC _ Key in the correct Month Day and Year and press YES or ENTER Year must be entered in 4 digit format it is not necessary to enter hyphens Page 11 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 8 0 RESULTS VIEWING PRINTING AND DOWNLOADING Single Car Test Results maybe viewed directly sent directly to a printer or downloaded and transferred to a personal computer PC PRINTER SETUP PROCEDURE The assignment of printing is the responsibility of the person designated by the end user such as air brake supervisor or yard foreman NOTE This procedure must be followed in sequence to avoid serious damage to the test device The ASCTD will only function with Printers that meet EEE 1284 specifications check the printer s owner manual for compliance to EEE 1284 specifications An IEEE 1284 Bidirectional printer cable is required between the Printer and the ASCTD The printer must also support WIN3 1 or MSDOS software a Set Up 1 Before any electrical power cords are plugged in install the printer cable between the printer and the ASCTD 2 Tu
35. L 3 FRANCAIS S BP _ A E BC _ Correct time and date must be shown on this screen If it is incorrect press NO and test device will direct the operator through screens to make necessary corrections At this time language preferences can made by select 1 2 or 3 If correct press YES to continue The following screen will appear MAIN MENU hh mm ss 1 SGL CAR TEST 4 DAILY TEST 2 RESERVED 5 UTILITIES 3 SPECIAL TESTS 6 VENT SYSTEM Sz_ BP _ A _ E BC _ October 2005 Page 8 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company The test device will show air pressure values on the bottom of the screen These values will change as the air pressure usage changes S the amount of supply pressure to the test device BP Brake Pipe Pressure A Auxiliary Reservoir Pressure E Emergency Reservoir Pressure BC Brake Cylinder Pressure upstream To access the Utilities Menu press key number 5 At this point the unit will require the use of a password as shown on the following screen UTILITIES MENU REQUIRES A PASSWORD TYPE PASSWORD PRESS ENTER YES END BS DEL S BP _ A E BC _ The password assigned to the supervisor during training must be typed in by the operator and press ENTER or YES to move to the next screen Back Space to exit delete UTILITIES MENU hh mm ss 1 CALIBRATION 4 RESULTS 2 TIME amp DATE 5 PROGRAM
36. S _ BP _ A E BC _ PRESS YES TO CONTINUE Unit will zero the transducers to avoid false readings as noted by this screen DRAINING TO ZERO TRANSDUCERS S BP _ A E BC _ Unit will do a system leakage and valve tests this will take several minutes If there are leaks found in the system the unit will display an error screen identifying the defect Some leaks may be found and identified using soapsuds Other leaks may require use of the troubleshooting guide No input is required by the operator until the following screen appears for brake cylinder gauge check Ifthe brake cylinder gauge check is not required the next screen that appears is the Push Emergency Drain Button screen BRAKE CYLINDER GAUGE CHECK PLUG IN THE QUICK DISCONNECT COUPLING WITH BC GAUGE INTO THE TEST PRESSURE TAP PRESS YES TO CONTINUE S _ BP _ A E BC _ Plug Brake Cylinder Gauge into Brake Cylinder Pressure Tap located on the underside of the ASCTD Blanking Plate and press YES to continue The following screen is a reminder that the Brake Cylinder Gauge and test Coupling must be calibrated every 92 days BRAKE CYLINDER GAUGE CHECK NOTE THE BRAKE CYLINDER GAUGE AND TEST COUPLING MUST BE CALIBRATED EVERY 92 DAYS PRESS YES TO CONTINUE S BP _ A _ E BC _ Press YES to continue and the following screen will appear BRAKE CYLINDER GAUGE CHECK CHARGE TO 80 PSI THE BRAKE CYLINDER PRESSURE GAUGE MUST READ BETWEEN 77 AND 83 PSI PRESS ANY KEY TO
37. Spool Valve Movement Test g i 7 _ AX EM and BC gt 40 psi Passed _ Range AX gt 40 0 psi Value 63 621 ange EM gt 40 0 psi Value 63 642 Range BC gt 40 0 psi Value 63 588 Reservoirs BC Leakage into BP _ o No leakage into BP BP lt 2 psi 60 seconds after emergency Passed a Range lt 2 00 psi Value 0 030 No leakage into BP BP change for an extra 60 second wait N A Range lt 1 00 psi Value 0 Piston Travel without blocks Piston travel within limits Yes Emergency Accelerated Release Test Emergency accelerated release valve OK Passed Range gt 30 0 psi Value 45 735 Empty Load Test n Pressure difference OK Passed E BC Pressure difference 42 000 S 2 T o BC pressure E L loaded 65 000 No test fitting leakage Yes BC pressure E L empty 23 000 Disconnect and Soap Test de Receiver cover sealed tight Yes Reservoirs drained Yes Billing Codes 11 2 2 SUMMARY REPORT SAMPLE Location WABCO ASCT Summary Report Freight Car Products 2002 10 02 09 27 30 z ooo Test Date Car Number Lot Number Stamp Number Operator Test Type Test Result 2002 09 11 13 03 31 ll iil ml BC Alt 4Hr BC Test Passed 2002 09 11 11 44 08 ni 111 BC Single Car Test Passed 20024 gt f Is Test 7 j 2002 09 11 11 40 42 11 mi itl BC Single Car Test Failed Figure 23 ASCT Reports Summary Report October 2005 Page 36 of 74 lt me lt none gt lt none g
38. TEST DEVICE OPERATIONS Important A System Fault occurs when the ASCTD is unable to conduct the test correctly The cause may be in the supply air the car orthe ASCTD The ASCTD will provide information to help the operator locate and correct faults A Test Failure occurs when a properly conducted test fails The cause is usually on the car and diagnostics are available to assist in pinpointing the failure It is extremely important to follow the instructions at the time they are given Failure to respond will result in improper or delayed testing If possible make the necessary repairs or contact your Wabtec Corporation Field Engineering Representative The Single Car Tests are performed in the following steps requiring the same starting point Turn on the unit and it will cycle to the screen shown below IS DATE AND TIME CORRECT DAY MONTH TIME YEAR PRESS YES OK NO CHANGE 1 ENGLISH 2ESPANOL 3 FRANCAIS S BP _ A E BC _ If the correct time and date are shown the operator should press the YES button and test device will move to the MAIN MENU screen Use the number keys to select the type of test the operator wishes to perform MAIN MENU hh mm ss 1 SGL CAR TEST 4 DAILY TEST 2 RESERVED 5 UTILITIES 3 SPECIAL TESTS 6 VENT SYSTEM S BP _ A E BC _ Press number 1 to start Single Car Test and the following screen will appear SINGLE CAR TEST MENU hh mm ss 1 ACCESS PLATE SSPB WITH RECEIVER 2 END OF CAR S BP
39. _ Az _ E BC __ This screen gives you the option to confirm or edit the car information Press 1 3 to edit or YES to continue TYPE APPROXIMATE BRAKE PIPE LENGTH TO NEAREST FOOT PRESS YES CONTINUE NO ABORT S BP _ Az E BC _ Brake pipe length does not have to be exact If the car is equipped with auxiliary brake pipe reduction devices brake pipe length must be shown as over 75 feet NOTE If brake pipe length is unknown add 8 feet to the actual car length for cars having conventional end hose arrangements or end hose arrangements similar to that depicted in AAR Standard S 4003 Add 20 feet to the actual car length for cars having end hose arrangements similar to that depicted in AAR Alternate Standard S 4003 Valid testing can only occur on cars with up to 150 feet of brake pipe Enter brake pipe length and press YES button to continue Unit will require certain information to ensure it performs the proper tests OPTIONS 1 3 TGLE YES END PG1 1 IS EMERGENCY PORTION AN ABD ABDS N 2 VENT VALVE 3 B 1 VALVE S _BP _ Az E BC __ zz Use buttons 1 3 to toggle between YES Y and NO N All answers have NO as the default when the ASCTD is turned on If the ASCTD is not turned off the answers to the previous test become the new defaults 1 ABD and ABDS emergency portions do not have an AAV function and therefore this function will not be tested All other emergency portions have an AAV function and will be tested 2
40. ad 90 5 to 91 0 Enter value to nearest tenth 90 7 example and press YES to continue TRANSDUCER CALIBRATION MASTER _ 90 7 CAL POINT 2 MAX 2 VOLTS BP 9 09 AX 9 07 EM 9 09 BC 9 08 GEN I VALUES VOLTS BP 4 10 AX 4 09 EM 4 11 BC 4 10 GEN II VALUES YES ACCEPT VALUES NO REPEAT QUIT ABORT October 2005 Page 62 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company 21 Priorto pressing YES record the values MASTER and XDCRS on the ASCTD Pressure Calibration Fill In Sheet The values for the GEN and GEN II will be different Nominal examples are provided for each 22 Press YES TRANSDUCER CALIBRATION CALIBRATION POINTS ARE READY PRESS YES TO CONTINUE 23 Press YES SYSTEM VENT UTILITY System vents and automatically proceeds to the next screen This message flashes very quickly 24 From SENSOR CALIBRATION UTILITY select YES SAVE SAVING CALIBRATION Calibration is saved This message flashes very quickly VERIFICATION OF CALIBRATION XDCRS 25 From CALIBRATION UTILITY select option 1 SENSOR CALIBRATIONI 26 Type password and press ENTER 27 From SENSOR CALIBRATION UTILITY select option 2 MONITOR 28 From SELECT SENSORS TO MONITOR select option 1 XDCRS TRANSDUCER MONITOR SECURELY INSTALL BLANKING PLATE TO INTERFACE CONNECTOR PRESS YES TO CONTINUE 29 Press YES TRANSDUCER MONITOR 5 ADJUST NO EXIT VOLTS PSI VOLTS PSI BP 0 544 5 49 AX 0
41. ages To access page 2 use the right cursor arrow key P at this time UTILITIES MENU NO EXIT PAGE 2 1 USER OPTIONS 4 MAG VALVE DIAG 2 SHOW CALIBRATION 5 LANGUAGE 3 SHOW DAILY RESULTS 6 UNITS S _ BP _ Az E BC __ Press 1 to access the User Options function UTILITIES MENU REQUIRES A PASSWORD TYPE PASSWORD PRESS ENTER YES END BS DEL S _ BP _ Az _E BC __ Key in password and press ENTER USER OPTIONS 1 3 TGLE YES END 1 CAR IDENTIFICATION LOT STAMP Y 2 LEAKAGE LIMIT 60 CIM N 3 RACK EXTENSION OPTION Y S _ BP _ Az _E BC __ Page 39 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual NOTES Use buttons 1 2 8 3 to toggle between YES and NO Button 1 will toggle car identification between YES and NO Button 2 will toggle leakage limit between YES and NO Button 3 will toggle rack extension option between YES and NO After the desired options have been selected press YES to return to page 2 of the Utilities Menu Press NO to return to Main Menu 12 2 SCREEN INFORMATION The test device will provide on screen instructions by responding to these instructions the ASCTD will automatically move through the test procedures The test device will provide a failure message when a test procedure fails generally due to a defective air brake component or procedure When a failure message occurs the test device may provide direction in findi
42. air to test valve stability on short cars Position 6 Service Stability Long Car Rapid reduction of brake pipe air to test valve stability on long cars And the letters E representing 3 8 cock to test emergency valve function F representing the Flowrator which is used to determine system leakage and comparing brake cylinder leakage October 2005 Page 58 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company TROUBLE SHOOTING GUIDE PROBLEM SOLUTION ASCTD will not power on Check if AC is connected Battery switch is turned to ON Single Car Test fails leakage test no 1 Check that the Interface Connector is securely fastened to the car leaks found on the car Interface Connector Pistons fail to operate within 5 second period during Daily Test Supply pressure low C 1 line is broken or leaking Daily Test fails for leakage Check for leakage at Interface Connector and hoses Check for internal leakage with snoop Gaskets maybe bad on the test plate Release Valve inside ASCTD is 1 blowing air Supply pressure maybe too high above 140 psi Page 59 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual CALIBRATION SPECIFICATION T 310251 O AUTOMATED SINGLE CAR TEST DEVICE Revision F July 15 2004 REQUIREMENTS a Calibration Kit Part No 310251
43. ake pipe BP auxiliary reservoir AX emergency reservoir EM and brake cylinder BC will change as the pressure increases CHARGING UP SYSTEM CHARGING B P BP AX EM ___ BC S __ BP A __ E _ BC _ Note change in the flow rate as the brake pipe charges FLOW BP AX EM __ BC PRESS YES TO RETURN TO MANUAL MENU S __BP _ A _ Ez_ BC _ Page 53 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 6 Minimum Application To initiate a minimum 6 psi drop brake application press 6 in Manual Operations Menu Test device will charge brake system as indicated Values of the brake pipe BP auxiliary reservoir AX emergency reservoir EM and brake cylinder BC will change as the pressure increases Once the system is charged a brake application will be made and the values will change again Once the Minimum Application is complete the values will appear in the screen below MINIMUM APPLICATION BP AX _ EM _ BC PRESS YES TO RETURN TO MANUAL MENU S __BP _ A _ Ez_ BC _ 7 Brake Cylinder Control To control the amount of brake cylinder pressure press 7 in Manual Operations Menu Test device will charge brake system as indicated Values of the brake pipe BP auxiliary reservoir AX emergency reservoir EM and brake cylinder BC will change as the pressure increases CHARGING UP SYSTEM BP AX EM BC S BP A _ E BC CONTROL B
44. ange lt 1 50 psi Value 0 052 No significant BC drop for 20 seconds with BC 16 psi Passed Range lt 1 50 psi Value 0 700 _ ___BC pressure always gt 10 psi during the 20 second wait Passed Range gt 10 psi Value 13 293 BC drops with retainer in exhaust Passed ange lt 5 00 psi Value 4 985 arg ange lt 225 or 60 in min Value 0 Vent Valve Stability 30 PSI Reduction No emergency occurred Passed E me Opsi Value 62 287 No AAV run on detected after 15 seconds BP dro Piston Travel with blocks Piston travel within limits Yes Piston travel 5 500 sging check with blocks system OK No binding or fouling Yes Rack extension 0 Manual Release Valve Test Final BP Pressure Range lt 7 00 psi Value 0 027 AX drop for 10 seconds after manual release is OK Passed Range lt 1 00 psi Value 0 375 EM drop for 10 seconds after manual release is OK Passed Range lt 1 00 psi Value 0 046 BC pressure after manual release is OK Passed _ i Ree 00 psi Value 0 046 BP increase for 10 seconds after manual release is OK Passed ange lt 2 50 psi Value 0 012 _Range lt 7 00 psi Value 0 024 Applied leakage OK with respect to gross BC pressure Passed A _____ Range 10 00 35 00 psi Value Applied leakage OK with respect to change in BC pressure Passed Range El 30 1 30 psi Value _Applied leakage OK with respect to AX Passed Range 0 70 0 70 psi Value Pre
45. ary a message box will notify you that the repair was completed and you should check the checkbox for Compact Database by clicking in the box beside Compact Database on the logon screen The user should occasionally optimize the database by checking Compact Database at logon The procedure takes progressively longer as the number of records imported increases and may take several minutes ona large database 10 2 WELCOME SCREEN The Welcome Screen displays program information title copyright etc information before the main screen is loaded and displayed Welcome This product is licensed to WABCO WABCO FREIGHT CAR PRODUCTS Pc 310227 Revision F AWabtec company C Copyright 1996 2004 This program is protected by U S and international copyright laws as described in Help About Figure 3 Welcome Screen e ASCT EXE will display the Welcome Screen Figure 3 for 3 seconds except e Ifthe user selected compact at the logon screen then ASCT EXE will display the Welcome Screen until the operation is complete with a message on the screen stating that a compact procedure is being performed NOTE The compact database operation requires additional disk space equivalent to the current size of the database The free disk space is checked before the compact takes place to ensure that there is sufficient disk space to continue 10 3 MAIN SCREEN The main screen shows the data grid and status bar along with the menu syste
46. base e The User must activate a filter field by clicking on the checkbox for that field e Select a comparison method e Complete the edit box For all comparison types except begins with and contains you must type the exact information that will be filtered e When all the checkboxes and text boxes are complete click on the Apply Filter Button The filtered state of the database table is indicated by the funnel icon on the status bar on the main screen This indicates whether or not you are seeing all the records or a smaller set of the table records filtered some of the records or no filter all the records are displayed Table of filter fields and combo box items Test Date EQUAL the test date is identical to the date entered in the edit box BETWEEN the test dates falls between the dates entered in the two edit boxes The second edit box appears only when between is selected lt The test date is less than the date entered in the edit box lt The test date is less than or equal to the date entered in the edit box gt The test date is greater than the date entered in the edit box gt The test date is greater than or equal to the date entered in the edit box Tip You can type today or now in the edit box to have today s date Car Number The Car Number filter field includes all of the operators above plus Begins With the Car Number begins with the characters in the edit box Contains The Car Number contains th
47. ce connector from holding area pull back on the connector cover Press YES button to continue The unit will prompt the operator to check for piston extension as indicated by the following screen VISUALLY LOOK TO SEE THAT ALL 4 INTERFACE CONNECTOR PISTONS HAVE EXTENDED FROM THE CONNECTOR FACE YES 0K NO FAIL S BP _ A E BC __ Look on the bottom of the interface connector to see if all four pistons have extended If pistons did not extend press NO button Unit will not continue with the test Repairs must be made See troubleshooting guide at back of this manual If the pistons have extended press YES button to continue Unit will test for piston retraction as indicated by the next screen VISUALLY LOOK TO SEE THAT ALL 4 INTERFACE CONNECTOR PISTONS HAVE RETRACTED INTO THE CONNECTOR FACE YES 0K NO FAIL S BP A E BC __ October 2005 Page 42 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company Responses to this screen are the same as for the previous screen Unit will require test plate connection Attach blanking plate found mounted on front housing of unit to interface connector When this is accomplished press YES to continue If you intend to perform any End of Car EOC tests before the next scheduled Daily Test the EOC Test Connector and a dummy Glad hand must be substituted for the blanking plate SECURELY INSTALL BLANKING PLATE YES CONTINUE
48. d and hold for 3 seconds Answer this screen by pressing YES or NO as applicable In accordance with AAR S 486 99 the removal of brake shoes instead of inserting blocks between the shoe and a wheel is a suitable alternative AX WARNING Make sure no airis present in brake cylinder s to prevent personal injury while performing the following task INSERT BLOCKS BETWEEN BRAKE SHOE AND WHEEL ON ONE END OF SINGLE SLACK ADJUSTER OR BOTH ENDS IF MULTIPLE SLACK ADJUSTERS YES WHEN DONE S _BP _ Az _ E BC _ CHARGING UP SYSTEM BP AX EM BC S __ BP Az _ E BC __ CHARGING UP SYSTEM CHARGING BP BP AX EM BC S BP _ Az _ E BC __ Page 55 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual Automated test device will cycle the brake system to activate the automatic slack adjuster Note as brakes will apply all safety procedures must be observed CYCLING BC BP AX EM BC S BP A E BC SETTING UP FOR PISTON TRAVEL BP AX EM __ BC S BP _ Az E BC _ CHECK PISTON TRAVEL NOW PRESS YES WHEN DONE NO EXIT S _BP _ Az _ E BC _ IS PISTON TRAVEL NOMINALLY THE SAME AS PREVIOUSLY NOTED PRESS YES CONTINUE NO EXIT S BP _ Az _ E BC _ DRAINING BP BP AX EM BC S BP _ Az E BC _ PULL MANUAL RELEASE ROD FOR 3 SECONDS DID CYLINDER FULLY RETRACT YES NO S _BP _ A _ Ez_ BC _ Operator must pull brake cylinder release rod
49. d information and add new information to an existing database The assignment of passwords is the responsibility of the person designated by the end user such as an air brake supervisor or foreman During Wabtec Corporation training a password will be assigned to the supervisor for access and entering passwords for the personnel carmen car mechanic responsible for the actual testing The supervisor should have access to Levels 1 2 4 5 and 6 These cover testing the utilities menu and allow the supervisor to change passwords The utilities menu allows access to change the time amp date passwords and view or print results The carmen should have access to only Level 1 Testing Page 7 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 7 0 EQUIPMENT SET UP If this unit has just arrived at your location before performing any test procedure visually inspect the unit to ensure there is no damage Any damage to the unit which may effect the operation of the unit must be reported to the Wabtec Corporation Field Engineering Group in Wilmerding PA 412 825 1000 Upon receiving ASCTD from shipping the battery switch must be toggled to the ON position The unit will not function properly if switch is not in the ON position NOTE Do not plug in AC power until the battery switch has been toggled ON To access the switch open front hose hanger c
50. e Battery Wire Ends The following are required Crimp tool for Blue sleeve Radio Shack 64 404 or equivalent Wire Cutters Radio Shack 64 404 or equivalent Wire stripper for 16AWG wire Radio Shack 64 404 or equivalent 4 insulated quick disconnect connectors 1 2 Radio shack 434 3133 or equivalent Procedure 1 Remove the battery cable and cut the Blue and Black wires as close to the crimp sleeve ends as possible strip insulation off wire end Remove the jumper cable and cut off the old crimp connectors again as close to the sleeve as possible strip insulation off wire end Open the crimp package and discard the Male crimp ends where applicable Crimp the new insulated female 1 4 quick disconnect connectors onto the stripped wire end Page 73 of 74 October 2005 5039 4 S 6 O WABCO FREIGHT CAR PRODUCTS AWabtec company ASCTD User s amp Set up Manual MAIN MENU
51. e Elapsed Sane SMHS ASCTD after importing to the database TOA Invalid records are records that are not complete or records that are not in the format expected by the ASCT EXE program Cw Figure 12 Import File Summary Message Box 10 6 USING ASCT EXE EXPORT TEST FILE F4 The export function will copy database records selected by the current filter to a file in the same format as the import file This will allow the user to transfer records to another database The ASCT exe application changes only the comment field to indicate to the program on import that the file is a previously exported file The comment line also contains the User name and the date time of export as well as the number of records in the file NOTE If the current filter returns no records or the database is empty the menu option for export will be disabled File Name Directories asctx001 dat c asct Select Export Test File from the File menu Saa dat Scar or press F4 gt asct res e The Export Test File dialog is presented Figure 13 Export File Dialog Save File as Type Drives ASCT Files asct dat c Figure 13 Export File Dialog The default name for the export file is ASCTX dat where the X defines the file as an export file and the is a consecutive number The file name can be changed by the user as well as the destination for the exported file Ifthe destination file exists the message box below will be di
52. e characters in the edit box See note following this table Lot Number The Lot Number filter field includes the same operators as the Car Number Field Stamp Number The Stamp Number filter field includes the same operators as the Car Number Field Operator Name EQUAL the Operator Name is identical to the Operator Name entered in the edit box e Begins With the Operator Name begins with the characters in the edit box e Contains The Operator Name contains the characters in the edit box Location e Any valid location from the pull down menu Test Type Single Car Tests or Repair Track Tests Overall Flag e Passed Failed e Quit Error Code Select and error code from the pull down menu NOTE The contains comparison can cause a very long search time to be incurred as the search value is matched incrementally along the search field As the database grows in size the search times will also compound this search time Page 31 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS AWabtec company ASCTD User s amp Set up Manual 10 8 CHANGE PASSWORDS SCREEN The User s default password is password to change this e Select Change Password from the Utilities Menu e Type in the new password and retype the password in the confirmation edit box to set the password The SuperUser can clear the passwords but cannot view or change a password The SuperUser must clear a password then letthe user change fr
53. ed auxiliary valves reservoirs brake cylinder s and brake pipe The Automated Single Car Test Device is designed to perform freight car air brake tests in accordance with AAR Standard S 486 latest revision With minimal input by the operator it will perform a more accurate and efficient test than the Manual Single Car Test Device and provide a record of the test procedure and results The ASCTD will also provide on screen diagnostics for single car test failures The ASCTDis a microprocessor controlled air piloted test apparatus for testing the operation of current standard freight car air brake systems The ASCTD will perform a single car test two different ways 1 Access plate receiver option Air is supplied and exhausted directly to brake pipe auxiliary reservoir emergency reservoir and brake cylinder volumes Access to these pressures is provided by four hoses bundled together and an interface connector mating with a receiver located on the car The receiver is mounted directly to the pipe bracket or to an access plate located between the standard AB pipe bracket and service portion The interface connector uses a manually operated securing mechanism for attachment to the receiver The interface connector will open and close check valves in the receiver to create a pneumatic path between the car and the test device The test device monitors pressure in each of the four lines described earlier 2 EOC End of Car test connector Air
54. ed characters password press ENTER or YES to continue and the next screen will ask for initials TYPE OPERATOR INITIALS PRESS ENTER END BS DEL S BP _ A _ E BC __ Enter operator initials and press ENTER or YES to continue to the next screen 1 CAR NUMBER 2 CAR STAMP NUMBER 3 CAR LOT NUMBER PRESS 1 3 EDIT YES CONTINUE NO EXIT S BP _ Az _ E BC __ For areas 1 3 information must be entered Only one field must have information entered Select the desired number of the field s to enter car information USE NUMBERS OR LETTERS CAR NUMBER PRESS ENTER YES END BS DEL S _BP _ Az _ E BC _ To enter the car number the unit will accept alpha characters followed by numeric digits to 16 characters i e WABX123456 A Intermodal car platform being tested To enter the car stamp number the unit will accept a maximum of 2 letters and 4 digits To enter the car lot number the unit will accept a maximum of 4 digits Example USE NUMBERS OR LETTERS CAR NUMBER WABX123456 A PRESS ENTER YES END BS DEL S BP _ Az E BC _ Page 47 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual After entering information in at least one of the fields indicated and pressing ENTER the unit will show the following screen Example 1 CAR NUMBER WABX123456 A 2 CAR STAMP NUMBER 3 CAR LOT NUMBER PRESS 1 3 EDIT YES CONTINUE NO EXIT S BP
55. een installed and the door is on turn on the tester Observe that the tester turns on when AC is not plugged in The battery indicate should show green NOTE lt is possible that the batteries were not charged when shipped but usually this is not the case 14 15 16 17 18 If the unit powers up and the battery indicator is green then you have completed this procedure If the unit does not power up or if the battery indicator is low plug AC into the unit Try to turn on the unit If the unit does not power up but the battery charger light is illuminated wait for the battery to charge If after 10 hours the unit will still not turn on without AC call a Wabtec Corporation Field Service Representative If the unit does power up with AC plugged in leave it for 10 hours and then check that the battery stays in the green when unplugging it If it does not call a Wabtec Corporation Field Service Representative End of procedure October 2005 Page 70 of 74 5039 4 S 6 FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtee company Sy Figure 1 Figure 2 Figure 3 Figure 4 Page 71 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS AWabtec company ASCTD User s amp Set up Manual Figure 5 Figure 6 Figure 7 October 2005 Page 72 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company Changing out th
56. ent during soap test o DISCONNECT NO RECEIVER COVER LEAKAGE Confirmation that the operator has attached the cover to the receiver and the cover is sealed tight RESERVOIR DRAINED Confirmation that the operator has drained the reservoirs by pulling the manual release rod ASCTD DOWNLOAD INSTRUCTIONS 1 Turn ON ASCTD and PC 2 Connect null modem serial cable from PC to ASCTD 3 From ASCTD MAIN MENU select option 5 UTILITIES and enter password 4 From UTILITIES MENU select option 4 Results and enter password 5 Select option 2 TRANSFER RESULTS TO PC The following message will appear on the ASCTD screen DOWNLOAD PROG REQUIRES A PASSWORD TYPE PASSWORD _ PRESS ENTER YES END BS DEL 6 Enter user password Press YES ENTER The following message will appear on the ASCTD screen START X MODEM TRANSFER RECEIVE WITH CHECKSUM ON HOST PC NOW CONSOLE RS232 PORT IS AT 38400 BAUD 8 DATA BITS PRESS ANY KEY TO START October 2005 Page 18 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company NOTE DO NOT PRESS ANY KEYS ON THE ASCTD AT THIS TIME 7 Select the X Modem16 Application from the program manager on your PC The following window should appear 8 Onthe PC click on File at the top of the Xmodem16 program window from the drop down menu select Start Transfer 9 Press YES on ASCTD to begin downloading process 10 After all the files are downloaded to t
57. for any binding or fouling e MANUAL RELEASE AUX lt 1 PSI DROP EM lt 1 PSI DROP BC lt 5 After the manual release rod is pulled for 3 seconds the ASCTD will confirm that auxiliary and emergency reservoir pressures do not decrease during a preset time This checks for leakage at the manual release valve The ASCTD will also confirm that brake cylinder pressure reduces This checks the operation of the manual quick release function BP INCREASE lt 2 5 After the manual release rod is pulled the ASCTD will confirm that brake pipe does not increase during a preset time This checks proper operation of the release valve to avoid recharging brake pipe Page 15 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual f VENT VALVE TEST Vent Valve Emergency Test BP lt 7 The ASCTD will confirm the auxiliary venting device vent valve or separate emergency portion goes to emergency and brake pipe pressure This checks proper operation of the vent valve or separate emergency portion g CUT OUT MINIMUM APPLICATION TEST Minimum Application and Applied Leakage Test DUMMY CONNECTORS REMOVED Confirmation that the operator has removed the dummy couplings BC lt 5 BC remains in released position BP DROP gt 3 The ASCTD will generate a 3 psi brake pipe reduction for the brake cylinder increase test BC INCREASE TO gt 6 After the 6 psi brake pipe
58. he PC Transfer Completed should appear on the PC Click OK to continue 11 Thefollowing screen should appear on the ASCTD TRANSFERRING RESULTS TO PC RESULT FINISHED PRESS ANY KEY TO CONTINUE PRESS ANY KEY ON THE ASCTD AND REPEAT STEPS 4 9 TO DOWNLOAD TESTER AGAIN DISCONNECT NULL MODEM CABLE AFTER SECOND TRANSFER HAS BEEN COMPLETED 12 The data files are stored in an RX_ FILES subdirectory ofthe X Modem16 application The range forthe received file names is from Asctw000 datto Asctw999 dat Check the RX_FILE subdirectory and compare the file sizes of the last two files downloaded will be the files with the highest numbers Both files should be the same size this ensures the download process was properly completed 13 Format the D drive on the ASCTD this will erase all results From MAIN MENU select option 5 UTILITIES and enter password From UTILITIES MENU select option 6 DISK and enter password Select option 2 FORMAT and press YES to format ASCTD will format press any key when done 14 Verify format From UTILITIES MENU select option 4 RESULTS Select option 1 SELECT AND DISPLAY RESULTS ASCTD display should read NO RESULTS FOUND Exit to MAIN MENU Page 19 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS AWabtec company ASCTD User s amp Set up Manual ASCTD External Database Program P C 0310337 Rev F User s Manual Revision D WABCO Automated Single Car Test
59. he retainer to Direct Exhaust the ASCTD will confirm that brake cylinder pressure reduces This is part of the retainer test October 2005 Page 14 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company HAND BRAKE SYSTEM OK Confirmation that the hand brake has been inspected and lubricated AN WARNING Use caution to prevent personal injury from moving parts FLOW lt Limit The ASCTD will confirm the system has flowrated to less than 225 cubic inches minute 60 cubic inches minute for the dead ball option After the system flowrates the device will wait an additional time out before recording the results This is the system leakage test c B 1AAV B 1 Quick Service Valve Test B 1 CHARACTERISTIC COUNT gt 0 The ASCTD will confirm an increase in the reduction rate of brake pipe pressure This will ensure that the B 1 Quick Service Valve is operating d SYSTEM STABILITY System Service Stability Test cut out cock open BP gt 5 The ASCTD will confirm the system did not go to an emergency application and that brake pipe pressure remains BP DROP lt 1 The ASCTD will confirm the Accelerated Application Valve does not continue to reduce brake pipe after the reduction has stopped PISTON TRAVEL WITHIN LIMITS Confirmation that the operator has measured piston travel and it is correct RIGGING SYSTEM OK Confirmation that the operator has checked the rigging
60. ica aaia a Rita 60 FEOW CALIBRATION E RSS Re tee tach dt ras iaa iii ii 64 BATTERY REPLACEMENT GUIDE cccccococccccnoncnononnnnnnnnonnnonn cnn rn 69 October 2005 Page 2 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company GENERAL INFORMATION The function of this manual is to describe appropriate procedures for setting up and operation of the Wabtec Corporation Automated Single Car Test Device IMPORTANT The operator must observe all AAR requirements for air brake testing For this reason copies of all applicable AAR standards should be readily available to the operator at the time of testing 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 also responsible for properly informing other designated operators the intended purpose of this test device This test device is designed to automatically test the operation of the air brake system on freight cars 1 0 INTRODUCTION Throughout this document the following will be referred to e SSPB will refer to Single Sided Pipe Bracket e ASCTD will be refer to Automated Single Car Test Device EOC will refer to End of Car Car will refer to one complete set of air brake equipment consisting of one control valve and all associat
61. ication and brake pipe pressure reduces This checks the function of the vent valve in the emergency portion k HIGH PRESSURE MOVEMENT AX EM BC WITHIN 5 PSI After the emergency application the ASCTD will confirm that auxiliary emergency and brake cylinder pressures are all equalized This checks the function of the high pressure spool valve in the emergency portion BP lt 2 After the emergency application the ASCTD will confirm the brake pipe pressure does not increase during a preset time This checks for leakage into brake pipe Note This result will read unused unless previous test failed Page 17 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual PISTON TRAVEL NOMINALLY THE SAME Confirmation that the operator has measured Piston travel and is nominally the same as measured before AX WARNING Use caution to prevent personal injury from moving parts I EMERGENCY ACCELERATED RELEASE BP gt 32 The ASCTD increases brake pipe to 28 psi and then stops The ASCTD will confirm that brake pipe pressure continues to increase This checks the emergency accelerated release function in the emergency portion m EMPTY LOAD TEST PRESSURE DIFFERENCE Empty Brake Cylinder pressure greater than or equal to 20 psi less than loaded pressure EMPTY E L BC gt 10 Brake Cylinder pressure greater than 10 psi E L SOAP NO LEAKAGE No leakage on Empty Load equipm
62. ieste ada batas 26 10 4 Menus and Command Definitions sisi 26 10 4 1 Menu System for the ASC T program iii 27 10 5 Usimg ASC TIEXE Import test tle ci use mn liens ain Minnie ut eee 27 10 6 Using ASCT EXE Exporttest file usine 29 10 The Flor WIN Wicca soii desde secs Nice asin 30 10 8 Change PASSWOrdS SCENE A eles 32 10 9 Log File Display Window unes ii liada 32 11 0 USERS MAINTENANCE SCREEN Superuser Access Only coccccccccconccccccnoonnncnoncanannncccnnn o nan nana cn nn nnn cnc nan nn ieai 33 11 1 The SQL Statement Window Superuser Access Only 33 TL2 External Database Reports ns om nat etes dodo laaetessia desadeetelare dees se et dde ner 34 11 2 1 Detail Report Sample ASCT Test Passed iii 35 11 2 2 Summary Report Sample aae aan aS aaa aaO eeeh Saanaa aS aaO GENNA 36 TALS ADOUTSCE SN usais dao 37 12 00 n USER OPTIONS aa eae e net aa a ta aaa eaaa Ee E a EE aea E eaa aaa aaan 39 121 CHANGING USER OPTION Soronia tanase eee Re aea aeaa aaa a 39 122 SCREEN INFORMATION oia A a er ice ieee 40 123 DAILY TESTFOR TEST DEVICE cotos id ne been 40 124 SINGLE CAR WES I iriaren oaiae a sae dalla eaea aea io na E ea Eada Taes 45 12 44 TES DEVICE OPERATIONS criin nien n hn en N OEE 46 125 SPECIAL TESTS aeneae ii da ii td a ETAN Nai 50 TROUBLE SHOOTING GUIDE anisitsi oneen ane aE aea EE aaa aa Ea ae eE E aa EE aea aaaea aea raea a 59 CALIBRATIONSPECIFIGATION wiscessatet nesses otis eezeeaaccg cn
63. ified PC keyboard On Off buttons Emergency button Quit button Yes No buttons up down left right arrow buttons and battery status lights 2 0 N WARNINGS Air will be discharged at intervals throughout the test To minimize any possible injury personal eye and ear protection must be worn when performing any work with this test device Supply air MUST FIRST BE BLOWN OUT and then coupled securely to ASCTD When charging or operating the test device while plugged in to a wall outlet the outlet must be equipped with a ground fault interrupter GFI When performing tests all personnel must be clear of car body and under frame mechanisms When storing the ASCTD for an extended period of time greater than one week the battery must be turned off Disconnect supply air from the ASCTD when not in use Test device must be calibrated every 365 days as per AAR S 486 par 2 2 Pretest Instructions contact a Wabtec Corporation Field Engineering Representative for Calibration Kit and procedures 412 825 1000 NOTE The internal components of this unit are extremely sensitive Only authorized personnel and qualified Wabtec Corporation technicians are allowed access 3 0 SAFETY CONSIDERATIONS Audible Warning The ASCTD is equipped with an audible warning to alert workers and bystanders of an impending brake action After the warning sounds any appropriate personnel should be verbally warned by the operator of an imminent brake action Emergency D
64. laceable internal battery pack that is charged through a 110 VAC power outlet The charging outlet is located on the right side of the test device when facing the screen For operation using AC power the test device must be plugged into a ground fault circuit interrupter GFI outlet to preclude potential electrical shock Battery Charging Battery life is approximately 8 hours within the operating temperature range of the device The battery status can be monitored through a series of lights on the control panel When the battery voltage is very low last red light a fault error will be displayed and all power will be shut down within 2 minutes NOTE If the battery power is drained and the 110 VAC power is needed the operator can only continue by waiting at least 10 minutes before the ASCTD power is recharged The batteries will continue to charge while the AC power is applied Supply Pressure Wabtec Corporation recommends the test device be operated with a minimum continuous supply pressure of 110 psi and a maximum of 150 psi The device is equipped with pressure relief protection capable of venting the device if the pressure exceeds 150 psi Environmental The test device has an operating range of 13 F to 150 F 25 C to 65 C The test device may not operate solely on battery power below 4 F 20 C 6 0 EQUIPMENT FUNCTION SUPERVISOR SETUP PASSWORD ASSIGNMENT Passwords are used to access information retrieve ol
65. m The startup state of the database has the records no filter displayed by date order with the most recent records displayed first Two icons at the bottom of the window in the status bar indicate e The sort order of the selected column of the table S ascending or descending The filtered state of the database table This indicates whether or not you are seeing all the records or a smaller set ofthe table records WA filtered some of the records or no filter all the records are displayed October 2005 Page 24 of 74 5039 4 S 6 O WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s amp Set up Manual NOTE The record count displayed is the count for the current set of records if there is no filter set all records are displayed Ifa filter has been set in the Filter window the filtered set of records will be displayed NOTE Click once on a grid header to sort the list in ascending order click again on the header to sort the list in descending order Pop up menu with close Database Grid with a vertical Scroll bar The database Se minimize window standard grid shows the top of the database on startup or the ania functions results of a search If you click on one of the column Minimize D Menu Bar headers the column will be sorted in ascending order button a Click the header again to reverse the sort A 191 2 MB sc none 71 12427 71 21427 71 15846 71 14407 2000 01 19 02 47 07 2000
66. mature release in the applied leakage test Passed Range lt 0 50 psi Value __ Applied leakage OK with respect to EM Passed _ Range lt 1 00 psi Value Applied leakage OK with respect to flow Passed ange lt 275 or 110 in min Value Control Valve AAV Test Slope change found Passed Limiting Valve Test Limiting valve OK Passed l Range gt 5 00 psi Value 6 180 Figure 22 ASCT Reporis Detail Report Passed Test Page 35 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s amp Set up Manual DETAIL REPORT SAMPLE ASCT TEST PASSED PAGE 2 Car number 11 WABCO ASCT Detail Report Test date 2002 09 11 11 44 08 Freight Car Products 2002 10 01 20 56 33 Test result PASSED Test type Single Car Test Location lt none gt Service Release Test 7 Service release OK Passed o Range 0 70 2 20 psi Value 0 793 Service release time is OK Passed Range 0 90 seconds Value 6 100 Service Stability Test i No emergency occurred during a reduction to 64 psi using E7 Passed en Range gt 5 00 psi Value 65 428 No AAV run on Passed Range lt 1 00 psi Value 1 003 Emergency Test o Emergency occurred as E3 and E7 were open for 1 5 seconds Passed y Range lt 5 00 psi Value 0 027 High Pressure
67. nally the columns can be sorted by clicking on the column headers The data stored in the database can also be exported to a file where it can be transported to another machine and imported into another database on another machine NOTE See the Automated Single Car Test Device ASCTD User Manual for assistance in obtaining the results file for import into the database Page 21 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS AWabtec company ASCTD User s amp Set up Manual 9 1 IMPORT DATA FORMAT To be imported into the database the ASCTD Results file must be in the upload format Revision R 6 16 97 or later The ASCT EXE program validates all fields in each record when the record matches the above format and version 9 2 PROGRAM INSTALLATION The ASCT EXE is shipped with its own installation program To install ASCT EXE on the computer Put disk 1 ofthe ASCT disk set in the floppy disk drive Select Run from the Program manager File menu Type a setup exe and press enter The setup program will proceed to install the program 5 The User designated as the local SuperUser will have to assign users to the program before anyone else can logon See User Maintenance for instructions NOTE Make sure there is no other application running PON gt e This is the first screen from installation procedure Click OK button to continue ASCT Setup Welcome to the ASCT installation program Pr
68. nel and keyboard See layout of control panel on the following pages Printer and Download Ports Used for connecting to computer and or printer for access to test records Interface Connector and Bundled Hoses Access connection used to connect unit to freight car for testing procedures Interface Connector Storage Storage of the interface connector is important to prevent damage and resulting leakage during the testing of individual cars Daily test plate is also stored here Page 5 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual Latches for Internal Access Opens the front cover of the unit Only authorized personnel are allowed access to the internal components of this unit Manual Drain Valve Newer units may be equipped with this valve located on the right side at the bottom edge of the test device front view Layout of the Control Panel Emergency On Off Drain Button Buttons Power On Cm 110 V AC Display DC Power Fault amy o 7 Screen w o AA Quit Battery Charging A H Function _ OQO9OVOOO00 e Status OOOVVVVAVOOE Lianie AOOOOVOVOVVE A 00000 Yes No Buttons Modified PC Keyboard Up Down Left Right Buttons Display Screen Uses 6 lines with a maximum of 40 characters The screen will provide directions and information for the user during the test procedures Keyboard Layout of the keyb
69. ng and correcting the failed component or situation The test device will provide error messages when a test procedure fails due to a fault related to the test device For error messages not correctable by the operator contact the Wabtec Corporation Representative NOTE Each Error message shown will have a FAULT CODE When contacting the Wabtec Corporation Representative please provide this fault code shown on the screen This information will facilitate quicker and more accurate responses to problems encountered 12 3 DAILY TEST FOR TEST DEVICE IMPORTANT ASCTD is to be tested each day prior to initial use any malfunction must be correc3etd before testing the valves To perform the daily test turn machine on by pressing the ON button Unit will turn on and perform internal tests showing various screens If the unit encounters problems during this procedure it will notify the operator through a diagnostic message Further use of the test device will not be possible until corrective action is taken Follow screen directions see troubleshooting guide in this book or contact your Wabtec Corporation Representative as applicable NOTE Notall screens will be exactly as depicted in this manual revision date of internal software will dictate the screen information shown IS DATE AND TIME CORRECT DAY MONTH TIME YEAR PRESS YES OK NO CHANGE 1 ENGLISH 2ESPANOL 3 FRANCAIS S BP _ A E BC _ If the correct time and date are shown the operat
70. ng screen indicating the daily test has passed DAILY TEST PASSED PRESS ANY KEY TO CONTINUE S __ BP _ A E BC _ Press any key to continue October 2005 Page 44 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtee company Pressing any key at this time will shut down the ASCTD The result of the daily test will be saved Any error code will be saved and the result written to the computer results file The date of the last daily test will also be saved and returned to the computer results file To restart the unit press the ON button 12 4 SINGLE CAR TEST AX WARNINGS Chock car wheels to restrict movement of the test car Warning placards blue flag indicating work is being performed should be placed in accordance with railroad safety practices All workers and bystanders must be clear of car under test The ASCTD will sound an audible warning just before brake applications except when using manual control for EOC Test Adapter in the Manual Operations Menu Bystanders should be alerted accordingly to protect their ears One beep Brake cylinder piston about to move and apply brakes Two beeps Emergency application expect a loud sudden discharge of air Before performing any work on the car valves and or any other air brake equipment make sure all air is depleted from the system to minimize potential personal injury A WARNING It is possible that the brakes may apply
71. oard is a modified version of a computer keyboard On Off Buttons Used for turning the unit ON and OFF Yes No Buttons Used to respond to questions and prompts shown on the display screen Up Down Left Right Buttons Use of these buttons will move the cursor on the screen Power On Indicator Indicates the device is turned on to battery power or plugged into 110 VAC Ground Fault Interrupter To prevent electrical malfunction the unit must be connected to a ground fault circuit interrupter GFI outlet DC Power Fault Light Indicates that the DC voltage is not within limits Battery Charging Light Indicates the battery is being charged Battery Status Lights Indicates the battery charge status When the battery power gets low amber lights plug the unit into AC Power October 2005 Page 6 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company Emergency Drain Button The ASCTD is equipped with an emergency drain function The emergency drain button should be pressed when an unexpected dangerous event occurs The emergency drain function is to be used only in emergency situations and is not intended as a quit function Quit Function Button The ASCTD is equipped with a quit function The quit function should be pressed when the testing needs to be stopped in a non emergency situation 5 0 REQUIREMENTS Electrical The test device is powered by a rep
72. om the default password Change Password Change Password for auser GATT o Coin Passar Figure 18 Change Passwords Screen 10 9 LOG FILE DISPLAY WINDOW The Log File display window Figure 19 Log File Display and Filter Window includes a filter capability where log file information can be queried by one of or a combination of log file date user logon or database file action The Log File display is filtered by user so the user only sees the user s own log records The log file data display grid is similar to the Main Grid and the User Maintenance data grid where the column can be sorted by clicking on the header The Status bar icons function identically to the status bar icons on the main screen For information on using the filters please review the main grid filter section NOTE The Log File Display Window will have a Delete Button which will allow the SuperUser to Delete records selected by the filter This button only appears when the SuperUser is logged on A T Log Date mkogbe mrkogbe micgilo mkog e kote mkogte rhogbe rhogbe rhogbe Figure 19 Log File Display and Filter Window October 2005 Page 32 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtee company 11 0 USERS MAINTENANCE SCREEN SUPERUSER ACCESS ONLY The SuperUser can add database users The SuperUser cannot assign or read the passwords the SuperUser can clear the
73. on rate for brake pipe pressure This is the AAV test which checks the Accelerated Application Valve function in the emergency valve BC gt 5 The ASCTD decreases the brake cylinder pressure and then stops The Quick Service Limiting Valve must reopen and increase brake cylinder pressure The ASCTD will confirm the brake cylinder pressure increases This is the quick service limiting valve test h SERVICE RELEASE Slow Release Test BP AX gt 0 7 AND lt 2 2 The ASCTD will increase brake pipe at a controlled rate After the control valve goes to release position the ASCTD will confirm that brake pipe pressure is higher than auxiliary reservoir pressure This checks the sensitivity of the service portion RELEASE TIME lt 90 The ASCTD confirms that the release differential is obtained within 90 seconds i SERVICE STABILITY Control Valve Service Stability Test cut out cock closed BP gt 5 The ASCTD will confirm the control valve did not go to an emergency application and that brake pipe pressure remains BP DROP lt 1 0 The ASCTD will confirm the Accelerated Application Valve does not continue to reduce brake pipe after the reduction has stopped Brake pipe pressure does not drop during a preset time j EMERGENCY TEST Control Valve Emergency Test EMBC FSBC gt 5 Emergency Brake Cylinder pressure at least 5 psi higher than Full Service BP lt 5 The ASCTD will confirm the control valve goes to an emergency appl
74. operator has ensured that both angle cocks and branch pipe cut out cocks are open AIR FLOW THROUGH HOSE Confirmation that the operator felt air flow from both ends of the brake pipe This will ensure continuity of the brake pipe It also verifies the supply air is connected DUMMY CONNECTORS INSTALLED Confirmation that the operator has installed the dummy couplings b CHARGE RETAINER LEAK HAND BRAKE AUXINCREASE 1 8 EM INCREASED 0 3 5 After the brake pipe is charged to 20 psi the ASCTD will confirm that auxiliary and emergency reservoir pressures charge within limits This is the charge test which ensures that the reservoirs charge properly through the control valve BC lt 1 5 The ASCTD will confirm that brake cylinder does not increase during a preset time while charging This checks for leakage to the retainer from the service or emergency portion BC DROP lt 1 5 After the brake cylinder has charged to 16 psi and the retainer is in High Pressure position the ASCTD will confirm the brake cylinder pressure does not drop during a preset time This is the retainer test BC AFTER DROP gt 10 The ASCTD will confirm at least 10 psi remains in the brake cylinder after a preset time This checks for a defective retainer that allows brake cylinder pressure to zero If the cylinder leaks to zero before the previous test the test will pass because no drop can occur from zero This is also part of the retainer test BC lt 5 After moving t
75. or should press the YES button and test device will move to the MAIN MENU screen MAIN MENU hh mm ss 1 SGL CAR TEST 4 DAILY TEST 2 RESERVED 5 UTILITIES 3 SPECIAL TESTS 6 VENTSYSTEM S BP _ A E BC _ Press 4 on keyboard to have unit perform the daily test October 2005 Page 40 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company The result of this testis intended to be stored and saved to a data file The results are also intended to be returned in the data file and transferred from the test device to a computer The Daily Test consists of e A Warning Check An Interface Connector Test A Test Plate Connection A Leakage Test A Valve Test e Brake Cylinder Gauge Test e e An Emergency Drain Test Running the daily test will overwrite the previous test result and may show the following screen DAILY TEST PRESS YES CONTINUE NO EXIT S _ BP _ A E BC _ To continue press the YES button If you do not want the previous test results erased press the NO button Test will abort and test device will return to main menu IFYES was pressed the following screen will appear WOULD YOU LIKE TO CHECK AND TEST A BRAKE CYLINDER GAUGE YES NO S _ BP _ A E _ BC __ If NO was pressed a Brake Cylinder Gauge Test will not be performed Select the appropriate option and the following screen will appear CONNECT SUPPLY AIR TO TESTER PRESS YES TO CONTINUE S
76. osing the needle valve press YES to continue FLOWMETER CALIBRATION MASTER 0 00 CAL POINT 1 MAX 12 VOLTS X XX YES ACCEPT VALUES NO REPEAT QUIT ABORT 15 Priorto pressing YES record the voltage value reading in the CALIBRATION column of the ASCTD Flow Calibration Fill In Sheet for the first CAL POINT OCIM Press YES to accept values FLOWMETER CALIBRATION MASTER 50 00 CAL POINT 2 MAX 12 SET FLOW METER TO 50 CIM PRESS YES TO CONTINUE 16 Set the flow meter to 50 CIM 2 line up from the bottom of the Flow Tube Press YES to continue FLOWMETER CALIBRATION MASTER 50 00 CAL POINT 2 MAX 12 VOLTS X XX YES ACCEPT VALUES NO REPEAT QUIT ABORT 17 Prior to pressing YES wait 10 seconds and record the voltage value in the CALIBRATION column of the ASCTD Flow Calibration Fill In Sheet for the second CAL POINT 50 CIM Press YES to accept values 18 Repeat steps 16 and 17 for the remaining calibration points After pressing YES to accept values for the last calibration point CAL POINT 12 the ASCTD will display the following screen FLOWMETER CALIBRATION CALIBRATION POINTS ARE READY PRESS YES TO CONTINUE 19 Press YES SYSTEM VENT UTILITY System vents and automatically proceeds to the next screen This message flashes very quickly 20 From SENSOR CALIBRATION UTILITY select YES SAVE SAVING CALIBRATION Calibration is saved This message flashes very quickly October 2005 Page 66 of 74 5039 4 S
77. over using the latches for internal access Figure 2 and locate aluminum box with a large yellow cable plugged into it Place the toggle switch to ON and close the front cover of the test device Switch must be turned OFF for shipping purposes Unit should be left on charge overnight before using for the first time When using this booklet for testing using the ASCTD the operator will note the following e This booklet was designed using Generation II ASCTD screen information e Screens or possible screens are shown in bold print e Not all screens shown in this booklet may be the same as the machine you are operating Set Up 1 After the battery switch has been turned ON plug in the unit to an electrical outlet to start the batteries charging and to perform the initial tests on the unit 2 Connect to a source of clean dry air See Supply Pressure Attach a flexible air hose to the air inlet of the test device and the other end to the air supply See IMPORTANT below IMPORTANT This unit and the control valves are very sensitive to condensation moisture and debris supply air must be blown out of the air hose before connecting to the ASCTD 3 Turn the unit ON It will sequence through several screens and perform a self analysis Eventually a screen will appear similar to the one shown below requiring input from the operator IS DATE AND TIME CORRECT DAY MONTH TIME YEAR PRESS YES OK NO CHANGE 1 ENGLISH 2ESPANO
78. port though the progress bar updates will occur less frequently e Select the Import file Selectthe source drive directory folder and file for import into the database ASCT EXE automatically searches for a disk in drive A first then in the directory where ASCT EXE is stored The Import Test File window is preset to only display files of the type from the ASCTD The file to be imported must be selected from the list or the exact file name typed in the File Name box Press OK to continue or cancel to abort the import 7371 dz Cancel e harel Bet PS act Lit Fier of Tepe ASET Files asot de Figure 7 Import Test File Open Dialog Page 27 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS AWabtec company ASCTD User s amp Set up Manual e ASCT EXE will display the message box below Figure 8 if the import file is a previously exported file ASCT This file is a previously exported test file Date Time 8 13 97 8 10 AM Records 125 User A User Do you want to continue Figure 8 You selected an ASCT Export File e Click the Yes button to continue importing a previously exported file The following message is displayed informing the user of the export file size so that if the file is larger the user is aware before the import takes place ASCT This is an export test data Do you want to continue Figure 9 ASCT Export file details
79. rain Function The ASCTD is equipped with an emergency drain function The emergency drain button should be pressed when an unexpected dangerous event occurs October 2005 Page 4 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company 4 0 EQUIPMENT FEATURES The Automated Single Car Test Device incorporates the following equipment features NOTE Certain models of the test device may differ slightly from the figures shown Please contact your Wabtec Corporation Representative for help or an explanation of any equipment not fully explained in this manual Display Screen 110V AC and Battery Bundled Charging Plug In Hoses Interface Connector and Daily Latches for Test Plate Printer and Internal Access e Sa Storage Download Ports Front View Back View Automated Single Car Test Device Automated Single Car Test Device Plug In for 110 Volt AC Power It is recommended the unit to be operated under AC Power It will operate on battery power for short periods of time The batteries will charge while the unit is being operated under AC power Unit will operate on battery power for approximately 8 hours Air Supply Connection Due to the diverse type of air connections in each individual shop Wabtec Corporation has not equipped the unit with any standard air supply coupling Control Panel All operating functions are initiated through the control pa
80. rd Details window All results record items saved to the database are listed in the window The memo field appears in its own box so that the user can read the entire message The yellow background is changed to a red background for the fields that failed Record Details x Car number Test date Test result PASSED Test type Location Device serial number Software version Version number Daily test date Daily test result Passed 00 Operator name Stamp number Lot number Test duration Temperature 11 C 222 Error code e ES Description No Errors Print Record Close Test Description Memo Figure 5 Record Details Window e Click on the Print Record button to print a Detail Report for this record see section on Reporting for details and example e Click on the Close button to close the Record Details Window and return to the Main Screen 10 4 MENUS AND COMMAND DEFINITIONS The ASCT EXE program uses a standard Windows menu system to access program functions The menu system is different for SuperUsers and for Users The SuperUser has access to additional program functions for maintaining the user database and the SuperUser can view the SQL statement used to filter the database October 2005 Page 26 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s amp Set up Manual 10 4 1 MENU SYSTEM FOR THE ASCT PROGRAM e NOTE The menu displayed is the menu
81. rn onthe test device 3 Wait for the main menu screen to appear on the ASCTD 4 Turn on the printer If the power light does not appear on the printer turn off the printer immediately and repeat the procedure b Disconnecting the Printer 1 Turn off the power to the test device 2 Turn off the power to the printer before disconnecting the printer cable All power has to be off before the printer cable is disconnected ACCESSING RESULTS The results can be searched by the following criteria operator e certain date before and after number of tests car number test type or any combination of the above For viewing purposes or using the printer after connecting the printer to the test device and with the unit turned on the Main Menu will appear To obtain information from the Main Menu select Utilities by pressing 5 Enter the password in the next screen as indicated earlier in this booklet The unit will move to the next screen requiring a prompt from the operator October 2005 Page 12 0f 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company UTILITIES MENU hh mm ss 1 CALIBRATION 4 RESULTS 2 TIME amp DATE 5 PROGRAM 3 PASSWORDS 6 DISK NO EXIT Sz_ BP _ A _ E BC _ Press 4 to access the Results function RESULTS 1 SELECT amp DISPLAY RESULTS 2 TRANSFER RESULTS TO PC NO EXIT Sz_ BP _ A _ E BC _ Press 1 to
82. s Once the system is charged a brake application will be made and the values will change FULL SERVICE APPLICATION FROM 90 PSI CHARGE PRESS 9 FROM 70 PSI CHARGE PRESS 7 ENTER THE OPTION S BP _ A __E BC __ October 2005 Page 52 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual A Wabtec company After selecting the desired option 7 or 9 the unit will automatically charge the car and make a FULL SERVICE APPLICATION 4 Emergency Application To initiate an emergency brake application press 4 in Manual Operations Menu Test device will charge brake system as indicated Values of the brake pipe BP auxiliary reservoir AX emergency reservoir EM and brake cylinder BC will change as the pressure increases Once the system is charged a brake application will be made and the values will change EMERGENCY APPLICATION FROM 90 PSI CHARGE PRESS 9 FROM 70 PSI CHARGE PRESS 7 ENTER THE OPTION S _BP _ A _ E BC _ After selecting the desired option 7 or 9 the unit will automatically charge the car and make an EMERGENCY APPLICATION 5 Charging the Brake Pipe To charge the brake pipe press 5 in the Manual Operations Menu Using this manual function the operator can observe the flow rating of the brake pipe to check leakage without performing a full air brake test Test device will charge brake system as indicated Values of the br
83. s the Main Screen The application stores the users and the passwords in a file with the database Only Wabtec Corporation personnel or the user designated as the SuperUser can add or delete users Any user can change their password once logged on to the application The maximum character length for the User ID is 32 characters and the maximum length for the password is 64 characters The User ID is saved from the last logon if there was one and the user is automatically placed to enter text at the password edit box The logon will only allow three unsuccessful attempts to logon failure to logon will cause the application to quit A message box appears if the password is not valid If the logon is successful the logon screen will be replaced by the Welcome screen e Enter your User ID and password e Click on the OK button once you have typed in your User ID and password e Click on the Cancel button to abort The application will quit D WABCO ASCT NOTE The SuperUser ID will never be saved as the default User User auser l Compact Database ma Figure 2 ASCT EXE Logon Screen Page 23 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 10 1 1 COMPACT DATABASE The application can detect corruption in the database during startup If the database needs to be repaired the application will start the repair procedure by itself If a repair was necess
84. sequence of screens The test device will show pressures in the following areas the brake pipe BP auxiliary reservoir AX emergency reservoir EM and brake cylinder BC These values will change as the pressure in the car brake system changes CHARGING UP SYSTEM BP AX EM __ BC NO EXIT S _ BP _ Az _ Ez_ BC __ lt DROP BP gt CHARGE BP NO EXIT BP AX EM BC S BP A E BC _ Use left arrow button to start and stop the brake pipe reduction Use the right arrow button to charge the brake pipe 2 20 psi Reduction To initiate a 20 psi reduction in brake pipe press 2 in Manual Operations Menu Test device will charge areas indicated Values of the brake pipe BP auxiliary reservoir AX emergency reservoir EM and brake cylinder BC will change as the pressure increases Once the system is charged a brake application will be made and the values will change 20 PSI REDUCTION FROM 90 PSI CHARGE PRESS 9 FROM 70 PSI CHARGE PRESS 7 ENTER THE OPTION __ S BP _ Az E BC __ After selecting the desired option 7 or 9 the unit will automatically charge the car and make a 20 psi reduction 3 Full Service Application To initiate a full service brake application press 3 in Manual Operations Menu Test device will charge brake system as indicated Values of the brake pipe BP auxiliary reservoir AX emergency reservoir EM and brake cylinder BC will change as the pressure increase
85. ser s Set up Manual REVISIONS The ASCT Tester External Database Program Source Details and Test Plans document revisions are listed in the table below Revision A 06 08 97 User Documentation Revision B 06 29 00 Changes for software Rev D Revision C 10 02 02 Changes for software Rev E Revision D 24 06 04 Changes for software Rev F October 2005 Page 38 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company 12 0 USER OPTIONS The end user may choose several options from this menu They are as follows Car Identification The operator may include the car stamp and car lot number prompts in the Car Identification Brake System Setup section of the Single Car Test Leakage Limit The set leakage limit is 225 cubic inches per minute red condemning limit on the manual test device flowrator There is the option to defaultthe leakage limitto 60 cubic inches per minute dead ball on the manual test device flowrator if desired 12 1 CHANGING USER OPTIONS Changes in the User Options are done in the following steps MAIN MENU hh mm ss 1 SGL CAR TEST 4 DAILY TEST 2 RESERVED 5 UTILITIES 3 SPECIAL TESTS 6 VENT SYSTEM S BP A Ez BC __ Press key 5 to access the Utilities Menu UTILITIES MENU NO EXIT PAGE 1 1 CALIBRATION 4 RESULTS 2 TIME amp DATE 5 PROGRAM 3 PASSWORDS 6 DISK S _ BP _ A _ Ez_ BC _ The Utilities Menu has 2 p
86. splayed ENASETDOA DAT C5 This tile already sisis Aeplace existing Get ves Lee Figure 14 Export File Destination file exists message box Page 29 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS AWabtec company ASCTD User s amp Set up Manual If the user clicks Yes then the export file will overwrite the existing file otherwise the user will be able to select another filename from the Export dialog e The user is prompted by a message box Figure 15 before the export will continue A Exporting 5797 records to C ASCT ASCTXO06 DAT Do you want to continue Figure 15 Export File Continue Message Tthe export file summary message Figure 16 ASCT Export ASCII File Export File Name CAASCTIASCTX006 DAT O Records exported from database file 5797 Elapsed time 00 06 18 Figure 16 Export File Summary Message 10 7 THE FILTER WINDOW Foi Figure 17 Filter Screen Define Filter Window NOTE The display grid might be empty if the filter is set for values that have been deleted or do not exist in the table NOTE Ifthe checkbox is not activated the field will not be included in the filter even though there is other filter information in the edit fields following October 2005 Page 30 of 74 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtee company To Apply a Filter to the data
87. t 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtec company 113 ABOUT SCREEN The about screen displays version and copyright information to the user e Clicking OK clears the About box and sets the focus back to the main screen ut WABCO ASCT This computer program is protected by copyright law and f international treaties Unauthorized reproduction or distribution L of this program or any portion of it may result in severe civil System Info and criminal penalties and will be prosecuted to the maximum extent possible under the law Figure 24 About Screen The System Info button starts the Microsoft Windows MSInfo program to provide system information for troubleshooting Microsoft System Info MS DOS version 6 20 Windows version 3 10 Mode 386 Enhanced Processor 80486 Math co processor installed Yes Available memory 14198 KB i e 73 GDI memory available 55 Total conventional memory 640 KB Total extended memory 15360 KB Swap file size 8188 KB Available space on drive C 313776 KB Available space on drive F 390080 KB Available space on drive H 284584 KB Available space on drive P 284584 KB Available space on drive Z 270280 KB Windows directory C WINDOWS TEMP directory CATEMP Figure 25 System Information Screen Page 37 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD U
88. test 1 2 10 11 12 Turn on the Digital Pressure Gauge HEISE let it warm up for 10 minutes Once warmed up zero the HEISE by depressing and holding the zero button until the display reads 0 00 psi Turn on the ASCTD connect air and plug unit in if necessary From MAIN MENU select option 5 UTILITIES From UTILITIES MENU select option 1 CALIBRATION Type password and press ENTER From CALIBRATION UTILITY select option 1 SENSOR CALIBRATION From SENSOR CALIBRATION UTILITY select option 1 CALIBRATE From SELECT SENSORS TO CALIBRATE select option 1 XDCRS TRANSDUCER CALIBRATION THE AMBIENT TEMPERATURE MUST BE WITHIN 60 TO 80 F 15 TO 26 C PRESS YES TO CONTINUE Press YES TRANSDUCER CALIBRATION SECURELY INSTALL BLANKING PLATE TO INTERFACE CONNECTOR PRESS YES TO CONTINUE Install the calibration test plate and connect the HEISE to the hose and the hose to the plate Press YES MUST USE TWO CALIBRATION POINTS WITH ONE AT ZERO PSI AND THE OTHER APPROX 90 PSI PRESS YES TO CONTINUE Press YES TRANSDUCER CALIBRATION MASTER CAL POINT 1 MAX 2 ENTER MASTER VALUE IN PSI PRESS YES CONTINUE NO REPEAT Page 61 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual 13 Master HEISE should read nominally 0 00 PSI Enter 0 00 and press YES to continue TRANSDUCER CALIBRATION MASTER 0 00 CAL POINT 1 MAX 2 VOLTS BP 0
89. the SuperUser sees This menu includes the Users Maintenance under the Utility menu This command is not seen by other users The File Reports and Help menus are the same for all users File Utilities Reports Help Import Test File F2 Export Test File F4 Filter Records F3 Print Detail Report Change Password Print Summary Report Contents F1 Search for Help On How to use Help Exit Change Location View Log File ErrorCodes Verify Data About Users Maintenance View SQL Convert Database From RevNew Convert Database From RevA B C The Menu Options Import Test File and Export Test File are only available when a normal user is logged in The Reports menu is only available Options when a normal user is logged on Language The Menu Options Users Maintenance View SQL Convert Database from RevNew and Convert Database From RevA B C are only available when the SuperUser is logged on Figure 6 ASCT Program Menu System 10 5 USING ASCT EXE IMPORT TEST FILE F2 Select Import Test File from the File menu or press F2 NOTE Although typical import files will be relatively small lt 1000 records it is possible to import a previously exported file It should be noted that the import time will be increased as the import file size is increased The progress bar will accurately reflect the progress of the im
90. upervisor will require levels 1 2 4 5 and 6 assigned during training b Time amp Date Setup If necessary the setting of the time and date is the responsibility of the person designated by the end user such as air brake supervisor or yard foreman From the Main Menu select 5 Utilities and press 5 The Utilities Menu will require a password as indicated next UTILITIES MENU REQUIRES A PASSWORD TYPE PASSWORD PRESS ENTER END BS DEL S _ BP A E BC _ The password assigned to the supervisor during training will be used The operator has to type the desired characters and then press ENTER UTILITIES MENU hh mm ss 1 CALIBRATION 4 RESULTS 2 TIME amp DATE 5 PROGRAM 3 PASSWORDS 6 DISK NO EXIT Sz_ BP _ A _ E BC _ Press 2 to access the Time Date function October 2005 Page 10 of 74 5039 4 S 6 FREIGHT CAR PRODUCTS ASCTD User s amp Set up Manual AWabtee company TIME amp DATE FUNCTION hh mm ss CURRENT Date Time 1 SET TIME 2 SET DATE NO EXIT S _ BP _A _ E _ BC _ The unit will display a time and date this information may be incorrect and changes are required Press 1 to change the time and 2 to change the date If the information displayed is correct press NO to exit If the operator selected the time to be changed the following screen will be shown TYPE TIME IN 24 HOUR FORMAT hh mm ss CURRENT TIME PRESS lt DEL gt BLANK PRESS Y
91. wing screens requiring input by the operator READY TO VENT SYSTEM VENT YES NO BP AX EM BC S BP A E BC _ Press YES to continue PLEASE WAIT BP AX EM BC S BP _ Az E BC _ SYSTEM VENT UTILITY WHEN SYSTEM IS VENTED YES CONTINUE BP AX EM BC S BP _ Az E BC _ Press YES to continue Page 57 of 74 October 2005 5039 4 S 6 WABCO FREIGHT CAR PRODUCTS A Wabtec company ASCTD User s Set up Manual b USING OPTION 2 MANUAL CONTROL GLAD HAND ADAPTER Select option 2 if you are using the GLAD ADAPTER and the following screen will appear CONNECT INTERFACE CONNECTOR AND GLAD HAND ADAPTER TO BRAKE PIPE HOSE CONNECT BRAKE CYL HOSE FROM BRAKE CYL READ DEVICE TO THE ADAPTER PRESS YES TO CONTINUE S BP _BC Follow the on screen prompts and press YES to continue on to the next screen MANUAL CONTROL FOR END OF HOSE ADAPTER 1 CHARGE 4 SLOW REDUCTION E EMERG 2 SLOWCHRG 5 SHORT STABILITY F FLOW 3 LAP 6 LONG STABILITY NO EXIT S BP _ BC __ This screen replicates the Manual Single Car Test Device Each corresponding number representing positions of the rotary valve handle Position 1 Quick charge of car brake system Position 2 Slow charge of car brake system Position 3 LAP No air movement Position 4 Slow reduction of brake pipe pressure to provide application of car brakes under control Position 5 Service Stability Short Car Rapid reduction of brake pipe

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