Whitmore LUBRICURVE ELECTRO 15 Instruction Manual

LUBRICURVE ELECTRO 15
Installation & Maintenance Manual
TRACKSIDE ELECTRIC RAIL / W EEL LUBRICATOR
SYSTEM
•Running Rail
o2 blades
o4 blades
•Top of Rail
o2 blades
o4 blades
•120kg Capacity

2
Warning!
This lubricator uses a 12V-115Ah battery which contains an acid based fluid the
electrolyte. Care must be taken to avoid the electrolyte coming in contact with the
skin or clothing as it may cause severe burns.
f the electrolyte is in contact with the skin then wash with large quantities of clean
water and seek medical advice.
DO NOT expose the battery to naked flames or cigarettes
During the charging process hydrogen gasses are vented from the battery and these
gasses when mixed with the air may explode if ignited.
Do not short circuit the battery terminals, as this may cause a spark or explosion.

3
Contents
1 General 5
2 Product Transport / Storage 5
3 Main Component Definitions 6
4 Preparation of Main Components for nstallation 7
5 Equipment Handling 8
6 Typical nstall Process 8
7 Site Preparation 9
8 nstallation Trackside tems 10
8.1 Fitting the Trackside Cabinet to Mounting Base 10
8.2 Earth Bond 10
8.3 Fitting the Cabinet mounted Solar Panel 10
8.4 Battery Charger Electrical Connection 10
8.5 Solar Systems 11
8.6 Mains Powered Systems 11
9 System Wiring Diagram 12
10 nstallation of Track tems 13
10.1 Wheel Sensor 13
10.2 Blade System 14
10.3 EasiBlade nstallation 14
Routing of delivery hoses, Cabinet to blade 15
10.4 Fitting the Main Delivery Hoses 15
10.5 Fill the Hoses and Blade’s 15
10.6 TOR EasiBlade nstallation (Top of Rail) 16
11 Commissioning / Setting 17
11.1 Filling the Reservoir 17
11.2 Wheel Sensor Heights and Operation 17
11.3 Pump Setting 17
12 Routine Maintenance 21
12.1 Control Panel 21
12.2 Pump Setting 21
12.3 Measuring the Reservoir 22
12.4 Cabinet Maintenance 22

4
12.5 Battery Maintenance 22
12.6 Solar Panel Maintenance 23
12.7 Replacing the Pump Sensor 23
12.8 Cleaning the Lubricator and Surrounding Site 24
12.9 Checking for Leaks 24
12.10 Measuring / Testing the Wheel Sensor 24
12.11 Checking for Airlocks 25
12.12 nspection of the Blade’s 25
12.13 Filling the Reservoir 26
12.14 Periodic Replacement of Components 26
Maintenance Log Sheet Example 27
13 Parts List 28
14 Basic nstallation Tool Kit 28

5
1 General
 Health & Safety legislation requires that rail lubricators are fitted by trained personnel only; warranty
will also be affected if un-trained teams work on the LubriCurve products.
Whitmore Rail provides suitable training courses.
This Manual should be used in support of training courses.
 This nstruction Manual is intended to be generic and concentrates on the full range of LubriCurve
Electro 15 systems to suit flat bottom running rails, both top of rail and gauge corner / gauge face
applications; system install differences are highlighted as necessary.
 Only lubricator greases or friction modifiers approved for use by Whitmore Rail and the rail user can
be used in these LubriCurve Electro 15 systems. Use of other greases or friction modifiers will
invalidate warranty and could affect operation.
2 Product Transport / Storage
 Goods are packed and delivered to the requested address in a form that is suitable for the product,
given good practice in the off-loading by the receiving company.
 LubriCurve systems are delivered on the basis that they will be installed within one month of receipt.
 Delivered systems are not intended for outside storage, equipment should be off loaded and stored
inside a secure watertight building until required for installation.
 All items are carefully checked prior to despatch and any damage or missing parts should be advised
to Whitmore Rail within five days of despatch from Whitmore Rail premises for consideration.
Note:
Keep the cabinet upright at all times from transport to install

6
3 Main Component Definitions
Pump
Cabinet
Each trackside Cabinet contains: Reservoir, gear pump, gear pump hose, control
panel, battery charger and cabinet mounting brackets.
The grease is delivered from the reservoir via the gear pump to hose at the base of
the Cabinet. Feed hoses then transfer grease to the Blade system.
Pump
Reservoir
This reservoir holds the rail grease or friction modifier. The LubriCurve Electro 15
reservoir is capable of holding 100 Kg of grease or friction modifier.
Pump The pump unit consists of a single or twin chamber gear pump driven by a close-
coupled 12V DC motor. The unit fits directly to the reservoir.
Pump
Control
Triggered from the Wheel Sensor the unit allows control of the pump and recording of
key data. A number of operational settings are user adjustable to suit the site and
application.
Wheel
Sensor
The wheel sensor clamps to the running rail and provides non-contact sensing of the
passing wheels. ndicating lamps provide local indication of correct operation during
the test. The sensor is connected to the control box through armoured cable.
Solar Panel Depending on the model of the solar panel supplied (optional). The unit fits onto the
rear of the cabinet and is required to provide power to the battery by utilising sun and
ambient light to generate electric power.
Delivery
ose
The delivery hose transfers the grease from the pump outlet to the Blade inlet.
Lengths of hose are supplied with each lubricator, which have to be cut into suitable
lengths to fit between the trackside Cabinet and Blade assemblies.
The hose is secured using a hose clip at each end of the hose.
Blade
(Grease
Dispensing
Unit - GDU)
Blades are provided that allow the grease to be delivered to the gauge corner, gauge
face or top of the rail, for the train wheels to pick up and spread along the curve. The
quantity supplied is dependent on the application specified.

7
4 Preparation of Main Components for Installation
Application Ensure the correct pump type and system options have been selected for the
application.
Training Ensure the installation team has been fully trained on the product, sighting
and the application.
Packing The Cabinet is delivered pallet mounted and wrapped, together with the
majority of loose items required for the install and larger items are secured to
a separate pallet and wrapped.
Ensure the package has not been damaged during storage or transport to the
rail site. Damage must be reported to the equipment supplier on initial receipt.
Dispose of all waste packaging materials responsibly.
Cabinet Visually inspect for any defects that will affect its operation.
Ensure that all loose items are available with reference to items ordered.
Ensure that the battery is fully charged with reference to the green indicator
lamp on the charge controller or the voltmeter display.
Blade Ensure they are not bent or damaged and all ports are free from blockages.
Ensure that all bolts are present and are fitted securely.
Ensure that the hose inlet tails which the delivery hoses attach to, are in place
and are not damaged.
Clamps Ensure that both Sensor and Blade clamps are not damaged.
Ensure that the threads on the clamp studs are not damaged.
Ensure that the threads on the hook bolts are not damaged.
oses (feed and
delivery)
Ensure that the hoses are intact and free of holes and splits.
Wheel Sensor and
cable
Ensure that the cable and sensor are intact and free of sharp kinks and any
damage.
Serial Numbers Lubricators are supplied with unique serial numbers; these should be recorded
prior to installation and recorded on installation record sheets as required.
Serial numbers are on both external and internal faces of the cabinet.

8
5 Equipment andling
Generally Electro 15 items required for each site are delivered on a pallet. The lubrication system is
heavy and care should be taken in general safe mechanical handling of the units from delivery truck
off-load to site install (cabinet weight excluding grease is approximately 90kg). The following methods
of handling the unit are appropriate:
Fork Lift Truck. Lift with forks fully engaged under the cabinet.
Personnel Two people are required to lift the cabinet – Take care not to trap your fingers or
feet when lowering to the ground.
The cabinet should be kept vertical at all times, take care to avoid damage to the paint finish as this
forms a part of the corrosion resistance and general integrity of the unit.
6 Typical Install Process
There are several possible sequences that can be followed to efficiently install the lubricator, this will
largely depend on personnel available, track access and general conditions – the following is
recommended as a guide.
Activity Manual Section
1. Equipment Handling 5
2. Prepare Base for Cabinet nstall 7, 8.1
3. Connecting Power Source (solar, mains, battery) 3
4. Electrical Connection 8.4 Error!
Reference
source not
found.
5. nstall Blades 10.2
6. nstall Track Mounted Wheel Sensor 10.1
7. Hose connection and routing from Blades to Cabinet 10.4
8. System Priming 10.5
9. System Settings 11

9
7 Site Preparation
To install a LubriCurve Electro 15 lubricator, the cabinet has brackets with mounting holes for attaching
directly to wooden sleepers or concrete base. The form and stability of the base is important as it resists
the wind loads on the cabinet.
 The base and cabinet must be positioned to maintain mandatory the track and OLE clearances.
 Vegetation should be cleared around the unit where necessary to ensure a safe working
environment.
 The base should be securely bedded into the ground / ballast to ensure stability, sleepers should be
level in both planes.
 As soon as the unit is manoeuvred onto the base, it should be securely bolted down.
 The equipment needed for the installation work includes:
oAll relevant P.P.E. needed to carry out the works safely.
oShovel or ballast fork whichever one is the most suitable.
oOrange pipe to protect delivery hose and sensor cable across the 4’ and 6‘.
oSpirit level.
oCompass.
oLubricator installation tool kit (see Section 14).
oWiring termination tools.
oCordless or portable drill and bits
Note: Other site specific mounting options may be used.
Control
DC31T
811.0
260.00
1070
750.0
545.0
1068.8
535.0
Optional mast shown in
this view
Cabinet mounted solar
panels shown in this

10
8 Installation Trackside Items
8.1 Fitting the Trackside Cabinet to Mounting Base
8.1.1 The sleeper or plinth base must have been fully installed before commencing any
installation of the unit.
8.1.2 The Cabinet includes mounting angle on the front and rear of the cabinet base.
8.1.3 Drill the base using the cabinet fixing holes as guides. Wood fixings require an 8mm pilot
hole and concrete requires a 12mm diameter hole. nsert the fixings and tighten securely.
One fixing in each corner of the cabinet is required. Suitable fixings are available from
Whitmore Rail to suit wood or concrete bases (part numbers LCS105-07 and LCS105-08
respectively).
8.2 Earth Bond
8.2.1 Subject to local regulation it may be required to bond the unit to the track. A 16.5 mm
diameter hole is to be drilled in the rear of the cabinet for a 16mm diameter earth stud
(Whitmore Rail part No. LCS105-11).
8.2.2 The bond itself must be supplied and fitted directly by the Rail owner authorised personnel
and not by the lubricator installer.
8.3 Fitting the Cabinet mounted Solar Panel
8.3.1 The solar panel is fixed directly to the rear and / or side of the cabinet. Using the M8
security bolts attach the spacers to the rear or side of the cabinet.
8.3.2 The cable from the solar panel is routed through a 20mm gland to the inside of the cabinet
and the ends of the cable are connected to the solar panel controller.
8.4 Battery Charger Electrical Connection
The majority of the electrical termination is completed in the Whitmore Rail factory prior to
despatch. A maximum of three site connections (including one for the Wheel Sensor, Section
10.1.4) are required, for battery charging:
8.4.1 Solar Panel Cabinet Mounted – (see section 8.5)
8.4.2 Mains Power – two pole MCB for incoming 110 or 220VAC fused and earthed mains power
(see section 8.6)
Warning!
This lubricator uses a 12V-100Ah battery which contains an acid based fluid the electrolyte. Care must be taken to avoid
the electrolyte coming in contact with the skin or clothing as the electrolyte may cause severe burns.
f the electrolyte is in contact with the skin then wash with large quantities of clean water and seek medical advice.
DO NOT expose the battery to naked flames or cigarettes
During the charging process hydrogen gasses are vented from the battery and these gasses when mixed with the air
may explode if ignited.

11
8.5 Solar Systems
Solar panel charged lubricator model uses the charger shown in
the picture. Cable connection is directly into the left hand side
screw terminals indicated on the charger.
The battery feed cable will have been factory connected, the free
end with ring terminals should be connected to the battery
terminals; blue core to negative and brown core to positive.
The round solar panel cable connects to terminals indicated with
the solar panel legend; Brown ‘+’, Blue ‘-‘
IMPORTANT NOTE: Damage will result if incorrectly connected.
The controller contains two indicator lamps:
•A Green LED and this will be illuminated as soon as there is power from the module. When
the controller starts to limit the charge current the LED will flash.
•The second LED can change colour from Red via Yellow to Green. Battery voltage is shown
by the colour and legend on the controller - Green full charge, Red low battery charge.
•When the battery voltage falls below approximately 11V the multi-colour LED will start to
flash FAST. While the battery remains at a low charge the LED will continue to flash slowly.
8.6 Mains Powered Systems
f solar charging is not possible an alternative system that utilises local mains power to maintain battery
charge may be used. Cable routing and connection should be undertaken by trained and authorised
personnel only. The procedure is as follows:
8.6.1 A suitable cable should be routed from the local trackside power source to the cabinet via
suitable armoured cable and routed into the cabinet through a suitable waterproof gland.
The cabinet can be drilled towards the base to suit the gland; care should be taken to avoid
damage to any internal cabinet components.
8.6.2 The cable incoming cable should be armoured and suitably routed and protected to avoid a
hazard.
8.6.3 Cable rating should be 220/110 Volt at 10 Amp.
8.6.4 Connection should be made on the two pole MCBs to the left of the main Control Box. All
other power wiring will have been completed during product assembly.
8.6.5 Connection should only be undertaken with the lubricator installer present.
The mains charger is suitable for input voltage between 95 and 240 Volt AC or DC.

12
9 System Wiring Diagram
Q H i
R a il
U K 0 1 5 2 5 6 2 2 2 0 2
w w w .q h ira il. c o m
S e r i a l N u m b e r
W h e e l
D e te c t e d O N
P u m p I n h ib i te d P u m p
L e s s
M o r e
W h e e l s S t e p s
W h e e l C o u n t P u m p S t e p s
W h e e l C o u n t
T o t al T o t a l
P u m p S t e p s
R u n
S t o p
R u n
P u m p
1 0 S e c M A X
B a tt e ry M o t o r
P u l s e o / p
0 V W h M t r
W h e e l S e n s e M o t o r S e n s e
+ - + - - s + - s +
B A T T E R Y
G E A R B O X S E N S O R W H E E L S E N S O R
T R A C K M O U N T E D
B A T T E R Y
S o l s u m 8 .8 c
re d
e m p t y
y e l l ow
green
fu ll
10
+ - + - + -
B A T T E R Y
3 6 W S O L A R P A N E L
S o la r P o w e r
C o n tr o l P a n e l
G e a r P u m p
B r o w n c a b le f ro m m o to r s p a d e to
M o to r + t e rm i n a l in C o n tro l B o x
B lu e c a b l e f r o m m o to r s p a d e to
M o to r - t e rm i n a l in C o n t r o l B o x
G e a r b o x s h a ft tu r n s
c lo c k w is e f o r c o r r e c t
p u m p o p e r a t i o n
P o w e r O p tio n s
1 2 v 1 0 a m p B a t te r y C h a r g e r
M a i n s w ir in g
b y o t h e rs
P l u g & M C B
s u p p lie d w it h
C h a r g e r
W A R N I N G !
T h is lu b r ic a t o r u s e s a 1 2 v - 1 0 0 a h b a t t e ry w h ic h c o n t a i n s a n a c id b a s e d f lu id , th e e le c tr o ly te . C a r e m u s t b e ta k e n to a v o id th e e le c tr o ly te
c o m in g in c o n ta c t w it h t h e s k in o r c lo t h in g a s t h e e l e c t ro l y t e m a y c a u s e s e v e r e b u r n s .
If th e e le c tr o ly te c o n ta c t s th e s k in , w a s h w it h la r g e q u a n t i t ie s o f c le a n w a t e r a n d s e e k m e d i ca l a d v is e .
D O N O T e x p o s e t h e b a t te r y t o n a k e d f l a m e s o r c i g a r e tt e s
D u rin g th e c h a rg in g p ro c e s s , h y d r o g e n g a s s e s a r e v e n te d f ro m t h e b a tt e ry a n d th e s e g a s s e s , w h e n m i xe d w i t h t h e a i r , m a y e x p lo d e if
ig n it e d . D o n o t s h o rt c ir cu i t t h e b a t te r y t e r m i n a ls , a s th is m a y c a u s e a s p a rk o r e x p lo s io n .
E a r t h C a b l e 1 0 7 - 1 -8 8
M a in s S u p p ly
2 2 0 / 1 1 0 v
50/60hZ
B y O t h e rs
E L E C T R I C M O T O R
M a in s P o w e r
S o l s u m 8 . 8 c
re d
e m p t y
y e l l ow
g r e e n
fu ll
10
+ - + - + -
B A T T E R Y 3 0 o r 5 0 W S O L A R P A N E L
3 6 W S O L A R P A N E L
S o la r p o w e r -
T w i n c a b in e t
m o u n te d 3 6 W
panels
S o la r P o w e r
S o la r p o w e r-
S in g l e M a s t
m o u n t e d 3 0 o r
5 0 W p a n e l
HRDi
W G P V B a t t1 Ba t t2
3 0 o r 5 0 W S O L A R P A N E L
W I N D G E N E R A T O R
B A T T E R Y
- + - +- +- +
S o la r & W in d P o w e r
R o u n d C a b l e
O v a l C a b l e
E l e c tr o 1 0 / 2 0 w i r in g d i ag r am [1 0 7 - 1- 8 6 ]
C a b in e t M o u n te d
M a s t M o u n te d
N o t e !
G e a rb o x s e n so r n o t r e q u ire d i f
t h e c o n t r o l b o x i s " P u m p T im e "
c o n tr o l
Note: Time Control versions will not
have a gearbox sensor

13
10Installation of Track Items
This aspect of the installation involves assembly of the Wheel Sensor to the running rail, assembly of
the Blade system and running of the feed delivery hose system.
10.1 Wheel Sensor
10.1.1 The Wheel Sensor is a non-contact proximity device that will detect a passing wheel when
correctly set. The unit is pre-assembled on an aluminium mounting plate and needs to be
clamped to the rail 3 to 6 metres upstream from the furthest rail mounted Blade. The
sensor will be in the 4’ and can be on either rail as best suited to the site.
•Sensor rail fixing clamps are similar to the EasiBlade arrangement and fitting is generally covered
in Section 10.3, where the key differences are:
Clamp the sensor to the M16 rail clamp studs with the sensor uppermost.
Adjust the height of the sensor to 42 / 45mm below the rail head crown and securely tighten the
M16 fixings.
Note: if required by site conditions the sensor can be reversed on the sensor mounting plate such
that the cable exits in the opposite direction.
10.1.2 Run the cable from the sensor along the foot of the rail on the cess or field side. Fix to each
rail clip using cable ties and into the trackside Cabinet through the lower mast pivot point
and into the cabinet.
10.1.3 The cable must route through protective pipe when running across the 4’ or 6’. n third rail
applications the cable should pass through robust insulated pipe work below the
conductor rail.
10.1.4 Route the cable within the Cabinet to the Control box. The sensor cable is armoured and
the ends will need to be prepared prior to connection.
10.1.5 Remove the two screw connector strip cover screws and route the sensor cable through
the cable gland and terminate all three cores as indicated below.
10.1.6 Cable connections are as follows:
Control Box: Wheel Sensor:
Brown: +Ve terminal Brown terminal 1
Black: –Ve terminal Black terminal 3
White: S terminal White terminal 4
Care should be taken to ensure connections are made correctly, that the terminals are not
over-tightened and damaged.
Note: On very small rails a simple plate with shims is used to mount the Wheel Sensor – see site specific
layout/ install drawings.

14
10.2 Blade System
The system allows use of a range of grease distribution units:
•Running Rail Blades
o2 blades on the high rail
o4 blades on the high rail and 4 blades on the low rail
10.3 EasiBlade Installation
10.3.1 EasiBlades are supplied as complete single units. From the 4’ / Gage and midway between
Sleepers / Ties slide the base (W bracket) over the rail foot as shown. Locate the hook bolt
around the opposite side of the foot and tighten the single Nyloc nut. Fully bed the base
onto the rail using a hammer on the vertical faces of the ‘W’ bracket. Retighten the Nyloc
nut.
10.3.2 Where 4 blades per rail systems are installed it is important that the two inner blades are
in adjacent beds, then an empty bed gap and then the outer blades. This arrangement
allows wheel circumference pick-up and also benefits hose layouts.
10.3.3 The blades are provided in left and right hand forms; the difference being the direction the
hose tail points, the correct layout is shown in the adjacent picture, outer pairs with hose
tails pointing towards each other.
10.3.4 Tilt the blade up so that the blade tip
is towards the rail head and as high as
possible, lightly tighten the two pivot
bolts.
10.3.5 Decide the required blade height and
tap the two steel lugs on the blade
evenly down using a hammer to
achieve the required height. The
setting gauge should be used to verify
the correct heights.
10.3.6 There may be a slight gap between the tip of the blade and the rail. To close this gap tap
the corner of the lug as necessary, do not hammer the blade itself. To angle the blade
strike where indicated with the red arrow.
10.3.7 Repeat process for each EasiBlade.
Note:
The Blade height should be set at approximately 6mm below the indicated wear line on the gauge face of
the rail. f no wear line is apparent a good starting point is 22mm below the top of the rail.

15
Routing of delivery hoses, Cabinet to blade
10.3.8 As outlined previously there are a number of
options to allow connection to the relevant Blade
option. The picture on the right shows an
EasiBlade layout with an empty bay between end
sleepers.
10.3.9 Hoses are 16mm bore for systems with pump
distances up to 8 metres. The correct type and
length of hose will have been despatched with the
system.
10.3.10 rrespective of hose type the principals of running
the hose are similar and shown below for a typical
installation with blades on both rails.
10.3.11 Hoses should be protected within suitable piping when passing under rails across the 4’.
10.3.12 Running Rail Systems
•Two blades have single hose from the cabinet to a “T” piece centrally between the two
blades.
•Four blades have single hose from the cabinet to a “Y” piece near each rail linked in
turn to a “T” piece centrally between each blade pair.
10.3.13 Top of Rail Systems
•Two blades have single hose from the cabinet to each blade.
•Four blades have single hose from the cabinet to a “T” piece centrally between each
blade pair.
10.3.14 Specific hose routing will depend on each site, note, to assist balanced flow:
•Main delivery hose runs should be of the same length.
•ndividual hose lengths between each interconnection should be the same length.
10.4 Fitting the Main Delivery oses
10.4.1 Having first filled the reservoir operate the pump by pressing the ‘run’ button until grease
is present at the hose tail fitting.
10.4.2 Fit one end of a delivery hose to the hose tail inlet on the Blade with a hose clip and after
routing and filling the delivery hose connect to the hose tails on the outside of the pump.
10.4.3 Repeat the procedure for the other hose ( f using a twin chamber pump with two hose
outlets).
10.5 Fill the oses and Blade’s
oThe main lubricator pump can be used to pump grease from the reservoir to the Blades.
oOn the Control Panel periodically press the Pump Run button.
oContinue the cycle until grease is evident at all Blade ports.

16
10.6 TOR EasiBlade Installation (Top of Rail)
10.6.1 TOR EasiBlades are supplied as
complete single units. From the Field
side and midway between Sleepers /
Ties slide the base (W bracket) over
the rail foot. Locate the hook bolt
around the opposite side of the foot
and tighten the single Nyloc nut. Fully
bed the base onto the rail using a
hammer on the vertical faces of the
‘W’ bracket. Retighten the Nyloc nut.
10.6.2 Tilt the blade up so that the blade tip is towards the rail head and as high as possible,
lightly tighten the two pivot bolts.
10.6.3 Decide the required blade height and tap the two steel lugs on the blade evenly down
using a hammer to achieve the required height.
10.6.4 There may be a slight gap between the tip of the blade and the rail. To close this gap tap
the corner of the lug as necessary.
IMPORTANT NOTE: Do not hammer the blade itself.
10.6.5 Tighten the two M16 bolts. Adjust the nuts on the two lock bars to restrain the blade from
vibration.
10.6.6 Repeat the process for each EasiBlade.

17
11Commissioning / Setting
11.1 Filling the Reservoir
The Electro 15 lubricators have been designed with a direct fill reservoir via a secure opening lid.
This direct fill method is the quickest and most user friendly filling method.
Access the Grease Reservoir
•Open the lid on top of the cabinet. There are two latches (padlocks may be used to secure the
lid) that need to be released and the lid can then be hinged upwards. There is a stay in the lid
that prevents the lid from closing accidently. When the lid is open you will be able to see the
grease reservoir.
Note – ensure only approved grease or friction modifier enters the reservoir. Any non-approved
materials could severely damage the system.
Filling the Grease Reservoir
•Grease can be poured directly from the drum or storage bag,
into the reservoir. An Electro 15 reservoir will hold 100 kg.
•Do not over fill the reservoir.
•Once filled close the lid by opening it slightly then release the
stay from its lock and then the lid can be closed fully. Press
firmly shut and secure using the latches. t is important that the
lid is locked correctly; if the lid is left open the grease / modifier
may biodegrade rapidly.
11.2 Wheel Sensor eights and Operation
Procedure for height adjustment and testing operation are covered in Section 12.10.
11.3 Pump Setting
The Electro 15 Lubricators are controlled and set by a control panel
located inside the cabinet. The control panel allows the user to set
the grease output from the Blade blades with respect to the rail
traffic using the line.
The following steps explain how to set and adjust the Lubricator
once installed.
The buttons and indicator lamps have been numbered to help
explain these instructions.

18
The first wheel of the train initiates the pump. The control panel counts the set number of wheels and
then operates the pump grease / friction modifier is then dispensed every time the set number of wheels
has been detected.
The volume output is set in two ways depending on the application:
Running Rail
Set the desired pump run time (time control systems) in seconds or desired pump steps (step
control systems)
Top of Rail
Set the desired pump steps, typically this would be between 2 and 4 steps.
Both types of control panel look very similar and the method of setting the pump step and pump run
time / steps is similar.
11.3.1 Backlight & voltage display feature panel - Running Rail
•n order to access the control panel, open the main door of the cabinet.
•Ensure the control panel is switched on. The power button (1) must be pressed on the “ ”
rather than the “O”. The controls are now sitting in a neutral state with the battery power
allowing basic function.
•The Electro 15 lubricators are activated by the Wheel Sensor ‘seeing’ the first wheels of a
train (step control option). When this occurs the Wheel Detected lamp (9) will illuminate as
the sensor registers a passing wheel. This situation can be replicated by passing a steel object
over the sensor. On time based systems the operation is not triggered by the first wheel but
on each wheel at the interval set irrespective of trains.
Battery
Back Light
ON
OFF
Volts
QHi
Rail
UK 01525 461123
www.qhigroup.com
Serial Number
Wheel
Detected ON
Pump
Inhibited
Pump
Less
More
Wheels Steps
Wheel Count Pump Steps
Wheel Count
Total Total
Pump Steps
Run
Stop
Run
Pump
10 Sec MAX
Battery Motor Wheel Sense Motor Sense
Drive
+ - + - - s + - s +
UK 01582 622202
www.Whitmore
Railrail.com

19
•On detecting a wheel the electric pump will operate and the Pump ON lamp (10) will
illuminate. When the electric pump operates, grease will be despatched onto the rail through
the blades.
•The pump will run for a set period of time or steps. The longer the pump runs for, the more
grease will be despatched onto the rail. This length of time is measured in pump seconds. One
revolution of the pump is equal to approximately 1.25 seconds.
•The number of pump seconds can be adjusted by pressing the Pump Seconds buttons, either
(4) for More second or (5) for Less seconds. The number of pump steps can similarly be
increased in a similar manner.
•Once the pump has been activated the controller enters an inhibited period, and the Pump
nhibited lamp (11) will be illuminated. The Wheel Sensor will continue to detect the wheels
but will not operate the pump again until a set number of wheels has been detected.
•The Wheel Count function controls this length of the inhibited period. To adjust the Wheel
Count press buttons (2) for More wheels to count or (3) for Less wheels to count. As a train
passes over the Wheel Sensor the number of wheels will be counted. When the number of
wheels reaches the set amount, the pump will be activated for the set number of Pump Steps.
Note: This inhibit function will reset after 45 seconds if the set number of wheels has not
been counted. This means the pump will be ready to go every time a train passes over the
Wheel Sensor (time based systems only).
•To more easily view the display panel, press the backlight button (12). The light will
automatically extinguish after a set time.
•Central to the display is a battery voltage read-out; this is disabled while the pump is running.
Initial Electro 15 Settings – Running rail – Time based systems
Speed Carriages Carriages Carriages
2 3 4
Speed mph Speed kph Wheel Count Pump Secs
Wheel
Count
Pump
Secs
Wheel
Count
Pump
Secs
<15 <25 3 0.3 3 0.3 4 0.4
<50 <80 3 0.3 3 0.3 4 0.4
<75 <120 3 0.3 4 0.3 6 0.4
<100 <160 3 0.3 4 0.3 6 0.4
<125 <200 - - - - - -

20
Initial Electro 15 Settings – Running Rail – Step based
Systems
Speed Carriages Carriages Carriages
2 3 4
Speed mph Speed kph
Wheel
Count
Pump
Steps Wheel Count
Pump
Steps
Wh
eel
Co
unt
Pump
Steps
<15 <25 3 4 3 4 4 5
<50 <80 3 4 3 4 4 5
<90 <120 3 4 4 4 6 5
<100 <160 3 4 4 4 6 5
<125 <200 - - - - - -
Speed Carriages Carriages
8+ 20+
Speed mph
Speed
kph
Whe
el
Cou
nt
Pum
p
Steps
Wheel
Count
Pump
Steps
<15 <25 4 4 3 4
<50 <80 6 4 8 5
<90 <120 6 5 30 10
<100 <160 40 8 - -
<125 <200 40 8 - -
Variation for TOR operation:
The Electro 15 is active once the control panel is switched on. The pump is activated every time the
control panel counts the set number of wheels. The wheel count may be split between two trains.
Setting the wheel count and pump seconds is accomplished as described in the section above.
11.3.2 The required pump settings will vary for each site and depends on such items such as train
type and speed. For guidance the table above should be followed and then adjustments
made to suit local conditions during subsequent visits.
Note: Settings for TOR applications are determined by site conditions.
11.3.3 For maintenance log purposes the display screen also records the total wheel count and
also the total pump steps. t is possible to zero the display following direct discussion with
Whitmore Rail.
11.3.4 The set of Test Buttons, Test Run (6) and Test Stop (7) can be used to run the pump
settings without the Wheel Sensor being activated. These buttons are useful during initial
Lubricator set-up or maintenance periods.
11.3.5 The Run Pump Button (8) can be pressed and held for continuous pump operation. This
button is useful during the initial priming of the pipes and blades.
A typical initial setting would be 2 steps and 20 wheels but will depend on the friction modifier being
used.