GEISMAR Amber User manual

Document No. GUK0018/2007 issue 02

Document No. GUK0018/2007 issue 02 2 of 53

Document No. GUK0018/2007 issue 02 3 of 53
The information, drawings and any other descriptive matter set out in this publication are
the confidential and copyright property of Geismar (U.K.) Limited and must not be
disclosed, loaned, copied or used for any manufacturing, tendering or for any other
purpose without their written permission.
The data and information contained in this publication are not binding and the
manufacturer reserves the right to make modifications at any time, for technical or
commercial reasons or in order to adapt to the legal requirements in the various
countries.
AMENDMENTS
Issue Number Page(s) Amended Date Authorised By
Preliminary
First issue
14/03/07
A Leyland
Issue 01 8,10,17,20,24,41,48- 03/04/07 A Leyland
Issue 02 For software version 3
onwards, narrow gauge added 11/03/08 A Leyland

Document No. GUK0018/2007 issue 02 4 of 53
Operating Manual
for GEISMAR Amber Manual Track Geometry Recording Unit
Contents
1.0 General Introduction...........................................................................................................6
2.0 Specification and measuring Parameters ......................................................................7
2.1Metric (Standard Gauge)...............................................................................................7
2.2Imperial (Standard Gauge) ...........................................................................................8
2.3Metric (Narrow Gauge) ..................................................................................................9
2.4Imperial (Narrow Gauge).............................................................................................10
3Principal components of the Amber unit..........................................................................11
3.1Folding Unit...................................................................................................................11
3.2Fixed Length Unit.........................................................................................................12
3.3Amber unit control buttons........................................................................................13
3.4Amber Unit event buttons ..........................................................................................14
3.4.1Programming the Event Button..........................................................................14
4Operation of the hand held PC software ..........................................................................15
4.1Operating the menu screen........................................................................................15
4.2Using the on-screen key board.................................................................................16
4.3Working Off Line or On Line......................................................................................17
5Set up and recording procedure ......................................................................18
5.1 On tracking............................................................................................18
5.2 Track Recording Setting up .................................................................21
5.2.1 Switching on - Unit and hand held PC(PDA)............................21
5.2.2 Closing the Job ..........................................................................28
5.2.3 Updating location.......................................................................29
5.2.4 Adding existing comments........................................................30
5.2.5 Creating a new comment...........................................................32
5.2.6 Cant re-zeroing whilst collecting data......................................34
5.2.7 Job settings, storing copying and deleting .............................34
5.2.7.1Copying or deleting a job setting .............................................34
5.3 System Security - Using your password and Operator ID .................................36

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6Operating Menu sequence................................................................................37
7Operating Menu function descriptions............................................................39
8Tolerance Profiles (Administrator and Supervisor levels only) ....................42
8.1 Creating a profile...................................................................................42
8.2 Editing a Profile.....................................................................................43
8.2.1 Copying a Profile..........................................................................43
8.2.2 Editing a Profile............................................................................43
8.3 Dealing with profile conflicts ...............................................................43
8.4 Updating profiles to other users..........................................................44
8.4.1 Circulating an updated profile...................................................44
8.5 Receiving an updated profile...............................................................44
9Data collection and transfer .............................................................................45
9.1 Typical Measurement Data ........................................................................46
9.2 Typical Exceedance Data............................................................................47
10 Pairing48
11 Maintenance 48
12 Battery Management and Charging .................................................................50
13 ReportingFaults.................................................................................................50
14 Confidentiality Notice........................................................................................51

Document No. GUK0018/2007 issue 02 6 of 53
1.0 General Introduction
The Amber is a battery powered compact manual track geometry recording unit. It is
designed for the continuous measurement of gauge, cross level, distance and twist
over two different twist bases.
Two design versions are available:-
(i) Folding single piece unit with integral push handle for gauges of 1100mm and
above.
(ii) Fixed length unit with detachable push handle for gauges below 1100mm.
Unless stated otherwise all details in this manual relate to both versions
The collected data is presented to the operator in real time and displayed and stored
on a PDA pocket PC utilising ‘Bluetooth®’technology and carried by the operator.
Collected data can be viewed on the PDA and is readily down loaded for emailing and
transferring to a Microsoft Excel® spreadsheet for presentation and analysis.
The GEISMAR Amber manual track geometry recording unit is accredited with setting
new standards in the presentation of collected data. This follows extensive trials and
market assessment which has produced key features including:-
·Hand held display Real time monitoring and display of all measurements
·Exceedance alerts Automatically monitors measurements against any chosen
track geometry profile to alert the operator visually and audibly to any tolerance
exceedance(s). Multiple tolerances can be created and stored for instant recall.
·Asset monitoring Store comments about track and line side conditions and
features by means of a text box and 3-button event marker. All comments can
be stored and retrieved for repeat notes.
·Management report in addition to producing a standard data file, an
Exceedance Data file is also produced which provides an immediate
management report of any exceedance(s) (highlighted in colour) and any
comments/events recorded on the track.
·Security Password protection of selected functions provides security for certain
features/settings whilst keeping the actual operating functions and set up
procedure on site to a minimum.

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2.0 Specification and measuring Parameters
2.1 Metric (Standard Gauge)
Measurements
Gauge: - -20 to +50 mm datum set at 1435mm
Measurement accuracy:- +/-1mm
Cross Level (Cant):- +/-200 mm
Accuracy:- +/-1mm over 0-200mm
Track Twist: - +/-100mm
Measurement accuracy:- +/-1.5 mm
Twist 1 base length :- adjustable in 0.125m steps
Twist 2 base length :- adjustable in 0.125m steps
Exceedance settings Gauge –1415 to 1485mm adjustable in 1mm steps
Cross level +/- 200mm adjustable in 1mm steps
Twist +/- 100mm adjustable in 1mm steps
Distance: - Recorded every 125mm
Accuracy < 5mm/m
Adjustable in steps of 1m when updating location
Measuring resolution 0.1mm
Manual Event:- 3 Button text input
Text comment box
Batteries:- Integral rechargeable NiMH
Autonomy:- 20 hours (PDA see manufacturers )
Charging:- Via external 230vac input charging unit (others by request)
Charging Time:- 24 hours for complete charge
Operating Temperature:- -5°C to +40°C
Weight :- 10.0Kg.excluding PDA
Size:- Folded for carrying, 1105mm long x 250mm high x 500mm wide
Transit Case 1215mm long x 320mm high x 565 mm wide
Total Shipping weight in transit case –29kgs

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2.2 Imperial (Standard Gauge)
Measurements
Gauge: - - 0.75”to +2.0”mm datum set at 58.5”
Measurement accuracy:- +/- 0.04”
Cross Level (Cant):- +/- 8.0”
Accuracy:- +/- 0.04”over 0 –8.0”
Track Twist: - +/- 4.0”
Measurement accuracy:- +/- 0.06”
Twist 1 base length :- adjustable in 0.125yd steps
Twist 2 base length :- adjustable in 0.125yd steps
Exceedance settings Gauge –57.2”to 60.5”adjustable in 0.1”steps
Cross level default 0 - adjustable in 0.1”steps
Twist default 0 - adjustable in 0.1”steps
Distance: - Recorded every 0.125yds
Accuracy < 0.2”/yd
Adjustable in steps of 1yd when updating location
Measuring resolution 0.01”
Manual Event:- 3 Button text input
Text comment box
Batteries:- Integral rechargeable NiMH
Autonomy:- 20 hours (PDA see manufacturers )
Charging:- Via external 230vac input charging unit (others by request)
Charging Time:- 24 hours for complete charge
Operating Temperature:- 23°F to +104°F
Weight :- ≤22 lbs.excluding PDA
Size:- Folded for carrying, 43.5”long x 9.85”high x 19.7”” wide
Transit Case 47.8”long x 12.6”high x 22.1”wide
Total shipping weight in Transit Case 64lbs

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2.3 Metric (Narrow Gauge)
Measurements
Gauge: - -20 to +50 mm datum set at 597mm
Measurement accuracy:- +/-1mm
Cross Level (Cant):- +/-90 mm
Accuracy:- +/-1mm over 0-200mm
Track Twist: - +/-100mm
Measurement accuracy:- +/-1.5 mm
Twist 1 base length :- adjustable in 0.125m steps
Twist 2 base length :- adjustable in 0.125m steps
Exceedance settings Gauge –577 to 647mm adjustable in 1mm steps
Cross level +/- 90mm adjustable in 1mm steps
Twist +/- 100mm adjustable in 1mm steps
Distance: - Recorded every 125mm
Accuracy < 5mm/m
Adjustable in steps of 1m when updating location
Measuring resolution 0.1mm
Manual Event:- 3 Button text input
Text comment box
Batteries:- Integral rechargeable NiMH
Autonomy:- 20 hours (PDA see manufacturers )
Charging:- Via external 230vac input charging unit (others by request)
Charging Time:- 24 hours for complete charge
Operating Temperature:- -5°C to +40°C
Weight :- 10.0Kg.excluding PDA
Size:- 1100mm long x 250mm high x 400mm wide with handle stored
Transit Case 1215mm long x 320mm high x 565 mm wide
Total Shipping weight in transit case –29kgs

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2.4 Imperial (Narrow Gauge)
Measurements
Gauge: - - 0.75”to +2.0”mm datum set at 23.5”
Measurement accuracy:- +/- 0.04”
Cross Level (Cant):- +/- 3.5”
Accuracy:- +/- 0.04”over 0 –8.0”
Track Twist: - +/- 4.0”
Measurement accuracy:- +/- 0.06”
Twist 1 base length :- adjustable in 0.125yd steps
Twist 2 base length :- adjustable in 0.125yd steps
Exceedance settings Gauge –22.75”to 25.5”adjustable in 0.1”steps
Cross level default 0 - adjustable in 0.1”steps
Twist default 0 - adjustable in 0.1”steps
Distance: - Recorded every 0.125yds
Accuracy < 0.2”/yd
Adjustable in steps of 1yd when updating location
Measuring resolution 0.01”
Manual Event:- 3 Button text input
Text comment box
Batteries:- Integral rechargeable NiMH
Autonomy:- 20 hours (PDA see manufacturers )
Charging:- Via external 230vac input charging unit (others by request)
Charging Time:- 24 hours for complete charge
Operating Temperature:- 23°F to +104°F
Weight :- 22 lbs.excluding PDA
Size:- 43.5”long x 9.85”high x 19.7”” wide with handle stored
Transit Case 47.8”long x 12.6”high x 22.1”wide
Total shipping Weight in Transit case 64 lbs

Document No. GUK0018/2007 issue 02 11 of 53
3 Principal components of the Amber unit
3.1 Folding Unit
Item No Description
Folding unit
1 Amber Main Unit
2 Hinge Clip
3 Push Handle Assembly
4 1 x Handle retaining strap
5 1x Handle retaining clip
6 Wheel Assembly
7 Contact Roller Assembly
8 Carry Handle Assembly
Mains charger charging socket

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3.2 Fixed Length Unit
Item
No
Description
Fixed length unit
1 Amber Main Unit
2 Not Applicable
3 Push Handle Assembly
Detachable
4
Handle retaining straps
5 Handle retaining clips
6 Wheel Assembly
7 Contact Roller Assembly
8 Carry Handle Assembly
1 8
3 64
5
7
Mains charger charging socket
Tacho wheel
Tacho wheel

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3.3 Amber unit control buttons
Button A - (lightning flash) switches the unit on. To operate depress and hold
until the word ‘discoverable’appears as pic below and note the battery level
indicator.
Button B –(thumbs up) switches the unit off but only following a data recording
run. When exiting the software the unit’s alarm will bleep continuously which is
the prompt to depress button to switch it off. To switch off the unit before a
recording has been set up, press buttons B and C simultaneously.
Button C –(tools) an auxiliary button for use in conjunction with A and C for
selected set up procedures.
C
A
B
Battery Indicator
level in nominal
steps of 10%

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3.4 Amber Unit event buttons
The Amber unit incorporates a programmable 3-button event marker for speedy
recording of pre selected events whilst carrying out a recording run. Pressing
any of the buttons will store the relevant event comment(s) in the data files.
When the event button(s) is pressed the red neon light will flash and the event
description(s) will flash briefly on the acquisition screen
3.4.1 Programming the Event Button
From menu select <Settings> - <Event Marker Text>
Select from the drop down menus an existing text or select New to create new
(key board will appear) or select Copy to modify an existing one or Delete to
delete an entry. See Para 4.2 using the on-screen keyboard.
Event button 2
Event button 1
Event button 3
Red neon light

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4 Operation of the hand held PC software
Each unit is provided with its own PDA (hand held PC) incorporating a touch screen
display using the stylus provided. Each PDA is ‘paired’to work with a specific Amber
unit and none other. To change this refer to Para10.0 section on ‘Pairing’
4.1 Operating the menu screen
.
Paragraphs 6.0 and 7.0 provide a menu layout and a detailed description of
each menu item. This section provides a guide to actually operating the screen
which comprises a series of scrolling menus and sub menus.
Scrolling through the menu:-
Tapping the screen in this area will
scroll the menu down wards
Tapping the screen in this area will
scroll the menu upwards

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Accessing different menu levels:-
When the item window is shadowed in green as above, it indicates that there is
a sub menu. To access the sub menu tap the item window. To return to any
previous menu level press hold and release the item window(s) until the desired
level is reached.
4.2 Using the on-screen key board.
Any keyboard or virtual keyboard provided on the PDA will be disabled when
used in conjunction with the Amber. In order to input information, values or
comments etc the Amber software provides its own virtual QUERTY keyboard.
This virtual keyboard will automatically appear when selecting NEW in any drop
down dialogue box or when tapping the dialogue screen for setting of tolerance
profiles and location details. The keyboard provides for entering letters,
numbers or symbols
To make an entry tap the appropriate button.
Where two characters share a common
button, tap once for the first character or tap
twice in quick succession (whilst the button is
depressed) for the second character. To
correct an entry, tap Del to erase character
by character progressing from the right hand
side. It is not possible to correct from a mid
point. Select Caps for an initial capital letter
or caps for entries to be all lower case or
CAPS for entries to be all upper case. The
dialogue window will display up to 16
characters but single entries can be of 200
character length.

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4.3 Working Off Line or On Line
It is possible to operate the Amber software whilst the Amber unit is switched
off (Off Line). When operated Off Line certain menu functions such as Cant
Rezero, Start Job or System Status (details in Para 7.0) will not be available.
The Off Line feature is an ideal facility for preparing Jobs in the office or
remotely whilst the Amber unit may be elsewhere or being charged (NB please
note that it is not possible to work On Line whilst the Amber unit is being
charged). To operate Off Line simply switch on the hand held PC and select
the Amber short cut. When Off Line and requiring to work On Line, switch the
Amber unit on and from Select Job menu page scroll to <Connect>and select.
(01) Off Line (02) On Line

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5 Set up and recording procedure
5.1 On tracking
Before use all operators must be familiar with the operation of the equipment in
relation to the requirements of the relevant Railway Administration for inspection and
safety on track.
A folding Amber unit should be carried as fig 1 when in its folded position. Always
ensure that the push handle is stored in the retaining clip and that the handle
retaining strap is in position and fastened before carrying in the folded position.
Apart from this carrying position NEVER carry any unit purely by the push handle.
Fig 2 and 3 show a folding unit being assembled in to position on track. Whilst resting
the partially extended unit on top of both rail heads as shown, use the hinge clip to
fasten the two arms together so that the unit becomes fully extended and secure.
Fig 1Carrying position for folding unit
when in the folded position
Fig 2
Fig 3

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To set up on track place the unit in the ‘four foot’(position the unit in the opposite
direction of planned travel if the cant rezero calibration is to be carried out as this will
save a little time). Position one side of the unit with the contact rollers against the
inside running edge of the rail and compress the unit so that the opposing set of
contact rollers can also fit against the opposite rail running edge.
For the fixed length unit screw the push handle in to position.
Once in position on track, check that the unit is seated on the track correctly by
pushing to and fro to ensure that it runs smoothly.
Brake Check Before proceeding you must check for the correct operation of
the unit’s self braking capability. Compress the unit manually whilst on track
and slowly release and observe that it freely opens out without any assistance.
If this does not happen STOP and return the unit to base. Otherwise proceed
with the measuring process which will be taken as confirmation that the units
braking is fully operational, the date for this being as recorded on the
subsequent recording runs.
For units fitted with nyloc retaining nuts as Fig 6
additionally check that at least one of the running
wheels will not spin freely. The wheels should be
free to turn but at least one must not spin. If this is
so it confirms that the wheel braking is operative
If this does not happen STOP and return the unit
to base.
Fig 5- carrying position for a fixed length unit.
Fig 4 carrying position for folding unit when set up
Fig 6

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When on track wait 45 seconds to allow the unit’s electronics to stabilise and then the
unit is ready for track recording setting up. When set up as described in Para 5.2 push
the unit as shown at a comfortable walking pace –do not run –taking care to avoid
any tripping hazards in or around the track. In particular take note of the following :-
·When pushing through S&C you must always stop to guide the unit past the
crossing nose by manually compressing the unit slightly.
·Exercise caution passing through breather switches when measuring in a
direction opposite to normal traffic flow. Depending upon the size of opening it
may be necessary to guide the unit over the breather switch by manually
compressing the unit slightly.
·In the event of a derailment of the unit check for any damage and avoiding any
turning of the tacho wheel. If the unit is not fit for use terminate the recording
run as described in Para 5.2.2.
Otherwise replace the unit back on track as near as possible to the point of
derailment to minimise any potential error in the distance measurement and
repeat the on track procedure described previously. (Re-zeroing should not be
necessary unless the unit has received a serious knock in which case it is likely
to be unfit for use any way.)
When you are ready to continue measuring pull the unit backwards to a position
approximately 1metre before the point of derailment and then proceed to
measure in the forward direction. Doing this will over write the previously
collected data starting from the point at which measuring recommenced. This
means that any irregular readings created by the derailment will have been
removed and over written. Please note that this over writing will also include
any comments or events that may have been recorded also. In other words
any events or comments affected will need to be re applied.
Folding amber Unit on track Fixed length unit on track with push
handle screwed in to position