DA-10 SWITCH MACHINE
Contents
1. Figure 2 1 Typical Layout of Style DA 10 Switch Machine 22 0 0 0000000000000 SMB711 12 08 UNION SWITCH amp SIGNAL Section 3 0 Retrofit Kit Installation 3 1 General Information The new DA 10 Retrofit Kit is designed to convert a DA 10 Pneumatic Switch Machine with a 5 piston built prior to December 1998 from US amp S iron clad style magnets to new coil style magnets The changeover procedure requires very little time due to complete replacement of the machine s head assembly Figure 3 1 DA 10 Retrofit Kit 3 2 Installation Installation of the Retrofit Kit requires the removal of the old valve head assembly which includes the Pilotair valve the magnet assemblies and the head The head assembly can be removed as a single unit and then disposed of properly The Retrofit Kit comes complete with hardware and gasket for immediate installation The air supply hose and electrical connections from the existing installation will connect directly to the new retrofit head Regarding electrical connections the new design includes an integral junction box with AAR style terminals for the termination of electrical leads This junction box is threaded to receive standard 1 2 NPT threaded conduit fittings which may or may not be used depending on the layout configuration SM5711 12 98 3 1 3 3 1 3 2 we Machine Body Retrofit Cylinder Head Kit Figure 3 2 DA2. ssseeeessssss A 1 Style DA 10 Switch Machine EB A 3 Valve Assembly for DA 10 Switch Machine ceeeeeeeeeeeeeeeee A 4 SM5711 12 98 UNION SWITCH amp SIGNAL Section 1 0 Introduction 1 1 Ordering Information Description Order No Reference Item See Figure 1 3 12Vdo DA 10 retrofitkit DA 12Vdo DA 10 retrofitkit retrofit kit N425002 01 Lowe 3 24Vdc DA 10 retrofit kit N425002 02 Le DA 10 12Vdc machine only DA 10 24Vdc machine only IN4as001 02 D DA 10 12Vdc with cover and base plate x425000 04 E DAT eag wineoveranase pae aeoo Fr Table 1 1 DA 10 Switch Machine Ordering Information 1 2 Description and Operation The model DA 10 Direct Acting Switch Machine combines fast piston action with a stable pressure level This is accomplished by eliminating all intervening mechanisms between the piston and switch which maintains cylinder air pressure at all times The DA 10 with its 5 piston and 6 stroke is designed to satisfactorily operate from 55 to 130 PSI with a 12 or 24 volt supply voltage With 100 PSI air pressure and a 22 volt supply the DA 10 Switch Machine achieves one cycle normal to reverse or reverse to normal within 0 4 seconds In addition the 5 diameter cylinder of the DA 10 suitably replaces both the 4 and 5 cylinders of its predecessors The layout of the machine including a switch circuit controller is illustrated in Figure 2 1 The control
3. A3 N371987 1 i 8 Follower Piston 1 M371907 1 9 Follower Piston Mon 1 10 Spacer PistonNut M3719886 1 11 Follower Piston M37198 1 12 Cotter 3 16 x 2 Steel T P C 2 1 JO048630 1 13 Nut 1 14 Hex Slotted Steel Cad P C 1 J480160 1 14 Packing dena 2 15 Ring 1 x 1 4 O J067427 2 16 ing Packing Back up M3719900 2 18 Fitting 1 8 P T Str Lub J039137 19 Eye Screw 0 N 1 20 Fitting 1 8 P T F Lub Pressure relief J039128 1 Gasket Cy Head M371998 1 mo jnm m0 l nminmi i lol Plug Exhaust M372007 Operating Valve comp 12V J3373850004 25 INOTUSED 26 INOTUSED 2 2 29 _ Terminal block SM5711 12 98 A 3 A 3 Valve Assembly for DA 10 Switch Machine NON Ip NLT TRL a U A M kan am NT gin TA kh IN NRA Detail showing captive exhaust O Ring SECTION A A Figure A 2 Valve Body Assembly For DA 10 Switch Machine item No Description Part Number ay Body B Plunger Spool D 0Ring Reference Only 4 Rebuild Kit J0675840015 Rebuild kit includes all soft seals required to rebuild operating valve A 4 SM5711 12 98
4. cups require periodic lubrication These areas are factory lubricated with Shell Aeroshell Grease 6 Reference Figure 1 3 for lubrication points Lubrication intervals for each location will differ and care should be taken to avoid excessive lubrication Be aware that excessive lubrication of the cylinder cavity can produce a grease build up and shorten the stroke of the machine The piston rod should remain well lubricated at all times The operating valve should be repacked with grease when rebuilt The original lubricant used is Texaco Molytex EP 2 however an equivalent lubricant may be suitable for rebuilding Texaco Molytex EP 2 meets AAR Specification M 929 75 Please note the OEM lubricants in the cylinder and operating valve are not compatible The two lubricants should not be mixed or substituted for one another 5 1 1 Air Line Lubrication In order to maintain reliability and normal life of machine components it is important to filter 40 50 microns and lubricate the air passing through the machine Regarding air line lubricator oils many brand name oils may be suitable for use if they have a paraffin base and aniline point in the range of 200 220 F 95 105 C Oils must be thin enough to atomize in the lubricator Users should be advised not to use penetrating oils or detergent type oils as they will damage the seals thicken in cold weather and wash out assembly grease Thick oils do not atomize sufficiently The t
5. 10 Retrofit Valve Head Kit Installation Procedure Installation Procedure Disconnect and inspect electrical leads and air hose Replace leads and or hose as necessary Remove existing valve head assembly from machine body 4 bolts Clean flange surface on valve head with suitable degreasing agent Examine piston seals and cylinder for excessive wear or damage Replace if necessary Remove junction box cover plate from new valve head Place gasket on new valve head Assemble valve head to cylinder with 7 bolts and lock washers included with kit Tighten bolts in an alternating pattern Connect the air line and electrical leads Verify air supply and wiring by cycling switch machine Replace junction box cover plate SM5711 12 98 UNION SWITCH amp SIGNAL SECTION 4 0 Operation 4 1 Machine Operation The switch machine can be operated automatically or manually Manual operation is achieved by pressing the appropriate Manual Operation button on either end of the Operating Valve as indicated by the Normal N or Reverse R labels Press and Release Button Figure 4 1 Manual Operation Button SM5711 12 98 4 1 This page is intentionally blank 45711 12 98 UNION SWITCH amp SIGNAL SECTION 5 0 Maintenance 5 1 Machine Lubrication The DA 10 Switch Machine is fully lubricated prior to shipment and no lubrication is necessary before installation However the piston rod and cylinder cavity U
6. circuits including a detector track circuit and switch circuit controller are generally arranged so that displacement of the switch caused by trailing traffic will reverse switch position when the switch reaches mid stroke This forces the switch full stroke to align for reversal of the trailing traffic as long as the detector track is occupied The track switch to which the machine is applied should have freely hinged point heels to prevent bending of the point and closure rail when the switch is thrown SM5711 12 98 1 1 Figure 1 1 Style DA 10 Direct Acting Switch Machine Figure 1 2 Switch Machine with Cover Removed 12 SM5711 12 98 UNION SWITCH amp SIGNAL Section 1 0 Introduction Cylinder Lubrication Rod Lubrication Point 37 22 29 9 3 8 6 1 2 Figure 1 3 DA 10 Switch Machine SM5711 12 98 1 3 1 3 Cylinder and Valve Head The cylinder and the piston rod guide of the DA 10 Switch Machine Figure 1 3 are constructed as a single component to ensure accurate rod alignment The rod packing consists of two shaft seals located in recess near the cylinder bore The open ends of the seals oppose each other such that the seal facing the cylinder guards against air loss from the cylinder cavity In addition the seal facing the grease reservoir prevents grease from being forced into the cylinder from the reservoir see Figure 5 1 The scraper ring
7. located at the outer end of the piston rod guide removes dirt from the rod on the return stroke The length of the piston rod guide prevents piston rod exposure for the bearing portion of the rod The rod is fitted with a piston two 5 packing cups and followers O rings are used to prevent secondary air leakage across the piston The cups are greased through a port located at the rod eye Lubricant is forced through a hole running the entire length of the piston rod The rod eye is threaded to the piston rod and then clamped to prevent rotation The valve head is mounted to the cylinder with four 4 bolts to retain the piston s motion In addition the head serves as a mounting platform for the operating valve and is ported to direct air flow appropriately 1 4 Operating Valve The operating valve is directly fastened to the valve head with three 3 screws The valve directs air to either the top or bottom of the piston depending on the direction movement is required For Normal movement air is forced to the track side of the piston For Reverse movement air is forced to the field side of the piston The flow of air through the valve is entirely dependent on the position of the valve s spool The spool moves back and forth within the valve body and is always in one of two positions Spool movement is achieved through a small pilot burst of air at the end of the spool The air burst is initiated by activation of the solenoid coil when
8. the machine is called to throw Reference Figure A 3 for Valve Body Assembly drawing 1 4 SM5711 12 98 UNION SWITCH amp SIGNAL Section 2 0 General Installation 2 1 Connecting to Switch The DA 10 Switch Machine design provides a six inch 6 maximum throw of the piston rod The following procedure adapts the DA 10 to a particular switch stroke Reference Figure 2 1 A Before connecting the machine to the switch push the piston rod into the cylinder as far as possible and mark the piston rod at the end of the cylinder housing Withdraw the piston rod three inches 3 to the mid position B Block the switch in the middle position Connect the switch operating rod to the screw eye at the end of the piston rod Tighten and lock operating rod nuts at the switch point adjuster basket C The above procedure will ensure that the mid point of switch stroke will correspond to the middle position of the piston rod The purpose of this adjustment is to guarantee that movement of the switch points is stopped by the stock rail rather than by the piston rod striking the valve head The DA 10 Switch Machine has been designed to require a minimum of servicing The length of the period between servicing is dependent upon the frequency of cylinder operations use and severity of climatic conditions SM5711 12 98 2 1
9. UNION SWITCH amp SIGNAL S DA 10 SWITCH MACHINE and Retrofit Valve Head Part Numbers N425001 01 N425001 02 N425002 01 N425002 02 X425000 04 Description B X425000 05 Installation WH Operation B Maintenance E December 1998 An Ansaldo Signal Company Union Switch amp Signal Inc Printed in the U S A Original Publication December 1998 SM5711 12 98 UNION SWITCH amp SIGNAL Table of Contents Section 1 0 1 1 1 2 1 3 1 4 2 0 2 1 3 0 3 1 3 2 3 3 4 0 4 1 5 0 5 1 5 1 1 5 2 5 2 1 5 2 2 Appendix A A 1 A 2 A 3 1 1 1 2 1 3 2E 3 1 3 2 4 1 5 1 5 2 Topic Page alice te 024 1 o a sa n RS 1 1 Ordering Information eerie recent citu ennt tipa ntn 1 1 Description and ODeratlOTi uicit etiain tetra trt e e Die De ote etta 1 1 Cylinder and Valve Head sssessseeesseeeeneenenne 1 4 Operating Valve o ansehen 1 4 General Instalatii 5 889 nenne 2 1 Connecting to Switch a Sao puces Nea up een ree 2 1 Retrofit Kit Installation ooo ro inni sh nao coco easier Pe ERA e ER eR Y Fore ego ecg 3 1 General Intormallo ic5 n i tia cep eR neo MIS tne S dates eee eee 3 1 IristalldtlOPio enisi 328222 Eagle 3 1 Installation PEOGSOUEIG oir chri oper eset ret anane nean e pesi depen di pend 3 2 ORATION saa rsen e naa Sake aana de caa EE dU DUNG Ia UE Fou durada 4 1 Machine Operation een 4 1 lip m 5 1 Machine EubfIG
10. able below lists commercially available light oils recommended for use as air line lubricant with the DA 10 Switch Machine They are compatible with the original equipment nitrile rubber seals of the machine However these oils may be detrimental to seal compounds in other equipment When choosing an air line lubrication oil consideration should be given to all equipment served by the lubricator to avoid detrimental effects on vulnerable sealing compounds Lubricant Table 5 1 Commercial Lubricants for use as Air Line Lubricant SM5711 12 98 5 1 a I te Scraper ha Ring 4 i hg ti Grease E Reservoir a Ir Shaft f Seals 4 Cylinder 4 Body T Piston T i Valve 4 Head U Packing 4 t Cups Ll S Main Supply Port NL S NR E Exhaust Port Operating p E N Normal Supply Port Valve b R Reverse Supply Port Figure 5 1 Operation of DA 10 Switch Machine 5 2 SM5711 12 98 UNION SWITCH amp SIGNAL SECTION 5 0 Maintenance 5 2 Service The DA 10 Switch Machine should be removed at least once every one or two years depending upon the use and be returned to the shop for servicing The Valve Head Assembly can be removed separately and replaced without removing the machine from the track Spare coils and seals should be available for replacement Reference Figures A 2 for appropriate seal components kits Piston Rod Clamp ae N37228 D B Scraper Installati
11. atlorzs tio edu Ga E nic ere reae 5 1 Air Line DODfIGallgri occidendi ardore a den tons 5 1 OCR VIG aa aga aana BEE D D ag a PEE Dd 5 3 Mulier EE 5 3 Operating VaVe o oxi aapa saba na kai cc use ead aaa aaa a a aja Dude 5 4 Parts List un A 1 Technieal Dalai ee A 1 Style DA 10 Switch Machine 444444444440000nn4n nn nnnnnnnnnnnnnnnnn A 3 Valve Assembly for DA 10 Switch Machine eeeeeeeeeeeeeeee A 4 List of Figures Style DA 10 Direct Acting Switch Machine sseussssss 1 2 Switch Machine with Cover Removed ccccccccsssseeseeeeeeeeeeeeeeeeeeeeees 1 2 DA 10 Switch Machine ieee ele Uc ue ebat is 1 3 Typical Layout of Style DA 10 Switch Machine 2 2 DA 10 Retrofit Rita 3 1 DA 10 Retrofit Valve Head Kit Installation Procedure 3 2 Manual Operation BUHOIa anne ee 4 1 Operation of DA 10 Switch Machine eeeesseesseessss 5 2 DA 10 Maintenance Tools cce io ion eec de od Cont at dac 5 3 SM5711 12 98 A 1 A 2 1 1 5 1 A 1 A 2 A 3 Style DA 10 Switch Machine Assembly Drawing A 2 Valve Body Assembly for DA 10 Switch Machine A 4 List of Tables Ordering Information ee 1 1 Commercial Lubricants for use as Air Line Lubricant 5 1 Electrical Operating Specifications
12. from each end of valve mechanism 2 Remove the spool from the valve body by pushing on either end of the spool 3 To reassemble lightly grease all parts with O ring grease Texaco Molytex EP 2 or equivalent and reassemble in the opposite order above 5 4 SM5711 12 98 UNION SWITCH amp SIGNAL A 1 Technical Data Rated Operating Voltage Voltage 9 6 to 13 2 APPENDIX A Parts List Pick up Current Draw Voltage Rated Voltage 9 6 0 78 19 2 to 26 4 19 2 0 38 Rated at 90 PSI air pressure and 70 F ambient temperature meets AAR 12 2 10 1993 Section 6i Different value than previous magnet equipped DA 10 Was 12Vdc 5 0 14Vdc 0 092 ampere draw 24Vdc 8 3 26Vdc 0 058 ampere draw Table A 1 Electrical Operating Specifications SM5711 12 98 A 1 dup 4 3 di RN din D dic ANT PIP 9 A qu 4 D ii OANA e ad US Sez ma 4263 Nez wg La NG DrD ME o r M aa FL gu een Figure A 1 Style DA 10 Switch Machine Assembly Drawing A 2 SM5711 12 98 UNION SWITCH amp SIGNAL APPENDIX A Parts List A 2 STYLE DA 10 SWITCH MACHINE P N N425001 01 12 Volt P N N425001 02 24 Volt 1 Ring Retaining J702883 1 2 Wiper J790579 1 3 Packing U Cup J067430 2 4 Retainer V Ring 3723192 2 5 Ring Retaining J791577 1 6 joyindr d M37199 1 i 7 fRodPison
13. on Tool M372292 Figure 5 2 DA 10 Maintenance Tools 5 2 1 Cylinder A Figure 5 2 illustrates special tools used for DA 10 maintenance To clean and service the switch cylinder proceed as follows 1 The extended piston rod should be clamped with tool M372298 before attempting to unscrew the rod eye Remove the rod eye by first loosening the clamp bolt and unscrewing the eye Remove the valve head and withdraw the piston and rod Clean the outer end of the rod before removing to prevent damage to the U cups Handle the cylinder rod carefully to prevent scratching or scoring the surface Remove the U packing gland by first removing the snap ring with a Waldes tool PN J39813 Clean and examine the packing for wear and replace any worn parts It may be advisable to replace the U cups at this time Remove the scraper ring at the outer end of the ring using a pointed tool to extract the rubber holding ring Examine parts and replace if necessary Clean the entire cylinder with cleanser and re grease with lubricant prior to reassembly SM5711 12 98 5 3 B To install the U cups proceed as follows 1 Place one packing back up ring in the recess Insert one U cup lip turned toward the cylinder Install the two V ring retainers back to back Install the second cup with the lip away from the cylinder Insert the second packing back up ring Insert retaining ring SM E M M a NO In
14. sert the wiper rings with their lips outward in the Piston Rod Guide The rubber compression ring portion is installed with tool UM372292 C The piston should be taken apart by removing the rod clamp nut spacers and cups All parts should be cleaned O ring seals and US amp S packing cup should be examined and replaced if worn excessively The piston and rod should be reassembled greased and then replaced into the cylinder Carefully insert the rod into the U packing The combination of the taper lead and the guiding washer will prevent damage to the cups if assembly is carefully made The large cups should be inserted in the cylinders without damaging the sealing lips 5 2 2 Operating Valve The operating valve is primarily constructed of two components the end operator and the valve mechanism The end operator is the component fastened to either end of the valve body The operating valve uses two end operators one for each end The valve mechanism includes the valve body and each of its internal component seals etc Reference Figure A 3 for illustration Regarding the end operator no maintenance or repair is recommended Should this item become defective the valve should be replaced The valve mechanism includes O ring seals that require periodic maintenance To disassemble the valve for inspection cleaning and reworking proceed as follows 1 Remove four 4 screws from each end of valve Remove the end operator
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