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M-3E Switch and Lock Movement

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3. CDI 2 1 Compartment ue eise i 2 1 1 The Transmission BOX eee dpa bnt 21 2 tute e ER EHE 21 83 AR dtt d eda 2 1 4 WAGO Terminal Strip 2 1 5 Field Cable Conduit 24 6 AAR Binding POSTS o iE crt e a rica 2 2 Gearbox Compartment nn 2 2 1 Gearbox Components and AssemblieSs pp 2 3 Circuit Controller Compartment 2 3 1 Frog PIATE ena 2 32 Vital Eocking Sensores n uel edet b arde re ied Hk 2 3 9 2 ECG BOX eoe aed ii 2 3 4 JUNCTION BOX an en DE 2 3 5 Captive Point Detection System CPDS pp 23 6 Point Detector Target ee en eesti nc ar Sd able ned Aas olde ag al 2 3 8 Vital Sensor Position Monitoring Ne 2 3 8 Non Vital Auxiliary Sensors 2 3 10 Local Remote Request Switches Optional sss 2 REMISE 3 1 O 3 1 1 POWEr Opera ios dee 3 1 2 Manual Operat
4. Figure 8 2 Switch Machine 422550 Left Hand Unit Sheet 2 The Right Hand Machine is the same except they are mirror images of each other SM 9194 Original October 2004 8 7 PARTS LIST UNION SWITCH amp SIGNAL E422853 Figure 8 3 Switch Machine N422550 XX Left Unit Sheet 3 Right Hand Machine is the same except they are mirror images of each other 8 8 SM 9194 Original October 2004 SWITCH amp SIGNAL PARTS LIST M fg XY Ar Figure 8 4 M 3E Circuit Controller SM 9194 Original October 2004 8 9 PARTS LIST UNION SWITCH amp SIGNAL 8 3 42205101 M 3E Transmission Assembly Figure 8 5 Table 8 3 Parts List for the M 3E Transmission Assembly 2 BERN 1777 Sa ro Washer Lock 1 2 Steel 8 Transmission Box Cover Transmission Box Cover Plate M42310401 78 PngershatAssemby __________ _ 9 DowelPin 3 8 Dia x 1 long Retaining Ring 1 3 16 Dia Reduction Gear Shaft M42311801 Ball Bearing 1 625 OD Olite Bushing A 1704 4 J790004 20 washer 25 Clutch Plate 4 574 _ e M146650 ing 3 2 NotUsed 1 100 000 000 Screw Socket Head Cap 1 4 20 x 3 4 Long Washer Lock 1 4 0 365 OD J4751210135 55 Reduction Gear Spacer 36 222 98 4 NotUsed 0 00 0
5. SWITCH amp SIGNAL Union Switch amp Signal Inc an Ansaldo Signal company 1000 Technology Drive Pittsburgh PA 15219 645 Russell Street Batesburg SC 29006 SM 91 94 Switch and Lock Movement with Electronic Circuit Controller ECC 422550 Installation Operation Maintenance Copyright 2004 Original October 2004 Union Switch amp Signal Inc SWITCH amp SIGNAL Proprietary Notice This document and its contents are the property of Union Switch amp Signal Inc hereinafter US amp 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 of 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 0585 constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it is
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7. 8 Sensors do not turn ON when target or lock box is in front of more than 50 of the sensor face A Cable TB2 is improperly connected terminated or is defective B Defective ECC or improper software execution by the ECC processor A Sensor not properly connected to junction box B Sensor air gap not properly adjusted TROUBLESHOOTING Confirm TB2 plug connector is properly secured and locked to ECC box Confirm all 10 color coded wires are properly terminated on the WAGO terminal strip and that all crimped wire ferrules are properly secured to the end of each wire Remove cable TB1 and reconnect initiating an ECC processor reset If the unit resets and the LEDs restore check for presence of voltage output on WAGO terminals 1 and 3 Even if output restores replace ECC box as an entire unit and return to US amp S for analysis Confirm proper termination of the brown and blue sensor wires to the corresponding terminals in the Junction Box Terminals are labeled on the PC board BR for brown and BL for blue For vital large diameter sensors confirm gap between sensor face and PD target lock box is adjusted to 0 075 On M 3E confirm that the locking sensors are adjusted to 1 2 turn less than being flush mount with the frog plate casting surfaces For non vital small diameter sensors confirm air gap between sensor face and target is adjusted to 0 040 SM 9194 Or
8. SM 9194 Original October 2004 4 5 WIRING AND MOTOR CONTROL UNION SWITCH amp SIGNAL Wiring Changes From 3 Wire and 5 Wire to 2 Wire Motor Control Connect Together 3 Wire PM Motor for 2 wire control D lt Controller 3 Wire to 2 Wire 5 Wire together 24 for 2 Wire Control Eliminate for 2 Wire Control ECC Controller For5 Wire to 2 Wire Conversion Normal amp Reverse Motor Cut Out Hand Crank Symbols Jl Figure 4 2 Wiring Changes from 3 Wire 5 Wire to 2 Wire Motor Control 4 6 SM 9194 Original October 2004 WIRING CONTROL lt 2 7 o E 2 2 5 pue IelHA uoN pue 2 Jeelo ol pesn JeAeu SIeuluuel elod Ig eoueuejure N ONINYVM CHHHLOHH NI G3TIISNISI 41 QLLOANNOO 6 AHQLHHHL NI CHTIVISNI SI SNIHOVW 31 HM __ 255 SLNIOd SAH ALHYICH ELY OINI NOLONNF 3HL JO SNOILCHNNOO HOSNES OLOHS Z670 QA HHH JOSNOIVOOTHOH V EB c 62 NNIIAHHL ODWM OL 3HIM 8 08 IVNIIAEHL OL 34MLOSNNOO 1 098 HOS HV39 1 68 HLIMLOdHHOO SHV 088 62 SIVNINEAL OL SV SNOILOANNOO G Pue y
9. a 4 Motor Adapter Plate mazarioo2 5 Screw BE 6001240002 6 Reduction Gear Spacer MSIE 8 ooy Screw Set 8 32 x 1 8 Long Screw Hex 3 8 16 x 3 4 8 14 SM 9194 Original October 2004 SWITCH amp SIGNAL PARTS LIST POSITIVE TERMINAL ES co ED Ze 4220026 Figure 8 7 Motor Assembly 42200201 9194 Original October 2004 8 15 PARTS LIST UNION SWITCH amp SIGNAL 8 16 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL PARTS LIST 9 RAIL TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link RAIL Team is comprised of experienced product and application engineers ready to assist and resolve technical issues concerning any US amp S product Any questions regarding the contents of this service manual can be answered by contacting the RAIL Team via e mail at railteam switch com or a toll free call to 800 652 7276 SM 9194 Original October 2004 9 1 PARTS LIST UNION SWITCH amp SIGNAL 9 2 SM 9194 Original October 2004
10. 5 5 5 43 Changing the Jumper Configurations pp 5 5 5 5 ECC Power and Indications Set up pp 5 5 5 5 1 Single Machine Indication sess 5 5 5 5 2 Multiple Machine Applications nenn 5 5 5 5 3 Point Detector Sensor Gap Adjustment pp 5 6 5 6 Operating Rod 1 das aa nn 5 6 5 7 Point Detector Linear Slide Adjustment 5 6 OO 5 7 5 9 Final Inspection and Testing After Installation nnns 5 7 6 Periodic 6 1 6 1 Required Tools diiniita ida 6 1 6 27 6 1 To IrOUBIESNOOUNG 7 1 LAM C CQGBl c 8 1 8 1 M 3E Switch Machine 422550 1 8 1 8 2 422550 Switch Machine LHNC 189 1 Figure 8 1 Figure 8 4 2 8 1 8 3 42205101 M 3E Transmission Assembly Figure 8 5 8 10 8 4 42280201 M 3E Gearbox Assembly Figure 8 6 00444 0 0000 000 8 12 8 5 Motor Assembly N42200201 Figure 87 8 14 9 Team
11. 0000 Screw Hex 1 2 13 x 1 1 2 Hex Screw Cap 1 2 13 x 1 Hex 8 10 SM 9194 Original October 2004 SWITCH amp SIGNAL PARTS LIST 37 TT LI gt mm L f 5 o5 u 528 4 7 SESS q 2252 Pee lt 1 N 82 gt gt 5 lt amp Li 00 Qo 6 9 21502273 Figure 8 5 M 3E Transmission Assembly N42205101 SM 9194 Original October 2004 8 11 PARTS LIST UNION SWITCH amp SIGNAL 8 4 N42280201 Gearbox Assembly Figure 8 6 Table 8 4 Parts List for the M 3E Gearbox Assembly tem Number Description Part Number 1 Gearbox win bronze busting assembly _Nazze0r0t 4 Re 5 pomar aenak _ 6 ___ e HenPlowBek 9 Release rin 0770005 Pipe Plug 1 2 Steel 18 Ser 1 2 13 x 2 1 2 Hex Hd 19 Washer 1 2 Plain Flat Not shown in Figure 8 6 8 12 SM 9194 Original October 2004 SWITCH amp SIGNAL PARTS LIST 082273 Figure 8 6 M 3E Gearbox Assembly N42280201 SM 9194 Original October 2004 8 13 PARTS LIST UNION SWITCH amp SIGNAL 8 5 M 3E Motor Assembly N42200201 Figure 8 7 Table 8 5 Parts List for the M 3E Motor Assembly Te Description Part Number 3
12. 3 5 Captive Point Detection System CPDS The captive point detection system CPDS consists of self lubricating bearing sleeve which holds captivative the point detector bar across the entire width of the machine By not extending the point detector bar outside the field side of the machine we eliminate any pinch point safety hazard with the hand throw lever which is now lower due to the reduced profile of the gearbox 2 3 6 Point Detector Target Attached to the captive point detector bar is a ferrous metal radial target used to activate the four vital point detection proximity sensors with respect to switch point position The target is fastened to the point detector bar with a 1 4 20 socket head cap screw that stays captive by the sleeve The end of the point detector bar extending outside of the machine on the trackside is rigidly connected to the point detector connecting rod lug The point detector bars are available with two connecting end styles 1 8 threaded end for use with a drop lug and a 5 8 pin machined end for use with a clevis lug 2 3 Linear Slides The linear slides are used to secure and provide adjustment of the vital point detection proximity sensors with respect to the point detector target on the point detector bar There are two linear slides one for each position of the switch point Each linear slide is equipped with a vital proximity sensor 18mm diameter and a non vital auxiliary proximity sensor 8m
13. 6 positive 4 1 2 3 No Output If there is no output on the paired terminals they are shunted 4 1 3 Terminals 10 12 13 and 15 Indication Input Terminals 10 12 13 and 15 are for indication input field connections from an adjacent machine s indication output circuit or can be jumpered in the application of a single machine 4 1 3 1 Normal Indication Normal indication input is defined between terminals 13 negative and 15 positive SM 9194 Original October 2004 4 1 WIRING UNION SWITCH amp SIGNAL 4 1 3 2 Reverse Indication Reverse indication input is defined between terminals 10 negative and 12 positive 4 1 3 3 Indication Output If the machine is used in a single machine application the battery must be fed to the indication input circuits to provide indication output Refer to wiring diagram illustrated in Figure 4 3 for proper jumper configuration Four indication input jumpers are factory installed on the WAGO terminal strip and must be removed for multiple machine applications 4 1 4 Wayside Battery Connections Terminal 17 is used for connecting wayside battery N12 Terminal 20 is used for connecting wayside battery B12 Note that there are factory installed jumpers between paired terminals 16 and 17 and between paired terminals 19 and 20 Wayside battery can be fed to either available terminal of each pair 4 1 5 Bipolar Auxiliary Sensor Output Terminals 21 and 2
14. amp SIGNAL INTRODUCTION Latch Out Restoration The term latch out restoration refers to resetting the machine to an operable switch machine indication state from a latched out condition Left Hand Switch position of a switch machine designated when the machine is located on the left hand side of the track looking into the switch points in the direction of the arrow shown in Figure 1 2 Linear Slides A device used to move the point detection proximity sensors in a direction parallel to the point detector bar Locking 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 MCU Motor Control Unit High current solid state device used to control motor power Non Vital Circuit circuit with a function that does not affect the safe operation of the train PD Point detector or point detection as in PD bar Point Detection Positive indication achieved when the switch points are closed adequately against the stock rail RHPC Right Hand Point Closed 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 2 Rear of Machine Physical area of the machine furthest from the motor Right Hand Switch Position of a switch machine designated when the machine is located on the right hand side
15. and Technical 9 1 9194 Original 2004 SWITCH amp SIGNAL TABLE OF CONTENTS Figure Figure 1 1 Figure 1 2 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 4 1 Figure 4 2 Figure 4 3 Figure 5 1 Figure 5 2 Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 Figure 8 7 Table Table 3 1 Table 6 1 Table 7 1 Table 8 1 Table 8 2 Table 8 3 Table 8 4 Table 8 5 List of Figures Page Switch et AA Ri 1 1 Right Hand and Left Hand Switch 1 3 M 3E Switch Machine 2 1 Detailed View of the Motor Compartment Unit essen rn 2 3 Detailed View of Transmission 2 4 Detailed View of GearbgX nc nan cnn 2 5 Top View of Gear 2 6 ControlleFCompartment a t tirita bank hau 2 9 Controller Compartment with Sensor View Nt 2 10 M 3E ECC System Block 4 0 0 2 11 Top View Controller Compartment 4 5 Wiring Changes from 3 Wire and 5 Wire to 2 Wire Motor Control 4 6 Internal Wiring 4 7 Proper Lifting Illustration 5 3 Sensor Gap Definitio Ne 5 6 Sw
16. box mounted directly to the end of the frog plate furthest from the gearbox provides termination for six proximity sensors through a six way cable grip In addition the junction box is equipped with two jumper configurations for determining the normally closed switch point RHPC or LHPC and latch out options manual automatic or disabled 2 3 4 1 Jumper Configurations See Figure 3 8 The junction box with two jumper configurations provides the ECC box with information for determining which point is normally closed left hand point closed LHPC or right hand point closed RHPC and which type of latch out configuration is selected manual restoration automatic restoration or latch out completely disabled Manual latch out restoration is achieved by depressing the pushbutton on the ECC box for one second and releasing Note that a latch out condition will only restore if all four vital proximity sensors indicate that the machine is fully locked and detected in one position 2 3 4 2 Vital and Non Vital Sensors Optional The junction box is where the four vital sensors two for point detection and two for locking detection and two non vital sensors are terminated via a six way cable grip into the junction box This termination method allows for convenient replacement of any individual sensor in the system See Figure 2 8 for ECC system block diagram SM 9194 Original October 2004 2 7 DESCRIPTION UNION SWITCH amp SIGNAL 2
17. for analysis SM 9194 Original October 2004 7 5 7 6 SM 9194 Original October 2004 SWITCH amp SIGNAL PARTS LIST 8 PARTS LIST 8 1 M 3E Switch Machine 422550 Table 8 1 Specialty Notes for the M 3E Switch Machine 15W 230V Motor Heater N344344 Obsolete 15W 115 230V Motor Heaters N294241 and N296578 001 wired for 115V Color Aluminum Silver Color Flat Black Surge Suppressor 8 2 422550 Switch 189 1 Figure 8 1 8 4 Table 8 2 Parts List for the 422550 Switch Machine Rem Number Description Part Number 2 BE GearboxAssomby s Transmission Box Assembly 1891 67 e Housing Gi Cont Screw Cap 1 2 13 x 1 Hwx Screw Ye 13 x 1 1 2 Hex Washer Plain Flat 1 2 J4751200116 SM 9194 Original October 2004 8 1 PARTS LIST UNION SWITCH amp SIGNAL tem Number Part Number 30 Washer Lock 1 4 J4751210135 Linear Slide Assembly with Aux Sensor N42210402 Pin 1 x 0 250 Dia M42371801 Linear Slide Insulator M42323201 ECC Assembly N42210101 Screw Rd Hd 8 32 x 3 4 J525107 Lock Rod Cover Track Side Compression Spring SS 21 Long J6801900008 8 2 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL PARTS LIST tem Number Description Part
18. impossible to take into account every eventuality that may arise with technical equipment in service Please consult your local US amp S sales representative in the event of any irregularities with our product We expressly disclaim liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved US amp S spare parts be used as replacements SM 9194 Original October 2004 Revision History Original October 2004 Original lssue FCC PART 15 COMPLIANCE This equipment has been tested and found to comply with the limits for Class A digital device pursuant to Part 15 Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with this instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense ii SM 9194 Original October 2004 SWITCH amp SIGNAL TABLE OF CONTENTS Table of Contents 1 Introduction a ia 1 4 General Rah 1 2 Definitions 2
19. maintained Every 6 to 12 months apply a small amount of gearbox lubricant into the hand crank insertion point to minimize difficulty in manual operation if the machine is not used frequently The transmission box is sealed and is supplied pre lubricated from US amp S No further lubrication inside the housing is required SM 9194 Original October 2004 6 1 PERIODIC UNION SWITCH amp SIGNAL 6 2 SM 9194 Original October 2004 TROUBLESHOOTING 7 TROUBLESHOOTING The following table is a troubleshooting matrix that covers possible ECC problems the possible cause s and the possible solution s To use the troubleshooting table identify the problem being experienced from the left hand problem category column The possible causes of the problem are listed in the center column and the possible solutions to the problem are to the immediate right of the potential causes in the right hand column of the table Table 7 1 Troubleshooting Guide PROBLEM CAUSE SOLUTION 1 Motor power A MCU wired 1 Confirm proper connections of MCU wires 1 present from wayside incorrectly and 2 in WAGO terminals 29 and 30 per the yet motor does not internal wiring diagram shown in Figure 4 3 run 2 Check terminations of white black and red MCU wires on AAR terminal posts B Motor is 1 In the M 3E confirm proper adjustment of DISABLED by ECC motor cutout proximity sensors in gearbox and R
20. monitoring the horizontal position of the hand crank When the plunger is retracted 1 4 the normally ON sensor turns OFF and the ECC disables the MCU accordingly The plunger assembly is on the transmission box Figure 2 3 CAUTION Although the motor cutout proximity sensors disable the motor power for manual operation it is strongly recommended that the Gold Nut in the motor compartment be opened before performing work on or inside the mechanism to prevent possible injury The Gold Nut will prevent the machine from throwing 3 5 ECC DIAGNOSTIC INFORMATION 3 5 1 LEDs 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 provided 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 1 describes what the ECC diagnostics represent 3 5 2 Vital Sensor Monitoring and Led Diagnostic Representation The ECC continuously monitors the state of each vital point and lock sensor in the machine By analyzing the current draw of the sensors it can determine if the sensor is On Off or Indeterminate Indeterminate can mean the sensor is open shorted or between the range of ON and OFF 3 4 SM 9194 Original October 2004 UNION SWITCH amp SIGN
21. of the track looking into the switch points in the direction of the arrow shown in Figure 1 2 Switch Machine Indication Vital determination of a safe switch configuration due to positive indication that the switch machine has properly thrown locked and detected switch point closure Switch and Lock Movement and or Mainline Switch Machine Device the complete movement of which performs the three operations of unlocking operating and locking a switch movable point frog or derail LEFT HAND RIGHT T Figure 1 2 Right Hand and Left Hand Switch Machines SM 9194 Original October 2004 1 3 INTRODUCTION UNION SWITCH amp SIGNAL Vital Circuit Any circuit with a function that affects the safe operation of the train WAGO Registered trademark of the WAGO Corporation WAGO Strip May also be referred as WAGO Terminal 1 4 SM 9194 Original October 2004 DESCRIPTION 2 DESCRIPTION Switch Machine 15 divided into three distinct compartments motor compartment gearbox compartment and the circuit controller compartment as illustrated in Figure 2 1 CIRCUIT CONTROLLER COMPARTMENT GEARBOX COMPARTMENT MOTOR COMPARTMENT Figure 2 1 M 3E Switch Machine Compartments 21 Motor Compartment The motor compartment Figure 2 2 and Figure 2 3 houses the modular transmission box the solid state motor control unit MCU the cycle counter the WAGO terminal strip where indication an
22. six sensor wires are brought into the junction box through a six way cable grip and their brown and blue wires are terminated in WAGO cage clamp connectors The PC board inside the junction box identifies which sensors connect to each terminal and the color designation of each sensor wire BR for BROWN and BU for BLUE If any of the four vital sensors are wired incorrectly the corresponding LEDs on the ECC will flashed RED If the auxiliary sensors are wired incorrectly they simply will not operate There is a yellow LED on the back end of each auxiliary sensor to determine if it is operating properly 4 4 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL WIRING AND MOTOR CONTROL GRDA LS2 POINT DETECTOR BAR SLEEVE POINT DETECTOR TARGET POINT DETECTOR SENSORS PS1 8 AUX 1 SENSORS PS2 8 AUX 2 SENSOR WIRE CABLE GRIP JB1 CABLE GRIP JUNCTION BOX SENSOR 151 Figure 4 1 Top View Controller Compartment 4 4 Three and Five Wire Control Conversion to Two Wire Control Figure 4 2 illustrates a typical three wire and five wire control relay scheme converted to the recommended two wire control system Conversion from a five to a two wire configuration 1 best suited for changes in the wayside house or bungalow Conversion of three to two wire control can be performed at the wayside location or in the machine using the spare AAR terminal posts to connect two of the three wires together as shown in the figure
23. vital sensors are to be gapped to 0 075 from the face of the PD target and the non vital sensors are to be gapped at 0 040 from the face of the target Figure 5 2 The tightness of the feeler gage between the head of the sensors and the target is not critical regarding the performance of the sensors T Figure 5 2 Sensor Gap Definition 5 6 Operating Rod Adjustment Throw the machine manually via the hand crank and adjust the switch adjuster basket nuts so that the switch point just closes against the stock rail CAUTION Do not over tighten the switch point Excessive point pressure may result in switch machine failure with minimal changes in physical or environmental conditions 5 7 Point Detector Linear Slide Adjustment The point detector target works between the two sensor sets All of the adjustment of the point detection system is made via the linear slides and not by adjusting the point detector connecting rod or track connections The slides are adjustable by loosening the 1 2 bolt on the top of the slide and rotating the knurled thumb wheels No specific adjusting sequence is required 5 6 SM 9194 Original October 2004 SWITCH amp SIGNAL INSTALLATION The threaded rod in the slides has 1 2 20 thread pitch This means there 20 threads per inch so every full rotation of the thumb wheel results in 0 050 of linear sensor displacement or movement 1 Throw the switch mac
24. 0 The locking sensors are also used to control the motor control unit MCU via the ECC to turn off motor power only after the lock dog on the lock box has fully engaged and extended beyond the narrow notch of the lock rod 2 3 3 ECC Box The ECC box houses a microprocessor and conditional power supply board which are used to determine the state of the switch machine and provide switch indication power to the outputs respectively The ECC provides advanced diagnostics to quickly determine the state of the machine and adjacent daisy chained switch machine indication circuits There is a momentary latch out restoration pushbutton on the front face of the ECC to manually restore a latch out condition when the ECC is configured in the manual or automatic restoration modes via the jumper in the junction box 2 3 3 1 AMP Plug Couplers The ECC uses three AMP plug couplers One coupler designated as JB1 connects the ECC to the junction box The other two couplers designated TB1 and TB2 connect the two 10 conductor cables that run through the PVC conduit underneath the gearbox housing and are terminated at the terminal strip in the motor compartment The ECC is a sealed non serviceable unit and can be replaced simply by removing the four 1 2 bolts securing the ECC adapter plate attached to the bottom of the ECC box and unplugging the three plug couplers See Figure 2 8 for ECC system block diagram 2 3 4 Junction Box The junction
25. 3 are for field connections to the two wire bipolar auxiliary sensor output 4 1 5 1 Normal Auxiliary Indication Normal auxiliary indication is defined as on terminal 23 and on terminal 21 4 1 5 2 Reverse Auxiliary Indication Reverse auxiliary indication is defined as on terminal 23 and on terminal 21 The maintenance output is NOT VITAL and should never be used to clear signals 4 1 6 Local Remote Request Switch Option Terminals 20 24 25 and 26 are for field connections to use the local remote request switch option This function is beneficial particularly when conducting monthly inspections In order for this function to work however the wayside must be configured properly The two toggle switches in the machine L R and N R interface with the local control panel providing the ability to control the machine as though operating directly from the local control panel Normally the local remote L R switch is to be in the remote position When placed in the local position battery is routed to terminal 26 The local control panel is thus activated to receive commands from 4 2 SM 9194 Original October 2004 eS SIGNAL WIRING AND MOTOR CONTROL maintenance personnel at the machine The second switch N R is a center OFF spring return toggle When held in the N position the machine is electrically driven from the wayside controller to the normal position If the switch is released before the stroke is c
26. 8 SIGNAL DESCRIPTION CIRCUIT CONTROLLER COMPARTMENT et ee t en ere ECC BOX JUNCTION MICROPROCESSOR 8 POWER SUPPLY DIAGNOSTIC LED DISPLAY LATCH OUT SENSOR TERMINALS RESTORATION PUSHBUTTON LHPC RHPC amp LATCH OUT OPTION JUMPER CONFIGURATIONS LATCH OUT RESTORATION VITAL POINT VITAL LOCKING AUXILLIARY POINT LOCAL REMOTE SENSORS SENSORS SENSOR REQUEST SWITCHES CYCLE COUNTER MOTOR CUTOUT HANDCRANK SENSORS FOR MANUAL OPERATION TERMINAL BOARD amp BINDING POSTS MOTOR CONTROL UNIT MCU FIELD CABLE AND WAYSIDE BATTERY FOR ECC MOTOR COMPARTMENT Figure 2 8 M 3E ECC System Block Diagram SM 9194 Original October 2004 2 11 DESCRIPTION UNION SWITCH amp SIGNAL 2 12 SM 9194 Original October 2004 OPERATION 3 OPERATION 3 1 General Overview The M 3E can be operated with a manual hand crank The transmission box is equipped with a hand crank opening and motor cutout plunger for manual operation protection The 3 4 hex crankshaft in the transmission box is designed so a standard 3 4 socket also can be used to move the mechanism 3 1 1 Power Operation Under power operation the worm shaft worm gear combination is driven by a series of reduction gears powered by the motor reduction gears can be either of two gear ratio combinations 189 1 or 360 1 3 1 2 Manual Operation via the Hand
27. AL OPERATION Table 3 1 Diagnostics GREEN Sensor On en d RED Sensor Off FLASHING RED Indeterminate GREEN Sensor On dod d RED Sensor Off FLASHING RED Indeterminate Indication GREEN Indication input power present from adjacent machine Input DARK No indication power present Indication GREEN Switch is locked and detected indication output is on Output DARK Switch is not locked and detected indication output is off Auxiliary GREEN Aux Sensor on aux bipolar output is on ico DARK Aux Sensor off aux bipolar output is off RED Latched out DARK Not latched out Motor RED Motor power disabled Disabled DARK Motor power enabled 3 5 3 Diagnostic Modes of Dual Colored LEDs As illustrated in Table 4 1 the dual colored LEDs that represent the states of the vital point and lock sensors have three possible diagnostic modes green red or flashing red Green simply means the sensor is on and is detecting its specified target Red means the sensor is off and not sensing the target In order to definitively distinguish between an On and an Off sensor state an indeterminate operating window is used between the two states flashing red As the target approaches the sensor the sensor will change from the Off state to an Indeterminate state and then to the On state The LED will represent this by changing from red to flashing r
28. Confirm machine is fully locked A latched out condition will only occur if the machine is fully locked and the switch point moves away from the stock rail Move latch out configuration jumper in the Junction box from the Disable to the Manual or Automatic jumper positions 7 4 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL CAUSE SOLUTION PROBLEM 11 A latched out condition does not restore when the restoration pushbutton is depressed for one second and released A Point detected and point locked sensors for that corresponding position are not ON i e the machine is not fully thrown and locked or the PD sensors are out of adjustment B Malfunctioning latch out restoration pushbutton on ECC 1 TROUBLESHOOTING Confirm proper linear adjustment of the PD sensors to indicate the presence of the point detector bar target and ensure that the machine is in the full locked position prior to restoring the latched out condition To verify move latch out configuration jumper to the automatic position in the junction box and manually cycle the machine to the opposite position and back If the latched out condition restores the pushbutton has malfunctioned Replace the ECC unit at your earliest convenience and return to US amp S for analysis If the latched out condition does not restore and all vital sensors are properly functioning replace ECC unit and return to US amp S
29. Crank Under manual operation via the hand crank the hand crankshaft in the transmission box drives the last reduction gear via a 1 1 bevel gear combination The driving of the reduction gears rotates the worm shaft worm gear combination ultimately resulting in rotation of the main crank via the vertical clutch assembly With all reduction gear combinations 189 1 and 360 1 the hand crank operates on a 2 1 gear ratio to the worm shaft i e two rotations of the hand crank results in one rotation of the worm shaft 3 1 3 Main Crank Rotation The lobes on the top of the lower main crank flange interact with the rollers on the slide bar moving the slide bar linearly along the length of the machine to unlock the lock rods Just before the slide bar stops moving the lower hub and roller on the bottom of the main crank flange begins to drive the operating bar The operating bar moves through a 6 stroke moving the switch points to the opposite position Just before the operating bar stops moving completing the point closure the slide bar begins to move again to begin locking the machine in the opposite position 3 1 4 ECC Monitoring The ECC continually monitors the state of the machine reporting the transition of the machine from one position to the other Switch indication circuits are OFF when the machine is in transit and the circuits are shunted for additional safety precaution 3 2 MANUAL OPERATION 3 2 1 Hand Crank Operation
30. Hand crank operation is performed by opening the hand crank cover door and inserting the hand crank onto the crankshaft Ensure that the motor disabled LED is illuminated on the ECC and that the hand crank or socket is fully seated on the hex crankshaft prior to operating the machine manually 3 2 2 Hand Crank Rotation The machine will crank from one extreme locked position to the other with approximately 33 rotations of the hand crank with the 189 1 gear ratio SM 9194 Original October 2004 3 1 OPERATION 3 3 POWER OPERATION When the M 3E is powered up moving the switch is as follows The switch indication is turned off and the machine is unlocked The switch is then thrown to the opposite position and locked in that position With the machine locked and the points detected in that position the switch indication is then turned on 3 3 1 Power Motor Operation When operating the machine under power energy is applied to the AAR binding posts and 4 and the motor begins to rotate The motor drives the reduction gears in the transmission box through either a 189 1 or 360 1 gear ratio depending on the application The reduction gears drive the clutch gear on the worm extension shaft and in turn rotates the worm shaft The rotation of the worm shaft rotates the worm gear directly driving the main crank through the vertical clutch assembly 3 3 2 Power Mode Main Crank Rotation In the power mode of operation the main crank rotat
31. Number Screw Phillips Hd 10 24 3 4 Long Resistor Heater N294241 N296578001 66 Switon Base Assembly with Studs N42220201 68 Operating Cover P4200 69 78 80 Loca Remote Assemby 2207 9485 nous Screw Cap 1 2 13 x 2 3 4 Long SM 9194 Original October 2004 8 3 PARTS LIST UNION SWITCH amp SIGNAL ter Number Description Part Number 5 9 se 98 ___ Washer 10 Flat Steel 475077 99100 NotUsed J 102 104 NotUsed Plug Pipe 3 8 Steel Roll Pin 1 8 Dia x 7 8 Long 8 4 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL PARTS LIST M391 200 Plate Rat M42301201 Protector 2 1 2 NPT T 43A J7015010015 PCB Surge Protector N49703101 Lubricant 1 Gal N320264 Shown in Figure 8 4 also Shown in Figure 8 4 only Not shown in Figure 8 1 through 8 3 SM 9194 Original October 2004 8 5 PARTS LIST UNION SWITCH amp SIGNAL Figure 8 1 Switch Machine N422550 XX Left Unit Sheet 1 Right Hand Machine is the same except they are mirror images of each other 8 6 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL PARTS LIST S a AN gt N A 8 UNS N SN ES DEPENDING ON HEATER CONFIGURATION N N e
32. R for brown and BL for blue For point detection sensors adjust linear sensor location away from ON OFF threshold as described in the Subsections 2 3 7 and 2 3 8 of this manual For locking sensors confirm the switch machine is in the fully locked position and has completed its stroke Note linear position of the locking sensors is not adjustable Confirm configuration jumper is installed in latch out jumper slots in junction box Confirm that one jumper is installed in the latch out jumper slots and one jumper is installed in the LHPC RHPC jumper slots The ECC will not work if either jumper is absent or if multiple jumpers are installed in any one configuration Confirm JB1 cable keys are aligned properly the connector is fully inserted and the locking ring is turned clockwise until it locks in place Confirm the presence of a continuous battery feed of at least 10 VDC with proper polarity on WAGO terminals 17 N12 and 20 B12 Confirm termination of all wires on cables and TB2 on WAGO terminal strip and that the cable plug connectors are properly secured to the ECC box 7 2 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL CAUSE SOLUTION PROBLEM 7 All diagnostic LEDs are properly lit on ECC a continuous vertical row of GREEN LEDs is observed yet no indication output is present on WAGO terminal strip no voltage is present between terminals 1 and 3
33. and slide bar to throw and lock unlock the machine accordingly 2 4 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL DESCRIPTION CAST GEARBOX HOUSING Figure 2 4 Detailed View of Gearbox SM 9194 Original October 2004 2 5 REAR PILLOW BLOCK WORM SHAFT WORM GEAR DRIVE T PLATE FRONT PILLOW BLOCK Figure 2 5 Top View of Gear Box 2 3 Circuit Controller Compartment The circuit compartment Figure 2 6 and Figure 2 7 houses the frog plate controller frame ECC junction box captive point detector system CPDS linear slides local remote control switches optional four vital proximity sensors and two non vital auxiliary sensors optional See Figure 2 8 for ECC system block diagram and Section 3 1 for a detailed description of the ECC system integration CAUTION Excessive heat may damage the ECC Heaters should not be placed in the circuit controller compartment 2 3 1 Frog Plate The frog plate is used as the base frame to mount the CPDS linear slides ECC box junction box and the vital proximity sensors The modular frog plate can be replaced completely if damaged 2 6 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL DESCRIPTION 2 3 2 Vital Locking Sensors Two vital locking sensors are threaded into the frog plate casting and are used to determine the linear position of the lock box The locking sensors are in a fixed location to ensure compliance to FRA Rule 236 33
34. atically 3 4 3 1 Manual Latch Out Restoration Restore the latch out manually by pressing the momentary latch out restoration pushbutton on the ECC for one second and releasing This can be done in either the manual or automatic restoration modes but will only occur if the point and lock sensors are properly indicating 3 4 3 2 Automatic Latch Out Restoration The latch out will be restored by moving the machine toward the opposite position until all four vital sensors are OFF and then by returning to the original position This will occur only in the automatic latch out jumper mode and only if the point and lock sensors are properly indicating 3 4 3 3 Disabling the Latch Out Feature The latch out feature can also be completely disabled by placing the junction box jumper in the disabled latch out position 3 4 4 Auxiliary Sensors Optional The ECC also continually monitors the states of the two auxiliary sensors mounted on the linear slides above the two vital point detector sensors The auxiliary sensors are biased toward the outside of each vital sensor by a 1 8 sensing range differential This means that if the vital sensor is adjusted to detect a 1 4 linear displacement of the point detector bar i e turn OFF the auxiliary sensor will turn OFF after the bar has displaced approximately 1 8 Similarly if the vital sensor is adjusted to sense 3 8 point detector rod movement the auxiliary sensor will turn OFF after
35. ck rods in each position so that the lock dog is centered in the narrow notches of each lock rod in their respective positions NOTE For some lock rod designs it is necessary to adjust one position before the other typically the far point before the near point 2 Place the appropriate switch obstruction in the switch point 6 back from the tip of the point The lock detected LEDs should be RED in both the normal and reverse positions 5 9 Final Inspection and Testing After Installation 1 Confirm that all switch connecting rods are square to the switch point prior to fastening the switch mechanism to the ties 2 Confirm that all rods operate without binding and properly clear the base of the stock rail 3 Nothing is gained by excessive point pressure Adjust the switch adjust basket until the switch points just close in either position 4 Confirm the switch machine 15 installed per the applicable installation drawings and all fasteners are properly secured SM 9194 Original October 2004 5 7 INSTALLATION UNION SWITCH amp SIGNAL 5 Perform final adjustment of lock rods and point detector system in accordance with standard railroad operating practices AREMA recommended practices and FRA Rules and Regulations 6 Perform independent breakdown testing of the switch machine circuitry in accordance with standard railroad operating practices AREMA recommended practices and FRA Rules and Regulations 7 If the mach
36. correct placement of straps or chains when handling the machine 5 2 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL INSTALLATION Always lift the M 3E switch machine with straps or chains around the switch base casting Straps or chains must be rated equivalent to or in excess of 1000 pounds Never lift the machine using eye hooks in the 1 2 tapped holes in the top of the main crank gearbox frog plate or switch base Failure to follow proper lifting procedures may result in property damage severe personal injury or death 5 3 2 Placing the on the Ties 1 Set the M 3E on the switch ties according to the installation drawings not contained in this manual and applicable railroad standards Make sure to maintain the centerline of switch machine to rail gauge dimension This is crucial in obtaining maximum adjustment capability of all connecting rods DO NOT FASTEN THE MACHINE TO THE TIES AT THIS POINT 2 Connect the front rod to the switch points and ensure the point opening is adjusted to the dimension specified on the installation drawing or in applicable railroad standards typically 4 3 4 1 4 3 Install the switch adjuster basket to the 1 spread rod SM 9194 Original October 2004 5 3 INSTALLATION UNION SWITCH amp SIGNAL 4 Install the internal lock rods in machine comes from US amp S with the internal point detector bar installed Note that the lock rods mu
37. d battery field wires are connected the field cable conduit entrance and AAR binding posts for motor control and motor compartment heater wire termination The MCU contains solid state electronics to handle the activation and deactivation of motor power Refer to Figure 2 8 for the system block diagram SM 9194 Original October 2004 2 1 DESCRIPTION UNION SWITCH amp SIGNAL 2 1 1 The Transmission The modular transmission box incorporates face mount motor 110 VDC reduction gears friction clutch assembly The transmission box module is sealed with a maintenance free lubricant US amp S P N A041750 0001 and houses the drive train reduction gears which are available in and can be converted to 189 1 and 360 1 gear ratios The first reduction gear of each ratio combination is equipped with a bevel gear which interacts with the hand crank bevel gear providing hand crank capability with a 2 1 advantage over existing M 3 designs Approximately 33 rotations of the hand crank are required to move the machine from one extreme position to the next 2 1 1 1 Hand crank Plunger Mechanism The transmission box is also equipped with a hand crank door mechanism which is monitored by a motor cutout proximity sensor When the hand crank cover door is opened to allow insertion of the hand crank the normally ON sensor turns OFF disabling motor power within the machine indicated by the illumination of the red Motor Disable
38. d LED on the ECC and turning OFF all switch indication outputs 2 1 2 Voltage The MCU is available in high voltage 110VDC configuration 2 1 3 Cycle Counter A non resettable cycle counter is installed in the motor compartment to assist in determining required maintenance frequency and to maintain a history of the machine s usage The cycle counter tallies each complete cycle of the switch machine 1 the counter increments each time the machine completes a cycle from normal to reverse and back to normal again The counter cannot be reset so the operational history of the machine is preserved 2 1 4 WAGO Terminal Strip Note 16 of the gas arrestors 0585 77927360109 do not electrically connect the ECC or MCU I O circuitry to the ground terminals The gas arrestors are normally open to the lines that they protect and will fire upon a local lightning strike bringing the surge currents to the ground terminals instead of into the machine s internal circuitry The arrestors can be fired multiple times at high potentials before their integrity 15 degraded WAGO terminal strip is the central termination point for ECC power and indication circuit connections It is where all field cables and wayside signal battery for the ECC are terminated The ECC requires continuous 12 VDC battery feed from the wayside 800mA continuous current draw max There are fourteen 14 gas arrestors mounted on the WAGO terminals t
39. d now read 12 volts 4 2 AAR Terminal Post Connections There are eight AAR binding post terminals labeled 1 through 8 Terminal 1 is the termination point for the red MCU control wire one of the two field motor control wires and a gas tube arrestor used for lightning protection Terminals 2 and 3 are common terminals used for grounding purposes and termination of the gas arrestors which are connected to terminals 1 and 4 Terminal 4 is the termination point for the second field motor control wire and is also used for mounting a gas tube arrestor for lightning protection Terminal 5 is the connection point for the jumpers to Terminals 4 and 6 Terminal 6 is the termination point for the negative motor terminal A Gold Nut test link is provided between Terminals 5 and 6 to disconnect motor power when performing maintenance on the machine Terminals 7 and 8 are designated for motor compartment heater wire termination 4 3 Sensor Identification and Termination in the Junction Box The vital point detector sensors are designated PS1 and PS2 The vital locking sensors are designated LS1 and LS2 The auxiliary point detector sensors are designated Aux and Aux2 It is important to note that PS1 and LS1 always work in combination together while PS2 and LS2 always work together as well Refer to Figure 4 1 The four vital and two non vital auxiliary sensors are all terminated inside the junction box located on the rear of the frog plate All
40. e the position of the hand crank cover access door actuated when the hand crank cover door is opened 1 2 Definitions AAR Association of American Railroads Communication and Signal Section currently known AMP Registered Trademark for AMP Corporation A R E A American Railway Engineering Association AREMA American Railway and Maintenance of Way Association formerly known as AAR CPDS Captive Point Detection System U S Patent No 6 186 448 B1 ECC US amp S Electronic Circuit Controller U S Patent No 6 484 974 B1 Front of Machine The physical area of the switch machine closest to the motor FRA Federal Railroad Administration Full Locking Refers to the locking operation in the hand throw mode where the slide bar completes its stroke and switch indication is obtainable LHPC Left Hand Point Closed 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 shown in Figure 1 2 note that Figure 1 2 represents a RHPC application Latch Out Device which does not allow switch point indication to restore if the switch point moves away from the stock rail point detection is momentarily lost This function will only be activated if the point sensors are actuated change state before their corresponding locking sensors are actuated change state 1 2 SM 9194 Original October 2004 UNION SWITCH
41. ed Motor Disabled on transmission box are adjusted properly and LED is ON both indicate ON by the illumination of the sensor s yellow LED C The Gold Nut 1 Confirm that the Gold Nut connection is circuit link on AAR closed and properly secured with an AAR jam terminal posts is open nut D Defective MCU 1 Test MCU per procedure outlined in Section 4 1 9 of this manual 2 Motor runs but not A Incorrect motor 1 Reverse motor wires on motor terminals not in proper direction polarity on AAR terminal posts causing friction clutch to slip SM 9194 Original October 2004 7 1 TROUBLESHOOTING PROBLEM 3 A single dual colored LED is flashing RED sensor wire 15 shorted open or not properly connected B Sensor is adjusted marginally between ON and OFF with respect to its target 4 Latch out LEDis A Missing Flashing RED configuration jumper 5 All four A Incorrect 1 dual colored LEDs configuration jumper are flashing RED installation in junction box B Junction box cable JB1 is not properly connected to ECC box 6 All LEDs on ECC A Insufficient low battery feed level to drop out and the controller may or may the ECC not reset UNION SWITCH amp SIGNAL CAUSE SOLUTION A Corresponding 1 Confirm proper termination of the brown and blue sensor wires to the corresponding spring terminals in the Junction Box terminals are labeled on the PC board B
42. ed and then to green During normal switch operation this transition will not be noticeable SM 9194 Original October 2004 3 5 OPERATION UNION SWITCH amp SIGNAL 3 6 SM 9194 Original October 2004 UNION SWITGH amp SIGNAL WIRING AND MOTOR CONTROL 4 WIRING AND MOTOR CONTROL 4 1 WAGO Terminal Strip Connections Terminals 2 5 8 11 14 18 and 22 are internally connected to the DIN rail and serve as a means by which the 14 gas lightning arrestors make contact with the base of the machine for grounding purposes Figure 4 1 maintain operability other wires should terminated to these points 4 1 1 Terminals 1 3 Two Wire Bipolar Indication Output Circuit Terminals 1 and 3 for field connections to a two wire bipolar indication output circuit 4 1 1 1 Normal Indication Normal indication is defined as on terminal 3 and on terminal 1 4 1 1 2 Reverse Indication Reverse indication is defined as on terminal 3 and on terminal 1 4 1 1 3 No Output If there is no output terminals 1 and 3 are shunted 4 1 2 Terminals 4 6 7 and 9 Four Wire Indication Output Circuit Terminals 4 6 7 and 9 are for field connections to a four wire indication output circuit 4 1 2 1 Normal Indication Normal indication is defined between terminals 7 negative and 9 positive 4 1 2 2 Reverse Indication Reverse indication is defined between terminals 4 negative and
43. es 220 degrees from one fully locked position to the other fully locked position 3 4 ECC OPERATION AND MONITORING The ECC system is functionally equivalent to that of the US amp S N285638 circuit controller mechanism but has no mechanical contacts or cam arrangements The MCU emulates the motor cutout contacts from the mechanical controller in that it is continuously set up to move the machine to the opposite direction when in the full Normal or Reverse positions This MCU provides the same make before break motor control circuitry as in the existing M 3 M 23 controllers 3 4 1 Proximity Sensors All proximity sensors used in the ECC system vital and non vital are active under NORMALLY ON conditions In other words no logic condition of the ECC is dependent upon the point detection locking auxiliary or even motor cutout sensors being OFF to make a decision The only time the OFF state of the sensors is relevant is when determining the locked and detected position of the machine In order for switch indication to be energized for example in the normal position both the normal point and lock sensors must be ON and the reverse point and lock sensors must be OFF 3 4 2 Vital Point and Lock Sensors The vital point and lock sensors work in predetermined pairs and each of the two paired sensors one point and one lock are linked together In other words in order to receive a normal switch indication output from the ECC both the poin
44. etection proximity sensors the ECC provides two auxiliary sensors which are used to predict switch failure The auxiliary sensors are preset to detect the linear position of the switch points 1 8 offset from the normal switch obstruction gauge dimension typically 1 4 or 3 8 The M 3E ECC proximity sensor system is a true linear detection device with no moving parts to wear The system requires no adjustment of the point detector bar but using linear slides provides internal adjustment capability of the vital point detection proximity sensors with respect to the point detector bar assembly The Captive Point Detection System CPDS provides a captive point detector bar and target combination that accurately reports the true displacement of the switch points The linear slide assemblies provide simple and dependable proximity sensor adjustment with respect to the ferrous metal target The ECC provides advanced diagnostics for identifying the current state of the machine and the indication state of an adjacent daisy chained machine The diagnostics verify 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 There are no mechanical contacts within the M 3E All indication and motor circuits are controlled with solid state equipment Motor cutout during manual operation is achieved with one proximity sensor to indicat
45. f the latch out function 15 to be disabled it will be necessary to move the latch out configuration jumper accordingly 5 4 3 Changing the Jumper Configurations Removing the cover to the junction box on the rear of the frog plate and positioning jumpers accordingly can easily change jumper configuration for both the RHPC LHPC and latch out functions Please note that there must always be one jumper in each of the two configurations Lack of a jumper or installation of multiple jumpers in the same configuration will violate the ECC logic which automatically disables the vital indication outputs 5 5 ECC Power and Indications Set up The ECC requires a continuous wayside battery feed of 12VDC connected to WAGO terminals 17 N12 and 20 B12 Indication input can be set up either for a single machine such as an end of siding application or multiple machines such as a daisy chained crossover 5 5 1 Single Machine Indication The single machine indication input to the ECC must be jumpered on the WAGO terminal strip in order to receive continuous battery feed The ECC is shipped from 1054625 with these jumpers installed and must be removed for multiple machine applications Referring to the wiring diagram illustrated in Figure 4 3 four jumpers must be installed Terminal 16 for N12 is connected to terminal 13 Normal which is also jumpered to terminal 10 Reverse Terminal 19 for B12 is connected to terminal 15 Normal which is al
46. he MCU circuitry Refer to Figure 2 8 for the system block diagram The MCU houses the electronic motor control circuitry The circuitry turns OFF motor power at the end of each stroke only after the lock box in the machine is fully locked through the narrow notch HAND CRANK PLUNGER TRANSMISSION BOX 110 VDC MOTOR AAR BINDING POSTS WAGO TERMINAL BOARD CYCLE COUNTER FRICTION CLUTCH CONDUIT ENTRANCE 2 1 2 NPT THREAD MOTOR CUTOUT UNIT MCU Figure 2 2 Detailed View of the Motor Compartment Unit SM 9194 Original October 2004 2 3 TRANSMISSION BOX COVER TRANSMISSION BOX HAND COVER PLATE PLUNGER HAND INSERTION POINT HAND CRANK MOTOR CUTOUT PROXIMITY SENSOR BRACKET WORM SHAFT DRIVE TRANSMISSION BOX HAND CRANK MOTOR CUTOUT PROXIMITY SENSOR Figure 2 3 Detailed View of Transmission Box 2 2 Gearbox Compartment The gearbox compartment Figure 2 4 and Figure 2 5 houses the worm shaft worm gear drive combination the main crank top bearing plate and main crank spacer 2 2 1 Gearbox Components and Assemblies The worm gear based drive train and main crank configuration of the M 3E is based on the design of the M 3 While the new transmission box itself is now modular in design the worm shaft worm gear ratio design is identical to that of the M 3 The 220 degree rotation of the main crank in the gearbox produces the timed operation of the operating bar
47. he voltages on the strip are not referenced to battery they are isolated from it 4 1 8 Motor Cutout Circuits Termination Points Terminals 32 through 34 are the termination points for the motor cutout circuits In an M 3E this is the termination point for the hand crank motor cutout proximity sensors 4 1 9 MCU Test Procedure Perform the following test on the MCU unit to validate safe operation 1 Open the Gold Nut to disconnect power from the motor 2 Remove the field wires on terminals 1 and 3 to disconnect motor power from the house SM 9194 Original October 2004 4 3 WIRING UNION SWITCH amp SIGNAL 3 Connect a 100 ohm resistor or signal lamp across terminals 3 and 4 This may not be necessary if an analog meter is being used to make subsequent measurements Connect a voltmeter across terminals 3 and 4 Connect battery either polarity to terminals 1 and 3 The meter will read either 0 12 volts if the machine is locked either normal or reverse SU UA ser Reverse the previous battery polarity If the previous reading was 12 volts it should now read 0 if the previous reading was 0 it should now read 12 99 Restore the polarity to achieve 12 volt reading 9 Lift the selector lever and confirm the reading is 0 10 Manually crank the machine to the opposite position and confirm that the meter remains at 0 11 Reverse battery polarity and the meter shoul
48. hine to either the normal or reverse position and confirm the switch point is fully closed before proceeding 2 Adjust the linear slide toward the appropriate outside edge of the target until the point detected LED on the ECC just turns green If for example a 1 4 obstruction is to be detected rotate the linear slide thumb wheel an additional three to four full turns further in toward the center of the target This will result in a detection range of 0 150 to 0 200 just under the 1 4 requirement If excessive lost motion is present in the track connections or the trackwork 1 loose rail braces rolling stock rail etc the linear slides can be adjusted to a more sensitive detection level The linear slides allow infinite adjustment from 0 to the maximum allowable 3 8 obstruction displacement 3 Place the appropriate obstruction as per railroad standards typically 1 4 in the switch point 6 back from the tip of the point It may be necessary to float the lock rods at this point to allow the machine to make its full movement 4 The linear slide should be adjusted so that the detected LEDs are RED in both the normal and reverse positions with the obstruction in the point This will directly result in the de energizing of the indication output from the ECC 5 8 Lock Rod Adjustment The lock rods must be installed in the machine so that the lock dog enters the narrow notch of the locking rod first 1 Adjust the lo
49. iginal October 2004 7 3 TROUBLESHOOTING PROBLEM 9 Point detected and A Indication input is point locked LEDs not energized are GREEN but indication output LED is dark ECC is latched out state C Motor is DISABLED by ECC Red Motor Disabled LED is ON D Point and or Locking sensor for opposite switch machine position is are ON 10 ECC does not latch out when point detector target is removed from in front of target face and restored A Machine is not fully locked B ECC is configured to Disable the latch out feature UNION SWITCH amp SIGNAL CAUSE SOLUTION Confirm indication input voltage with proper polarity is present on WAGO terminals 13 and 15 for normal and terminals 10 and 12 for reverse Voltage should be obtained from an adjacent machine or jumper connected per Section 5 of this manual Reset the latch out by depressing the latch out restoration button on the front of the ECC Reset can be accomplished by holding the latchout button for one second and releasing On M 3E confirm hand crank is removed from top of transmission box and hand crank cover door is securely closed and latched energizing the motor cutout proximity sensor Confirm proper linear adjustment of the PD sensor and verify proper 0 075 vital sensor air gap to obtain proper sensor response Remove any loose metallic objects or obstructions from the vicinity of the sensors
50. ine is equipped with a local remote feature confirm the local remote toggle switch is in the remote position 8 Confirm all covers are properly installed and locked 5 8 SM 9194 Original October 2004 UNION SWITOH amp SIGNAL PERIODIC MAINTENANCE 6 PERIODIC MAINTENANCE 6 1 Required Tools Table 6 1 lists the required tools to perform periodic maintenance on the M 3E switch machine Table 6 1 Required Tools US amp S Part No Tool Use if applicable Ratchet 3 8 or 1 2 drive 10 Removes and replaces most N A extension 3 4 socket 1 long serviceable parts Thin Head Screwdriver Release the WAGO cage clamp J03900001 34 terminals for wire insertion and release US amp S Track Wrench Set Adjust the lock rods the lock rod X491253 05 connecting rod and the operating rod 6 2 Lubrication The gearbox must be filled with US amp S switch machine lubricant US amp S part number A041750 0001 or Lubriplate 5555 US amp S part number N320264 to a level even with the top of the bronze worm gear This will require approximately 1 1 2 to 2 gallons of lubricant US amp S recommends changing switch machine lubricant A041750 0001 every three to five years depending on the environmental conditions of the application and how well the machine is maintained US amp S recommends changing Lubriplate 5555 every one to two years depending on the environmental conditions of the application and how well the machine is
51. ion via the Hand Crank sse eene enne nnns nennen 3 1 3 Main Crank Rotation ON 3 14 ECC MONTONG recte E ero ete eap iota Pet ba e iba ec a tene ide 2 2 MANUAL OPERATIQN 5 tereti e Up m fa En Gee Ere Hep ERA de id 3 2 1 Hand Crank Operation 3 2 2 Hand Crank rct e ir 3 3 POWER OPERAT ON E22 a rt ete 3 3 1 Power Motor Operations triada its 3 3 2 Mode Main Crank Rotation 3 4 ECC OPERATION AND MONITORING 3 4 1 Proximity Sensors AA Ile 9 42 Lock Sensors 3 4 3 ss iin a die aetna aie lee Vedra Stl ieee 3 44 Auxiliary Sensors Optional 0 3 45 Manual Operation Motor Cutoff Protection 3 5 ECC DIAGNOSTIC INFORMATION Nt 3 5 1 zb EET EE 3 5 2 Vital Sensor Monitoring and Led Diagnostic Representation 3 5 8 Diagnostic Modes of Dual Colored LEDS Nt SM 9194 Original October 2004 TABLE OF CONTENTS UNION SWITCH amp SIGNAL 4 Wiring and Motor Control ns 4 1 4 1 WAGO Terminal strip Connections sinn 4 1 4 1 1 Terminals 1 3 Two Wire Bipolar Indication Output Circuit 4 1 4 1 2 Terminals 4 6 7 and 9 Four Wire Indication Output Circuit pp 4 1 4 1 3 Terminals 10 12 13 and 15 Indication InpPUt 4 1 41 44 Wayside Bat
52. itch Machine N422550 XX Left Hand Unit Sheet 1 8 6 M 3E Switch Machine N422550 XX Left Hand Unit Sheet 2 8 7 Switch Machine N422550 XX Left Hand Unit Sheet 8 8 M 3E Circuit Controle tis ne eine 8 9 M 3E Transmission Assembly N42205101 8 11 M 3E Gearbox Assembly 32280201 8 13 M 3E Motor Assembly N42200201 nennen nnnm 8 15 List of Tables Page BIT Te oils 3 5 FROQUINCO TOONS pM 6 1 Troubleshooting Guide 7 1 Specialty Notes for the Switch Machine sess 8 1 Parts List for the N422550 XX Switch Machine Ne 8 1 Parts List for the M 3E Transmission 8 10 Parts List for the Gearbox Assembly 1 nnne 8 12 Parts List for the M 3E Motor 8 14 SM 9194 Original October 2004 V TABLE OF CONTENTS UNION SWITCH amp SIGNAL vi SM 9194 Original October 2004 INTRODUCTION 1 INTRODUCTION 1 1 General Figure 1 1 Switch Machine The M 3E PN N422550 XX Figure 1 1 is the next generation style switch machine devel
53. m diameter Adjustment of the linear slides is accomplished by loosening the 1 2 bolt at the top of the slide and rotating the thumb wheels accordingly The thumb wheels rotate a 1 2 20 threaded rod therefore one full rotation of the thumb wheels results in a 0 050 linear displacement of the proximity sensors parallel to the point detector bar 2 3 8 Vital Sensor Position Monitoring The state ON OFF SHORTED or OPEN of each vital sensor is continually monitored by the ECC processor every 50 milliseconds The vital sensor s position is adjusted with respect to the point detector target s position to detect a defined linear change in position of the target for example a 1 4 obstruction in the switch point 2 3 9 Non Vital Auxiliary Sensors Optional Like the vital sensors the non vital auxiliary sensors also monitor the point detector target s position but their sensing range is mechanically offset by approximately 1 8 This enables the auxiliary sensors to detect target movement before vital sensor detection When the auxiliary sensors are no longer sensing the target a normally ON auxiliary bipolar output on the WAGO terminal strip becomes de energized This feature is used to predict switch failures As an example if the vital sensor is adjusted to detect a 1 4 obstruction in the switch points the target must be displaced by that same distance before the vital sensor changes from the ON to the OFF state The
54. non vital sensor however changes from the ON to the OFF state after an approximate 1 8 displacement in linear target position This can be used to indicate that the machine moved marginally and is on the verge of failure i e the switch points have moved due to temperature or the point is still closing but is being gradually obstructed by an element such as sand ice etc 2 8 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL DESCRIPTION 2 3 10 Local Remote Request Switches Optional The local remote request switches are used to locally operate the machine similar to that of a wayside local control panel One toggle switch is used to take local or remote control and the other toggle switch is used to cycle the machine from normal to reverse and back in the local control mode of operation OPTIONAL LOCAL REMOTE CONTROL SWITCHES JUNCTION BOX CAPTIVE POINT DETECTION PROXIMITY SYSTEM CPDS SENSORS FROG PLATE Figure 2 6 Controller Compartment SM 9194 Original October 2004 2 9 NON VITAL PD SENSOR AUX 2 VITAL PD SENSOR PS2 VITAL LOCKING SENSOR 151 JUNCTION BOX POINT DETECTOR TARGET POINT DETECTOR BAR CAPTIVE POINT DETECTOR SLEEVE ESPE NON VITAL PD k SENSOR AUX 1 VITAL PD i SENSOR PS1 VITAL LOCKING SENSOR LS2 Figure 2 7 Controller Compartment with Sensor View 2 10 SM 9194 Original October 2004 SWITCH
55. o protect the ECC I O lines from external lightning and surge potentials The ECC box is connected to the WAGO terminal strip in the motor compartment with two plug coupled cables TB1 and TB2 Both plug couplers are keyed differently so they cannot be interchanged on the ECC box The terminal strip 15 the integration point of the ECC system where all field wires for 2 2 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL DESCRIPTION switch indication and the wayside battery feed to the ECC system Refer to Figure 2 8 for the system block diagram The WAGO terminal strip is also the termination point for the machine s cycle counter the local remote request switch option and the two motor cutout sensors for disabling motor power when manually operating the machine by either hand crank or the hand throw lever 2 1 5 Field Cable Conduit The field cable conduit entrance is designed to accept a threaded 2 1 2 NPT connection which can be reduced to accommodate any watertight threaded conduit application 2 1 6 AAR Binding Posts The motor compartment is also equipped with an eight way AAR binding post strip for field motor power cable wires and motor control unit termination Two of the AAR posts are strapped with a Gold Nut to disable motor power to the machine while allowing ECC signal battery to power the ECC for diagnostic analysis These terminals are equipped with two 2 additional gas arrestors to protect t
56. omplete the motor will coast to a stop The LOCAL REQUEST will override the dispatcher s control of the machine It is important to return the L R switch to the REMOTE position upon completion of maintenance to return control of the machine to the dispatcher 4 1 7 Motor Control Unit and Cycle Counter Termination Terminals 27 through 31 are for termination of the motor control unit MCU and are also used to terminate the cycle counter 4 1 7 1 Motor Control ON MOTOR FRONT and ON MOTOR REAR are used to turn off motor current at the end of the stroke For example if the motor is turning to produce motion of the lock box toward the motor compartment front end of the machine both ON MOTOR FRONT and ON MOTOR REAR are relative to GND When lock sensor LS2 turns ON the ON MOTOR FRONT line switches to GND In response the motor controller opens the motor to the polarity of current that would continue motion in the same direction Additionally the counter is energized momentarily and one count is registered Operation in the opposite direction is the same with ON MOTOR REAR switching to stop the motor however the counter does not respond NOTE Normally there should be no need to measure voltage on the WAGO terminal strip because LEDs on the ECC accurately display voltages at the strip The one exception is if the connection to the strip is open If there is reason to make a measurement do not use battery as a reference t
57. oped by Union Switch amp Signal Inc US amp S The design of the M 3E provides a state of the art Electronic Circuit Controller ECC simple mechanical modular construction and a lower level of required maintenance In addition all serviceable parts of the M 3E can be maintained with a single tool a 3 8 or 1 2 drive ratchet with a 1 long 3 4 socket and a 10 extension The M 3E provides full locking in the hand crank mode The M 3E utilizes the same basic drive train design as all other style machines This design has provided many years of reliable service The machine is equipped with a 110 VDC permanent magnet motor The M 3E incorporates many design improvements over the previous M 3 style machine These include a significantly lower vertical profile 9 3 4 overall height an optional local remote control capability self lubricating bearings and direct interchangeability with competitor mechanisms The ECC is a microprocessor based controller that monitors the state of four vital point detection proximity sensors and can identify each possible sensor state on off shorted or open The ECC uses SM 9194 Original October 2004 1 1 INTRODUCTION UNION SWITCH amp SIGNAL two of the four vital point detection proximity sensors to detect the position of the switch points normal or reverse and two to detect that the machine is fully locked normal or reverse In addition to the vital point d
58. r bar in the vertical plane are identical to that of the M 3 2 15 16 and 6 1 4 from the bottom of the switch base respectively Elevation of the M 3E s operating bar is 7 16 lower than the M 23 2 vs 2 7 16 measured from the switch base bottom to the top of the operating bar This difference in elevation is negligible due to the length of operating rods and lost motion present in standard switch adjuster basket assemblies The mounting lugs on the switch base are machined to a width of 18 1 4 Mounting lug extension plates are available to fit gauge or saddle plates designed to the standard M 3 cast dimension of 18 1 2 5 3 Field Installation of Machine To avoid personal injury always keep hands and feet clear of switch points and internal moving parts of the machine Open the Gold Nut test link in the motor compartment prior to performing any internal machine maintenance Ensure that loose clothing is properly secured prior to working on the switch machine 5 3 1 Lifting and Handling the M 3E Handling of the M 3E should be accomplished by applying two lifting straps preferred or chains rated equivalent to or in excess of 1000 pounds The switch machine should always be lifted with all three covers on each of the compartments to avoid damage to the machine s internal components Care must be exercised to avoid chain or strap interference with the cover hinges See Figure 5 1 for proper lifting and
59. roper position to define the normally closed switch point reference Section 2 3 4 1 SM 9194 Original October 2004 5 1 INSTALLATION UNION SWITCH amp SIGNAL 5 1 2 Operating Bar Conversion 1 Remove the operating bar lug bear paw from the operating bar s current position and secure it to the operating bar on the opposite side of the machine 2 Reverse the sheet metal lock rod and operating rod covers from one side of the machine to the other 5 2 M 3E Mounting Details Mounting of the M 3E is identical to the mounting of existing M style machines The mounting footprint of the M 3E can be configured to mount in a standard M 23 application with 16 bolt centers or in an Alstom GRS application with 15 1 2 bolt centers simply by rotating the mounting lug insert plates end over end The holes in insert plates can be provided with single or multiple hardware sizes to make applications more universal When properly mounted the vertical profile of the M 3E is 9 3 4 at the machine s highest point which minimizes the need to dap ties and enables mounting of the machine closer to the stock rail while still clearing standard car clearance envelopes All connecting rods in the horizontal plane are the same distance apart as the M 3 Centerline of operating bar to centerline of lock rods is 20 Centerline of lock rods to centerline of point detector bar is 2 5 8 Elevation of the lock rods and point detecto
60. so jumpered to terminal 12 Reverse With proper jumper configuration in place both green LEDs for indication input will always be illuminated in the ECC box to indicate continuous power is being supplied to the indication input circuits 5 5 2 Multiple Machine Applications If the machine is the first machine in the crossover i e the indication output is not dependent upon the indication input from an adjacent machine the indication input circuits are to be jumpered as described in Section 6 5 1 for a single machine application If the machine is the second machine in a crossover application i e requires indication input from the first machine in order to properly deliver indication output to the wayside indication input jumpers are not used The indication input circuits of the second machine are to be fed from the indication output of the first machine to ensure that both machines in the crossover are locked and detected in the correct position Only up to three machines can be daisy chained however line loss and ECC amplifier loss limitations may require the use of a DC to DC converter to boost the signal to a level high enough to drive wayside correspondence relays SM 9194 Original October 2004 5 5 INSTALLATION UNION SWITCH amp SIGNAL 5 5 3 Point Detector Sensor Gap Adjustment The vital and non vital point detector sensors must be located at a fixed dimension to optimize sensor response and performance The
61. st be installed in the machine so that the lockdog enters the narrow notch of the locking rod first 5 Install the operating and lock rod connecting rods to the trackwork Do not install the connecting rods to the machine at this time Center all fasteners in threads to maximize adjustment capability 6 Bar the switch points to the mid point position 1 2 the point opening and install the point detector connecting rod first to the trackwork and then to the internal point detector bar Adjust the connections so that the point detector target is centered in the switch machine This will provide maximum adjustment capability of the linear slides in both the normal and reverse positions No further adjustment of the point detector track connections is required as all of the adjustment is made inside the machine via the linear slides 7 Bar the switch point to the most convenient position to connect the operating and lockrod connecting rods to the machine 8 Make sure all three connecting rods are perpendicular to the switch points To ensure efficient operation move the machine forward or backward in a direction parallel to the stock rail to provide the best alignment of all three connecting rods 9 Confirm that all three connecting rods properly clear the base of the stock rail and that they do not interfere with the sides of the switch ties when the machine is in either position 10 Fasten the machine to the ties per the installation dra
62. t and lock sensors for the normal position must both be energized or ON The same is true for both point and lock sensors for the reverse position If either one of the two paired sensors are OFF in either switch position the switch indication output is OFF for that position The paired sensors are labeled PS1 amp LS1 and PS2 amp LS2 and work together respectively Which pair of sensors corresponds to the normal position is dependent upon the position of the LHPC RHPC jumper position in the junction box When the machine is locked and the points are detected in either the normal or reverse positions illustrated by the point detected and point locked LEDs and the corresponding indication input is 3 2 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL OPERATION present or energized the indication output LED for that switch position will be illuminated on the ECC This is a direct confirmation that indication power 12VDC is leaving the machine 3 4 3 Latch Out If the machine is locked and detected in either the normal or reverse positions and the points move 3 8 of an inch away from the stock rail the ECC will electronically latch out turning OFF the indication output for that position and holding it out in a manner depending on the latch out jumper position in the junction box A latch out condition is indicated by the illumination of the RED latch out LED on the ECC The latch out can be restored either manually or autom
63. tery Connections sssini iana aan a aaa a ania AEE aANT An inesset nennen 4 2 4 1 5 Bipolar Auxiliary Sensor OUtpUt inet een e ftiit tee sb V rad 4 2 4 1 6 Local Remote Request Switch Option pp 4 2 4 1 7 Motor Control Unit and Cycle Counter Termination 4 4 3 4 1 8 Motor Cutout Circuits Termination Points 0 2 111 00 enne 4 3 44 9 MCU Test Procedure Nil 4 3 4 2 AAR Terminal Post Connections pp 4 4 4 3 Sensor Identification and Termination in the Junction 2 422 000 4 4 4 4 Three and Five Wire Control Conversion to Two Wire Control sese 4 5 LM cir mp L 5 1 5 1 Component Conversion 5 1 5 1 1 Circuit Controller 9 5 1 5 1 2 Operating Bar Conversion 5 2 5 2 Mounting coca ERR RAS 5 2 5 3 Field Installation of 5 2 5 3 1 Lifting and Handling the 5 2 5 3 2 Placing the on the 5 3 5 4 Junction Box Jumper Configuration pp 5 4 5 4 1 REHPC EHPG J mp 6rs edt ner gatus e chr des Fed ped eee EE ned cp ata 5 4 5 4 2 Latch Out Jumper
64. the bar has moved approximately 1 4 This approximate 1 8 differential provides the ability to predict a switch failure caused by sand ice accumulation in the switch points or switch point movement resulting from extreme temperature changes etc The auxiliary sensors indicate that while the machine is still within the FRA guidelines for maintaining switches the machine is on the verge of being obstructed A normally energized bipolar output is provided on the WAGO terminal strip to be used on the wayside to notify operators or maintenance personnel that a problem is developing SM 9194 Original October 2004 3 3 OPERATION UNION SWITCH amp SIGNAL NOTE This adjustment should be factory set and should not have to be set in the field Adjust the vital sensor until the Point Detector of the ECC LED turns on Turn the adjusting wheel four turns so the vital sensor is farther in front of the target At this point turn the adjusting wheel in the opposite direction The non vital sensor should be set to turn off between two and three turns This will set the non vital sensor to turn off at approximately 1 8 as the point moves away from the stock rail The gap between the target and the sensor is to be approximately 0 040 3 4 5 Manual Operation Motor Cutoff Protection Manual operation motor cutoff protection is provided with the use of one 8mm diameter inductive proximity sensor The hand crank sensor is continuously
65. wing or applicable railroad standards 11 Wire the machine per the instructions and definitions defined in Section 4 1 of this manual 5 4 Junction Box Jumper Configuration 5 4 1 RHPC LHPC Jumpers All M 3E machines are originally configured with the switch point closest to the machine designated as the normally closed or normal point Therefore all right hand machines are shipped with the jumper in the RHPC position and all left hand machines are shipped with the jumper in the LHPC position Because the same terminals on the WAGO terminal strip are always used for normal and reverse indication regardless of the RHPC LHPC jumper position it is necessary to move the jumper to the opposite position if the normally closed switch point is furthest from the machine installation Never change the position of the RHPC LHPC jumper configuration after the machine has been installed and properly tested The jumper position should never be altered when troubleshooting or performing maintenance on the machine Altering the jumper configuration will cause the ECC to assume it is in the normal position when it is really in the reverse position or vice versa This may result in a train derailment 5 4 SM 9194 Original October 2004 UNION SWITCH amp SIGNAL INSTALLATION 5 4 2 Latch Out Jumper Configuration All US amp S machines are configured for manual latch out restoration If automatic restoration is desired or i
66. y 10 11 12 Remove the five 1 2 bolts two 1 long two 1 1 2 long and 4 1 2 long securing the frog plate to the switch base Insert two T handle wrenches into the top ears on either side of the frog plate and lift the frog plate straight up to remove it The frog plate assembly weighs approximately 50 pounds and proper lifting procedures should be followed to minimize the risk of back injuries Remove the lock box from the top of the slide bar and rotate it 180 degrees along the length of the slide bar 1 the locking dog that was initially on the top is now on the bottom but in the same linear position with respect to the slide bar and vise versa Reinstall the lock box on the slide bar studs Replace the frog plate and secure it with the five 1 2 bolts removed in Step 4 of this section two 1 long two 1 1 2 long and one 4 1 2 long Replace the CPDS rotating it end to end from its original position so the point detector bar is now extending out of the track side of the machine In addition rotate the point detector sleeve 180 degrees so the point detector target now faces the gearbox Secure the CPDS with the eight 1 2 bolts 1 1 2 long removed in Step 2 of this section Install the ECC assembly and secure with the two 1 2 bolts 1 1 2 long removed in Step 3 of this section Reconnect the three ECC cables Ensure the LHPC RHPC jumper in the junction box is in the p

M-3E Switch and Lock Movement

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