Culvert Unloader - Help Needed

Shorling,

I had the same issue, it wasn't an electronic problem. It was caused by the sensitive IR receivers. There was a thread here somewhere that helped me fix it but I can't find it now.

Try taking some electrical tape and cover the top half of the eye on the post. Often it is the overhead lights that cause it to function incorrectly so covering part of the sensor fixes it. Depending on your lighting you may need to cover another part of the sensor.

Jay in Ottawa

Thanks for the input Jay, I'll give it a try.

I had to cut and tape a small piece of black construction paper over the top of the IR beam. That seemed to provide consistent triggering.

I tried masking off the receiver mounted on the post with no success.  If I illuminate the receiver with a LED flashlight the receiver responds and the flashing Unloader lights shut off.  If I interrupt the flashlight beam, the Unloader lights flash as expected.  Seems like the infrared source is weak or not working ?  Any thoughts.

I have the same problem now. I have the parts to replace but not sure it is the light source or the receiver

Still working to solve this issue.  I used my cell phone camera to verify that the infrared LED was working.  My Unloader LED was the same intensity as the Loader.  Next I going to use the phone camera to check the target area of the infrared LED.  The target area should be the receiver on the Unloader post.

I tried unsuccessfully to get a reflection of the infrared LED using the cell phone camera although I could detect the bright LED image directly using the camera.  I also noticed that sometimes if I slowly removed a LED flashlight from the receiver sensor the Unloader flashing lights would remain off.  I also observed if I touched the wires coming from the receiver sensor on the post the light would start flashing again.  Movement of the wires seems to change this failure effect but doesn't restore normal operation.  I'm guessing there is a connection issue with the sensor termination at the post.

The problem was the ambient lighting, especially fluorescent lights.  the sensor in the post was altered with a black rubber sleeve around it so only the very tip was exposed.  Did you try moving it from where you have it or turning down the ambient lighting to confirm the cause?  If it is then make sure the entire sensor is wrapped in black except the very tip of it.  Your other theory on a loose connection could also definitely be a cause if the sensor is going on and off.  Should be a simple fix.  

I had the ambient lighting turned down, off actually and still had the problem.  My sensor is encased in a black sleeve.  The sleeve covers the tip well and the entire sensor length except for maybe 1/32 at the rear.

I just got a little more aggressive with the wiring exiting the sensor at the post.  I bent the wires in the direction that was indicating more favorable operation.  Bending the wires restored normal operation.  Bending the wires does not result in physical movement of the sensor.  The sensor is really jammed in the post.

Sounds like you have a broken wire, solder, crimp, or whatever they do in there.

But also... 

 Usually a receiver picks up lighting it should ignore, but its the overhead lights fault. That is why the receiver is shrouded.

 Incandescent bulbs love to throw all kinds of light waves too. But just before they die.

(maybe 3-5 days before, maybe 10 seconds before, maybe not at all) 

 Smoke will catch any light beam, making it more visible, and easy to aim. I never tried it with a phone camera. The one I used always saw the spot that the projected light hit. But then again I don't have the slightest idea of which light band is used on these. Your on your own for suggestions on a PC "healthy" way to do it, but filling everything you can with smoke fluid, and running them like mad might workout. 

 You can try to adjust emitter aim using the flashing l.e.d. as your meter. Cut an iris slightly larger than the receiver in your paper. Center it on the receiver. Lift, drop, and/or move left, to right. If you lift with no effect, move the emitter aim down. If you drop it with no effect aim up. Left no effect, aim right etc. If you can get a meter on it, you can see changes better. 

Thanks to everyone for the help !!!!  I did order a spare receiver and infrared LED the other day from Lionel to have on-hand just in case.  I'm hoping it will continue working while waiting for the part to arrive.

I did look for beam positioning errors, stray light effects and beam intensity but these investigations had no effect on unit operation.  Only sensor wire re-positioning at the post had an effect and in some cases restored normal operation.  in some instances gently tapping the wire would effect unit operation which seems a clear indication of a electrical connection problem.