Union Switch & Signal - Ansaldo STS
Contents
1. Section 5 1 Switch Position LEDs Appear as Step No Required 1 Initial Switch Set UP As stated in Step 1 2 Initial Switch Set Up PASS FAIL 3 DIRECTION switch in RHPC position PASS FAIL 4 DIRCTION switch in NONE position PASS FAIL 5 DIRECTION switch in LHPC position PASS FAIL POINT SENSE 1 pushbutton in OFF position 6 POINT SENSE 1 pushbutton in ON position PASS FAIL 7 LATCHOUT switch in MANUAL position PASS FAIL POINT SENSE 1 pushbutton in OFF position 8 POINT SENSE 1 pushbutton in ON position PASS FAIL 9 LATCHOUT switch in AUTO position PASS FAIL POINT SENSE 1 pushbutton in OFF position 10 LOCK SENSE 1 pushbutton in OFF position PASS FAIL POINT SENSE 1 pushbutton in ON position Then LOCK SENSE 1 pushbutton in ON position 11 LATCHOUT switch in NONE position PASS FAIL 12 LATCHOUT switch in MANUAL position PASS FAIL AUXILIARY SENSE 1 pushbutton in OFF position 13 AUXILIARY SENSE 1 pushbutton in ON position PASS FAIL AUXILIARY SENSE 2 pushbutton in ON position SM 9020 Rev 0 September 2002 A 3 UNION SWITCH 8 SIGNAL Appendix A Data Sheet Section 5 1 Switch Position LEDs Appear as Step No Required 14 AUXILIARY SENSE 2 pushbutton in OFF position PASS FAIL HAND THROW switch in OFF position 15 HAND THROW switch in ON position PASS FAIL HAND CRANK switch in OFF position 16 HAND CRANK switch2. WAGO Terminal Block Connection ECC Field Test Unit Connection Signal Block Number 20 Red Power Terminal B12 Battery Block Number 16 Black Power Terminal N12 Battery SM 9020 Rev 0 September 2002 2 1 Section 2 Eguipment Description NORMAL Point Detected Point Locked Indication Input Indication Output Auxiliary Point Detected UNION SWITCH amp SIGNAL REVERSE Point Detected Point Locked Indication Input Indication Output Auxiliary Point Detected Latch Out Motor Disabled LED Diagnostics UNION SWITCH amp SIGNAL ECC N47303401 Latch Out Restoration Press for 1 Second and Release BROWN BLUE VITAL SENSOR TEST NON VITA NONE RHPC DISABLE MANUAL l NONE A y AUTO DIRECTION LATCHOUT Vital Sensors POINT SENSE 1 POINT SENSE 2 LOCK SENSE 1 LOCK SENSE 2 Non Vital Sensors AUXILIARY SENSE 1 AUXILIARY SENSE 2 HAND THROW HAND CRANK ECC FIELD TEST UNIT UNION SWITCH 8 SIGNAL 645 Russell St Batesburg SC 29006 POWER 9 8 16 2VDC Figure 2 1 Field Test Unit to ECC Connections SM 9020 Rev 0 September 2002 UNION SWITCH 8 SIGNAL Section 3 Functional Description Section 3 Functional Description 3 1 ECC DIAGNOSTIC INFORMATION The ECC is equipped with a series of LEDs to indicate the current state of the switch machine Dual colored LEDs are provided to indicate the state of each vital point and lock sensor Green LEDs are provi
3. 5 2 1 Vita Sensor TeSt 3 222 a a eee eae 5 5 5 2 2 Non Vital Sens rilest u u ii fa tac u ohna dre u BE he tail 5 6 Section 6 Maintenance Repailr iii isis ki si ia Tal 6 1 Section 7 Technical SUppot in ni a a ui aa e ld 7 1 Appendix A Data Sheet iii rn anne ES a GR R A 1 List of Fiqures Figure 2 1 Field Test Unit to ECC Connections 2 2 List of Tables Table 2 1 WAGO Block to ECC Field Test Unit Power Wiring en 2 1 Table 3 1 ECC Diagnostic LED Definitions no on nn 3 1 SM 9020 Rev 0 September 2002 Page iii Table of Contents UNION SWITCH amp SIGNAL iv SM 9020 Rev 0 September 2002 UNION SWITCH amp SIGNAL Section 1 Introduction Section 1 Introduction This service manual describes the use and function of the Field Test Unit for the Electronic Circuit Controller ECC for the M23E and M23 retrofitted style switch machines For detailed information on the installation operation maintenance and adjustment of the ECC please refer to Service Manual 6263A For detailed information on the installation operation maintenance and adjustment of the M style machines please refer to Service Manuals 6263 and 7100 The US amp S Electronic Circuit Controller ECC is used on US amp S M 3 and M 23 A or B style switch machines The ECC uses four vital proximity sensors two to detect the position of the switch points normal or reverse and two to detect that the machine is fully locked normal or reverse
4. by performing the tests in Section 5 using an ECC and vital non vital sensors that are known to be properly functioning SM 9020 Rev 0 September 2002 6 1 UNION SWITCH amp SIGNAL Section 6 Maintenance Repair 6 2 SM 9020 Rev 0 September 2002 UNION SWITCH amp SIGNAL Appendix 7 Technical Support Section 7 Technical Support The Rapid Action Information Link Team RAIL Team is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product Contact the RAIL Team at 1 800 652 7276 or by e mail at railteam switch com SM 9020 Rev 0 September 2002 7 1 Appendix A Data Sheet UNION SWITCH amp SIGNAL 7 2 SM 9020 Rev 0 September 2002 UNION SWITCH amp SIGNAL Appendix A Data Sheet Appendix A Data Sheet SM 9020 Rev 0 September 2002 A 1 Appendix A Data Sheet UNION SWITCH amp SIGNAL A 2 SM 9020 Rev 0 September 2002 UNION SWITCH 8 SIGNAL Appendix A Data Sheet Test Data Sheet for Testing the ECC Using the Field Test Unit N42252601 ECC Serial Number Test Unit Serial Number Technician s Name Date Note In completing this form please circle PASS or FAIL to indicate if the step has Passed or Failed Do not use check marks or try to mark out a result Merely circle the appropriate response ECC Diagnostic Test Refer to Section 5 1 for the test procedure
5. performing any internal machine maintenance 2 Always keep hands and feet clear of switch points and the internal moving parts of the machine Ensure that loose clothing is properly secured prior to working on the switch machine The Field Test Unit attaches to the ECC and can test the ECC to ensure it is properly operating without actually cycling the switch While connected to the ECC the Field Test Unit can also verify the proper operation of the sensors on that switch machine 1 2 Purpose of Manual This service manual provides descriptive information on the use of the Field Test Unit for the US amp S Electronic Circuit Controller which is installed on the M23E M 3 and M 23 Switch Machines The SM 9020 Rev 0 September 2002 1 1 Section 1 Introduction UNION SWITCH amp SIGNAL Field Test Unit itself is used in the maintenance of switch machines and is intended for use as a diagnostic tool to provide feedback on the status of an ECC unit and all related proximity sensors 1 3 Conventions in Manual 1 3 1 ac AAR AREA AREMA AWG CAUTION dc ECC Front of Machine FRA Latch Out Latch Out Restoration LED Left Hand Switch LHPC Point Detection Locking MCU MOV Abbreviations Acronyms and Definitions alternating current Association of American Railroads Communication and Signal Section currently known as AREMA American Railway Engineering Association American Railway Engine
6. solid state device used to control motor power Metal oxide varistor protection device for electronic components SM 9020 Rev 0 September 2002 UNION SWITCH amp SIGNAL LEFT HAND Non Vital PCB Rear of Machine Reference Designator Right Hand Designator RHPC RMS Switch Machine Indication Switch and Lock Movement and or Switch Machine US amp S Vital Circuit WAGO WARNING SM 9020 Rev 0 September 2002 Section 1 Introduction 1 RIGHT HAND Figure 1 1 Left Hand and Right Hand Switch Machines Any circuit with a function that does not affect the safety of train operation Printed circuit board The physical area of the switch machine closest to the motor An abbreviation assigned to designate an electrical component It generally consists of a capital letter and a number Each letter designates a particular type of component For example L identifies an inductor and R identifies a resistor The position of a switch machine designated when the machine is located on the right hand side of the track looking into the switch points in the direction of the arrow shown in Figure 1 1 Right hand point closed which refers to the switch point position when the point is normally closed to the right hand side of the track looking into the switch points in the direction of the arrow shown in Figure 1 1 root mean square method for expressing ac voltage rating A vital deter
7. AUXILIARY POINT DETECTED DARK UNION SWITCH 8 SIGNAL REVERSE POINT DETECTED GREEN LOCK DETECTED GREEN INDICATION INPUT GREEN INDICATION OUTPUT GREEN AUXILIARY POINT DETECTED GREEN LATCHOUT DARK MOTOR DISABLED DARK 4 Move the DIRECTION switch on the Field Test Unit to the NONE position Verify that the LEDs on the ECC controller appear as follows NORMAL POINT DETECTED BLINK RED LOCK DETECTED BLINK RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED DARK REVERSE POINT DETECTED BLINK RED LOCK DETECTED BLINK RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED DARK LATCHOUT DARK MOTOR DISABLED RED 5 Move the DIRECTION switch on the Field Test Unit to the LHPC position Set the POINT SENSE 1 push button switch on the Field Test Unit to OFF or RED Verify that the LEDs on the ECC controller appear as follows NORMAL POINT DETECTED RED LOCK DETECTED GREEN INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN REVERSE POINT DETECTED RED LOCK DETECTED RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED DARK LATCHOUT RED MOTOR DISABLED DARK 6 Set the POINT SENSE 1 push button switch on the Field Test Unit to ON or GREEN and verify the LEDs on the ECC controller return to the configuration of Step 2 7 Move the LATCHOUT switch on the Field Test Unit t
8. ETECTED RED LOCK DETECTED GREEN LOCK DETECTED RED INDICATION INPUT GREEN INDICATION INPUT GREEN INDICATION OUTPUT DARK INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN AUXILIARY POINT DETECTED DARK LATCHOUT DARK MOTOR DISABLED RED 17 Set the HAND CRANK and HAND THROW push button switches to ON Verify the LEDs on the ECC appear as in Step 2 If the ECC responded correctly the ECC is operating properly and should not be causing any problems In this case any operating problem is due to the switch machine itself Refer to the switch machine manual for troubleshooting procedures If the ECC did not respond as it should have during the test there is a problem with the ECC Because there are no field or shop maintenance procedures for the ECC US amp S recommends that the ECC be replaced and the unit be returned to the US amp S Batesburg location for repair 5 2 ECC Vital Non Vital Sensor Testing To test a vital or non vital sensor connect the Field Test Unit to an ECC per Section 4 Press down on the black quick connect terminals at the top of the unit for the type of sensor to be tested VITAL SENSOR TEST or NON VITAL SENSOR TEST Insert the two sensor wires per the color indicated on the Field Test Unit label See Figure 2 1 5 2 1 Vital Sensor Test Initially when the sensor is connected it is not in circuit for the ECC to be able to test Press and hold the momentary push button below the terminals
9. LIARY POINT DETECTED GREEN REVERSE POINT DETECTED RED LOCK DETECTED RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN LATCHOUT DARK MOTOR DISABLED DARK 14 Reset the AUXILIARY SENSE 2 push button switch to OFF Set the HAND THROW push button switch to OFF Verify that the LEDs on the ECC controller appear as follows NORMAL POINT DETECTED GREEN LOCK DETECTED GREEN INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN REVERSE POINT DETECTED RED LOCK DETECTED RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED DARK LATCHOUT DARK MOTOR DISABLED RED 15 Set the HAND THROV push button switch to ON Set the HAND CRANK push button switch to OFF Verify that the LEDs on the ECC controller appear as follows SM 9020 Rev 0 September 2002 UNION SITES SIGNAL Section 5 Operating Procedures NORMAL REVERSE POINT DETECTED GREEN POINT DETECTED RED LOCK DETECTED GREEN LOCK DETECTED RED INDICATION INPUT GREEN INDICATION INPUT GREEN INDICATION OUTPUT DARK INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN AUXILIARY POINT DETECTED DARK LATCHOUT DARK MOTOR DISABLED RED 16 Set the HAND CRANK push button switch to ON Set the HAND CRANK and HAND THROW push button switches to OFF Verify that the LEDs on the ECC controller appear as follows NORMAL REVERSE POINT DETECTED GREEN POINT D
10. The ECC is a microprocessor based controller that vitally monitors the state of the four vital proximity sensors and can identify each possible sensor state on off shorted or open In addition to the four vital proximity sensors the ECC can be eguipped with an optional auxiliary point detection system This system provides a normally ON bipolar output to warn maintenance personnel of marginal switch machine operation The sensing threshold of each auxiliary sensor is offset from the vital point detector sensors by approximately 1 8 to detect switch point displacement before the vital sensors indicate point detector bar movement With the auxiliary system switch point displacement that is caused by debris build up or expansion and contraction of the rail can be detected before a switch failure occurs The ECC provides advanced diagnostics for identifying the current state of the machine and the indication state of an adjacent daisy chained machine LEDs on the ECC indicate the delivery of indication power and auxiliary indication power to the wayside as well as provide information on motor power availability and the state of the latch out function 1 1 Application The ECC Field Test Unit is a diagnostic tool for testing an ECC while installed in a switch machine it can also test individual proximity sensors associated with a given switch machine To avoid severe personal injury open the gold nut test link in the motor compartment prior to
11. UNION SWITCH 8 SIGNAL Union Switch 8 Signal Inc an Ansaldo Signal company 1000 Technology Drive Pittsburgh PA 15219 e 645 Russell Street Batesburg SC 29006 SM 9020 Field Test Unit N42252601 for the Electronic Circuit Controller ECC Operation Copyright 2002 SM 9020 Rev 0 September 2002 Union Switch 8 Signal Inc UNION SWITCH amp SIGNAL Proprietary Notice This document and its contents are the property of Union Switch amp Signal Inc hereinafter US S This document has been furnished to you on the following conditions no right or license under any patents or any other proprietary right in respect to this document or its content is given or waived in supplying this document This document or its content are not to be used or treated in any manner inconsistent with the rights of US amp S or to its detriment and are not to be copied reproduced disclosed to others or disposed of except with the prior written consent of US amp S Important Notice US amp S constantly strives to improve our products and keep our customers abreast of changes in technology Based on US amp S s experience our customers will obtain the best possible operational reliability by following the recommendations contained in the attached service manual The data contained herein purports solely to describe the product and it is not a warranty of performance or characteristics Within the scope of the attached manual it is impo
12. ded for indication input indication output and auxiliary sensor state definition Red LEDs are provided to determine when the motor is disabled and when the ECC is in a latched out state Table 3 1describes what the ECC diagnostics represent Table 3 1 ECC Diagnostic LED Definitions LED Name NORMAL or REVERSE Point Detected State 1 Meaning GREEN Normal Point Sensor Detected State 2 Meaning RED Point Sensor Not Detected State 3 Meaning DARK ECC Malfunctioning Flashing Meaning FLASHING RED Point Sensor in Indeterminate State or LHPC RHPC not selected Point Locked GREEN RED DARK FLASHING RED Normal Point Lock Sensor Point Lock Sensor Not ECC Malfunctioning Point Lock Sensor in Detected Detected Indeterminate State or LHPC RHPC not selected Indication GREEN DARK FLASHING GREEN Input Power is present to Power is not present to ECC Malfunctioning generate an Indication generate Indication Output Output Indication GREEN DARK FLASHING GREEN Output All ECC internal Power is not present to ECC Malfunctioning diagnostics complete generate Indication Output correctly machine state even if the machine state dictates that all vital dictates configuration sensors are in legal states Jumpers not installed or configuration jumpers are multiple jumpers installed installed in legal positions ECC internal diagnostics and power is present to failure generate the Indication Output Auxil
13. ering and Maintenance of Way Association formerly known as AAR American wire gauge Caution statements indicate conditions that could cause damage to eguipment direct current Electronic Circuit Controller The physical area of the switch machine furthest from the motor Federal Railroad Administration A device that does not allow switch point indication to restore 1f the switch point moves away from the stock rail point detection is momentarily lost This function will be activated 1f the point sensors are actuated before their corresponding locking sensors are actuated The term latch out restoration refers to resetting the machine to an operable switch machine indication state from a latched out condition Light emitting diode The position of a switch machine designated when the machine 1s located on the left hand side of the track looking into the switch points in the direction of the arrow as shown in Figure 1 1 Left hand point closed which refers to the switch point position when the point is normally closed to the left hand side looking into the switch points in the direction of the arrow as shown in Figure 1 1 The positive indication achieved when the switch points are closed adeguately against the stock rail Locking is achieved when the lock box connected to the slide bar enters the narrow locking notch of the lock rods and extends a minimum of 1 2 into the locking rod Motor control unit a high current
14. hen set the LOCK SENSE 1 push button switch back to ON or GREEN Verify the LEDs on the ECC controller return to the configuration of Step 2 above 11 Move the LATCHOUT switch to the NONE position Verify that the LEDs on the ECC controller appear as follows NORMAL POINT DETECTED GREEN LOCK DETECTED GREEN INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN REVERSE POINT DETECTED RED LOCK DETECTED RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED DARK LATCHOUT BLINK RED MOTOR DISABLED RED SM 9020 Rev 0 September 2002 9 3 Section 5 Operating Procedures UNION SWITCH 8 SIGNAL 12 Move the LATCHOUT switch to the MANUAL position Set the AUXILIARY SENSE 1 push button switch to OFF Verify that the LEDs on the ECC controller appear as follows NORMAL POINT DETECTED GREEN LOCK DETECTED GREEN INDICATION INPUT GREEN INDICATION OUTPUT GREEN AUXILIARY POINT DETECTED DARK REVERSE POINT DETECTED RED LOCK DETECTED RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED DARK LATCHOUT DARK MOTOR DISABLED DARK 13 Reset the AUXILIARY SENSE 1 push button switch to ON Set the AUXILIARY SENSE 2 push button switch to ON Verify that the LEDs on the ECC controller appear as follows NORMAL POINT DETECTED GREEN LOCK DETECTED GREEN INDICATION INPUT GREEN INDICATION OUTPUT GREEN AUXI
15. iary Point GREEN DARK FLASHING GREEN Detected Auxiliary Point Sensor Auxiliary Point Sensor Not ECC Malfunctioning Detected Detected Latch Out RED DARK FLASHING RED Machine is latched out Machine is not latched out No latchout mode selected or multiple latchout modes selected Motor Disabled RED DARK FLASHING RED Motor power is disabled WARNING The GOLD Nut must be removed when performing machine maintenance Motor power is enabled ECC internal diagnostics fail Both Indication Input LEDs will be GREEN when using the Field Test Unit NOTE When using the Field Test Unit if this state exists the ECC box has failed and needs to be replaced SM 9020 Rev 0 September 2002 3 1 3 2 ECC Field Test Unit Controls The controls on the ECC Field Test Unit are comprised of eight push button switches that are illuminated GREEN when pushed in ON state and are illuminated RED when released OFF state These buttons represent the eight possible sensors that can be installed in an M23E or M23 retrofit switch machine and simulate the LEDs on the ECC Some configurations of switch machines do not include all of the non vital sensors but the ECC does not distinguish this fact It does not illuminate the auxiliary sensor LEDs if they are not installed The hand crank and hand throw sensors are simulated on the WAGO terminal block by a resistor such that the ECC still reads a return current as if they were instal
16. in ON position PASS FAIL HAND THROW switch in OFF position Then HAND CRANK switch in OFF position 17 HAND CRANK switch in ON position PASS FAIL HAND THROW switch in ON position ECC Operating Properly PASS FAIL Technician DATE Vital Sensor Test Refer to Section 5 2 1 for the test procedure Section 5 2 1 Sensor Position LEDs Appear as Step No Required 1 Sensor NOT NEAR metallic or conductive surface PASS FAIL 2 Sensor NEAR metallic or conductive surface PASS FAIL 3 Optional Sensor gt 1 2 mm but lt 4mm from metallic or conductive surface PASS FAIL Vital Sensor Operating Properly PASS FAIL Technician DATE Non Vital Sensor Test Refer to Section 5 2 2 for the test procedure Section 5 2 2 Sensor Position LEDs Appear as Step No Required 1 Sensor NOT NEAR metallic or conductive surface PASS FAIL 2 Sensor NEAR metallic or conductive surface PASS FAIL Vital Sensor Operating Properly PASS FAIL Technician DATE A 4 SM 9020 Rev 0 September 2002
17. ing parts of the machine Ensure that loose clothing is properly secured prior to working on the switch machine CAUTION When reconnecting the machine cables ensure the collars are turned until they lock Additionally if power is fed from the WAGO terminal block carefully remove the wires without disturbing other connections If other connections are disturbed removed cut or otherwise disconnected then breakdown or other types of testing may be required to be performed again NOTE The cables for TB1 and JB1 are keyed in the same manner Cable lengths and cable ties should prevent cross connections however in the event they are incorrectly re connected and power is applied the ECC will appear as if no power has been applied If cross connections are made no damage to the unit will occur Swapping the connectors should return the ECC to normal operation if no problems were found during diagnostic testing Connector keying will prevent any other incorrect connections SM 9020 Rev 0 September 2002 4 1 UNION SWITCH amp SIGNAL S Section 4 Installation UNION SWITCH amp SIGNAL 4 2 SM 9020 Rev 0 September 2002 UNION SWITCHES SIGNAL Section 5 Operating Procedures Section 5 Operating Procedures The ECC Field Test Unit may be used to fully gauge the performance of an ECC unit by connecting it to the ECC as shown in Figure 2 1 It may also test individual vital and non vital sensors used in a switch machi
18. labeled VITAL SENSOR TEST while implementing all test steps SM 9020 Rev 0 September 2002 5 5 Step 1 If the sensor is not near a metallic or conductive surface more than 1 2mm the LED that corresponds to Point Detected on the NORMAL side of the ECC will be steady RED indicating the sensor is OFF or is not sensing a target Step 2 Move the sensor near a metallic or conductive surface less than 1 2mm The LED that corresponds to Point Detected on the NORMAL side of the ECC will be steady GREEN indicating the sensor is in ON or is sensing a target Step 3 Optional Under normal circumstances the sensor is either ON or OFF However careful placement of the sensor near a metallic or conductive surface more than 1 2mm but less than 4mm may result in the Point Detected LED flashing RED indicating the sensor is in the indeterminate state between ON and OFF This may be difficult to achieve If the NORMAL side Point Detected LED is flashing RED steady RED or steady GREEN regardless of sensor position the sensor is not functioning properly Additionally if the NORMAL side Point Detected LED does not function as indicated in Steps 1 and 2 the sensor is not functioning properly 5 2 2 Non Vital Sensor Test Initially when the sensor is connected it is not in circuit for the ECC to be able to test Press and hold the momentary push button below the terminals labeled NON VITAL SENSOR TEST while implementing the test Ste
19. led So regardless of the machine s configuration the ECC can still be tested using the Field Test Unit as described below Two rotary switches simulate the jumper configurations that are contained in the junction box The DIRECTION rotary switch tells the ECC if the switch 1s configured as Left Hand Points Closed LHPC or Right Hand Points Closed RHPC The LATCHOUT rotary switch tells the ECC how to respond to a latchout situation that can be simulated by the Field Test Unit Both of these rotary switches provide a NONE position to simulate no jumper being installed in the junction box for that function The ECC should respond correctly to that condition as well The two momentary push buttons at the top of the Field Test Unit are used to switch a vital or non vital sensor into the circuit for testing 3 2 SM 9020 Rev 0 September 2002 UNION SWITCH amp SIGNAL Section 4 Installation Section 4 Installation Installation of the Field Test Unit is accomplished by removing the three cables connected to the ECC and connecting the corresponding cables from the Test Unit to the ECC Power is applied as described in Section 2 1 No other connections are required The ECC under test does not need to be removed from the machine To avoid severe personal injury open the gold nut test link in the motor compartment prior to performing any internal machine maintenance Always keep hands and feet clear of switch points and the internal mov
20. mination of a safe switch configuration due to positive indication that the switch machine has properly thrown locked and detected switch point closure A device which performs the three operations of unlocking operating and locking a switch movable point frog or derail Union Switch amp Signal Any circuit with a function that affects the safety of train operation Registered trademark for WAGO Corporation Warning statements indicate conditions that could cause physical harm serious injury or loss of life UNION SWITCH amp SIGNAL Section 1 Introduction 1 4 Safety Read and thoroughly understand this manual before attempting any of the procedures listed Pay particular attention to the WARNING and CAUTION statements that appear throughout this manual Always exercise care and observe standard precautions familiar to properly trained personnel Always adhere to all safety regulations stipulated by the railroad 1 4 SM 9020 Rev 0 September 2002 UNION SWITCH amp SIGNAL Section 2 Equipment Description Section 2 Eguipment Description For information regarding the system functions and components related to the electronic control system inside of the switch machine refer to service manuals SM 6263 A for M23 retrofit machines and SM 7100 for M23E machines The ECC Field Test Unit connects directly to the three front connectors of the ECC and does not reguire that the ECC be removed from a switch machine When looking a
21. ne NOTE The sensors used for both Auxiliary Point Detection sensors and for both the Hand Crank and Hand Throw functions are all electrically identical and are all considered non vital types They may vary in barrel length The following procedure verifies the correct performance of an ECC and or any of the proximity sensors Record the results of the procedure on the Data Sheet supplied in Appendix A 5 1 ECC Diagnostic Testing 1 After power up set switches on the Field Test Unit as follows DIRECTION LHPC LATCHOUT DISABLE POINT SENSE 1 ON GREEN POINT SENSE 2 OFF RED LOCK SENSE 1 ON GREEN LOCK SENSE 2 OFF RED AUXILIARY SENSE 1 ON GREEN AUXILIARY SENSE 2 OFF RED HAND THROW ON GREEN HAND CRANK ON GREEN 2 Verify that the LEDs on the ECC controller appear as follows NORMAL REVERSE POINT DETECTED GREEN POINT DETECTED RED LOCK DETECTED GREEN LOCK DETECTED RED INDICATION INPUT GREEN INDICATION INPUT GREEN INDICATION OUTPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN AUXILIARY POINT DETECTED DARK LATCHOUT DARK MOTOR DISABLED DARK 3 Move the DIRECTION switch on the Field Test Unit to the RHPC position Verify that the LEDs on the ECC controller appear as follows SM 9020 Rev 0 September 2002 5 1 Section 5 Operating Procedures NORMAL POINT DETECTED RED LOCK DETECTED RED INDICATION INPUT GREEN INDICATION OUTPUT DARK
22. o the MANUAL position Set the POINT SENSE 1 push button switch on the Field Test Unit to OFF or RED Verify that the LEDs on the ECC controller appear as follows 9 2 SM 9020 Rev 0 September 2002 UNION SWITCH 8 SIGNAL NORMAL POINT DETECTED RED LOCK DETECTED GREEN INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN Section 5 Operating Procedures REVERSE POINT DETECTED RED LOCK DETECTED RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED DARK LATCHOUT RED MOTOR DISABLED DARK 8 Setthe POINT SENSE 1 push button switch on the Field Test Unit to ON or GREEN push the Latchout Restore button on the ECC Controller for a minimum of 1 second and verify the LEDs on the ECC controller return to the configuration of Step 2 9 Move the LATCHOUT push button switch to the AUTO position Set the POINT SENSE 1 push button switch to OFF or RED Verify that the LEDs on the ECC controller appear as follows NORMAL POINT DETECTED RED LOCK DETECTED GREEN INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTED GREEN REVERSE POINT DETECTED RED LOCK DETECTED RED INDICATION INPUT GREEN INDICATION OUTPUT DARK AUXILIARY POINT DETECTEDE DARK LATCHOUT RED MOTOR DISABLED DARK 10 Set the LOCK SENSE 1 push button switch to OFF or RED then set the POINT SENSE 1 push button switch back to ON or GREEN and f
23. p 1 If the sensor is not near a metallic or conductive surface more than 1 mm the LED that corresponds to Auxiliary Point Detected on the NORMAL side of the ECC will be DARK indicating the sensor is OFF or is not sensing a target Step 2 Move the sensor near a metallic or conductive surface less than 1mm The LED that corresponds to Auxiliary Point Detected on the NORMAL side of the ECC will be steady GREEN indicating the sensor is ON or is sensing a target If the NORMAL side Auxiliary Point Detected LED is flashing GREEN the ECC is not functioning properly If the NORMAL side Auxiliary Point Detected LED is steady GREEN or DARK regardless of sensor position the sensor is not functioning properly Additionally if the NORMAL side Auxiliary Point Detected LED does not function as indicated in Steps 1 and 2 the sensor is not functioning properly If the sensor is not functioning properly change the sensor Repeat the test to verify proper operation of the sensor before replacing it in the switch machine 5 6 SM 9020 Rev 0 September 2002 UNION SWITCH SICNRE Section 6 Maintenance Repair Section 6 Maintenance Repair There are no maintenance or repair procedures that field or shop personnel can perform on the Field Test Unit If there are any problems with the Field Test Unit US amp S recommends that the Unit be returned to the US amp S Batesburg location for repair Proper operation of the Field Test Unit may be verified
24. ssible to take into account every eventuality that may arise with technical equipment in service Please consult US amp S local sales representative in the event of any irregularities with our product We expressly decline liability for damages resulting from any improper handling or use of our equipment even 1f these instructions contain no specific indication in this respect We stress the fact that only genuine approved US amp S spare parts should be used for replacements SM 9020 Rev 0 September 2002 Revision History UNION SWITCH amp SIGNAL Revision History Original September 2002 ii SM 9020 Rev 0 September 2002 UNION SWITCH 8 SIGNAL Table of Contents Table of Contents Section T INTOdUCtION u l ar eat dic N na hd hd hna 1 1 1 1 Apps eek us r sa 1 1 1 2 Purpose of Manual u comit re di ee mar sin sa uyu 1 1 1 3 Conventions in Manual uum s u in a a aa 1 2 1 3 1 Abbreviations Acronyms and Definitions 1 2 1 4 SELS ARR fea tn int lia tl r rn au T t nal tra 1 4 Section 2 Equipment Description 2 1 2 1 Power RegulfemM flssssa ass u uu naa ua A hl hula e a hla en ile 2 1 Section 3 Functional Descriptions u ar aa dial Era 3 1 3 1 ECC DIAGNOSTIC INFORMATION iii 3 1 3 2 ECC Field Test Unit Controls coincida 3 2 Section4 Installati n 000 rn dia 4 1 Section 5 Operating Procedures seen 5 1 5 1 ECG Diagnostic Testing nase a Timer 5 1 5 2 ECC Vital Non Vital Sensor Testing 5 5
25. t the Field Test Unit from the top side the three cables are connected directly to the ECC for testing without crossing them Figure 2 1 NOTE The cables for TB1 and JB1 are keyed in the same manner Cable lengths and cable ties should prevent cross connections however in the event they are incorrectly re connected and power is applied the ECC will appear as if no power has been applied Because there is no power if cross connections are made no damage to the unit will occur Swapping the connectors should return the ECC to normal operation if no problems were found during diagnostic testing Connector keying will prevent any other incorrect connections The Field Test Unit is designed to simulate the equipment that is connected to the ECC and to manipulate the states of that equipment to determine how the ECC responds This provides fast indication as to the status of the ECC and assists in the diagnosis of any problem that may arise 2 1 Power Requirement When connected to an ECC and power is applied to the Field Test Unit the ECC will also be powered on The power required for the ECC Field Test Unit is 9 8Vdc to 16 2Vdc a 1 5A and may be brought from an independent external source or power may be fed from the WAGO terminal block and connected as detailed in Table 2 1 Approximately 8 feet of 20AWG wire minimum is recommended for each of these connections Table 2 1 WAGO Block to ECC Field Test Unit Power Wiring
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