Abtus ABT-7100 User manual

ABT-7100 Abtus Track Geometry Measurement
Device
Instruction Manual

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1.0 Index
1.0 Index...........................................................................................................................................2
2.0 Item List ......................................................................................................................................3
3.0 Specification ...............................................................................................................................4
4.0 Getting Started ...........................................................................................................................5
4.1 Overview............................................................................................................................... 5
4.2 Assembly .............................................................................................................................. 6
5.0 Maintenance .............................................................................................................................13
5.1 Every 3 Months................................................................................................................... 13
5.2 Annual................................................................................................................................. 13
6.0 Measurement Characteristics...................................................................................................13
6.1Gauge ................................................................................................................................. 13
6.2 Super-Elevation .................................................................................................................. 13
6.3 Twist ................................................................................................................................... 14
6.4 Distance.............................................................................................................................. 14
6.5 GPS .................................................................................................................................... 14
7.0 Transportation and Storage......................................................................................................14
8.0 Software Introduction................................................................................................................15
8.1 Track Geometry Measurement Device Software ................................................................ 15
8.2 Initial Setup ......................................................................................................................... 15
9.0 Before going on track ...............................................................................................................15
9.1 Check Battery Levels.......................................................................................................... 15
9.2 Check Wireless Connection................................................................................................ 15
9.3 Before Each Use................................................................................................................. 16
9.4 Training and responsibilities ............................................................................................... 16
10.0 Step by Step Guide to Recording Geometry Measurements on Track.....................................17
10.1 Tools ................................................................................................................................... 23
11.0 Troubleshooting........................................................................................................................25
12.0 Software Updates .....................................................................................................................26
13.0 Directive and standards ............................................................................................................27

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2.0 Item List
1. TGMD = R(Right Side –Sprung end) + L(Left Side –Fixed end) + H(Handle)
(See assembly section of this manual)
•(1) (Right Side) contains: Gauge Retraction Lever (A)
•(2) (Left Side) contains: 2x Removable 12V Lithium Ion Batteries (B), On/Off Power
Button (C) & Locking Lever (D)
2. FZ-G1 Panasonic Tablet + User Manual & Charger
3. FZ-G1 Panasonic Tablet Holder
4. Battery Charger + Accessories
5. TGMD Instruction Manual
6. Transit Bags
L
A
R
H
6
6

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3.0 Specification
Weight
- TGMD on Track
- Bag 1 & Bag 2
- Panasonic Fz-G1 Tablet
- Chargers & Other
- TGMD in Bags
25 kg
3 kg ea. (Total 6 kg)
1.1 kg
1 kg & 1 kg
35 kg
Physical Dimensions
- TGMD on Track
- Bag 1
- Bag 2
Length: 1610 mm to 1700 mm
Height: 1000 mm
Width: 720 mm
Length: 850 mm
Height: 250 mm
Width: 450 mm
Length: 850 mm
Height: 250 mm
Width: 345 mm
Operating Temperature
-
-10°C to + 50°C (-4°F to 122°F)
Environmental Rating
-
IP65 Assembled
Battery Life
- TGMD 2x Lithium Ion
- Panasonic FZ-G1 Tablet
Up to 6 hours per battery
Up to 11 hours
Operating System
-
Windows 64 bit
Trolley Connectivity
-
Wi-Fi

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4.0 Getting Started
4.1 Overview
The Abtus ABT-7100 is a measuring device which records track geometry while being pushed by an
operator at walking speed.
The device can be assembled by one operator. Since the trolley weighs 25 kg, it should only be lifted
in its entirety if the user feels feel fit to do so, otherwise the trolley should be disassembled and carried
by two operators. The device can be dismantled to fit into two protective storage bags.
Track geometry data is transmitted from the measuring device via Wi-Fi to a Panasonic FZ-G1
running a Windows 64-bit operating system supplied with the Track Geometry Software. The software
displays track geometry data including Distance, Cant/ SE, Twist and Gauge in real time. The data
is saved as a .csv file that you can open in excel. Saved data and fault reports can be transferred
from the tablet via a USB flash drive or via email.
The TGMD is designed with the following characteristics:
•This product is used to accurately record Distance, Cant/SE, Twist and Gauge.
•Non-conducting: The trolley is insulated and therefore does not create electrical contact
between the two running rails. This is achieved by using plastic wheels and also
accommodates a non-conductive insulation block between the wheel arm and contact
bearings.
•Compact: The TGMD breaks down into 5 separate parts to allow it to fit into most vehicle.
•Portability: The TGMD is designed to be easily lifted onto and off the track. This is done
using the plastic lifting handles provided.
•The unit has been designed to be user-friendly with only limited training required.

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4.2 Assembly
•Place the wheel arm labelled ‘L’ and the fixed end of the track geometry trolley side by side as
shown in Figure 1.
•Push the locating pins at the end of the trolley body into the corresponding slots on the wheel
arm.
•Once they are placed square, push the wheel arm attachment screw inwards and start
tightening the screw in clockwise direction using the knob. When tightened there should be no
gap between the two parts and they should be secure.
•Repeat the same process for the right-hand side wheel arm (labelled ‘R’) and the sprung end
side of the trolley (Figure 2).
Figure 1 Attaching wheel arm to trolley (Left side)
Figure 2 Attaching wheel arm to sprung end of the trolley
(Right side)

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•Position the locking lever towards the left as shown in Figure 3.
•Push the two halves together as shown in Figure 4 & Figure 5.
Figure 3 - Initial Locking Position
Figure 4 - Joining of the Fixed & Rotating Halves
Figure 5 - Two Halves Together

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•Lock the two halves together by pushing the locking lever towards the right until it firmly snaps
into position.
•Before attaching the handle, ensure that the locking levers are positioned towards the
plunger on the back of the handle block as shown in Figure 7Figure 7.
Handle
Rotation
Plunger
Orientation
Indication
Mark
Figure 6 - Locked Position
Figure 7 - Handle Locking Lever
Position

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•Attach the handle to the TGMD ensuring that the indication marks are aligned as shown in
Figure 8.
Figure 9 - Handle Before Locked (levers towards green dot)
Figure 8 - Attaching the Handle

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•To lock the handle into position, rotate the locking levers away from the indication mark (green
dot) as shown in Figure 10.
•The TGMD comes with a tablet holder for the Panasonic FZ-G1 as shown in Figure 11, which
is spring loaded for ease of insertion and removal.
Figure 11 –Panasonic FZ-G1 Tablet and Holder
Figure 10 - Handle in its Locked Position

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•To attach the holder to the TGMD handle, simply insert the two 1” diameter rubber balls into
the short double socket arm cups as shown in Figure 12Figure 12.
•The TGMD has been designed with the user in mind. The trolley has a rotating handle to
prevent the user having to lift and rotate the trolley on track. The handle has three locking
positions and a position has been added to allow the user to push the trolley in the cess or in
areas of limited access. To rotate the handle please see Figure 13.
Figure 12 - Short Double Socket Arm
Figure 13 - Handle Rotation

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•The TGMD trolley has a retraction lever to allow the user on track to retract the gauge
through switch and crossing. The trolley uses a spring to self-align in the running rails, the
gauge is in its released position when the lever is towards the right as shown in Figure 14.
The gauge is in its retracted position when the lever is towards the left as shown in Figure 15.
Figure 14 - Fully Extended
Figure 15 - Fully Retracted

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5.0 Maintenance
The TGMD does not require any lubrication as all the moving parts have sealed or dry running
bearings. However, the following routine checks must be carried out on the trolley:
5.1 Every 3 Months
•Visually inspect the TGMD for signs of damage. If necessary, contact your distributor for
help.
•Check that when the trolley is assembled, there is no play in the central joint.
5.2 Annual
The TGMD must be returned to Abtus Ltd annually for re-calibration to ensure measurements are
within specification. The condition of all components will be checked at this time and replaced as
required. Each trolley should have at least one trained operator who is responsible for returning the
trolley.
The trolley is marked with a calibration sticker inside of the battery compartment showing the next
annual due date and must be returned to Abtus for annual calibration and maintenance. If the trolley
is used beyond the calibration due date, the performance may be degraded.
If the equipment becomes defective, or if it has an out of date calibration sticker, a warning notice
should be placed on the device to prevent further use and should be returned to Abtus for repair,
maintenance and re-calibration.
6.0 Measurement Characteristics
6.1 Gauge
Note: This measurement is taken from the internal running edges of the tracks at P-point (usually -
14mm) distance from the top of the rail.
Range
-25/+65mm (on nominal gauge 1435mm)
Accuracy
±1mm
Resolution
0.1mm
6.2 Super-Elevation
Range
±250mm
Accuracy
±1mm
Resolution
0.1mm
Super Elevation (SE) is measured across the running rails and is displayed as height differential
between the high and low rail in millimetres.

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The default sign convention is: Left rail up is positive Cant/SE.
During geometry measurements the left and right side is determined by the direction of travel.
The user is able to spin the handle around and whichever direction they are walking in, the left
rail up is positive cant.
6.3 Twist
Range
±250mm
Accuracy
±1mm
Resolution
0.1mm
Twist is when one rail has a downward gradient while the other rail has an upward gradient, causing
the carriage to twist. Twist is normally calculated over the bogie length (Traditionally 3m) and the
bogie centre to centre distance (Normally 12m).
6.4 Distance
Maximum limit on the number of measurements
per recording for Gauge, SE & Twist
50,000
Recording Increment
0.1, 0.2, 0.25, 0.5 & 1.0 m
Accuracy
±1%
Resolution
10mm
6.5 GPS
Accuracy
±4 m (In sunny clear sky conditions)
The GPS accuracy varies by time and location thus the user should wait 1 –2 minutes to achieve the
best accuracy.
7.0 Transportation and Storage
The TGMD must be transported inside its transportation bags. The bags should be moved by two
people following safe manual handling practices. The bags should be stored flat to prevent them
falling over.
If the trolley is not going to be used for several weeks, it is strongly recommended that the batteries
be fully charged and that the trolley be stored away from direct sunlight in a location of low humidity
where the temperature will be between: +15ºC & +25ºC (68OF to 77OF).

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8.0 Software Introduction
8.1 Track Geometry Measurement Device Software
The Track Geometry Measurement Device software is installed on the Windows device that comes
with the TGMD. This guide explains the important features of the TGMD software that are
necessary for measuring and analysing Track Geometry faults.
8.2 Initial Setup
No initial setup is required as Abtus will install the TGMD software and any necessary wireless
drivers. If the Windows device does not connect to the TGMD, contact Abtus for support.
9.0 Before going on track
9.1 Check Battery Levels
The TGMD has two removable batteries which are accessed from the lid in the top of the
Measurement Device. Press the battery indicator button to check the charge of the batteries and
charge them if necessary. Check the battery levels on the Panasonic FZ-G1 Tablet.
9.2 Check Wireless Connection
Switch on the TGMD and ‘Track Geometry SNXXX’should appear in the list of wireless networks
available and windows should automatically connect to it. Open the TGMD software on the
Windows tablet and click ‘Connect via Wi-Fi’ to check that the connection is working between the
tablet and the trolley.
Figure 16 - TGMD Software Home Screen

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9.3 Before Each Use
The following checks should be carried out in the office or depot before taking the trolley onto the
track.
•The condition of the trolley should be checked by the operator before it is used. The trolley
must be in good condition with no loose or broken components.
•The trolley must be marked with a valid calibration sticker showing the next annual due
date located inside of the battery compartment. The trolley should not be used after the
calibration due date.
•The batteries should have sufficient charge before the trolley is taken onto track. This is
shown by pressing the battery indicator button on each battery.
•The electrical connection pins between the two parts of the device should be clean.
•An appropriate and adequate safe system of work must be in place before the trolley is
used.
•Ensure that all wheels rotate freely.
•Ensure that there is nothing on the wheels. (dried mud, leaves or any other debris)
•Check for dirt and grease build up around the guide bearing shroud, ensure this is clear to
allow the bearings to run freely.
•The trolley is fitted with a dead man brake which can cause flat spots on the wheels if the
brakes are engaged whilst pushing the trolley. Check all wheels for flats or grooves. If any
are found, the trolley must be returned to Abtus as this can result in inaccuracies.
•The safety brakes should be functioning correctly. The brakes are applied to two of the
wheels which can be tested by spinning the wheels and releasing the brake lever on the
main handle ensuring that both wheels lock firmly.
9.4 Training and responsibilities
Only trained and competent people should use the trolley.
•All users must have received adequate training for the use of the trolley.
•A trained person will be responsible for the trolley during the work shift. This includes
carrying out the safety and performance related checks described in the user manual.
•Operators should have read the instruction manual for the TGMD and have access to it for
reference. Operators should understand the accuracy levels of the trolley.
•The trained operator is responsible for using the trolley safely in accordance with the safety
guidelines in the ABT7100 HAZOP Safety Risk Assessment and for ensuring that any risks
identified are kept as low as reasonably practical. They are responsible for informing any
other staff of safety requirements relating to the trolley that affect the planning of the work
to be carried out. The trained operator should challenge any instruction that compromises
safe use of the equipment and is responsible for communicating the risks involved.

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10.0 Step by Step Guide to Recording Geometry Measurements
on Track
Step 1 Setting New Geometry Profiles
Open TGMD software on the windows tablet and click “Geometry Profiles” to set the tolerance
parameters (Figure 17).
You can create a new profile by clicking on the “Create New Profile”, which will open the window shown
in Figure 18. Enter the required details and click “OK” to create the new geometry profile.
Figure 18 Creating new profile
Figure 17 Chaining Geometry Profile

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Figure 20 shows the newly Geometry Profile. Pressing the “Make profile active” button will make
this profile the active profile used in the succeeding recordings.
Figure 19 Profile settings
Figure 20 Activating the profile

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STEP 2. Put the TGMD on the track
The TGMD should be positioned on the track with the fixed side (marked L) on the left rail, facing
the desired direction of travel.
STEP 3. Connect the Windows device to the TGMD
- Turn on the TGMD and the Windows device.
- Open the TGMD software to see the home screen.
- Click ‘Connect to Wi-Fi’ in the top left corner of the screen.
- The trolley begins to send real time data to the Windows device. The Gauge, Cant/SE are
displayed below the ‘Connect to Wi-Fi’ button, but they are not recorded.
Figure 21 Connecting to TGMD

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STEP 4: Start Geometry Recording
Once the TGMD is in position press the “Set Zero Position” to reset the position reading to zero.
Press “Geometry Recording” to open the window shown in Figure 23.
- Input the Operator name.
- Input the Filename.
- Click ‘Start recording’
The other fields in the window are optional. The “Counting” can be “Up” or “Down” depending on
the direction of travel and will change the on-screen position of the trolley when it is moved.
Figure 22 Setting the zero position
Figure 23 New geometry recording settings