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SM-9662 - Ansaldo STS

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1. CLUTCH HOUSING N 1 N INGA INGAAS JINN l az s lt AS ill L ES elo gt EE E BB GEAR FELT WASHER Pp OIL SEAL FABRIC DISC CLUTCH PLATE Figure 2 12 Friction Clutch Assembly F P B2 B1 C2 H SEE FIGURE 2 13 2 FOR LEGEND E a y m i Lk a S NY c USS lt BAZ s ia ERN Ns OX 5 Z 540 a z wi pel rum DI AS SUE Ir 2 K NY Y N 2 x Y f NS ac a PET CN 7 22222222222222222222 hir Figure 2 13 Sectional View of M23 Gearbox From Motor End Right Hand Assembly Shown SM 9662 Rev 1 October 2009 2 28 AnsaldoSTS Installation and Adjustments A2 SAG ce LEGEND 65 ee CN i TE H E pl al DN S FOR FIGURES L 1 a 210 REDUCTION GEAR ner 157 REDUCTION GEAR A3 BOLT A4 BOLT Z 1 NUT 2 WASHER BEARING C1 KE
2. 1 6 SWwilchiNIachine MOTO S t u 1 6 SWitchiMaGhine Eal 1 6 Switch Machine Controllers uuu uu ced lated dah e aee etes 1 7 Gear Ratio Reduction Gear Relationship 3 6 Preventive Maintenance Schedule 4 2 Table ERE EE T 4 5 Adjustme ntto u eda 5 17 and M 23 Switch Machine Lubrication Specifications 5 22 ECC Troubleshooting W MQDL J sss 6 1 nu 6 4 M 3 Switch Machine 7 2 M 23A Switch Machine 7 2 M 23B Switch Machine 7 3 M 3 Switch Machine Parts 7 4 M 23 Swlien Machine 191 2 uu uuu u yu deals 7 12 M 3 Geal Box isuu u uu a uma u 7 19 M 23 Gear BOX Parts EIS 7 22 Motor Blue Assembly 451161 17 Parts List 7 26 Motor Black Assembly N4220
3. a pi t SLIDE BAR SWITCH MAIN HAND CRANK OPERATING GRANK INSERTED HERE BAR LOCK BOX FOR POINT DETECTOR ROD WIRE OUTLET MAIN CRANK ROLLER NOTE SWITCH POSITION INDICATION PROVIDED TO ECC USING LOCK ROD PROXIMITY SENSORS 642 0011 00 Figure 1 1 M 3 Switch Machine Outline Diagram 1 2 SM 9662 Rev 1 October 2009 2 AnsaldoSTS General Information CIRCUIT CONTROLLER GEAR MOTOR COMPARTMENT BOX 59 pa H octet j Nes J HAND H Mri THROW 25 25 LEVER SELECTOR LEVER WHICH SLIDE BAR SWITCH MAIN SHIFTS SELECTOR CLUTCH OPERATING CRANK ALONG SPLINES ON MAIN BAR CRANK SHAFT SEE NOTE A LOCK BOX HAND THROW LEVER WHICH ROTATES HAND THROW PINION WIRE OUTLET 21 I a a if FOR POINT DETECTOR ROD MAIN CRANK ROLLER NOTE A NOTE B CLUTCH OVERALL HEIGHT IS SUCH THAT TOP SWITCH POSITION INDICATION PROVIDED TOOTH MUST ENGAGE HAND THROW GEAR BEFORE USING LOCK ROD PROXIMITY SENSORS BOTTOM TEETH CAN DISENGAGE WORM GEAR OR VICE VERSA THUS THE MAIN CRANK IS NEVER FLOATING BUT AT ALL TIMES IS ENGAGED WITH EITHER THE MOTOR OR THE HAND THROW LEVER 642 0010 00 Figure 1 2 M 23 Switch Machine Outline Diagram SM 9662 Rev 1 October 2009 1 3 General Information i AnsaldoSTS
4. Table of Contents 00515 Figure 1 1 Figure 1 2 Figure 1 3 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 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 5 1 Figure 5 2 Figure 5 3 vi List of Figures M 3 Switch Machine Outline Diagram a 1 2 M 23 Switch Machine Outline Diagram 1 3 Left Hand and Right Hand Switch Machines 1 9 M 3 Switch Machine Typical Application 2 2 M 23 Switch Machine Typical Application 2 3 M 3 Switch Machine Typical Mounting Plan 2 4 M 23 Switch Machine Typical Mounting 2 5 ECC with MCU Internal Wiring 2 9 ECC with EBNC Internal Wiring Diagram 2 11 sensor Gap Definition Non Vital Sensor Shown is
5. Z 71 0 1 X LZ lt ISES SS S Z zN Z peus lt A3 K M GN EU SE SSS u SS N dr c mr mri 5 1365 s Figure 3 6 Sectional View of M 23A Gearbox Looking from Motor End The friction clutch housing has a tubular neck supported an bushing pressed into the gearbox bore The inside diameter provides slight clearance for the worm shaft The housing has a felt washer and an oil seal to prevent seepage of oil into the friction clutch The worm shaft 1s grooved and the housing has ribs to drive alternate friction discs that are compressed by the action of the heavy coil spring This spring force is contained between the adjusting nut and Oilite thrust plate supported on the tapered shoulder on the worm shaft Note that the clutch gear hub has a three finger engagement with the clutch housing tubular neck so that the clutch housing 1s driven by the motor Drive between the clutch housing and the worm shaft 1s through the friction discs 3 4 Operation By Hand Crank M 3 Only Provision is made in the M 3 switch machine for hand operation by inserting a removable hand crank through the hand hole in the gearbox cover Motor cutout contacts O see Figure 3 7 are operated by means of a linkage to open the motor circuit and in some cases to open a control circuit when the hasp for the hand hole cover is re
6. s 8 47303402 Ose E 2 FE x x y s Local Request Sud 9 E 7 B O B O Normal Request MOIS g Frame 855 E Remote L Reverse Request D ic S AAGO 50 mi ser JTO Maintenance Bi Polar Normal Ground Stud 66888 8 3 x AN 2 6 ES BL Ground Terminal SY 2 2 I 4 a cal Maintenance Bi Polar Normal g E se to o Battery Input 812 4 5 2 T 2928908 z SE SS o S 5 o 50 OS PE E d Terminal gt 99 E round Termina AAR 51 AAR 52 5 4858 Motor cutout 83 eu O Battery input N12 contacts ref 95886 ms o Black g I fe e input vA A Ground Terminal i ES o D en BI S o O eU LIV L e Normal input EEA Reverse Input WARNING G dT Motor End afl Maintenance Bi Polar Terminals 2 o e li v oj Reverse Input 21 and 23 are Non Vital and should Auxiliary Sensor 1 2 O Normal Output never be used to clear signals Jh Ground Termina
7. L LOCKING RADIAL DOG PORTION S STRAIGHT SEE DETAIL SWITCH OPERATING BAR UPPER LOCKING GROOVE gt DOG X 2 SWITCH OPERATING ROD WIDE NOTCH LOWER NARROW NOTCH LOWER DETAILA NOTE DIRECTION OF MOVEMENTS SHOWN ARE FOR ALEFT HAND SWITCH MACHINE THE DIRECTION OF MOVEMENTS ARE REVERSED FOR A RIGHT HAND MACHINE THE SLIDE BAR AND OPERATING BAR STROKE TIMING RELATIONSHIPS REMAIN THE SAME 6A2 0052 00 Figure 3 2 Diagram of Driving Parts Sheet 1 of 2 SM 9662 Rev 1 October 2009 3 3 a Operation Z AnsaldoSTS MAIN CRANK A y INITIAL POSITION CW LUG 1 SWITCH ROLLER 4 OPERATING BAR B MID POSITION SLIDE BAR R SWITCH CK OPERATING b OPPOSITE SWITCH OPERATING 57 BAR oY 6A1 0049 00 Figure 3 3 Diagram of Driving Parts Sheet 2 of 2 3 2 Switch Point Locking The lock rods in Figure 3 4 are comprised of two rectangular rods side by side Each has a narrow notch only slightly wider than the locking dogs this narrow notch in one rod being on top 3 4 SM 9662 Rev 1 October 2009 77 AnsaldoSTS Operation and in the other rod the bottom To allow for variations in switch throw the two rods adjustable longitudinally with respect to each other and each has a wide notch located alongside the narrow notch of the other As the notch is on top of the lock rods for one position of the swi
8. M 23A and M 23B machines use different hand throw pinions which affects the hand throw locking Power operation is the same in both machines In the M 23A operation using the hand throw lever gives the same mechanism stroke including full lock rod protection and point indication as during power operation In the M 23B machine however operation using the hand throw lever does not provide lock rod protection the slide bar and lock box do not move full stroke Motors and gear ratios are available for operating the machines from 110 or 20 VDC All M 3 machines use the same gearbox but different gear sets Similarly all M 23 machines use the same gearbox but different gear sets Two gear ratios are available for the low voltage 20 VDC machines one to provide relatively fast operation and the other to provide slower operation at locations where current requirements must be held to a minimum third gear ratio is used with the high voltage 110 VDC motors The machines are completely wired at the factory with the internal wiring connected to AAR posts and a WAGO strip inside the motor compartment An internal wiring diagram 1 enclosed with each machine when shipped showing where external connections are to be made to the terminal boards These diagrams are also included in this manual as Figure 2 5 and Figure 2 6 1 2 1 Operating Mechanism Three compartments are provided for both the M 3 see Figure 1 1 and the M 23 machin
9. 9 Clutch Spring 92 ____11 ____ 316x22 Tin Phy ____13 ____ Screw 1 4 20 3 4 Hex Hd Figure 5 1 Friction Clutch Assembly SM 9662 Rev 1 October 2009 5 3 Shop Maintenance Z AnsaldoSTS 5 4 5 Gearbox Removal 3 See Figure 7 1 Remove the two screws located on etther side of the cotter key 2435 that links the push rods and the motor cutout contact controls Hold the push rod 2805 at the end nearest the motor compartment and pull it until the opposite end clears the shaft 2810 Remove the push rod by lifting and pulling it until the motor cutout pushrod 2245 clears the hole in the side of the housing Remove the four screws 2995 and washers 2200 that secure the gearbox to the base and lift the gearbox from the base of the switch machine If further disassembly of the gearbox 15 required see Figure 7 5 NOTE Before proceeding with further disassembly become thoroughly familiar with the information and illustrations in Sections 1 and 3 These illustrations will aid in final disassembly of the switch machine 5 4 6 Main Crank Removal For all M 3 and M 23 machines the main crank must be taken out through the bottom of the machine 1 Remove the bottom cover and wear plates supporting the operating bar This allows the operating bar and crank roller to drop down 2 Rotate the crank turn
10. Use machine as a target Is point and or locking sensor for opposite switch machine opposing sensor to indicate on ON CREEN Is machine fully locked A latch out condition will occur only ifthe If YES go to 10 The ECC does not machine is fully locked and the latch out when point switch point moves away from the detector target is stock rail Lock is indicated by If NO correct condition preventing removed from in ECC point locked indicating machine from locking front of target face GREEN and restored Is configuration jumper in junction If YES ECC will not latch out when box installed in the disabled configured as latch out disabled position If NO ECC may be bad SM 9662 Rev 1 October 2009 6 3 Troubleshooting 77 AnsaldoSTS Table 6 2 ECC Troubleshooting w EBNC Symptom Troubleshooting Possible Cause A Motor power present on motor If YES motor may be bad or binding terminals If NO go to B B Machine motor cutout contacts closed If NO correct motor cutout open condition C Motor disable LED on ECC YES go to D If NO go E D Check motor cutout circuit If YES to continuity ECC may be bad inui WA 2 SM cos UM RT NO check wiring continuity to motor ECC TB1 1 1 2 gene cutout contacts 49 and 50 1 Motor power If YES 12V on 30 or 29 ref 31 and present from E os a polarity on 34 36 correct
11. gt 1000 Technology Drive Pittsburgh 15219 7 AnsaldoS S Russell Sl SP shua Sc 29006 SM 9662 M 3 M 23A M 23B Electric Switch Machines with Permanent Magnet Motor and Electronic Circuit Controller ECC and Motor Control Unit MCU or Electronic Biased Neutral Controller EBNC ASTS USA Part No 429500 M 3 w EBNC N426500 xx M 3 w MCU N426501 xx M 23A w MCU N426502 xx M 23B w MCU Installation Operation Troubleshooting Copyright 2009 SM 9662 Rev 1 Ansaldo STS USA Inc October 2009 2 AnsaldoSTS Notices Proprietary Notice This document its contents are the property of Ansaldo STS USA Inc formerly known as Union Switch amp Signal and hereinafter referred to as ASTS USA This document is furnished to you on the following conditions 1 That no proprietary or intellectual property right or interest of ASTS USA 1 given or waived in supplying this document and its contents to you and 2 That this document and its contents are not to be used or treated in any manner inconsistent with the rights of ASTS USA or to its detriment and are not to be copied reproduced disclosed or transferred to others or improperly disposed of without the prior written consent of ASTS USA Important Notice ASTS USA constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contai
12. Latch out LED is flashing RED All four dual colored LEDs are flashing RED All LEDs on the ECC dark and some or all may or may not return or appear to flash Could also appear as a flickering condition with possible clicking sounds from ECC Commonly only motor disable LED appears to flash B Junction box may contain short or open C ECC may be bad Replace ECC B Junction box may be bad C ECC may be bad C ECC may be bad If NO MCU is not turning on though direction signals applied verified at step E Verify red and white MCU connections are properly connected MCU may be bad If YES 12V on 30 amp 29 referenced to 31 ECC may be bad Only 29 or 30 should be ON with machine locked at end of stroke Both 29 and 30 should be ON during throw Motor disable will turn both OFF Verify not reversed If NO MCU may be shorted If replacement sensor operates correctly reinstall original sensor and verify target adjustment Replace sensor if problem persists If replacement sensor does not operate correctly go to B If replacement junction box does not correct problem go to C K Check motor power present from motor negative to motor positive A Are both direction voltages applied to MCU terminals 29 and 30 ref 31 when point detected and point locked sensors indicate locked in normal or reverse A Temporarily plug replacement sensor in junction box and
13. 7 26 SM 9662 Rev 1 October 2009 a AnsaldoSTS Parts Lists 041000601 AO HO Figure 7 7 Motor Blue Assembly N451161 17xx Parts Location SM 9662 Rev 1 October 2009 7 27 5 Parts Lists 2 AnsaldoSTS Table 7 9 Motor Black Assembly N422008 xx Parts List E Motor Black Electric 20 VDC 528 1 Gear Ratio J717216 0501 Gear 1 1 2 Steel Round Key 3 16 Square Steel Screw 10 32 x 1 4 Allen Head 7 28 SM 9662 Rev 1 October 2009 EN a AnsaldoSTS Parts Lists Figure 7 8 Motor Black Assembly N422008 xx Parts Location SM 9662 Rev 1 October 2009 7 29 Sy Parts Lists 2 AnsaldoSTS 7 7 Circuit Controller Assembly Table 7 10 contains the parts list for the N426007 xx circuit controller assemblies listed in Table 7 1 Table 7 2 and Table 7 3 See Figure 7 9 for a location diagrams showing the listed parts Table 7 10 Circuit Controller Assembly Parts List Assembly Point Detector Sensor w Auxiliary Sensors 03 ____06 Sensor Bracket Compete M423706 02 07 Assembly Local Remote Switch 08 Screw 5 16 18 x 1 Socket Head Cap 500124059 09 5 16 SpringLock 470138012 Screw 1 4 20 x 3 4 Socket Head Cap ii 14 Washer 1 4 High Collar Lock 16 Washer M18 Lock Internal Toot
14. 5 4 5 Gearbox Removal M 3 r 5 4 546 Mall Crank Removal u uu 5 4 5 4 7 Main Crank Replacement M 23 Machines 5 4 5 48 Selector Cl tchi RemigVal us te eet e 5 12 5419 Worm u ben ste kasi Buia 5 12 5 4 10 Final Disassembly 5 12 54 1 Gesdrbox M 23 Disassembly uu unun ERR 5 13 5 5 5 13 5 5 1 Gearbox 3 Reinstallation 5 13 5 5 2 Gearbox M 23 Reassembly Convert between RH 5 13 IV SM 9662 Rev 1 October 2009 77 AnsaldoSTS Table of Contents 55 9 Motor BrusiTneilietallali o flyy u uu l a 5 15 5 5 4 Motor Assembly Reinstallation a 5 15 5 5 5 Friction Clutch Assembly Reinstallation 5 15 5 5 6 Electronic Circuit Controller ECC Reinstallation 5 18
15. zi 8962 0022 Bs 0822 9 0262 00 1 00 9 ME YN Figure 7 1 M 3 Switch Machine Parts Location 7 9 SM 9662 Rev 1 October 2009 N Parts Lists 77 AnsaldoSTS Figure 7 2 M 3 and M 23 Circuit Controller End Parts Location 7 10 SM 9662 Rev 1 October 2009 2 AnsaldoSTS Parts Lists Q C O ac gt lt 7 DETAILA VIEW B EXISTING BASE SEE EXPLODED VIEW EXPLODED VIEW G VIEW OF SURGE SUPPRESSOR PCB LO 7 pe C C C CO 2 nO TSAO gt cc LH 4 4p uL e gt lt NE EXPLODED VIEW B CN 5 O 2 m di 5 F 8 uim Figure 7 3 3 23 Motor End Parts Location SM 9662 Rev 1 October 2009 7 11 5 Parts Lists 2 AnsaldoSTS 7 3 23 Switch Machine Parts List Table 7 5 contains the parts list for the N426501 xx M 23A and N426502 xx M 23B switch machines listed in Table 7 2 and Table 7 3 See Figure 7 4 switch machine Figure 7 2 circuit controller end and Figure 7 3 motor end for location diagrams showing the listed parts Table 7 5 23 Switch Machine Parts List Base M 23A Machines Suffixes 01 09 11 12 17 22 31 32 2005 Base M 23B Machines Motor Assembly M 23A Machines 110 VDC Suffixes
16. 001 The wayside provides a fixed polarity two wire motor power feed one of the wires is always and the other wire is always The ECC EBNC controls the polarity applied to the motor terminals to select Normal or motion Table 7 2 M 23A Switch Machine Configurations Part Number Circuit Control Right Hand Left Hand Option Ref Base Motor Assembly Gear Box Ratio Controller Wiring 142650101 422008 01 110 VDC n s N426501 02 N287073 0001 189 1 MCU mE SO N291057 N422008 01 110 VDC E O 42600704 Two wie N426501 04 N287072 0001 360 1 MCU 4291057 451161 1701 110 VDC 51 106 N426501 06 N287073 0001 189 1 MCU ___ _ N426501 07 N291057 422008 02 20 VDC Ee S 426501 08 N287074 0001 528 1 MCU NER 426501 09 r N291057 N451161 1701 110 VDC 287073 189 1 N426007 03 03 26501 11 287073 189 1 i A D H K 291057 451161 1701 110 VDC 426007 04 7 N426501 13 N293975 N451161 1703 20 VDC 6252 426007 04 Wi N426501 14 N287074 0001 528 1 MCU aaa ee N426501 1 N291057 451161 1701 110 VDC A Nagori Mo e 426501 18 N287073 0001 1891 MCU s N426501 19 N291057 N451161 1701 110 VDC e l
17. 22 5281 20 VDC Blue 528 1 0 The motor current listed for gear ratio 189 1 must be checked in both directions and set for a minimum of 14 amps A variance of about 1 to 3 amps may exist due to mechanical alignments and motor characteristics 20 VDC black motor machines are shipped from the factory set to slip at 20 amps The clutch may be set to slip at 23 amps for field applications if desired SM 9662 Rev 1 October 2009 5 17 y Shop Maintenance Z AnsaldoSTS CLUTCH SPRING CLUTCH HOUSING A ws NE NS 717 2 j Ni T Z 7777777 ADJUSTING CLUTCH PLATE FABRIC DISC OIL SEAL 1 3 8 j q 5 32 dM 1 5 8 1 5 16 1 716 1 1 4 AM PC 173641 159 HOLE 821 DRILL SIZE PINS PRESSED IN SOCKET FOR 11 16 11 16 LEVER 1 TEMPORARY TOOL MAY MADE BY FILING PINS ON THE END OF A PIECE OF 1 PIPE AS SHOWN Figure 5 5 Friction Clutch Assembly and Special Wrench for Packing Gland Nut 5 5 6 Electronic Circuit Controller ECC Reinstallation The ECC is located between the junction box and the point detector sensors with the text readable from the point detector side Place the ECC in this location Reinstall the three socket head cap screws that retain it one from the front between the cables one at each rear corner Reconnect the three cables
18. 6 N426501 20 287073 0001 189 1 MCU 7 2 SM 9662 Rev 1 October 2009 5 77 AnsaldoSTS Parts Lists Part Number Circuit Control Right Hand Left Hand Option Ref Base Motor Assembly Gear Box Ratio Controller Circuit Wiring __ N4260121_ N291057 N451161 1703 20 287074 5281 N426007 03 Two Wire N426501 22 0001 528 1 MCU ___ _ N426501 27 N293975 N451161 1703 20 VDC B or oe eod a Naor oa TWO N426501 28 E M 0001 528 1 MCU ___ N42650129 N293975 451161 1701 110 N287073 189 1 N426007 03 Two Wire N426501 30 0001 189 1 26501 31 287072 360 1 1 ng N291057 422008 02 20 VDC 426007 04 The wayside provides bipolar two wire motor power feed to select Normal when of wires is the other wire is The ECC MCU passes the wayside polarity to the motor terminals to obtain either Normal or Reverse motion Table 7 3 M 23B Switch Machine Configurations PartNumber Number Circuit Control DD Hand Left Hand Option Ref Base Motor Assembly Gear Box Ratio Controller Circuit Wiring ___ 10426502011 451161 1701 110 VDC ET UE 19880 T N segozga WO re N426502 02 N287076 0001 189 1 MCU m N291057 N422008 02 20 VDC j 0 N426007 04 wo Wire N426502 08
19. Clutch SNES 90 X Bee ZF 105115 NotUsd 01 000 185 NotUsd 1 00 J500097 0112 Washer 5 16 Plate Steel Lock Pipe Plug 1 2 Stee 200 SM 9662 Rev 1 October 2009 7 19 Sy Parts Lists 2 AnsaldoSTS Key 9 WDF 3 4 x 3 16 Cotter 3 16 x 2 Spring Steel Bushing Oilite 1 003 OD 7 20 SM 9662 Rev 1 October 2009 Parts Lists AnsaldoSTS QOIS 7 555 L a UOLER N 22 2 77 KISSIN x 222 y UL lt gt 53 SU SS NS GY Z i Z NIN L 091 lt SSS Z 08 9 T 08 69 HV3O OL 681 M3 Z s 1 VS NN KS _ Z I A gt gt I Na i o c ER zi DES EDS OTN TIT M 00766007279 7 21 Location Figure 7 5 M 3 Gear Box Parts SM 9662 Rev 1 October 2009 j Parts Lists 7 AnsaldoSTS 7 5 M 23 Gear Box Parts List Table 7 7 contains the parts list for the N28707x and 28707 0001 M 23 gear boxes listed in Table 7 2 and Table 7 3 See Figure 7 6 for a location diagrams showing the listed parts Table 7 7 M 23 Gear
20. Lock is indicated by If NO correct condition preventing target Is removed ECC point locked indicating machine from locking from in front of GREEN target face and restored If YE B 10 The ECC does not S go to If YES ECC will not latch out when configured as latch out disabled If NO ECC may be bad Is configuration jumper in junction box installed in the disabled position 6 6 SM 9662 Rev 1 October 2009 77 AnsaldoSTS Parts Lists 7 PARTSLISTS 7 1 Configuration Guide B ____ LockRodOpeningsClosed D Equipped with Local Remote Feature _ 30 Watt 115 230V Motor Heater 451589 0101 Wired for 115V _ Paint Final Assembly per PP 7905 Aluminum A040331 0101 G 15 Watt 115 230V Motor Heaters N294241 and 296578 001 Wired for 115V H_ Surge Suppressor PCB N497039 01 LV Use Crankcase Cover Item 175 N146290 0002 C9190 Sh 4 Item 545 J032902 Not Required Motor Compartment Heater ON OFF switch L_ Surge Suppressor PCB N497039 02 HV SM 9662 Rev 1 October 2009 7 1 A Parts Lists 77 AnsaldoSTS Table 7 1 M 3 Switch Machine Configurations Part Number Circuit Control Right Hand Left Hand Option Ref Base Motor Assembly Gear Box Ratio Controller Wiring N429500 13 94752 N451161 1701 110 VDC 87485 189 1 N426007 02 N429500 14
21. N287077 0001 528 1 MCU mA N426502 09 N293975 N451161 1701 110 VDC WU S N426502 10 ___ __ 87076 0001 189 1 MCU ___ N4260219 N433297 Nasi 161 1701 110 VDC N426007 03 o Wire 426502 20 N287076 0001 189 1 MCU ___ N4260221 N433297 N451161 1701 110 VDC N426007 03 wo Wire N426502 22 ___ 87076 0001 189 1 MCU The wayside provides a bipolar two wire motor power feed to select Normal or Reverse motion when one of the wires is the other wire is The ECC MCU passes the wayside polarity to the motor terminals to obtain either Normal or Reverse motion SM 9662 Rev 1 October 2009 7 3 Sy Parts Lists 2 AnsaldoSTS 7 2 M 3 Switch Machine Parts List Table 7 4 contains the parts list for the N429500 xx M 3 switch machines listed in Table 7 1 See Figure 7 1 switch machine Figure 7 2 circutt controller end and Figure 7 3 motor end for location diagrams showing the listed parts Table 7 4 M 3 Switch Machine Parts List ITEM DESCRIPTION PART NUMBER Plate 1 8 x 1 CF Steel Roller 1 3 4 Steel Key 3 8 x 1 Steel Tubing Rigid PVC 30 L Gasket 1 4 Felt 2160 2180 2190 Washer 10 Flat Steel J475077 7 4 SM 9662 Rev 1 October 2009 AnsaldoSTS Parts Lists ITEM DESCRIPTION PART NUMBER 2191 Washer 10 Lock Steel J047733 2195 M00242
22. Terminals 2 and 3 are common earth terminals used for grounding They are also terminals for the line to ground surge suppressor PCBs connected to Terminals 1 and 4 External ground connection should be connected at terminal 3 2 16 SM 9662 Rev 1 October 2009 m 4 AnsaldoSTS Installation and Adjustments 3 Terminal 5 15 the termination point for Terminals 10 4 through the motor cutout contacts Terminal 6 1 the termination point for the negative internal permanent magnet motor wire A gold nut test link is provided between terminals 5 amp 6 to remove power from the motor when performing maintenance on the machine 4 Terminals 7 and 8 are designated for motor compartment heater wire termination 2 9 Sensor Identification and Termination in the Junction Box The vital point detector sensors are designated PS1 and PS2 The vital locking sensors are designated LSI 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 as do PS2 and LS2 see Figure 2 5 for ECC or Figure 2 6 for EBNC The four vital and two optional auxiliary non vital sensors are all terminated at the Junction Box see Figure 7 9 located 1n back of the ECC six sensor wires are brought to the junction box and screwed down in their proper positions The labels identify which sensors connect to each terminal If any of the four vital sensors are wired in
23. check wiring continuity to motor 1 14 slate Note 1 cutout contacts 49 and 50 1 Motor power is E Motor disable LED off Are IF YES 12 on 30 29 referenced to present from the direction voltages applied to 31 go to F wayside but motor MCU terminals 29 or 30 ref 31 If NO ECC TB1 harness may be bad Bees NORU IfYES gotoeG F Check motor power present from TES godo Cr Start at A and check from 10 to troubleshoot down AAR 9 to AAR 4 AAR 4 G Check motor power present from us wire from AAR 10 to AAR 9 to AAR 5 If YES go to H If NO check wiring continuity to motor H Check motor power present from cutout contacts 51 amp 52 AAR 9 to AAR 6 If YES 10 Check motor power present from If NO check gold nut AAR 9 to motor negative If YES to J J Check motor power present from If NO check wire from AAR 6 to motor negative motor negative to AAR 1 If YES go to K Note 1 N47303401 ECC boxes used on previous generation machines use an external 750 ohm resistor in place of short to ECC B Machine motor cutout contacts closed SM 9662 Rev 1 October 2009 6 1 N 77 AnsaldoSTS Troubleshooting Troubleshooting Possible Cause 2 Motor continues to run at end of stroke in one or both directions causing friction clutch to slip A single dual colored LED is flashing RED
24. detected before switch failure occurs The ECC proximity sensor system 1 true linear detection device with no moving parts to wear The system requires no adjustment of the point detector bar instead the sensors are positioned along serrated linear slides and gapped with respect to the sensor target mounted on the point detector bar The lock sensors are similarly gapped no position adjustment is required with respect to the target mounted on the lock box The ECC diagnostic indicators LEDs show the current state of the local machine and the indication state of an adjacent daisy chained machine where required Table 1 1 lists the monitored items and the indications provided Table 1 1 ECC Diagnostic Indicators Indication State Lit LED Red Motor power disabled Dark Motor power enabled D Separate indication for Normal and Reverse position Bicolor LED SM 9662 Rev 1 October 2009 1 5 General Information 7 AnsaldoSTS 1 3 Specifications Table 1 2 Switch Machine Physical Characteristics 63 1 2inches 63 1 2 inches 10 1 4 inches 810 pounds 860 pounds Table 1 3 Switch Machine Operating Characteristics VU Nominal voltage at motor terminals Switch over time measured in accordance with AREMA AAR Manual Part 12 2 5 These times will vary depending upon motor terminal voltage and machine operating load and conditions Table 1 4 Switch Machine Motors Motor Part No Motor V
25. in the hand throw bevel gear F 6 Secure the lever shaft bearing M to the gearbox with the two 1 2 inch bolts A4 and washers removed during disassembly 7 ensure that the motor position of the selector lever is toward the motor end of the machine the selector lever and lever interlock must be reassembled 180 from the original position on the shaft as follows a Remove the 7 8 hex nut lock washer and flat washers from the end of the selector lever shaft and slide the selector lever and lever support K from the shaft Be careful not to lose the steel ball the lever support SM 9662 Rev 1 October 2009 2 31 10 11 12 13 2 32 nl Installation and Adjustments Z AnsaldoSTS NOTE If the stop screw 15 used in the hub instead of the hand throw lever it will be necessary to also remove this lever and interchange the stop screw and cap screw refer to Figure 2 10 Replace the hand throw lever and fasten it in place with the clamping bolt b Reassemble the lever support K with the hole for the steel ball on the motor side of the shaft Insert the steel ball and reassemble the selector lever on the shaft so that the lever is 180 from its original position The stop screw if used may require positioning the hand throw lever to align the recess with the hole in the lever support so that the steel ball will not interfere when the selector lever 15 applied c Reinstall the hex nut a
26. monitor operation using ECC LED indications Use machine as a target f YES go to B If NO install jumper and verify operation Replace jumper and then junction box to see if condition is corrected If go to C Replace ECC If jumpers correctly installed go to B A Is the configuration jumper properly installed A Verify jumper installed in LHPC or RHPC and jumper installed in only one of the three latch out configurations B Junction box may be bad or not fully seated If jumpers NOT correctly installed correct jumpers Replace junction box If problem is not corrected go to C Replace ECC If voltage is low or reversed correct and verify operation A Verify proper voltage at least 10 applied with proper polarity to WAGO terminals 17 and 20 with sufficient current B Remove JB1 from ECC and check for both indication inputs motor disable and flashing RED point locked detected indications If voltage applied is correct go to B If condition is not as described go to C If condition is as described problem is probably junction box or sensors If connections are fully seated and harness good ECC may be bad C Check TB1 connections to ECC If bad connection correct by reseating connector or replacing bad harness SM 9662 Rev 1 October 2009 gt Z AnsaldoSTS Troubleshooting 7 All diagnostic A 2 harness connection LEDs are
27. this procedure 2 16 6 Inverting the Lock Box The lock box dogs must enter the narrow notches of the lock rod before reaching the wide notch In some cases it may be necessary to invert the lock box to obtain this condition When necessary to invert the lock box remove the lock rods and proceed as follows see Figure 3 7 Place the machine in the end stroke position which brings lock box G nearest the motor Unscrew bolts T that hold the ECC to the case Swing the controller upward pivoting it about the edge of the case adjacent the wire conduit Turn lock box G upside down taking care that it is reinstalled properly on the driving studs of the slide bar Reinstall the ECC and fasten the circuit controller in place with bolts T 2 17 Prior to Placing Machine In Operation 1 Check lids for proper fit Adjust if necessary 2 Check motor cutout to be certain it is operating properly Be sure that the crank cannot be inserted without the cutout contacts being latched out M3 machine Adjust if necessary per Section 5 7 1 and Section 5 7 2 3 Check wiring for proper connections 4 Check the clutch adjustment With an obstruction of at least 3 8 inch between the switch point and the stock rail electrically operate the machine When the switch point jams against the obstruction the worm gear and worm shaft will be stopped but the motor should continue to run during the overload time delay period slipping the friction clutch Motor
28. 05 06 09 11 12 17 20 29 30 Motor Assembly M 23A Machines 20 36 VDC 2015 Suffixes 13 14 21 22 27 28 Motor Assembly M 23B Machines 110 VDC Suffixes 01 02 09 10 19 22 Motor Assembly M 23B Machines 20 36 VDC Screw 3 8 16 x 1 1 4 Hex Head Screw 1 2 13 x 1 2 Round Head Roller 1 3 4 Steel Key 3 8 x 1 Steel Tubing Rigid PVC 30 L Screw 7 8 9 x 3 Hex Head Pipe Nipple 3 4 Brass Tubing 7 12 SM 9662 Rev 1 October 2009 77 AnsaldoSTS Parts Lists ion Nut 2 1 8 Steel Lock Washer 3 8 Steel Lock Extra Washer 7 8 Steel Lock Extra Screw 10 32 x 9 16 Fillister Head Cotter 3 16 x 2 Spring Steel SM 9662 Rev 1 October 2009 7 13 Parts Lists Z AnsaldoSTS Pate Nut 3 47 Conduit Lock Bushing 1 1 8 Hex Steel Lube Fitting 1 8 67 Angle Screw 3 8 16 x 1 2 Hex Head Bushing 1 2 x 0 502 Oilite Bearing Cable Clamp 3 Position Ring 1 1 2 Dia Max Pipe Plug 3 8 Steel Screw 8 32 x 1 1 4 Round Head Steel Wire Tag 12 Bundle Washer 1 2 Steel Plate 7 14 SM 9662 Rev 1 October 2009 77 AnsaldoSTS Parts Lists Gear Box M23A 189 1 Left Hand Suffixes 01 05 09 11 17 19 29 Gear Box M23A 360 1 Gear Box M23A 528 1 2760 Gear Box M 23B 189 1 Gear Box M23B 360 1 Left Hand Not Currently Available Right Hand Not Currently Available
29. 2009 77 AnsaldoSTS Operation Moving the selector lever out of the motor position also actuates a pair of motor cutout contacts see Figure 3 9 to open the motor circuit and in some cases control a line circuit The cutout contacts are mounted in the circuit controller compartment and are operated by a spring return push rod projecting into the gearbox This push rod 1 shifted toward the circuit controller by the action of a cam ledge on the selector clutch yoke engaging an adjustable rocker arm 3 5 2 M 23A and M 23B Mechanisms The mechanical difference between M 23A and M 23B mechanisms is the hand throw pinion see Figure 3 10 The single tooth on the hub of the hand throw pinion on the M 23B mechanism has a shorter arc than the M 23A mechanism This introduces sufficient lost motion between the pinion and the selector clutch to permit full stroke of the hand throw lever and thus the switch points without moving the slide bar far enough for the locking dogs to engage the lock rods and thereby lock the switch points The travel of the main crank is ample however to lock the switch operating bar against back thrust 3 5 3 Lever Interlock The hand throw and selector levers are interlocked by means of a steel ball and suitable recesses in the lever hubs to prevent operation of the hand throw lever unless the selector lever is in the Hand position and also to prevent return of the selector lever from its Hand position unless the
30. 3 4 Spring Steel J048618 2440 Cotter 3 16 x 2 Spring Steel J048636 2445 Plug 1 4 Galvanized Steel J032901 SM 9662 Rev 1 October 2009 7 5 Parts Lists AnsaldoSTS Lube Fitting 1 8 67 Angle Nut 5 16 18 UNC 2B 2490 A041353 2495 A773010 2510 N294241 2515 S000333 2520 J700590 2525 J525111 2530 J052256 2545 Pipe Plug 3 8 Steel J032902 2550 J078399 2555 S000169 2560 J522151 2570 J475121 0109 2575 S001857 2580 N242441 2610 M397927 001 2615 N294241 2620 S000333 2625 J700590 2630 J525111 2635 J052256 2655 9705 11 2695 1047503 Mechanism Gearbox Complete 3 189 1 Gear Ratio 360 1 Gear Ratio Not Currently Available 528 1 Gear Ratio Not Currently Available Spacer 3 8 Round Brass Plate Cover LH Only Screw 1 2 13 x 2 1 2 Hex Head Cap Spacer 3 8 Round Brass Plate Cover Motor Cutout Push Rod Pipe Nipple Bushing Worm Gear Screw 2700 287485 2705 2710 2720 2740 2745 2805 2810 2815 2820 2825 4725920 451611 2401 4050101 4725920 451611 2401 180861 146723 296122 074805 302256 is SM 9662 Rev 1 October 2009 gt Z AnsaldoSTS Parts Lists 285 Rod 64_______ Hand Crank 2920 Nut 3 87 16 UNC Screw 5 16 x 1 2 Hex Rd Screw 1 2 20 x 1 2 Cup Point Set Screw 1 2 13 x 1 5 Flat Head Screw 3 8 16 x 1 1 4 Hex Head Screw 1 4 20 x 1 5 Socket Head Cap Washer 1 4 SST Lock SM 9662 Rev 1 October
31. 5 2 and 5 5 5 3 SM 9662 Rev 1 October 2009 5 15 y Shop Maintenance Z AnsaldoSTS 5 5 5 1 Felt Washer and Oil Seal in Clutch Housing Replacement See Figure 5 5 Measure the length of clutch spring before disassembling and record this dimension as information for reassembling Swing terminal board out of the way remove the adjusting nut and clutch spring and slide the clutch housing off the shaft Remove the discs and plates and take out the small lock screw using the special tool ASTS USA No N173641 to remove the packing gland nut Remove the old packing and clean the shaft and the inside of the clutch housing by washing with a non flammable grease solvent Apply a new felt washer 7047335 and oil seal 77900260003 to the housing recess and assemble the packing gland nut Using the spanner end of the special wrench pull down nut only until it is flush with the bottom of the clutch housing Then the locking screw should be inserted and drawn down securely Coat rubbing surfaces of packing rings with gearbox lubricant Assemble housing to the shaft Clean lubricant from shaft surface inside the clutch space Old fabric discs should be discarded and replaced Old clutch plates should be thoroughly cleaned in a non flammable grease solvent to remove any accumulation of lubricant and then reassembled as shown in Figure 5 5 Note that a fabric disc goes in the bottom of the housing and the first metallic disc 15 one with teeth e
32. Gear Box M 23B 528 1 Screw 1 2 13 x 2 1 2 Hex Head Machine Screw 12 28 x 1 1 8 Rd Hd S Plated Screw 5 16 18 x 1 3 4 Hex Head Steel Cap SM 9662 Rev 1 October 2009 7 15 Sy Parts Lists 2 AnsaldoSTS Assembly Circuit Controller ECC wo Aux wo L R M 23A Sufixes 09 21 22 29 30 N426007 03 3005 M 23B Suffixes 19 22 Assembly Circuit Controller M 23 ECC w Aux wo L R M 23A Suffixes 01 08 11 14 17 20 27 28 31 32 M 23B Suffixes 01 02 07 10 Screw 1 4 20 x 3 4 Socket Head Screw 1 2 13 x 1 5 Flat Head Screw 3 8 16 x 1 1 4 Hex Head Washer 3 8 Steel Lock Extra Spring Pin 3 16 x 1 5 7 16 SM 9662 Rev 1 October 2009 77 AnsaldoSTS Parts Lists Cord Grip 1 2 Male Motor Control Unit High Voltage 110V M 23A Suffixes 01 06 09 11 12 17 22 29 30 M 23B Suffixes 01 02 09 10 20 22 Motor control Unit Low Voltage 24V Ser Cable Clamp 5 8 x 3 4 0 406 Mounting Hole Screw 10 32 x 9 16 Fillister Head Heater For Motor Compartment Not Shown 30W 115 230V Wired for 115V 15W 115 230V Wired for 115V 5 473048 01 SM 9662 Rev 1 October 2009 7 17 AnsaldoSTS aV Parts Lists GZEZ 0 12 0982 me 0982 Q3in038H LON 1 M201 N3HA OEVZ 092 0292 1 1 NOLL23S 0 66 6905 0782 97 2 09 EN Cl 00 Sete
33. NL Ground Terminal L EE I 13 Ooo G 0 JP p m 12 Ls E Motor 8 WARNING o 9 O Reverse Input Maintenance Bi Polar Terminals HV N49703902 Auxiliary Sensor 1 O Normal Output 21 and 23 are Non Vital and should LV N49703901 never be used to clear signals O ES EE JL LI L Point Sensor 1 Ground Terminal O Normal Output Point Sensor 2 Auxiliary Sensor 2 O Reverse Output IVNOIS HOLIMS B B E ICE i terminal 5N CONNECT TO GROUND ROD IF MACHINE IS INSTALLED IN Reverse Output ELECTRIFIED TERRITORY au Hoe sese O Bi Polar Normal AN FOR TOP LEVEL ASSEMBY MACHINES N429XXXXX DERAIL STYLE View A Proximity Sensor Layout amp Identification THE POINT SENSORS 51 AND PS2 STILL CONNECTED THE JUNCTION BOX IN THE SAME PLACES THE SENSORS Bi Polar Normal THEMSELVES ARE PHYSICALLY SWAPPED op View Tape lead to harness only for 115V source for field applications with 115V source disconnect 7 for 230V SEE VIEW A FOR LOCATION AND IDENTIFICATION OF SENSORS CONNECTIONS AS SHOWN TO WAGO TERMINALS 29 amp 30 ARE n nn his rminal 7 JUMPERS BE PLACED PER DESIRED APPLICATION CORRECT WITH 18
34. Optional 2 18 Initial Point Detector Bar 2 19 LOCK BOX SensolS 2 22 Standard Lever Interlock Assemblies M 23 2 25 Wiring Changes from Three or Five Wire to Two Wire 2 27 Friction Clutch nnn nnn nnn 2 28 sectional View of M23 Gearbox From Motor End Right Hand Assembly Shown 2 28 Sectional VIEW awu saa 2 29 M 23 Dual Control Mechanism Sectional Views 2 33 Diagram of Switch Operating Mechanism 3 2 Diagram of Driving Parts Sheet 1 of 2 3 3 Diaoram of Driving Parts Sheet 2 0f 2 aa 3 4 Adjustable Lock Rods for RH LH Operation 3 5 Sectional View of M 23A 3 7 Sectional View of M 23A Gearbox Looking from Motor End 3 8 Motor Cutout nennen nnn nessun nnn nnns nnns 3 9 Sectional Views of M 23 Dual Control
35. UNS RENI 1 6 1 4 Abbreviations Acronyms and Definitions nennen 1 7 129 UD Sos aaa 1 9 2 INSTALLATION AND ADJUSTMENTS J J 2 1 2 NE General a ha cote 2 1 2 NE 2 1 2 3 Switch Rod Installation and 2 1 2 4 Lock Rod Installation and a 2 6 2 5 Junction Box Jumper 8 nnns nnns 2 6 25 1 REIPG JUI DOES Quya L ya aya 2 6 2252 Eie OUI MINE m DEM 2 6 2 5 3 Changing the Jumper Configuration nnne 2 6 2 6 Power and Indication Input nnns 2 7 2 5 1 Single Machine 2 7 2 5 2 M llipleMachile u uy uhu 2 7 2 7 Wiring and Motor Control 2 13 2 Ae WAGO Terminal GOMMECIONS uu E de oed ate u e eate u a 2 13 2 7 2 WOON COMM u uz uy i tudo dm et ease 2 15 2 9 AREMA Terminal Post COnFneCllOFis Z 2 16 2 9 Sensor Identification and Termination in the Junctio
36. Where drain plugs are used a moisture check should be made prior to anticipated freezing weather A freeze up of excessive moisture could result in improper switch machine operation 6 Reinstall plugs in drain holes NOTE These pipe plugs should have been installed initially only if the switch machine is in a location where blowing sand or dust is troublesome otherwise drain holes should be open During cold weather periodically check that the holes are open 7 Check that motor control contacts indication contacts motor cutout contacts and associated cams and linkages are clean and do not show excessive wear refer to Section 4 2 8 Check that all switch machine parts are properly and adequately lubricated refer to Section 5 6 9 Check that conduit between switch machine motor compartment and junction box 1 not crimped nicked cut or otherwise damaged 10 Remove two screws securing access plate over motor commutator Not possible on all motors a Check that commutator is smooth and clean b Check that commutator brushes are free in their holders and are not excessively worn 4 2 Lubrication After the switch machine has been inspected and cleaned it must be lubricated to ensure optimum operation Refer to Section 5 6 4 3 Switch Machine Performance Test Conduct a performance test on the switch layout s The performance test should be done in accordance with customer s operating rules The te
37. and M 23 Motor End Parts 7 11 Figure 7 4 M 23 Switch Machine Parts Location 7 18 Figure 7 5 NES Gear BOX Paris u uu Den um qa oe 7 21 Figure 7 6 Gear Box Paris oec u u u u a 7 25 Figure 7 7 Motor Blue Assembly N451161 17xx Parts 7 27 Figure 7 8 Motor Black Assembly 422008 Parts Location 7 29 Figure 7 9 Circuit Controller Assembly Parts Location 7 31 Figure 7 10 Point Detector Sensor N426006 xx Parts Location 7 33 Figure 7 11 Local Remote Switch Assembly Parts Location 7 35 SM 9662 Rev 1 October 2009 Vil Table of Contents Table 1 1 Table 1 2 Table 1 4 Table 1 5 Table 1 6 Table 3 1 Table 4 1 Table 4 2 Table 5 1 Table 5 2 Table 6 1 Table 6 2 Table 7 1 Table 7 2 Table 7 3 Table 7 4 Table 7 5 Table 7 6 Table 7 7 Table 7 8 Table 7 9 Table 7 10 Table 7 11 Table 7 12 viii 77 AnsaldoSTS List of Tables ECC Diagrostc IndiCalOfS ee hn OU 1 5 Switch Machine Physical Characteristics
38. and assuming no restraining friction between the teeth at the bottom the selector clutch assembly will shift upward without deflection of the spring At times however there may be a torque load on the lower teeth when the selector lever is operated for example if the switch is stalled on an obstruction and this may cause sufficient friction to hold the clutch down while the yoke is lifted This compresses the spring as the lower spring cup is lifted by the lower rollers on the yoke until the top of the lower spring cup engages the bottom of the upper spring cup Further operation of the selector lever provides a positive drive to pull the lower teeth apart far enough that the chamfered corners of the teeth are in engagement instead of the nearly vertical working faces At this point the single tooth at the top of the clutch assembly is raised sufficiently to start engaging the hand throw pinion and will be moved into engagement with it by the spring force and any upward thrust due to the torque load on the lower teeth provided of course the two upper teeth are aligned to permit such engagement If these upper teeth are not aligned the spring will hold the clutch for hand operation against the hand throw pinion tooth until the hand throw lever is operated to obtain alignment The spring functions In a similar manner if the worm gear teeth are not aligned when the selector lever 15 returned to the motor position 3 12 SM 9662 Rev 1 October
39. and washers that secure the lever shaft bearing M to the gearbox Grasp the hand throw bevel gear and remove the shaft assembly from the gearbox case The shaft will pull free of the bevel gear as it 1s pulled from the gearbox case Be sure that the bevel gear does not fall into the case as the shaft 15 removed SM 9662 Rev 1 October 2009 N AnsaldoSTS Installation and Adjustments NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating surfaces it may be reused 2 16 2 2 Reassembly 1 The lever assembly is to be installed on the opposite side of the gearbox case after the yoke support has been removed 2 Place the bevel gear inside the gearbox case on the side where the lever shaft will be installed 3 Insert the lever shaft into the opening on the gearbox case As the shaft enters the case position the bevel gear so that the shaft slides through the center of the bevel gear and that the keyways match It may be necessary to lift the yoke a bit to facilitate the eccentric pin P on the lever shaft assembly entering the slot on the end of the yoke NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating sur
40. as labeled TB1 TB2 and JB1 5 5 7 Lever Interlock Assembly The sectional views In Figure 2 10 illustrate the lever interlock assembly It contains recesses in both lever hubs and a steel ball carried in a hole in the lever support In reassembling BE CAREFUL NOT TO LOSE THE BALL when the lever is taken off As can be seen in the diagrams the diameter of the ball is greater than the thickness of the wall of the lever support Thus with the selector lever in the MOTOR position as shown part of the ball is held in the recess of the hand throw lever and thereby prevents operation of the hand throw lever Reversing the selector lever aligns the ball recess in its hub to permit the ball to shift out of the recess in the hand throw lever hub thereby releasing the hand throw lever 5 18 SM 9662 Rev 1 October 2009 While the hand throw lever is at any position between the ends of its stroke the ball is held in the recess in the selector lever hub and thereby locks the selector lever The hand throw lever hub has two ball recesses 180 apart so that at either end of the lever stroke one of the recesses will be aligned with the ball to unlock the selector lever If it is desired to make it compulsory that the hand throw lever be in the Normal position before allowing the selector lever to be operated one of the ball recesses In the hand throw lever must be plugged by the use of stop screw ASTS USA M287186 as indicated in Figure
41. coat of gear lubricant Lubriplate 5555 from the container shipped with the switch machine to the teeth of the spur gear only Put the remainder of the lubricant into the worm gear compartment to a level no higher than the top of the worm gear See the lubrication diagrams in Figure 5 6 and Figure 5 7 All other working parts of the machine have been sufficiently lubricated at the factory and do not require additional lubrication at this point NOTE When applying lubricant it is not necessary to remove oil slushing compound with which parts are factory coated to protection against corrosion during shipment and storage The pins holding the lock rod control rod point detector control rod and operating rod should also be lubricated at this time 2 14 Lever Position and Interlock In general the position of the selector and hand throw levers will be as shown in Figure 2 10 and the interlock will ordinarily permit the selector lever to be returned to MOTOR when the hand throw lever 1s In either Normal or Reverse However certain deviations from these usual standards are feasible The various arrangements are as follows 1 Both levers must always be on the field side of the machine that 1s on the left side for LH machine for LH layout and on the right side for RH machine for RH layout To change between RH and LH refer to paragraph 5 5 2 2 The hand throw lever will always move the switch in the direction to close the near point
42. ee rr a ____ 5 m Ij A AE 2 4 TT a c El Od I NN 23130 N O SS ASS Fg NN ANA YOA KK A W WWWYWWWYwwwwww om P aN S Sr ere ay A GGLC Via 0912 9982 0982 GayINDaY LON SI A YOLISLIG LNIOd N3HM Joozz 9212 0806 6707 NOLL23S 6 8 S Hem JA WE 0 8 0882 m 0906 0102 9062 MOMHL 5962 l aczz A A NOILO3S Ga 02 5282 OF 0986 00 0555 0 82 0212 fo d d 9182 Se EN TA M 9982 SEZ GZZZ 0902 5982 9692 4 gt 26 304 9956 XlgGW3SSV X201 YMN o n hj l 9622 GEZZ 9586 7 7 NOILO3S S062 00 2 0962 0652 0062 s aq 6 05 0582 0912 GLEZ Figure 7 4 M 23 Switch Machine Parts Location SM 9662 Rev 1 October 2009 7 18 7 AnsaldoSTS Parts Lists 7 4 Gear Box Parts List Table 7 6 contains the parts list for the N287485 M 3 gear box listed in Table 7 1 See Figure 7 5 for a location diagrams showing the listed parts Table 7 6 M 3 Gear Box Parts List Gear Box Complete Includes Bushings and Oil Seals N287085 002 60 Washer 92 Plate 0 0966 x 48 x 120 Steel ____80 Gear
43. is shown by Figure 3 2C Roller 4 on the main crank acting in the groove has moved the switch operating bar to the reverse position and secured it against back thrust lug 2 has come into contact with roller 2 during the last 40 degrees of rotation of the main crank thus driving the slide bar to its full reverse position The lock box rests on and is operated from an extension of the slide bar as shown in Figure 3 2 During the first 40 degrees of rotation of the main crank the motion of the slide bar withdraws the lower locking dog of the lock box from the lower notch of the lock rod thus unlocking the switch points The following 140 degrees of rotation of the crank operates the switch and the lock rod stops with its upper notch aligned to receive the upper locking dog of the lock box The final 40 degrees of rotation of the crank completes the stroke of the slide bar driving the upper locking dog into the lock rod notch to lock the switch points in the reverse position SM 9662 Rev 1 October 2009 3 1 N Operation 77 AnsaldoSTS A E ROLLER 3 TE YT ROLLER 2 ROLLER 1 ROLLER 4 SWITCH OPERATING BAR Figure 3 1 Diagram of Switch Operating Mechanism 3 2 SM 9662 Rev 1 October 2009 EN 77 AnsaldoSTS Operation MOTOR END ROLLER 3 SLIDE BAR ROLLER 2 ROLLER 1 LOCK RODS WIDE NOTCH UPPER LOCK lt gt gt
44. it by tightening bolt G firmly Check that the machine can be operated by power and also that it shifts to hand throw operation from both Normal and Reverse positions Check that all bolts are drawn down tightly on their lock washers and that all cotter pins are place 19 Reinstall the gearbox cover and secure it to the gearbox with the two 5 8 inch bolts removed during disassembly 2 16 2 Lever Assembly For removal and insertion of the lever assembly ASTS USA recommends that two persons perform the procedure one to insert the lever assembly and one to hold and guide the hand throw bevel gear onto the lever assembly shaft If only one person 1s available ASTS USA recommends dismantling the lever assembly to move it to the other side of the gearbox 2 16 2 1 Disassembly l 2 34 Remove the 7 8 1nch hex nut lock washer and flat washers from the end of the selector lever shaft and slide the selector lever from the shaft Be careful not to lose the steel ball in the lever support Lift the hand throw lever to the vertical position and loosen the set screw F1 on the hand throw bevel gear F Remove the hand throw lever from the lever shaft Remove the two 1 2 inch bolts A3 and lock washers that secure the lever support K to the gearbox and slide the lever support from the shaft It may be necessary to lift up on the yoke N to free the eccentric pin P on the selector shaft Remove the two 1 2 inch bolts A4
45. latched padlock hasp There should be about 1 16 inch free play between the edge of the staple notch and the front of the hasp then a solid connection should be felt SM 9662 Rev 1 October 2009 5 2 AnsaldoSTS GEAR BOX CIRCUIT CONTROLLER COMPARTMENT Z I K J GEAR BOX G WHEN USED NORMAL RELEASE LEVER Murmber Description Push Rod 2 Sewa ____ TO BE pen Shop Maintenance dac gt L F D CRANK COVER COVER PUSH ROD PAD LOCK STAPLE jloknt Figure 5 8 Adjustment of Motor Cutout Contacts M 3 Machine SM 9662 Rev 1 October 2009 5 25 q Shop Maintenance Z AnsaldoSTS i If necessary repeat Steps c through h to adjust the free play to about 1 16 inch then tighten the pushrod locknut O Reinstall the gearbox cover using the bolts removed Step c Latch the padlock hasp onto the padlock staple Ensure that the hasp is fully seated in the staple notch 6 Repeat Steps 2 through 5 as necessary until satisfactory adjustment is obtained 7 Reinstall the circuit controller cover using the hardware removed in Step 1 8 If required restore power to the machine 5 7 2 M 23 Switch Machine Motor Cutout Contacts Motor cutout contact for the Styles M 23A and M 2
46. mounting plate slide the sensor holding bracket toward the target until the LED for Point Detected Normal just turns green on the ECC This 1 the starting point for the Vital Sensor 18 mm Slide the sensor holding bracket two more serrations into the target corresponding to the 1 8 point movement differential each serration is 1 16 inch on center and hand tighten to prevent movement Slide the auxiliary sensor toward the target until the LED for Auxiliary Point Detected just turns green After ensuring a gap of 0 040 inch between the target and sensor face secure the hardware for the sensor Tightness of the feeler gauge between the sensor head and the target 1 not critical For the Reserve position operating bar out based on RH or LH configuration repeat Steps through 5 above This time look at the LEDs that correspond to the Reverse Position on the ECC Lock Box Sensor Adjustment The lock box sensors see Figure 2 9 thread into a holder that bolts to the controller frame To access to the lock sensors the ECC must be removed from the frame l 2 2 20 Remove logic control power from the switch machine Remove the ECC from the controller frame refer to paragraph 5 4 4 Move the switch machine to either full stroke position Normal or Reverse it is not critical Ensure that the switch point 1s closed and up against the stock rail One of the lock box sensors will be aligned with its target on the lock box L
47. normal position If the switch is released before the stroke is complete the motor will coast to a Stop CAUTION The LOCAL REQUEST overrides the dispatcher s control of the machine Return the L R switch to the Remote position at completion of maintenance 2 14 SM 9662 Rev 1 October 2009 N AnsaldoSTS Installation and Adjustments 8 Terminals 32 33 are the termination points for the motor cutout circuits An open connection between these two terminals puts the ECC into motor disable which in turn disables the motor controller Note that WAGO connections at 32 amp 33 are blue and unlike other WAGO terminals on block are isolated from one side to the other This allows for alternate wiring options if external monitoring of the motor cutout contacts is desired 9 Terminals 34 and 36 are motor controller specific For MCU machines they are a solid state relay for external monitoring of the motor controller disable status For EBNC machines they are the bipolar logic switch control inputs 2 7 2 Motor Controllers Two types of motor controller be installed Each type is available in high or low voltage versions The MCU does not have an integral overload function the EBNC does 2 7 2 1 MCU Terminals 29 30 and 31 are ON MOTOR FRONT and ON MOTOR REAR signals from the ECC they are used to turn off motor current at the end of the stroke For example if the motor is turning to produce motio
48. on the motor shaft clears the drive opening in the gear box case See Figure 7 7 or Figure 7 8 To remove the motor 10 from the frame 5 loosen the set screw 40 and gently pull the pinion gear 30 and key 35 from the motor shaft Remove four 3 8 inch socket head screws 25 and lock washers 70 then remove the motor from motor frame 5 4 3 Friction Clutch Assembly Removal See Figure 5 1 Remove the cotter key 11 from the clutch adjusting nut 10 or 10A then remove the adjusting nut from the worm shaft 12 Remove the clutch spring 9 Remove the two cap screws 13 securing plate to the gear box case then remove the plate and gasket 1 Disengage the clutch housing tubular neck 7 from the worm gear hub Continue pulling until the tubular neck clears the opening in gear box case exposing worm shaft 5 4 4 Circuit Controller Removal See Figure 7 2 The Electronic Circuit Controller is a self contained and sealed unit The unit 15 secured by three socket head cap screws To remove the ECC disconnect the three cables from the front point detector end of the unit at TB2 and JB1 Remove the cap screw at the center front of the unit and the cap screw at each rear corner junction box end Lift the ECC out of the compartment 5 2 SM 9662 Rev 1 October 2009 c we 4 AnsaldoSTS Shop Maintenance M245192 147400 1047335 6 Clutch Disk 8 Clutch End Plate 65
49. pin 7 8 inch nut washer and bolt removed in Step 2 5 Install the operating bar covers on the sides of the switch machine One of the covers is designed to fit over the operating bar lug and can only be installed over the lug Secure the covers with the 1 2 inch bolts and washers removed Step 1 2 16 4 Selector Clutch Adjustment The selector clutch adjustment should be checked annually When the selector lever is in the Motor position and the selector clutch teeth are in full engagement with the teeth on top of the worm gear so the motor drives the crank the top rollers on the operating yoke should be just clear of the upper spring cup This relation can be varied by adjusting the eccentric bushings G1 As shown in Figure 2 13 and Figure 2 14 the selector clutch yoke has one end supported on and driven by the finger on the selector lever shaft and its other end pivots on the eccentric bushings that are fixed by G When this bolt is loosened the eccentric bushings may be rotated to raise or lower the center line for the pivot holes in the yoke arms affecting the elevation of the yoke rollers The eccentric bushings have hexagonal heads one flat is stenciled N and the flats on either side of the N flat are marked and The N will be on top when the eccentric bearing 1s in its mean position When the eccentric bushings are turned to bring the mark up the yoke and its rollers lift Alternately when the mark
50. position Be sure that bevel pinion remains in line With selector lever in MOTOR position rotate friction clutch housing so that motor clutch teeth are fully engaged Reapply top bearing assembly and secure with hold down bolts Al Motor cutout push rod should be held back to clear the adjusting rod until top bearing 15 down Apply top bearing bushing C2 rectangular key washer B2 and tighten castle nut firmly then back off to nearest cotter hole and apply cotter after operating machine by hand throw lever to be sure that mechanism does not bind Check adjustment of motor cutout push rod Contacts should open when end of selector lever has been raised about 6 from the horizontal motor position SM 9662 Rev 1 October 2009 9 Readjust both yoke eccentric bushings as described in Section 5 7 3 then secure by tightening bolt G firmly 10 Check that machine can be operated by power and also that it shifts to hand throw operation from both normal and reverse positions 11 Check that all bolts are drawn down tightly on lock washers and that all cotters are in place 12 Reinstall covers 5 5 3 Motor Brush Reinstallation See Figure 7 7 or Figure 7 8 Before installing the motor brushes check that the motor commutator is smooth and free from grease and oil To dress the commutator use a fine grain commutator stone or a piece of No 00 sandpaper Never use emery cloth for cleaning the commutator or brus
51. properly red WAGO 3 to TB2 3 and iton the EC a green WAGO 1 61827 continuous vertical row of GREEN LEDS is observed yet no indication B ECC may be bad Replace ECC output is present on WAGO terminal strip 1 amp 3 A Verify proper sensor air gap adjustment Gap should be 0 075 for vital sensors large diameter and 0 040 for auxiliary Sensor indication sensors small diameter 2 B Temporarily plug replacement If replacement sensor operates 9 sensor in junction box and correctly replace sensor when target is more 2 monitor operation using ECC than 50 in front of LED indications If replacement sensor does not operate sensor face correctly go to C C Junction box may have bad If replacement junction box does not connection correct problem go to D D ECC may be bad Replace ECC If YES go to n indinat If NO verify corresponding indication Is the corresponding indication g input LED GREEN input at WAGO 13 and 15 or WAGO 10 12 Verify TB2 harness Point Detected Point Locked Is the unit in latch out Indicated LEDs are GREEN by RED latch out LED on front of ECC for at least one second but indication If NO go to C output LED is 15 motor disabled by ECC If YES correct motor disable condition dark Indicated by RED motor disabled reference section 1B of this chart If sensor adjustment does not correct problem go to B
52. the friction clutch by hand until the bottom end is cross wise to the machine 3 Unscrew the nut at the top of the main crank shaft and allow the crank to drop out through the bottom of the machine Removing the main crank will also release the worm gear and the slide bar 5 4 7 Main Crank Replacement M 23 Machines These procedures cover replacement of a broken main crank without complete disassembly of the gear box It is intended primarily for use in the field but can be used the shop with modifications to reflect that the machine 1s not installed in a layout NOTE It is strongly recommended that both the crank removal and crank installation procedures be reviewed before proceeding It is CRITICAL that some data be recorded at specific times during disassembly to ensure that the machine is reassembled correctly 5 4 SM 9662 Rev 1 October 2009 y gt 27 AnsaldoSTS_ Shp Maintenance NOTE A minimum clearance of 14 inches is required underneath the center of the switch machine to allow removing or installing the crank through the bottom of the gear box 5 4 7 1 Main Crank Removal If performed in the field obtain permission from the cognizant authority before beginning See Figure 7 6 for the location of items called out by number 1 Remove power from the machine Ensure that there is no possibility that the motor can be energized from any source 2 Place Motor Hand selector lever fully to
53. when the lever is operated toward the motor end of the machine This characteristic cannot be changed 3 For the standard arrangement the selector lever will be assembled to be toward the motor end of the machine when the lever is in its MOTOR position as shown in Figure 2 10 When desired however the lever can readily be assembled to be toward the circuit controller end of the machine for MOTOR position and the interlock arranged to suit as described under Assembly The cast MOTOR and HAND marker plates on the selector lever are interchangeable 2 24 SM 9662 Rev 1 October 2009 77 AnsaldoSTS 6A2 0025 00 INTERLOCK ASSEMBLY DIAGRAM A L H LAYOUT L H POINT NORMALLY CLOSED LEVER INTERLOCK ASSEMBLY STOP SCREW WHEN USED DIAGRAM C L H LAYOUT L H POINT NORMALLY OPEN Installation and Adjustments LEVER INTERLOCK ASSEMBLY STOP SCREW WHEN USED DIAGRAM R H LAYOUT R H POINT NORMALLY CLOSED LEVER INTERLOCK ASSEMBLY IN EA 7 NY STOP SCREW WHEN USED DIAGRAM D LAYOUT R H POINT NORMALLY OPEN Figure 2 10 Standard Lever Interlock Assemblies M 23 SM 9662 Rev 1 October 2009 2 25 Sy Installation and Adjustments AnsaldoSTS 4 The lever interlock can be arranged to either 1 allow the selector lever to be returned to MOTOR position when the hand throw lever is In the Normal or the Reverse position or 2 require t
54. 08 xx Parts 51 7 28 Circuit Controller Assembly Parts List 7 30 Font Detector Sensor LS assets uu k u u uad es 7 32 Local Remote Switch Assembly Parts List 7 34 SM 9662 Rev 1 October 2009 I7 AnsaldoSTS General Information 1 GENERAL INFORMATION 1 1 Introduction This service manual covers the M 3 and M 23 switch machines using a permanent magnet motor an Electronic Circuit Controller ECC and either a Motor Control Unit MCU or Electronic Biased Neutral Controller EBNC The EBNC includes a motor overload protection function the MCU does not protection is provided by wayside control equipment Existing installations using five or three wire control must be converted to two wire control when installing an ECC with either MCU or EBNC machine Refer to Section 4 of this manual for details on how to convert the control wiring The EBNC is used with the ECC to enable direct control of an M Style switch machine using a bipolar output of a vital logic controller such as the Microlok system or an Object Controller In an EBNC machine the motor power is fed from a fixed polarity source direction determined by the EBNC In a MCU machine the motor power 1 fed from a bipolar source direction d
55. 1 up the yoke and its rollers lower To avoid twisting the yoke these marks should be kept turned to a like degree or Tightening bolt G holds the adjustment of the eccentric bearings When it is necessary to adjust the eccentric bushings check that the top rollers are free from the bearing on the upper spring cup while the selector clutch is fully down and in addition check that the rollers are not too high as follows 1 Place the selector lever in the Motor position when the worm gear 1 not in position to receive the selector clutch so that the teeth of Clutch for Motor Operation Figure 2 15 ride on top of the corresponding teeth of the worm gear 2 36 SM 9662 Rev 1 October 2009 N AnsaldoSTS Installation and Adjustments 2 Insert a 1 8 inch length of a 14 soft copper wire between the opposed teeth The eccentric bushings should be adjusted the same degree or so that with the bolt tight the force between the opposed teeth will crush the wire to not more than 1 32 inch thick when the selector lever 1s thrown to the horizontal position for motor operation 3 Check that the upper rollers are free to turn when the selector clutch is fully engaged with the worm gear 2 16 5 Jumper Configuration Changeover When the switch machine is converted from right to left hand operation the red RHPC LHPC jumper has to be inserted in the proper location in the junction box Refer to Section 2 5 3 for
56. 2 10 When used the stop screw must be applied to a particular recess in the hand throw lever hub as follows With the hand throw lever in the Normal position the stop screw must be in the recess on the side of the shaft opposite to the side the selector lever is on when In its MOTOR position see Figure 2 10 The lever support can be assembled with the hole for the ball on either side of the lever shaft center However it must be assembled so that the hole for the ball 1 on the same side of the shaft as the selector lever 1s in for MOTOR position see Figure 2 10 The selector lever can be assembled on the square end of its shaft In either of two positions 180 degrees apart so as to have the MOTOR position of the lever either toward the motor compartment or toward the circuit controller compartment Machines are shipped from the factory with the selector lever assembled for MOTOR position toward the motor compartment If the lever assembly 1 reversed in the field the transfer must be made while the crank finger on the end of the shaft is at the bottom of its stroke to force the selector clutch down toward its motor position Be sure to reassemble the lever support to shift the hole for the ball to meet the requirements in the preceding paragraph Similarly if a stop screw 15 applied to one of the ball recesses in the hand throw lever hub as previously described it must be shifted so as to be on the side of the shaft opposite to that for MO
57. 2009 7 N Sy Parts Lists 2 AnsaldoSTS ITEM DESCRIPTION PART NUMBER Washer 1 2 SST Lock Cord 1 2 Male Cable 5 8 x 3 4 0 406 Mounting Hole 8240 NotUsd 14 0 O 3242 NotUsed 14 025 Heater for Motor Compartment Not Shown 15W 115 230V Wired for 115V 7 8 SM 9662 Rev 1 October 2009 A l o ape 6145 0702 0062 0565 0922 9980 1982 6 282 9022 _ 8982 1 5272 Geez 0012 ZZ TAS 1 SS Xem 22224222272 E 2 22 SI YOL mA j N 23130 LNIOd N3HM Sp X X NOILDIS amp SN lez XK RF veu S 0902 992 0562 9 82 ND A Pp p 692 n ae s 0682 LON n di ogzz 9082 ins 09 0006 SI 4201 N3HM 0812 oore __ 0912 M M NOILO3S 59 2 2 NOILO3S 9 66 GOZZ GZOE 0962 O 0182 008 0085 0982 1 1 4535 6 06 G67 GOZZ 0 22 0192 us 0782 ae Sive 9702 NO1123S S8 Z QU 0092 0822 98 OS 0612 9602 lt 8 2 T Ozvz Oevz seiz 2222 0952 16 Z
58. 3 2200 M286594 2205 Spring Steel for Lock Movement M181001 2210 Cover Lock Rod 269671 2215 Screw Locking PN242122 2220 Cover Lock Rod M165752 2225 Plate 3 16 x 1 7 Steel M165751 2230 Spring Steel 12 Wire J068431 2235 Point Detector Bar Cover Complete N296126 2240 Point Detector Bar Cover Complete N296125 2245 Nut 2 1 8 Steel Round Lock M223351 2250 Collar 2 Round CF Steel M074741 2255 Nut 1 8 Jam M074742 2260 Operating Crank M071158 2270 M067454 me PN152633 J047286 001 2280 Motor Cutout Trigger N146670 2285 Motor Cutout Pushrod M146675 2290 Nut 5 16 18 UNC 2B Jam J048007 2295 Latch C Brass Cutout M186209 2300 Stud 1 4 Steel Hex M181032 2310 N281552 2340 Plate Cover M296066 2345 Washer W 08 SK Lock J047821 2350 Lube Fitting 1 8 Straight J039137 2355 Lug Bung Cap W 14x J320015 2360 Screw 6 x 1 4 Parker J052607 2365 Screw 1 4 20 x 3 4 Fillister Head J052025 2370 Screw 5 16 x 1 2 Hex Head J050034 2375 Screw 3 8 16 x 1 1 4 Hex Socket J052362 0003 2380 Screw 1 2 13 x 2 Hex Head J050098 2385 Screw 1 2 13 x 3 4 Hex Head J050086 2390 Screw 1 2 13 x 1 Hex Cap J050088 2391 Screw 1 2 13 x 1 1 4 Hex Head Steel Cap J050090 2400 Screw 1 2 13 x 1 1 2 Hex Head J050092 2405 RH Only Screw 1 2 13 x 1 1 2 Socket Head Ca J050236 y 2415 Washer 1 2 Steel Lock J047769 2420 Washer 7 8 Steel Lock Extra J047773 2430 Nut 7 8 9 UNC 2B Heavy J048136 2435 Cotter 1 8 x
59. 30K2 J725707 0674 Switch Toggle SPST 8530 9 J725707 0602 06 ____ ShrinkTubing 6 177424 ____08 ____ Ferrule 20 AWG Grey 216 222 ________________ 709146 1427 7 34 SM 9662 Rev 1 October 2009 5 2 AnsaldoSTS Parts Lists IVOO ALOWSY WIRE 4 1 GREEN YELLOW JUMPER WIRE Figure 7 11 Local Remote Switch Assembly Parts Location SM 9662 Rev 1 October 2009 7 35 Parts Lists AnsaldoSTS e AnsaldoSTS 36 SM 9662 Rev 1 October 2009 N AnsaldoSTS RAIL Team and Technical Support 8 RAIL TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link Team RAIL Team is group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product Contact the RAIL Team in the United States at 1 800 652 7276 or by e mail at railteam ansaldo sts us SM 9662 Rev 1 October 2009 8 1 lt m RAIL Team and Technical Support Z AnsaldoSTS 77 AnsaldoSTS End of Manual 8 2 SM 9662 Rev 1 October 2009
60. 3B should open when the selector lever is lifted six inches out of the MOTOR position measured at the hand grip and open between 1 8 and 3 16 inch when the selector lever is in the HAND position When the selector lever is in MOTOR position the end of the push rod should be 1 16 inch clear of the contact operating bar and the contacts should be closed with between 1 1 2 and 2 pounds pressure A spring bender must be used to adjust the closed pressure when necessary With selector lever in the MOTOR position the rocker arm Figure 3 9 should be screwed up or down as necessary until it just touches the machined cam surface on the selector yoke Then the adjusting rod should be turned so that its eccentric head holds the end of the push rod 1 16 inch clear of the contact operating bar 5 7 3 M 23 Selector Clutch Adjustment Selector clutch adjustment should be checked occasionally When the selector lever In the MOTOR position and the selector clutch teeth fully engaged with the teeth on top of the worm gear so the motor drives the crank the top rollers on the operating yoke should be just clear of the upper spring cup To set this relation adjust the eccentric bushings G1 Figure 3 5 See Figure 3 5 and Figure 3 8 Note that the selector clutch yoke has one end supported on and driven by the finger on the selector lever shaft and its other end pivots on eccentric bushings Cl Figure 3 5 held fixed by through bolt G When this bolt is loos
61. 4 1 19 MACHINE INSPECTION waki 4 2 42 rcd os 4 3 4 3 Switch Machine Performance 4 3 4 4 4 5 Corrective 4 5 u uuu Dc Tr 4 5 4 5 2 Switch Machine to Switch Adjustments 4 6 4 5 3 Motor Cutout Contact Adjustment 4 6 4 5 Proceduro usa 4 6 5 SHOP MAINTENANGE uuu una 5 1 6 2 OOS En 5 1 5 257 5 1 er 5 1 54 WMISASSSIND u uu u umu 5 2 5 4 1 Motor Brush 5 2 5 42 Removal 5 2 5 4 3 Friction Clutch Assembly 5 2 544 CIreulb Controller Removals o o 5 2
62. 5 5 7 Lever Interlock 5 18 SUM BU SETTE TET T rnm TE 5 19 UP 5 23 5 7 1 M 3 Switch Machine Motor Cutout Contacts 5 23 5 7 2 M 23 Switch Machine Motor Cutout Contacts 5 26 5 7 3 M 23 Selector Clutch Adjustment a 5 26 6 aq ah winashun usupa qu ka eai uud 6 1 Te 7 1 Tels COMMOUPATION 2 5 chads nuh SD 7 1 7 2 M 3 Switch Machine Parts 1110 awak Qa 7 4 7 9 NI OS SWiIch Machine Parts uuu uuu uu u n ea eee 7 12 TAL Med Gear BOX IP ans US u uuu a duse ids 7 19 7 5 M 23 Gear LIS ioi eio 7 22 nr e gie mer 7 26 Lle Credit Gohlroller ASSeITDIV u eve aman ems 7 30 7 8 Point Detector Sensor 7 32 7 9 Local Remote Switch Assembly Optional 7 34 8 RAIL TEAM AND TECHNICAL SUPPORT 22 22 222 2222 2 8 1 SM 9662 Rev 1 October 2009 V
63. 7772272777772777774 LOOP OM LED AAA MELE 21220 22 2 D e7 l ar SSS y es 93 85 J 2 OSS SSS wn bio e 4 52 27 lt C py S 4 es mE 55 00 665 Ta Mu aw ee WE c 3 7 SS LW A rM A Q Eur 2 ep K Dove v LE AD Rifi a a eel T S X p ii S m an ens S S i TE 69 ez 6A2 0034 00 Figure 7 6 M 23 Gear Box Parts Location SM 9662 Rev 1 October 2009 7 25 5 Parts Lists 2 AnsaldoSTS 7 6 Motor Assemblies Table 7 8 contains the parts list for the N451161 17xx motor assemblies listed Table 7 1 Table 7 2 and Table 7 3 See Figure 7 7 for a location diagrams showing the listed parts Table 7 9 contains the parts list for the N422008 xx motor assemblies listed in Table 7 2 and Table 7 3 See Figure 7 8 for a location diagrams showing the listed parts Table 7 8 Motor Blue Assembly N451161 17xx Parts List 15 Motor Blue Electric 20 VDC 528 1 Gear Ratio 1520 jJNotUsd 1 00 Gear 1 1 2 Steel Round Key 3 16 Square Steel Snap Ring External Retaining 0303 Motor Only 17 64 x 9 16 Copper J047818 0303 Motor Only Washer 5 16 Lock External Countersink J475143 0001 Washer 3 8 Lock External Countersink J475143 0002
64. 9 1 GEAR RATIOS 360 1 AND 528 1 CONNECT Combine leads BROWN WIRE TO BNC TERMINAL 30 amp WHITE WIRE TO BNC pete eT URS JAN LOCAL REMOTE OPTIONAL MAY NOT BE ON ALL MACHINES TERMINAL 29 to terminal 8 6 ALL DISCRETE 18AWG WIRING TERMINATED IN A WAGO STYLE Connnect lead to CONNECTION USE WAGO FERRULE J7091461419 AND WAGO CRIMP terminala TOOL 206 204 ALL DISCRETE 14 WIRING MOTOR POWER 6A2 0024 01 TERMINATED USING J730044 AND CRIMP TOOL 46387 OR P47387 Figure 2 6 ECC with EBNC Internal Wiring Diagram SM 9662 Rev 1 October 2009 2 11 2 12 N AnsaldoSTS Installation and Adjustments 2 7 Wiring and Motor Control 2 7 1 WAGO Terminal Strip Connections Figure 2 5 with MCU and Figure 2 6 with BNC show the internal wiring diagram of the ECC system WAGO Terminal strip connections are as follows 1 Terminals 2 5 8 11 14 18 22 and 35 are internally connected to the DIN rail and provide the earth ground connection for the 16 gas tube lightning arrestors Terminal 35 also provides the earth ground connection for the switch logic control inputs No other wires Should be terminated to these points 2 Terminals and 3 are for field connections to a two wire bipolar indication output circuit a Normal indication 15 defined as on Terminal 3 and on Terminal 1 b Reverse indication 15 defined on Terminal 3 and on Terminal 1 If there is no output Terminals 1 and 3 are shunted 3 Ter
65. AnsaldoSTS lt N iagram 5 RU UE ion D SM 9662 Rev 1 October 2009 t 4 B lt j HI lt Figure 5 6 M 3 Switch Machine Lubr 00 vvVOO 279 Shop Maintenance 5 20 gt Z AnsaldoSTS Shop Maintenance it m aaa 245 ko 50 gt lt oP he 4 lt gt Pre pd 2 i 2j 2 1 oa n S N 4 ix T SR d a xs 6 2 0043 00 gt p ar E g nr d c Figure 5 7 M 23 Switch Machine Lubrication Diagram SM 9662 Rev 1 October 2009 5 21 Shop Maintenance Z AnsaldoSTS Table 5 2 M 3 and M 23 Switch Machine Lubrication Specifications Type of Point of Lubricant amp Application ASTS USA Spec Known Products Complying With Spec Alemite Solidified Oil Pressure Gun 32 Alemite Temprite Grease Grease Apply until surplus Grease Spec qus 5 is visible at edges M 7650 01 Solidified Oil E P Gun Fittings our Prime Mfg Co Same as above sun Or Surface Grease Spec Paddle M 650 01 OR and rear 9 9 surtace Viscosity at SAE 140 Paddle 210 F 120 200 7 few drops Medium Bod Oil Can periodically as Oil Viscosit Automobile Engine Oil p required 130 F ie 220 S A E 30 Recess Fill reces
66. Box Parts List 15 60 Washer Ma ____80 Clutch Gear Includes Bushing 77 269 9 90 1 820 15 __ 0002 7 22 SM 9662 Rev 1 October 2009 AnsaldoSTS Parts Lists 210 NotUsd 270 _ NotUsd Gear Box Cover Bushing Oilite 285 505 NotUsed 02002 Lube Fitting 1 8 Plate Washer 7 8 S Plated Lock Washer 7 8 Plain S Plated Set Screw 3 8 16 x 1 1 2 Square Cap Screw 1 2 13 x 1 1 4 Hex Plated ocrew 1 4 20 x 3 4 Hex Head SST 385 NotUsd Cap Screw 5 16 18 x 3 4 Hex Plated Lock Washer 5 16 Plain S Plated SM 9662 Rev 1 October 2009 7 23 Sy Parts Lists 2 AnsaldoSTS Plug 1 2 Pipe Jam Nut 1 2 13 UNC 2B Screw 1 2 13 x 2 1 2 Hex Bushing Oilite 1 003 OD Bushing Oilite 1 0025 OD 7 24 SM 9662 Rev 1 October 2009 2 AnsaldoSTS Parts Lists 15 85 19 659 2 1 2 TN 9 pam SZ NES Ns ANS 7 42 eie T NG i 72777 ISSN DM D EM o amit a SS N 7 JUL SX e ES y A OO w Sy EN 12 2 2 ain 2 7 VIEW SHOWING 189 TO 1 GEAR RATIO ASSEM lt NM SE SN TS al rn ZL e 2 02 274277772772
67. E Do NOT move the hand throw lever or slide bar while the crank is removed from the machine The orientation of the gears and slide bar will be disturbed 5 6 SM 9662 Rev 1 October 2009 gt Z AnsaldoSTS Shop Maintenance p hi 227 MAIN KR SLIDE un eh ve ee es LEFT HAND MACHINE VIEWED FROM TOP Figure 5 2 Crank Lobe Slide Bar Rollers Relationship Sketch Left Hand SM 9662 Rev 1 October 2009 5 7 y Shop Maintenance Z AnsaldoSTS MAIN n OPERATING BAR SLIDE BAR RIGHT HAND MACHINE VIEWED FROM TOP Figure 5 3 Crank Lobe Slide Bar Rollers Relationship Sketch Right Hand 5 8 SM 9662 Rev 1 October 2009 5 4 7 2 Crank Installation Do NOT try install the replacement crank unless its machined surfaces are completely clean and smooth There should be no nicks coating or film of any kind 1 Inspect the machined surfaces of the replacement crank If required a solvent may be used to remove any rust inhibitor heavy grease or wax film 2 Apply a light coat of grease to the machined surfaces of the replacement crank 3 Place the operating bar and wearing brackets within easy reach They must be installed into the machine to hold the replacement crank in position NOTE The crank 1s installed in the same orientation for eithe
68. FOR HAND OPERATION ROLLER SELECTOR CLUTCH SPRING UPPER ROLLER SELECTOR LEVER SHAFT UPPER SPRING CUR SELECTOR CLUTCH YOKE LOWER SPRING CUP LOWER ROLLER MAIN 71 E SELECTOR CLUTCH ASSEMBLY COMPRISES PARTS MARKED BEARING CUP UPPER SPRING CUP HAND THROW BEVEL GEAR HAND THROW LEVER SHAFT sees HAND THROW 28950758 HAND 2 BEEN ECCENTRIC BUSHING 7 7 SELECTOR CLUTCH YOKE SELECTOR CLUTCH SPRING LOWER SPRING CUP WORM GEAR MAIN CRANK SHAFT Figure 2 15 M 23 Dual Control Mechanism Sectional Views SM 9662 Rev 1 October 2009 2 33 nl Installation and Adjustments Z AnsaldoSTS 14 Install the top bearing bushing C2 rectangular key and washer B2 on the top of 15 16 17 18 the main crank Tighten castle nut firmly then back it off to the nearest cotter hole and insert a cotter pin after operating the machine manually with the hand throw lever to be sure that the mechanism does not bind Flare the end of the cotter pin per standard installation practice Check the adjustment of the motor cutout push rod Contacts should open when the end of the selector lever has been raised about six inches from the horizontal motor position Readjust both yoke eccentric bushings as described in Section 2 16 4 then secure
69. HOLES FOR HOLES 2 718 PIN 2L TOP VIEW gt 15 316 E UNFINISHED tm LUGS O 1 do 18 250 FINISHED LUGS LEVER 16 718 1E GRRE ion A 1 21 38 SHORT i COVER 1 9 MIN LONG COVER E ose 34 V8 Sy g I Ne Jj N sea 1 4 328 K aa 1 4 LOCK wn YT Y 0 eod md m 21516 ATA 3 edt lt END VIEW awama w rom T ae Bp c eee 6 2 0013 00 Figure 2 4 23 Switch Machine Typical Mounting Plan SM 9662 Rev 1 October 2009 2 5 Sy Installation and Adjustments AnsaldoSTS 2 4 Lock Rod Installation and Adjustment With the covers removed and machine at mid stroke apply the lock rods Be sure that the flat plate snow cover is assembled on the track side where applicable when applying the lock rods be sure the rods are so assembled that the locking dogs in the lock box will enter the narrow notches first In some instances it may be necessary to invert the lock box to suit the rod notches in this case refer to instructions in Section 2 16 6 Preliminary adjustment should be made by setting the nuts so that the narrow notches are approximately centered on the locking dogs at each end of the stroke This requires that the M 23B machine be operated by power or by turnin
70. Hand If required move the hand throw lever fully to Normal If the crank is broken the operating bar may need forced to Normal by prying over the switch points Ensure that the hand throw lever is fully seated in the latch stand and that the internal slide bar is at the end of its stroke 3 Disconnect the switch operating rod at the lug on the switch machine operating bar 4 Remove four 1 2 inch bolts and lock washers securing the gear box bottom cover Remove the cover from the machine 5 Remove four 5 8 inch bolts and washers securing the gear box top cover Remove the cover from the machine 6 Remove the cotter pin 430 castle nut 425 and flat washer 200 from the top of the crank 105 CAUTION Two dowel pins one on each side help position the top bearing cap in the gear box If vertical force is required to remove the cap apply the force evenly on both sides to prevent breaking the pins 7 Remove the four 1 2 inch bolts 350 or 370 and lock washers 445 securing the top bearing cap to the casting The bolts are two different lengths note the length of the bolt removed from each mounting hole for reference during reassembly The brass bushing 155 will come off the crank along with the bearing cap 8 Remove the key 160 from the machined slot in the top of the crank 9 Mark the orientation of the hand throw pinion gear 95 to the timing marks the hand throw gear 100 the orientation must b
71. M 23 Switch machines are assembled at the factory to suit particular layouts when sufficient information 1 provided in the order but can be changed between right hand and left hand in the Conversion of the M 3 is very simple and no detail instructions are required Detail instructions for changing the M 23 dual control machines are given in paragraph 2 16 After the machine has been properly assembled for the layout check the following a Two 3 8 inch pipe plugs are enclosed in bag tied in the motor compartment They are for application to two drain holes located in the cover under the gear box compartment when the machine Is in a location where blowing sand or dust 1s troublesome but should not be applied unless this condition prevails and if used should be removed at intervals to drain the compartment especially prior to freezing weather b Two other drain plugs which consist of slotted head bolts and lock washers are provided in the circuit controller compartment These drain plugs are shipped in place but not fully tightened Like the pipe plugs they should be left applied only at locations where blowing sand or dust is troublesome 2 2 Mounting Mount and secure the switch machine on ties according to the layout plans applying to the particular location Adjust the height of the lever stand so that selector and hand throw levers on M 23 machines are held horizontal and parallel with the top of the gearbox 2 3 S
72. Mechanism 3 11 Motor Cutout Contact Assembly M 23 Machines 3 14 Hand Throw Bevel Pinions M 23 3 14 Heaters for Motor 3 15 5 3 Crank Lobe Slide Bar Rollers Relationship Sketch Left Hand 5 7 Crank Lobe Slide Bar Rollers Relationship Sketch Right Hand 5 8 SM 9662 Rev 1 October 2009 77 AnsaldoSTS Table of Contents Figure 5 4 Crank to Slide Bar Relationship Viewed from Top of Machine 5 10 Figure 5 5 Friction Clutch Assembly and Special Wrench for Packing Gland Nut 5 18 Figure 5 6 M 3 Switch Machine Lubrication Diagram 5 20 Figure 5 7 M 23 Switch Machine Lubrication Diagram 5 21 Figure 5 8 Adjustment of Motor Cutout Contacts Machine 5 25 Figure 7 1 M 3 Switch Machine Parts 7 9 Figure 7 2 M 23 Circuit Controller End Parts Location 7 10 Figure 7 3
73. RETURN SPRING MOTOR CUT OUT CONTACTS at VIEW HAND 6 VIEW HAND THROW BEVEL PINION THROW BEVEL PINION FOR 23 MOVEMENT FOR M 23B MOVEMENT Figure 3 10 Hand Throw Bevel Pinions M 23 Machines 3 14 SM 9662 Rev 1 October 2009 AnsaldoSTS Operation 3 7 Overload Protection EBNC equipped switch machines provide internal overload protection for the motor refer to Table 1 6 for specific values MCU equipped switch machines do not For the MCU equipped switch machines overload protection is provided by wayside equipment such as the ASTS USA Switch Machine Lock SML series relay These relays and the EBNC overload protection function have a variable response time depending on the magnitude of the motor current the higher the current the shorter the response time The standard plug in type relay for the overload protection of DC switch machines is the Style 15050 relay This relay is used conjunction with the style PN 150BM switch control relay and the style PP 151 magnetic stick relay for overload and short circuit protection When ordering an SML series or other overload relay the clutch slippage current or the gear ratio and type of the machine with which it is to be used should be specified The gear ratio is stamped on the switch machine name plate 3 8 Heaters Fifteen 15 watt heaters are available for application in the motor compartment T
74. Sensor indication diameter gap should be 0 040 steady RED and B Temporarily plug replacement If replacement sensor operates does not turn green sensor in junction box and correctly replace sensor when target is more monitor operation using ECC LED than 50 in front of indications If replacement sensor does not operate sensor face Use machine as a target correctly go to C C Junction box may have bad If replacement junction box does not connection correct problem go to D D ECC may be bad Replace ECC f YES go to B Is the corresponding indication If sensor adjustment does not correct problem go to B If NO verify corresponding indication 110 amp 12 Point Detected Verify TB2 harness connection and Point Locked espana ayaka Indicated If YES depress and hold restore button LEDs are GREEN by RED latch out LED on front of ECC for at least one second but indication If NO go to C output LED is Is motor disabled by ECC If YES correct motor disable condition dark Indicated by RED motor disabled reference section 1B of this chart LED f NO go to D 15 point and or locking sensor for If YES correct condition causing opposite switch machine opposing sensor to indicate on ON GREEN NO ECC may be bad Is machine fully locked A latch out condition will occur only if the machine is fully locked and the latch out when switch point moves away from the point detector stock rail
75. Shop Maintenance Z AnsaldoSTS 3 Release the padlock hasp and open the hand crank cover Install the hand crank onto the top of the crankshaft Check that the motor cutout contact s are open by at least 1 8 inch If machine includes latchout function check that the latch G 15 actuated 4 Remove the hand crank 5 If the condition in Step 2 and or 3 is not met adjust the motor cutout linkage as follows a b 5 24 Remove power from the machine Latch the padlock hasp onto the staple Ensure that the hasp is fully seated in the staple notch Measure the exposed length of pushrod A Remove the gear box cover Check the length of spring E The total length including washers should be 5 8 inch Adjust nuts as necessary to obtain this length This ensures that the spring will not act as a stop by becoming fully compressed Depress pushrod A to the distance measured in Step b With the pushrod A in this position the yolk B should be about 1 16 inch from the machined stop surface of the top bearing C If not loosen locknut O and adjust the pushrod A to obtain this clearance This adjustment ensures maximum travel of the linkage Reinstall the gearbox cover using only two of the bolts removed in Step c Latch the padlock hasp onto the padlock staple Ensure that the hasp is fully seated in the machined notch of the staple Check the adjustment of the pushrod A by pressing on the
76. TO MCU TERMINAL 30 amp WHITE WIRE TO MCU TERMINAL 29 Figure 2 5 ECC with MCU Internal Wiring Diagram 2 9 2 10 Z AnsaldoSTS Installation and Adjustments Lock Sensor 1 Point Sensor 1 Lock Sensor 2 Point Sensor 2 Brown Auxiliary Sensor 1 Auxiliary Sensor 2 per Red jum To AAR 5 14 R_AAR 51 m 52 14 i5 AAR 4 Input 18 49 AAR 50 18 BNC Unit Jim N47304901 Low voltage N47304902 High volt 5 0 5 High voltage e_ w E 8N Yellow jumper PAR nd g ume O Se 588 5 er o O Local Request Heater 9 9 285 O Normal Request Frame 6 g e Q Remote Reverse Request To WAGO 88 ace 6 gt Maintenance Bi Polar Normal Ground Stud 6 gt K Ground Terminal 90000 F i ele 9 Ix Maintenance Bi Polar Normal OCIO CGO _ 5 se 6 mam Battery Input 812 afro Hu SS eso 5S 20262 5 gt 92 A c_ Ground Terminal AAR51 52 o o eal er Battery Input N12 MAOT Guten coc gt z Og contacts ref ce 256 S x B mE
77. TOR position of the selector lever 5 6 Lubrication Regular and systematic lubrication Is recommended however the period between times of lubricating depends upon the frequency of operation and upon local climatic and conditions and therefore can be established from experience by the Supervisory Department Before leaving the factory all working parts of the machine except the worm gear compartment are well lubricated Unpainted and unplated parts are coated with a special lubricant designed to protect these parts against corrosion until installation This lubricant need not be removed since it will mix readily when new lubricants are added For best results only lubricants complying with strict specifications are recommended The recommended lubricants can be purchased in convenient quantities from ASTS USA Figure 5 6 and Figure 5 7 identify the areas of the switch machine that need lubrication These points and the proper lubrication are further described in Table 5 2 The following steps present the general lubrication requirements for the switch machines SM 9662 Rev 1 October 2009 5 19 QO ivt Tat 4 HT A UKA E 2 p RP 91 Y lt S iN w TE Lh aa Y ee ee r aaa Z f A r4 s 4 7 4 4 7
78. Used to control fixed polarity motor power input using a bipolar logic input The physical area of the switch machine closest to the motor Federal Railroad Administration A device that 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 be activated if the point sensors are actuated before their corresponding locking sensors are actuated SM 9662 Rev 1 October 2009 1 7 General Information Latch Out Restoration LED Left Hand Switch LHPC PD Point Detection Locking MCU MOV Non Vital Circuit PCB Rear of Machine Reference Designator Right Hand Switch RHPC rms Switch Machine Indication Switch and Lock Movement and or Mainline Switch Machine Vital Circuit 5 77 AnsaldoSTS The term latch out restoration refers to resetting the machine to an operable switch machine indication state from latched out condition Light Emitting Diode The position of a switch machine designated when the machine 1s located on the left hand side of the track looking into the switch points the direction of the arrow as shown in Figure 1 3 Left Hand Point Closed which refers to the switch point position when the point is normally closed to the left hand side looking into the switch points in the direction of the arrow as shown in Figure 1 3 Point Detector or point detection as in PD
79. Y C2 BEARING BUSHING TOP VIEW D PINION 4 A4 X Ji gt F1 SET SCREW G1 YOKE BUSHING H YOKE SUPPORT N C1 5 BIEN 22 A Ay _ YOKE RIGHT SIDE VIEW P PIN EN gt FRICTIONCLUTCH lie z lt galile NE US ES Me s VY Coss Y LE AN ss Nul MENS TMT p P a 3 Se eee E x ____ eA RNA a Figure 2 14 Sectional View of Gearbox NOTE The rectangular key may come out with the top bearing Check under the top bearing to see if the key has been removed and if so place the key in a safe spot for reinstallation SM 9662 Rev 1 October 2009 2 29 5 10 1 nl Installation and Adjustments Z AnsaldoSTS Remove the rectangular key C1 from the top bearing bushing C2 Remove the top bearing bushing hand throw pinion D and spacing collar E from the top end of the crank Lift the hand throw lever to the vertical position and loosen the set screw F1 on the hand throw bevel gear F Remove the two 1 2 inch bolts A3 and lock washers that secure the lever support K to the gearbox Remove the two 1 2 inch bolts A4 and washers that secure the lever shaft bearing M to the gearbox Holding the levers securely and guiding the shafts from the gearbox carefully remove the lever
80. aringly to motor commutator if brushes chatter From the container shipped with the machine apply the gear lubricant Spec M 7652 3 This 1 a low temperature all weather lubricant that has little change In consistency with temperature variations It will retain its lubricating properties at the highest temperatures encountered and not become so stiff at low operating temperatures as to require thinning If sustained unusually low temperatures are expected a special lubricant may be ordered Contact your salesman or the Engineering Department for an ordering reference number Apply a light coat of gear lubricant to spur gear teeth The gear lubricant must be packed well around the worm gear and the selector clutch in the gear box It must be replaced as necessary to keep the worm gear covered CAUTION Lubrication at proper intervals is essential to ensure proper equipment operation Do not permit grease or oil to enter spring end of friction clutch otherwise friction clutch may malfunction Adjustments M 3 Switch Machine Motor Cutout Contacts See Figure 5 8 for a detail view of the motor cutout contact and actuator arrangement l 2 Remove the circuit controller cover With the hand crank cover closed padlock hasp seated in the staple notch check that the plunger end of the pushrod F clears the contact actuator bracket H by 1 16 to 1 8 inch see enlarged view SM 9662 Rev 1 October 2009 5 23 Y
81. artment Both ball bearings are lubricated by the worm gear lubricant A cap on the outside seals the outer side of the double row ball bearing and an oil seal pressed into the opening 15 provided on the spur gear side of the single row ball bearing 3 6 SM 9662 Rev 1 October 2009 4 7 AnsaldoSTS Operation A2 G1 A xo NUL ZZ RN JN pl A u LEGEND SE FOR FIGS 3 5 amp 3 6 2 REDUCTION GEAR A1 BOLT SH UST A2 BOLT 1 REDUCTION GEAR A3 BOLT EE B2 WASHER C BEARING TOP VIEW C1 KEY C2 BEARING BUSHING D PINION A E COLLAR 3 F GEAR E F1 SET SCREW G BOLT SUE G1 YOKE BUSHING E Bo i Zi M BEARING PEE Ke R RIGHT SIDE VIEW N YOKE SS SEXY P PIN urs aS R FRICTION CLUTCH X He 2 SS N 2254 1 S E Gi cuu T CL a lr ER er mE Legend A Tes ue M ee RN RU Z Si 0 Figure 3 5 Sectional View of M 23A Gearbox SM 9662 Rev 1 October 2009 3 7 Operation 77 AnsaldoSTS RIGHT HAND VIEW P B2 Bi C2 C H SS X ERE BOE yw NES 71777 9 2 s Z P Si
82. assembly from the gearbox Hold the hand throw bevel gear so that as the lever shafts are removed the bevel gear doesn t fall onto the bottom of the gearbox CAUTION Removal of the lever assembly requires two persons to perform the procedure one to remove the lever assembly and one to hold the hand throw bevel gear and prevent it from falling into the gearbox as the lever assembly is removed NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating surfaces it may be reused Lift the hand throw bevel gear F from the gearbox Remove the 1 2 inch bolt G nut and two lock washers securing the yoke eccentric bushings G1 to the yoke support H Note the positions of the eccentric bushings and take care to avoid changing their position when removing the bolt Remove the four 1 2 inch bolts and lock washers securing the yoke support H to the gearbox Remove the yoke support NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it is torn it must be replaced If it is intact on one of the two mating surfaces it may be reused SM 9662 Rev 1 October 2009 N AnsaldoSTS Installation and Adjustments 2 16 1 2 Reassembly 1 With the gearbox disassembled grasp the yo
83. bar The positive indication achieved when the switch points are closed adequately against the stock rail Locking is achieved when the lock box connected to the slide bar enters the narrow locking notch of the lock rods and extends a minimum of 1 2 into the locking rod Motor Control Unit a high current solid state device used to control motor power Metal Oxide Varistor protection device for electronic components Any circuit with a function that does not affect the safety of train operation Printed Circuit Board The physical area of the switch machine furthest from the motor An abbreviation assigned to designate an electrical component It generally consists of a capital letter and a number Each letter designates a particular type of component For example L identifies an inductor and R identifies a resistor The position of a switch machine designated when the machine 1 located on the right hand side of the track looking into the switch points In the direction of the arrow shown in Figure 1 3 Right Hand Point Closed which refers to the switch point position when the point 1s 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 3 Root Mean Square method for expressing AC voltage rating A vital determination of a safe switch configuration due to positive Indication that the switch machine has properly thrown lock
84. causing friction sensors indicate locked normal Motor disable will turn both off clutch to slip or reverse If NO may be shorted 6 4 SM 9662 Rev 1 October 2009 gt Z AnsaldoSTS Troubleshooting Symptom Troubleshooting Possible Cause If replacement sensor operates A Temporarily plug replacement correctly reinstall original sensor and sensor into junction box and verify target adjustment Replace monitor operation using ECC sensor if problem persists 3 A single dual qe D If replacement sensor does not operate colored LED is Jek correctly go to B flashing RED B Junction box may contain short If replacement junction box does not or open correct problem go to C C ECC may be bad Replace ECC A Is the configuration jumper If YES go to B properly installed If NO install jumper and verify operation B Junction box may be bad Replace jumper and then junction box Latch out LED is to see if condition is corrected If not flashing RED go to C Replace jumper and then junction box to see if condition is corrected If not go to C C ECC may be bad Replace ECC A Verify jumper installed in LHPC or If jumpers correctly installed go to B RHPC amp jumper installed in only one of the three latch out 2 correctly installed LEDs are flashing configurations RED B Junction box may be bad or not Replace junction box If problem is not full
85. correctly the corresponding LEDs on the ECC will be Flashing 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 2 10 Point Detector and Auxiliary Sensor Adjustment NOTE Auxiliary sensors are optional non vital sensors and are only supplied when required by the customer 2 10 1 Point Detector Sensor Gap The vital and auxiliary non vital point detector sensors Figure 2 7 must be located at a fixed dimension to optimize sensor response and performance The vital sensor gap should be 0 075 inch from the face of the PD target The auxiliary non vital sensor gap should be 0 040 inch from the face of the target The tightness of the feeler gage used to check the gap between the head of the sensors and the target 1 not critical it will not significantly affect sensor performance 2 10 2 Point Detector Sensor Adjustment The vital point detector sensors see Figure 2 7 are mounted on serrated adjusting brackets which can be adjusted in 1 16 inch linear increments Adjust the point detector bar so that the PD target 1s centered or equally balanced in the machine see Figure 2 8 when the points are in the mid stroke position The point detector bar should SM 9662 Rev 1 October 2009 2 17 7 Installation and Adjustments AnsaldoSTS travel equidistant from the center of the con
86. ctor lever is thrown to horizontal position for MOTOR operation the force between the opposed teeth will crush the wire to not more than 1 32 inch thick Also check that upper rollers are free to turn when the selector clutch 1s fully engaged with the worm gear SM 9662 Rev 1 October 2009 5 27 Kx y Shop Maintenance Z AnsaldoSTS 77 AnsaldoSTS 5 28 SM 9662 Rev 1 October 2009 7 AnsaldoSTS Troubleshooting 6 TROUBLESHOOTING Table 6 1 1s a troubleshooting matrix that covers failure modes problems the possible cause s of the problem and the possible solutions to the problem To use the troubleshooting table identify the problem being experienced from the left hand symptom category column The possible causes of the problem are listed in the right column of the table Follow the troubleshooting sequence of each symptom by starting at A under troubleshooting section and working down Table 6 1 ECC Troubleshooting w MCU Symptom Troubleshooting Possible Cause A Motor power present on motor If YES motor may be bad or binding terminals If NO go to B IYES gotoC IYES gotoC to C If NO correct motor cutout open condition ba If YES go to D C Motor disable LED on ECC is lit If NO go E D Check motor cutout circuit If YES to continuity ECC may be bad continuity between WAGO 32 and 1 16 blue and If NO
87. current during this period should be within 1096 of the values specified 1n Table 5 1 in paragraph 5 5 5 3 If necessary readjust the friction clutch spring to obtain the specified clutch slip current refer to paragraph 5 5 5 3 SM 9662 Rev 1 October 2009 2 37 j Installation and Adjustments Z AnsaldoSTS NOTE If the friction clutch slips too easily the motor current may not operate the overload relay and battery exhaustion might follow If the friction clutch adjustment is too tight unnecessary wear on mechanical parts may occur due to absence of shock protection In normal operation without obstruction of the switch points the clutch might slip slightly at both ends of the power stroke 2 38 SM 9662 Rev 1 October 2009 77 AnsaldoSTS Operation 3 OPERATION 3 1 Switch Operating and Locking Mechanism The main crank drives both the switch operating bar and the slide bar The slide bar carries the lock box with its locking dogs which enter notches in the lock rods when the switch points are in proper position Assuming the machine to be at one end of its stroke operation to the opposite end of the stroke involves rotation of the main crank by the motor or by the hand crank M 3 or hand throw lever M 23 As the main crank turns it first shifts the slide bar so as to withdraw the locking dog from the lock rod notch before the switch points start to move then the main crank holds the slide bar in the mid p
88. d lock washers securing the top bearing C One of these bolts will be 3 4 inch longer than the others 4 Remove the cotter pin at the top of the main crank Remove the 1 2 inch castle nut and washer B2 from the top of the main crank Lift the top bearing C from the dowel pins being careful not to bend the bearing plate 2 26 SM 9662 Rev 1 October 2009 gt Z AnsaldoSTS Installation and Adjustments Connect Together 3 Wire PM Motor for 2 wire control FROM M23 with ECC Retrofit N24 R Fo ai onsistent wi ear Ratio and Retrofit of M23 with ECC For 3 Wire to 2 Wire Conversion 5 Wire Wound Field Motor FROM Connect together B24 gt 2 H and return to N24 for 2 Wire Control 3 4 2 5 N24 N O 9 2 T Eliminate for 2 Wire Control 2 2 M23 with ECC Retrofit LO B245 N Observe Polarity Convention R Consistent with Gear Ratio and E Retrofit of M23 with ECC N TO Normal Reverse Motor Cut Out Hand Throw Symbols Motor Cut Off N24 Figure 2 11 Wiring Changes from Three or Five Wire to Two Wire Control SM 9662 Rev 1 October 2009 2 27 A 2 AnsaldoSTS i w Installation and Adjustments ADJUSTING NUT R
89. e kept the same during re assembly Remove the hand throw bevel pinion gear from the top of the crank SM 9662 Rev 1 October 2009 5 5 Shop Maintenance 77 AnsaldoSTS NOTE crank through the bottom of the machine 10 Remove the spacer 170 from the top of the crank Rotate the crank roller stud 195 to align the body of the crank as viewed from below the machine parallel to the operating bar of the machine NOTE It is CRITICAL to note the relationship between the lobe of the crank and the slide bar rollers 2065 at this time Use Figure 5 2 left hand machine or Figure 5 3 right hand machine to sketch this relationship for reference during reassembly WARNING When the wearing brackets for the operating bar are removed the crank may fall out through the bottom of the machine Support the crank while removing the wearing bracket mounting hardware 11 Remove the hardware holding the operating bar wearing brackets to the base of the machine Remove the operating bar roller and crank from the machine NOTE Do NOT try to remove a broken upper portion of the crank through the top of the machine It must be pushed out through the bottom of the machine 12 If the crank is broken the remaining part of the crank may need forced out through the spring loaded clutch assembly 13 If damaged remove and repair the clutch yoke assembly 180 This will ensure easy re assembly with the new crank NOT
90. e left permanently connected Motor polarity 15 controlled entirely by the bi polar input Overload protection based on the product of time and current terminates motoring after 26 seconds at 20 amperes with a low voltage machine and 15 seconds at 13 amperes with a high SM 9662 Rev 1 October 2009 2 15 Sy Installation and Adjustments AnsaldoSTS voltage machine The red LED illuminates on overload Once motoring 1 terminated from an overload it is necessary to change polarity of the bi polar input to regain motor control The bi polar input to the EBNC will operate over a range of 9 to 36 volts The operating current closely replicates the following equation I 34 76 Vjy 153 8 Where 1s the input voltage to the EBNC across terminals 34 amp 36 WR NWR Maximum current is calculated at Vin 9 volts the minimum operating voltage of the EBNC or 0 167 amperes Maximum line resistance based on minimum battery voltage 1s then given by 9 0 0 167 Fora minimum battery voltage of 10 volts maximum line resistance is nearly 6 ohms This equates to 2 376 ft of 14 AWG wire or 1 188 linear ft If two machines are operated in parallel over the same wires 3 ohms would be the maximum wire resistance based on minimum battery voltage of 10 volts If the line wire resistance restrictions are too severe with a nominal 12 volt system the bi polar EBNC driver N34801701 is recommended It deliver
91. e time to transmit this torque the friction clutch should not be so tight as to prevent protection of the mechanism from shock To check the friction clutch adjustment refer to paragraph 5 5 5 3 CAUTION Friction disks must be kept free of oil otherwise motor may be damaged due to excessive clutch slippage If contamination occurs friction disks must be replaced NOTE If clutch discs are oily and it is found that oil is entering along the shaft 1t 1s recommended that the felt washer and oil seal be renewed in the clutch housing as described in Section 5 5 5 1 SM 9662 Rev 1 October 2009 4 5 a Field Maintenance Z AnsaldoSTS 4 5 2 Switch Machine to Switch Adjustments If it is necessary to readjust the switch machine refer to Section 2 Installation and Adjustments Sections 2 3 2 4 and 2 5 4 5 3 Motor Cutout Contact Adjustment Refer to procedures provided in Section 5 7 1 M 3 and Section 5 7 2 23 4 6 Repair Procedures Repair of the switch machine in the field consists of removing and replacing the motor brushes and major switch machine assemblies It 1 not recommended that major overhaul or repair to the machine requiring disassembly to the component part level be done in the field The switch machine should be removed from service and sent to the ASTS USA service or repair shop for this level of repair To remove the switch machine from service refer to Section 2 Installation and rever
92. ed and detected switch point closure A device which performs the three operations of unlocking operating and locking a switch movable point frog or derail Any circuit with a function that affects the safety of train operation SM 9662 Rev 1 October 2009 n Z AnsaldoSTS General Information Registered trademark WAGO Corporation Warning statements indicate conditions that could cause physical harm WARNING NU i serious injury or loss of life LEFT HAND RIGHT HAND Figure 1 3 Left Hand and Right Hand Switch Machines 1 5 Safety Read and thoroughly understand this manual before attempting any of the procedures listed Pay particular attention to the WARNING and CAUTION statements that appear throughout this manual Always observe standard precautions familiar to trained electrical technicians Always adhere to all safety regulations stipulated by the railroad SM 9662 Rev 1 October 2009 1 9 General Information 77 AnsaldoSTS 77 AnsaldoSTS 1 10 SM 9662 Rev 1 October 2009 N AnsaldoSTS Installation and Adjustments 2 INSTALLATION AND ADJUSTMENTS 2 1 General Information In general the application of the M 3 and M 23 switch machines is as shown in Figure 2 1 M 3 and Figure 2 2 M 23 but detail mounting plans approved by the railroad should be followed when installing the machine Mounting dimensions are shown in Figure 2 3 M 3 and Figure 2 4
93. elationship Switch Machine 110 110 20 20 M 3 M 23A or M 23B VDC VDC VDC VDC 189 1 3601 360 1 5281 Number of Teeth Clutch Gear 43 43 4 4 Reduction Ger 3 3 3 Figure 3 5 Pin 6 6 2 2 Reduction 4 4 6 Figure3 5 Pinion 2 22 22 See Operating Characteristics Paragraph 1 3 The pinion end of the motor 1 supported in an opening in the gear box which locates the pinion properly relative to the other gear centers The motor can be removed by taking out the two bolts in the motor bracket at the commutator end For detail information on the motor see Section 3 6 The reduction gears are assembled on shafts supported in Oilite bearings The shafts are held in place endwise by the shaft end plate which is slotted to fit over a neck in each shaft To remove these shafts to change out the reduction gears it is necessary to first shift the motor out of the way see previous paragraph The clutch gear which 1 the final spur gear has an Oilite bushing to support it on the worm shaft This gear 1s connected to the worm shaft through the friction clutch The worm shaft meshes with the worm gear on the main crankshaft and 1 supported at the end adjacent to the controller by a double row ball bearing that takes both radial load and end thrust It also is supported by a single row ball bearing in the wall between the worm gear compartment and the spur gear comp
94. ened however the eccentric bushings may be rotated to raise or lower the center line for the pivot holes in the yoke arms thus affecting the elevation of the yoke rollers The eccentric bushings have hexagonal heads for application of an adjusting wrench On each eccentric bushing one flat is stenciled N and will be on top when the eccentric is in its mean position The adjacent flat on one side of the N is stenciled and when the eccentric bushings are turned to bring the mark up the yoke and its rollers are lifted The flat on other side of the N is stenciled The two eccentric bushings should be kept turned a like degree or to avoid twisting the yoke Then tighten pivot bolt to hold the adjustment 5 26 SM 9662 Rev 1 October 2009 5 77 AnsaldoSTS When necessary to adjust the eccentric bushings check that top rollers do not bear the upper spring cup while the selector clutch is fully down Also check that the rollers are not too high To do this operate the selector lever to the MOTOR position when the worm gear is not in position to receive the selector clutch so that the teeth of clutch for motor operation Figure 3 8 ride on top of the corresponding teeth of the worm gear Insert 1 8 inch length of 14 soft copper wire between the opposed teeth Adjust the eccentric bushings for the same degree or so that with their bolt tight when the sele
95. ents 77 AnsaldoSTS 2 17 Prior to Placing Machine In 2 37 3 OPERATION NEN 3 1 3 1 Switch Operating and Locking 3 1 um me tin t Pase Le bb 3 4 SS MASAI gU cC To p 3 5 9 4 Operation By Hand Crank M nete Eau Iu 3 8 3 5 IDual Control Mechanism M23 cuts 3 10 3 5 1 Operation By Selector Leve xn ite t a aa has 3 12 3 5 2 M 23A and M 23B Mechanisns 3 13 370 04 dle qut 3 13 LO NO M 3 13 3 7 Overload 3 15 20 Healer nls 3 15 4 4 1 4 1 Preventive 4 1 AMG De CUOM 4 1 4 1 2 Switch Layout
96. er 2009 N y aAnsaldoSTS Shop Maintenance proper operation of the overload relay the clutch must be maintained to slip at a current value above the minimum current rating of the relay or no protection will be obtained To check the friction clutch adjustment apply a temporary jumper across the binding posts of the pick up coil on the overload relay See NOTE and insert an ammeter in the motor circuit as follows Connect negative ammeter lead to binding post A on switch machine terminal board and positive ammeter lead to binding post 5 or 10 depending upon switch point position The average peak current taken by motor with clutch slipping should be within 10 of the nominal value shown in Table 5 1 for the particular motor and gear ratio involved The motor current must be checked in both directions If necessary remove cotter and screw the friction clutch spring adjusting nut see Figure 5 5 in or out to obtain desired current After tests are completed remove temporary jumper from overload relay NOTE In addition to a temporary jumper across the binding post of the pick up coil on the overload relay called for in the maintenance and adjustment section of this manual all 6 1 4 amp Fusetrons on the 110 VDC side of a bridge rectifier 1 used should also be temporarily jumpered out Table 5 1 Adjustment to Slip the Clutch Adjust Clutch 110 VDC Blue 110 VDC Black 140 83601 20 VDC Black
97. es see Figure 1 2 e Motor Compartment This compartment houses the motor motor controller EBNC terminal boards and a wire outlet for the external wiring The friction clutch of the gear train projects into this compartment e Gearbox There are two compartments in the gearbox one for the spur gear portion of the reduction gearing and the other for the main crank and worm gear drive Connection between the spur gears and the worm shaft 1s through the friction clutch which projects into the motor compartment The friction clutch protects the mechanism from shock at the end of the stroke or when travel 1s stopped suddenly by an obstruction in the switch point or by lock rod fouling The gearbox also houses the hand operating mechanism a hand crank on the M 3 or dual control mechanism on the M 23 e Circuit Controller Compartment This compartment contains the electronic circuit controller locking features point detectors and a separate set of motor cutout contacts which open the motor circuit during manual operation A slide bar runs lengthwise in the base of the machine It is driven by the main crank and operates the lock box in the circuit controller compartment Perpendicular to the mechanism and beneath the slide bar 1 a switch operating bar also driven by the main crank to which the switch operating rod is connected see Figure 3 1 The point detector rod and lock rods operated by connections to the switch point
98. etermined by the wayside control equipment The design of both the MCU and EBNC adds no height to the switch machine a standard profile is maintained 1 2 Description The M 3 and M 23 switch machines with ECC consist essentially of a motor gear train motor controller and circuit controller with electronic point detection Each machine type uses the same base casting and is generally interchangeable as to mounting and connections In a switch layout Some differences exist from machine to machine due to application requirements for different mounting lug hole sizes or machined lug widths Also the M 23 machines are taller than the M 3 machines which may affect clearance see dimensions in Figure 2 3 and Figure 2 4 Typical applications are shown in Figure 1 1 M 3 and Figure 1 2 M 23 The M 3 and M 23 machines are normally motor operated The M 3 machine has no hand throw capability but can be operated manually using a removable hand crank The M 23 machines have dual control capability with hand throw and selector levers to allow manual operation This dual control capability of the M 23 machines requires a different gearbox than that used on the M 3 switch machine The M 23 machines may also be hand operated using a ratchet wrench applied to the friction clutch adjusting nut SM 9662 Rev 1 October 2009 1 1 ax z g General Information 7 AnsaldoSTS CIRCUIT CONTROLLER GEAR MOTOR COMPARTMENT BOX COMPARTMENT
99. ever to HAND The selector clutch should ride against but not engage the hand throw pinion tooth The selector clutch spring should be compressed taking up the clearance between the upper and lower spring cups Now operate the hand throw lever toward Reverse The selector clutch should snap up into engagement with the hand throw pinion just before the hand throw lever 1 fully down in the Reverse lever stand Check that the hand throw lever will now operate the machine 5 Repeat step 4 for opposite end of stroke With the hand throw lever in Reverse position operate the machine by power to Normal Operate the selector lever to HAND The selector clutch should ride against but not engage the hand throw pinion tooth The selector clutch spring should be compressed taking up the clearance between the upper and lower spring cups Now operate the hand throw lever toward Normal The selector clutch should snap up into engagement with the hand throw pinion just before the hand throw lever is fully down in the Normal lever stand Check that hand throw lever will now operate the machine SM 9662 Rev 1 October 2009 2 23 Sy Installation and Adjustments AnsaldoSTS 2 13 Initial Lubrication It is highly recommended that the switch machine be completely lubricated upon installation prior to being placed into service Refer to Section 5 6 for all recommended lubricants and locations to be lubricated As a minimum apply a light
100. faces it may be reused 4 Secure the lever shaft bearing M to the gearbox case using the two 1 2 inch bolts A4 removed during disassembly 5 Putthe hand throw lever on the lever shaft The lever 1s keyed to the shaft and can be put on in either direction Be sure it 15 positioned on the shaft so that it moves the proper direction 6 Slide the lever support K onto the lever shaft Secure it to the gearbox case with the two 1 2 inch bolts A3 and lock washers removed during disassembly 7 Putthe selector lever onto the lever shaft The lever 15 keyed to the shaft and can be put on in either direction Be sure it is positioned on the shaft so that it moves in the proper direction 8 Secure the selector lever to the shaft with the 7 8 inch hex nut lock washer and flat washers removed during disassembly SM 9662 Rev 1 October 2009 2 35 S J Installation and Adjustments AnsaldoSTS 2 16 3 Operating Bar 1 Remove the two operating bar covers from either side of the switch machine by removing the 1 2 inch bolts and washers that secure it to the machine These have to be installed on the other side of the switch machine when the lug is installed 2 Remove the cotter pin 7 8 inch nut washer and bolt that secure the operating bar lug to the operating bar 3 Remove the operating bar lug and place it on the operating bar on the other side of the switch machine 4 Secure the operating bar lug with the cotter
101. g four 1 2 inch bolts and lock washers removed during disassembly Inspect the gear box lubricant level and add lubricant as required Reinstall the top cover using four 5 8 inch bolts and lock washers removed during disassembly 5 4 8 Selector Clutch Removal For M 23 machines removal of the selector clutch and associated parts can readily be understood from the information given for changing between RH and LH configuration However when reassembling the selector clutch note that all its overall height including top and bottom teeth 1s 5 9 32 inches maximum to 5 17 64 inches min This dimension is adjustable by turning the top and bottom parts of the clutch assembly with respect to each other This can best be done by inverting and placing hand portion on the crank splines and turning motor portion with screw driver or bar in motor clutch teeth Splines in both parts must be aligned to permit reassembly For timing of the dual control gearing upon reassembly see Section 5 5 2 5 4 9 Worm Shaft Removal To remove the worm shaft it is necessary to take the gearbox off the base casting otherwise the end of the shaft would strike the wall of the circuit controller compartment The slide bar can be removed through the motor compartment after first removing the lock box and the motor 5 4 10 Final Disassembly After removing all major subassemblies per the above paragraphs continue to disassemble the remaining compo
102. g the friction clutch housing by applying a ratchet wrench to the clutch adjusting nut with the selector lever the MOTOR position and power disconnected The upper narrow notch can be seen directly Index marks are provided on the top surface opposite the notched ends for the lower notch Make final adjustments 1n accordance with AREMA Signal Section or railroad instructions WARNING To avoid severe personal injury open the gold nut test link in the motor compartment prior to performing any internal machine maintenance Always keep hands and feet clear of switch points and the internal moving parts of the machine Ensure that loose clothing is properly secured prior to working on the switch machine 2 5 Junction Box Jumper Configuration 2 5 1 RHPC LHPC Jumpers The Right Hand Point Closed RHPC and Left Hand Point Closed LHPC jumpers are set at the factory as specified on the order If necessary a machine can be changed in the field by moving the red jumper on the controller junction box between RHPC and LHPC as required 2 5 2 Latch Out Jumpers The latch out jumper for all ASTS USA M style switch machines is set for the automatic manual or disable function This configuration 1 set at the factory based on customer preference at the time the order was placed To change this configuration see Section 2 5 3 2 5 3 Changing the Jumper Configuration 1 Ensure that the machine is in the full locked position with loc
103. go to F J Check EBNC motor connections 1 2 3 and Gr Y properly attached overload circuit and proper request present on If YES go to G G Check motor power present from If check wiring continuity to motor Check motor power present from If YES go to J AAR 1 to AAR 6 If NO check wire from AAR 9 to AAR 1 If NO correct condition 2 Motor continues A Are both direction voltages If YES 12V on 30 amp 29 ref 31 ECC wayside but motor direction voltages applied to If NO ECC TB1 harness or NWR WR Start at A and bipolar input 34 36 NWR WR signal applied to WAGO If NO check wire from AAR 10 to AAR 4 9 to 5 cutout contacts 51 and 52 If YES EBNC may be bad Verify 1 N473034 01 ECC boxes used on previous generation machines use an external 750 ohm to run at end of applied to EBNC terminals 29 amp may be bad Only 29 or 30 should be EBNC terminals 29 or 30 ref 31 does ROC TUR harness be bad Verify correct 34 36 if missing down F Check motor power present from AAR 9 to AAR 4 If YES go to H H Check motor power present from If YES go to 910 6 If NO check gold nut EBNC notin overload red LED lit resistor in place of short to ECC stroke in one or 30 reference 31 while point ON when machine is locked at end of both directions detected and point locked stroke Both should be ON during throw
104. h Screw 8 32 x 3 4 Fillister Head SST 2229 NoUsd 0502 7 30 SM 9662 Rev 1 October 2009 Parts Lists AnsaldoSTS lt N Location 9 Circuit Controller Assembly Parts Figure 7 7 31 SM 9662 Rev 1 October 2009 Sy Parts Lists Z AnsaldoSTS 7 8 Point Detector Sensor Assembly Table 7 11 contains the parts list for the N426006 xx point detector sensor assemblies listed in Table 7 10 See Figure 7 9 for a location diagrams showing the listed parts Table 7 11 Point Detector Sensor Parts List 03 TA Sensor Inductive Custom 8 x 40 mm 04 Proximity Sensor Inductive Custom 18x50 mm 37381040025 06 ____ Holder 423 0202 08 TerminalPost 0909 Washer 5 16 Lock internal Tooth 02 04 Controllers Only J475120 0162 7 32 SM 9662 Rev 1 October 2009 Parts Lists AnsaldoSTS lt N A e 7 7 33 Figure 7 10 Point Detector Sensor 426006 Parts Location SM 9662 Rev 1 October 2009 5 Parts Lists 2 AnsaldoSTS 7 9 Local Remote Switch Assembly Optional Table 7 12 contains the parts list for the N422528 01 local remote switch assembly listed in Table 7 10 See Figure 7 11 for a location diagram showing the listed parts Table 7 12 Local Remote Switch Assembly Parts List Bracket Local Remote Switch M423729 01 Switch Sealed Toggle 85
105. hand throw lever is In one or the other of its full stroke positions The interlock can also be assembled to require that the hand throw lever always be returned to Normal before the selector lever can be returned from its Hand position Details of the interlock are illustrated in Figure 2 10 and described in Section 2 14 Moreover it is possible to apply the selector lever to its shaft in either of two ways 180 degrees apart so as to have the Motor position of the selector lever toward either the motor end or the circuit controller end of the machine for both right hand and left hand assemblies 3 6 Motor Two low voltage two 20V nominal and two high voltage 110V nominal DC motors are available for the M 3 and M 23 switch machines The low voltage motors are used on machines with gear ratios of 360 1 and 528 1 The high voltage motors are used on machines with gear ratios of 189 1 and 360 1 For low voltage motors under the most adverse conditions of load temperature and battery voltage the voltage at the motor terminals should not be less than 20 VDC High voltage DC motors should have not less than 85V at the motor terminals The voltage at the motor terminals should be measured with the clutch slipping Refer to paragraph 5 5 5 3 for information on the adjustment to slip the clutch SM 9662 Rev 1 October 2009 3 13 5 Operation 77 AnsaldoSTS ROCKER ARM MOTOR HAND POSITION POSITION CAM ADJUSTING ROD
106. he hand throw lever to be in Normal position only before a selector lever can be returned to MOTOR position Machines are shipped with option 1 assembly unless the order specifies that the hand throw lever must be Normal only 2 15 Three and Five Wire Conversion to Two Wire Control All ECC machines use two wire control Conversion from five to two wire control is best suited for changes implemented at the wayside house or bungalow Conversion from three to two wire control can be performed either at the wayside location or within the switch machine by connecting two of the three wires together Figure 2 11 shows typical three and five wire relay control systems converted to the two wire system 2 16 Conversion between Right Hand and Left Hand Operation 2 16 1 Conversion of Gearbox NOTE Although this procedure can be done in the field ASTS USA recommends it be done in the shop 2 16 1 1 Disassembly See Figure 2 12 Figure 2 13 and Figure 2 14 1 Remove the two 5 8 inch bolts securing the gearbox cover to the gearbox Lift the cover retain the cover to use as a receptacle for the parts which will be removed 2 Place the hand throw lever Normal and the selector lever in Motor The machine must be in its full stroke position Insert a 1 2 inch drive into the adjusting nut on the friction clutch assembly R and turn it to drive the mechanism to its complete full stop Figure 2 12 3 Remove the four 1 2 inch bolts A1 an
107. he heaters operate on 24 110 VDC or 115 230 VAC A dual element heater is available for operation on either 115 or 230 VAC HEATER E 15W 115 230 VOLTS P 15W 115 VOLTS Er s ss OR 15W 24 VOLTS HEATER HEATER FOR MOTOR COMPARTMENT BLUE MOTOR APPLICATION Figure 3 11 Heaters for Motor Compartments SM 9662 Rev 1 October 2009 3 15 Operation 77 AnsaldoSTS e AnsaldoSTS 3 16 SM 9662 Rev 1 October 2009 4 FIELD Disable the motor control circuit before work is performed on the switch machine otherwise electrical shock or physical injury may result NOTE The field maintenance procedures covered in this manual are those recommended by ASTS USA The field maintenance policy of the customer will depend on actual operating experience and capability 4 1 Preventive Maintenance The following preventive maintenance procedures are intended to detect possible causes of switch machine failure before an actual failure occurs Detection of such possible failures is accomplished by a scheduled maintenance process whereby the switch machine 15 inspected cleaned lubricated and performance tested in the field on a periodic basis The preventive maintenance procedures outlined herein ensure that all switch machine functions are operational A recommended schedule for performing preventive maintenance
108. hes These commutators must not be undercut For motors with external brush covers Fit brushes to commutator using No 00 sandpaper Install motor commutator brush in holder Install spring hold down by pushing into slot beside brush and hooking it over the end of the brush holder Repeat for other brush Check that motor commutator brushes are free in the holders Install motor brush commutator covers with two screws on each cover Install motor cover Operate switch machine motor to determine if brushes are properly installed 5 5 4 Motor Assembly Reinstallation See Figure 7 3 Lower motor bracket onto base of switch machine so that pinion end of motor 1 inserted through motor shaft opening Position motor so that pinion is mated properly with reduction gear Align mounting holes in motor bracket at commutator end with holes in base of switch machine Insert two 1 2 inch cap screws and associated lock washer in motors mounting bracket commutator end Reattach wires to surge suppressor PCB 3340 EBNC machines or motor terminals MCU machines 5 5 5 Friction Clutch Assembly Reinstallation See Figure 5 1 Before assembly check that the friction discs 6 are free of oil If clutch discs are oily and it is found that oil is entering along the shaft it is recommended that the felt pad and oil seal be renewed in the clutch housing Refer to Section 5 5 5 1 If the felt washer and oil seal are not to be replaced continue with Sections 5 5
109. ing the pin into the housing and lowering the push rod Install push rod 27 by sliding the cutout contact end through the shaft 31 Align the holes at the end of the push rod with their respective swivels and install the two screws Mount and adjust knob to yoke 5 5 2 Gearbox M 23 Reassembly Convert between RH and LH See Figure 3 5 and Figure 3 6 1 2 Transfer the yoke support H to the other hub rotate yoke 180 degrees and reapply eccentric bushing bolt G without disturbing eccentric bushing positions Reapply lever assembly to the hub on opposite side of gearbox with shaft splines entering hand throw gear F and with eccentric pin P on selector shaft entering the slot on the end of the yoke With hand throw lever vertical reapply set screw F1 in hand throw gear F Reinstall 1 2 inch bolts A2 to secure yoke support H Reinstall the two top bolts A4 to hold lever shaft bearing M in place So that Motor position of selector lever will be toward motor end of machine as shown for standard assemblies Diagram A B or D of Figure 2 10 selector lever and lever interlock must be reassembled 180 from original position on shaft as follows SM 9662 Rev 1 October 2009 5 13 5 14 Shop Maintenance Z AnsaldoSTS a Remove hex nut and washers from end of selector lever shaft and slide selector lever and lever support K from the shaft Be careful not to lose steel ball in lever support NOTE If st
110. iring harness or ECC should never be immersed cleaning solution otherwise damage to these parts will occur 5 3 Inspection After cleaning carefully check the case cover and other structural components for hairline cracks breaks weak points or any other signs of physical damage During disassembly carefully check each part for signs of damage Replace any part found to be damaged SM 9662 Rev 1 October 2009 5 1 Shop Maintenance 77 AnsaldoSTS 5 4 Disassembly 5 4 1 Motor Brush Replacement NOTE When replacing motor brushes both brushes should be replaced at the same time See Figure 7 1 M 3 or Figure 7 4 M 23 For motors with external brush covers Remove the motor compartment cover Remove the motor brush commutator covers by removing the two screws on each side of the cover Lift and push to release the spring holder then remove the motor brush Install the new brush and secure it in place with the spring holder Repeat for the other brush 5 4 2 Motor Removal See Figure 7 3 Remove the motor compartment cover Tag and remove the wires attached to the surge suppressor PCB 3340 EBNC machines or motor terminals MCU machines and motor compartment heater 1f used Position the wiring harness out of the way Remove two 1 2 inch cap screws and lock washers holding the motor frame to the switch machine base Lift the motor assembly upward and pull it towards the conduit outlet until the pinion gear
111. isassembly and lock washers Reinstall the key 160 Into the keyway the top of the crank and bearing Place the brass bushing 170 over the top of the crank Ensure that the keyway slot in the bushing is in line with the keyway Press down on the bushing until it seats fully into the top bearing cap Reinstall the flat washer 200 and castle nut 195 over the top of the crank Tighten the castle nut until it is snug and the crank has been pulled up fully threads should be exposed above the top of the nut Loosen the nut one half turn then install the cotter pin to lock the nut in place Reconnect the switch operating rod to the lug on the switch machine operating bar Place Motor Hand selector lever to Hand and cycle the machine between Normal and Reverse Verify that the machine operates smoothly throughout its full stroke SM 9662 Rev 1 October 2009 5 11 Shop Maintenance Z AnsaldoSTS NOTE It is recommended that all track settings be checked at this time to ensure that the layout is in sound operating condition At this time the Motor Hand selector lever should be returned to Motor and the cognizant authority notified that powered switch operation needs to be verified Cycle the switch between Normal and Reverse using the motor Verify that the machine operates smoothly throughout its full stroke 17 After confirming proper operation of the machine and layout reinstall the bottom cover usin
112. k box extended toward the gearbox 2 Locate the Junction Box Figure 2 5 or Figure 2 6 directly behind the ECC 2 6 SM 9662 Rev 1 October 2009 N AnsaldoSTS Installation and Adjustments 3 Unscrew the dust cover from the desired position and move the jumper to that location Reinstall the dust cover on the unused connection 2 6 ECC Power and Indication Input Setup The ECC requires a continuous wayside battery feed of 12 VDC nominal 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 2 6 1 Single Machine Setup The indication input to the ECC must be jumpered on the WAGO terminal strip to receive continuous battery feed The 1 shipped from ASTS USA with these jumpers installed and must be removed for multiple machine applications Four jumpers must be installed refer to the wiring diagram in Figure 2 6 Terminal 16 for 12 18 connected to Terminal 13 normal input which 1 also jumpered to Terminal 10 reverse input Terminal 19 for B12 1s connected to Terminal 15 normal input which 1 also jumpered to Terminal 12 reverse input With the above jumper configuration in place both indication input green LEDs inside the ECC box will be lit to show that continuous power is being supplied to the indication input circuits 2 6 2 Multi
113. ke N firmly and lifting upward rotate the yoke 180 Be sure that the yoke assembly seats firmly on the main shaft after it is moved 2 Transfer the yoke support H to the other side of the gearbox Insert it into the gearbox and secure it with four 1 2 inch bolts and lock washers When inserting the yoke support into the gearbox be careful not to disturb the position of the eccentric bushings NOTE There is a paper gasket between the lever shaft bearing and the gearbox case Check it after removal of the lever assembly If it 1s torn it must be replaced If it is intact on one of the two mating surfaces it may be reused 3 Secure the yoke to the yoke support using the 1 2 inch bolt G nut and two lock washers removed during disassembly 4 Insert the lever assembly into the hub on the opposite side of the gearbox As the shaft enters the gearbox position the hand throw bevel gear F so that the gear slides onto the keyed shaft Position eccentric pin P on the selector shaft of the lever assembly so that it enters the slot on the end of the yoke Ensure the gear 15 firmly seated on the shaft CAUTION Insertion of the lever assembly requires two persons to perform the procedure one to insert the lever assembly and one hold and guide the hand throw bevel gear onto the lever assembly shaft 5 With the hand throw lever vertical and the bevel gear firmly seated against the lever shaft tighten the set screw
114. l 8N CONNECT TO GROUND ROD IF MACHINE IS INSTALLED IN Auxiliary Sensor 2 2 z gt ELECTRIFIED TERRITORY e Ground Terminal o Reverse Output 5N FOR TOP LEVELASSEMBY MACHINES N426XXXXX DERAIL STYLE pA e EUR AL THE POINT SENSORS 51 AND 52 ARE STILL CONNECTED TO THE 12 mr 0 O Bi Polar Normal JUNCTION BOX IN THE SAME PLACES BUT THE SENSORS View A Proximity Sensor Layout amp Identification mai E Ground Terminal THEMSELVES ARE PHYSICALLY SWAPPED Heater Bi Polar Normal AN INDICATED POLARITY DRIVES POINTS RIGHT SEE VIEW Top View Tape lead to harness only for 115V source for field applications with 115V source disconnect 7 for 230V and connect this lead to terminal 7 9N JUMPERS TO BE PLACED PER DESIRED APPLICATION LOCAL REMOTE OPTIONAL MAY NOT BE ON ALL MACHINES 7 ALL DISCRETE 18AWG WIRING TERMINATED IN A WAGO STYLE CONNECTION USE WAGO FERRULE J7091461419 AND WAGO CRIMP TOOL 206 204 ALL DISCRETE 14 WIRING MOTOR POWER TERMINATED USING J730044 AND CRIMP TOOL 46387 OR P47387 Combine leads and connect to terminal 8 Connnect lead to terminal 7 6A2 0041 00 SM 9662 Rev 1 October 2009 3 SEE VIEW A FOR LOCATION AND IDENTIFICATION OF SENSORS CONNECTIONS AS SHOWN TO WAGO TERMINALS 29 amp 30 ARE CORRECT WITH 189 1 GEAR RATIOS 360 1 AND 528 1 CONNECT BROWN WIRE
115. leased and the crank inserted Latch G which can be removed if not desired serves to hold the motor cutout contacts latched out until reset manually a useful feature when someone other than the signal maintainer is authorized to use the hand crank 3 8 SM 9662 Rev 1 October 2009 77 AnsaldoSTS Operation lt GEAR 8 ae 9 9 Vaa Y H Th GEAR BOX G WHEN USED NORMAL RELEASE LEVER Figure 3 7 M 3 Motor Cutout Mechanism WARNING In certain cases particularly on transit properties the clearance is such that if the hand crank is left in the machine it could come in contact with the vehicle collector shoe causing a hazardous condition Do not permit traffic through the switch with the hand crank left in the M 3 switch machine otherwise property damage may result Always remove the hand crank when not in use SM 9662 Rev 1 October 2009 3 9 e U y Operation Z AnsaldoSTS 3 5 Dual Control Mechanism M 23 Switch operation switch locking and circuit controller operation are all performed by the vertical main crank in the gear compartment shown in Figure 3 8 This crank 1s always engaged with either a the motor through the reduction gear train and its friction clutch or b the hand throw lever through the hand throw pinion The selector clutch slides along splines on the shaft of the main crank and 15 shifted up or down by the se
116. lector lever To permit the selector lever stroke to be completed even though the top tooth of the selector clutch may not be in alignment with the tooth space the hand throw pinion hub when shifting from motor position shown to hand throw position connection between the selector lever and the selector clutch 1s made through a coil spring mounted on the selector clutch NOTE The top tooth 1 shown in alignment with the tooth space in the hub of the hand throw pinion because the switch and the hand throw lever are both in Normal position There may be times when the switch 1s blocked mid stroke by an obstruction so that the main crank will not be in Normal position and of course if the last motor operation left the switch In the reverse position the teeth likewise are not aligned The selector clutch snaps into engagement with the hand throw pinion when the hand throw lever is operated to a position corresponding with the switch position This spring connection acts similarly when returning the selector lever to the motor position however in this case it 1s the motor that must be operated to align the worm gear hub teeth to receive the selector clutch teeth The main crank remains engaged with its original connected driving elements until it is engaged with the other elements The clutch overall height 15 such that the top tooth must engage the hand throw gear before the bottom teeth can disengage from the worm gear or vice versa Thu
117. minals 4 6 7 and 9 are for field connections to a four wire indication output circuit a Normal indication is defined between Terminals 7 and 9 b Reverse indication is defined between Terminals 4 and 6 c If there is no output on the paired terminals they are shunted WARNING When connecting the ECC indication outputs to the drive switch correspondence relays ensure the relay controls are properly snubbed with a resistor to minimize possible inductive kickback to the ECC when the field in the relay coil collapses Ensure that no external source is applied across of the outputs 4 Terminals 10 12 13 and 15 are for indication input field connections from an adjacent machine or they can be jumpered for single machine applications a Normal indication input 16 defined between Terminals 13 and 15 b Reverse indication input is defined between Terminals 10 and 12 SM 9662 Rev 1 October 2009 2 13 Sy J Installation and Adjustments AnsaldoSTS c Ifthe machine is used in a single machine application battery must be fed to the indication input circuits to provide indication output Refer to Section 2 6 for proper jumper configuration NOTE Four indication input jumpers are factory installed on the WAGO terminal strip and must be removed for multiple machine applications 5 Terminal 17 is used for connecting wayside battery N12 Terminal 20 is used fo
118. n Box 2 17 2 10 Point Detector and Auxiliary Sensor Adjustment1 2 17 2 10 1 Poibt Detector Sensor 2 17 2 10 2 Point Detector Sensor 2 17 2 10 3 Auxiliary Sensor Adjustment Non Vital 2 20 2 1 1 Lock Box uuu u 2 20 2 12 Lever Stand raid oes 2 23 29 2 24 2 14 Lever Position and nnne nnns 2 24 2 15 Three and Five Wire Conversion to Two Wire Control 2 26 2 16 Conversion between Right Hand and Left Hand Operation 2 26 2 16 1 Gonvelrsion or GOANDOX uuu uu b ce Desi 2 26 2 62 Leve ks 2 34 2 16 OHEAN Ba uu ote actui Que t de rcu ec mu LM M RM 2 36 2 46 AGIUSIMEN zie iato lav Su sua nasa 2 36 2 16 5 Jumper Configuration 2 37 2 16 6 nverning me LOCK BOX uu u w a son tuc uc 2 37 SM 9662 Rev 1 October 2009 iii of Cont
119. n 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 1 the same direction If the proper motor power polarity is applied to AAR terminals the motor will then operate in the correct direction Additionally the counter 1 energized momentarily through Terminals 27 and 28 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 2 7 2 2 Terminals 29 30 and 31 are ON MOTOR FRONT ON MOTOR REAR and GND signals from the ECC They are used in conjunction with bi polar input WR NWR on terminals 34 and 36 to control polarity of the motor connected on wires amp 2 See Figure 2 6 With WR amp NWR wire 1 is positive with respect to wire 2 With terminal 30 high motoring is terminated when terminal 30 switches low The opposite motor polarity is achieved with a reversal of WR NWR being controlled by input on terminal 29 Illumination of the green LED indicates a bi polar input The EBNC provides a method of motor control from a bi polar input that does not require any power switching relays for safe operation of a switch machine Motor power on wire 3 and on GR Y can b
120. nd washers on the end of the shaft to hold the selector lever in place then secure the lever support K with the two 1 2 inch bolts A3 and lock washers removed during disassembly These bolts also secure the bottom of the lever shaft bearing Move the selector lever to MOTOR toward the motor end of the machine and check to make sure that it moves the yoke N down Interchange the MOTOR and HAND nameplates on the selector lever to correspond with the new lever positions With the hand throw lever vertical place the collar E with the chamfer down on top of the main crank end Install the hand throw bevel pinion D engaging the tooth marked R for right hand assembly or L for left hand assembly with the punched marked master tooth space in the center of the hand thrown bevel gear F Carefully place the hand throw lever in Normal Be sure that the hand throw bevel pinion D remains in the proper position relative to the hand thrown bevel gear F With the selector lever in Motor rotate the friction clutch housing so that the motor clutch teeth are fully engaged Place the top bearing assembly C on the gearbox using the dowel pins as guides and secure it with the four 1 2 inch bolts A1 and lock washers removed during disassembly The motor cutout push rod should be held back to clear the adjusting rod until bearing 1s down SM 9662 Rev 1 October 2009 i AnsaldoSTS Installation and Adjustments CLUTCH
121. ned 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 15 impossible to take into account every eventuality that may arise with technical equipment in service Please consult an ASTS USA local sales representative in the event of any irregularities with our product ASTS USA expressly disclaims 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 ASTS USA spare parts are used as replacements SM 9662 Rev 1 October 2009 Revision History 77 AnsaldoSTS Revision History DATE NATURE OF REVISION Revised part numbers on cover and j Copyright 2009 Ansaldo STS USA Inc 1000 Technology Drive Pittsburgh PA USA 15219 3120 645 Russell Street Batesburg SC 29006 www ansaldo sts com All rights reserved li SM 9662 Rev 1 October 2009 2 AnsaldoSTS Table of Contents Table of Contents T GENERALINFOBMATION u uu uya u uuu a SS sus Ta Use pe LEE 1 1 Tels npe 1 1 152 mm rre M 1 1 1 2 1 Operating nnn nns 1 4 2 2 MECANISM ista Lu S esc onda 1 5 To SSS CHICO
122. nents by referring to Figure 7 1 or Figure 7 4 and associated parts list for parts location and identification Disassemble only to the degree necessary to repair the machine 5 12 SM 9662 Rev 1 October 2009 gt 5 4 11 Gearbox M 23 Disassembly See Figure 3 5 and Figure 3 6 I 5 5 5 5 1 Remove gearbox and motor compartment covers use them as receptacles parts removed Place hand throw lever In Normal position and selector lever in MOTOR posttion Remove 1 2 inch bolts Al 2 and 4 securing top bearing C yoke support lever support K and lever shaft bearing Remove castle nut and washer B2 from top of main crank and lift top bearing C from dowel pins carefully to prevent bending Remove the rectangular key Cl Figure 3 5 from top bearing bushing C2 hand throw pinion D and spacing collar E on top end of crank Lift hand throw lever to vertical position and remove set screw F1 from hand throw bevel gear F Remove lever assembly and lift out hand throw bevel gear Remove 1 2 inch bolt G securing yoke eccentric bushings G1 then remove yoke support H Positions of eccentric bushings should be noted and care should be taken to avoid changing their position when removing the bolt Assembly Gearbox M 3 Reinstallation See Figure 7 1 Place gearbox onto switch machine base Align mounting holes in gearbox with holes in the base Install four screws 134 Install push rod by insert
123. ngaging the shaft 5 5 5 2 Friction Clutch Assembly See Figure 5 1 Install gasket 1 In gearbox opening Install plate 2 with two 1 4 inch hex head cap screws 13 Align tubular neck of clutch assembly and worm shaft 12 Insert tubular neck of clutch assembly partially over worm shaft and through gearbox bushing Align three finger end of tubular neck with matching slots in clutch gear hub Push tubular neck into gear hub slots until neck hub is in clutch gear hub Push tubular neck into gear hub slots until neck hub is solidly engaged Install the following items on the worm shaft 1 Insert clutch disc until it sits against inner wall of clutch housing 2 Insert clutch plate in groove on worm shaft until it mates with clutch disc 3 Insert another clutch disc 4 Insert another clutch plate 5 Repeat steps c and d for three remaining clutch discs and two remaining clutch plates 6 Insert clutch end plate on worm shaft Slide clutch spring over worm shaft until it rests against clutch end plate Install clutch adjusting nut on worm shaft Tighten clutch adjusting nut in accordance with friction clutch adjustment procedures Recheck this adjustment after a brief wearing in period 5 5 5 3 Friction Clutch Adjustment Friction clutch adjustment should be checked to be sure the clutch slips at a torque which will protect the mechanism from shock yet adequate to carry nominal operating loads Also for 5 16 SM 9662 Rev 1 Octob
124. oint detection connections 6 Tighten the AAR hardware to properly secure the sensor bracket 7 Place a 1 4 inch obstruction in the switch point six inches back from tip of point It may be necessary at this time to float the lock rods to allow the switch machine s slide bar to travel full stroke to properly check the point detection settings This 1 accomplished by loosening the hardware on the lock rod assembly and moving the lock rods so that the lock dog of the machine can enter the narrow notch 8 With the obstruction placed in the switch point the corresponding normal or reverse point detected LED should be RED If not repeat the serrated bracket adjustment procedure Steps through 4 moving the bracket only two serrations into the target instead of three 9 If the machine has been equipped with the optional auxiliary sensors their position 1 fixed and no adjustment is required SM 9662 Rev 1 October 2009 2 19 ae nl Installation and Adjustments Z AnsaldoSTS 2 10 3 Auxiliary Sensor Adjustment Non Vital 2 11 NOTE Auxiliary sensors are optional non vital sensors and are only supplied when required by the customer Place the switch machine in the Normal position operating bar based on RH or LH configuration Move the point detector bar to the Normal position matching the machine Starting with the sensor holding bracket outside the target area at the extreme position of the bracket
125. oltage Table 1 5 Switch Machine Heaters Heater Part No Electrical Characteristics N294241 15W 115V AC or DC N451589 0101 30W 115 230V AC or DC N294291 and N290578 001 15W 24VDC 1 6 SM 9662 Rev 1 October 2009 2 AnsaldoSTS General Information Table 1 6 Switch Machine Controllers Controller Electrical Data Operating Voltage 12 10 16 VDC Operating Voltage 12 10 33 VDC MCU 1 2 12 10 33 VDC Motor Overload HV 13A 13 0 10 4 15 6 gt 16 lt 3 Amps Time Seconds lt 6A No Overload 20A 26 4 21 2 31 6 gt 22A lt 3 Motor Overload LV At below 13A the time to overload nominally equals 169 divided by the current At below 20A the time to overload nominally equals 520 divided by the current 1 4 Abbreviations Acronyms and Definitions AC AAR AREA AREMA ASTS USA AWG CAUTION DC ECC EBNC Front of Machine FRA Latch Out Alternating Current Association of American Railroads Communication and Signal Section currently known as AREMA American Railway Engineering Association American Railway and Maintenance of Way Association formerly known as AAR Ansaldo STS USA Inc formerly known as Union Switch amp Signal Inc American Wire Gauge Caution statements indicate conditions that could cause damage to equipment Direct Current Electronic Circuit Controller Electronic Biased Neutral Controller
126. ommon to Cable 1 Wire 1 Connect multimeter positive to Cable 1 Wire 2 Connect test source common to the WAGO terminal labeled 36 Connect test source positive to the WAGO terminal labeled 34 NOTE There are no serviceable parts within the EBNC If it has been determined that the unit is not functional 1t must be replaced SM 9662 Rev 1 October 2009 y Table 4 2 Logic Table BiPolar Input Motor Control WAGO Terminal Motor Output Voltage lt S G Vcontrol 1 Logic Control 12 VDC Nominal No Feet No Effect X __ Vbipolar Vb Bipolar Control 12 VDC Nominal Vbipoarc ve avn Motor Output Source from 3 and GY Input Vmoor Vm 4 5 Corrective Maintenance The following paragraphs describe the M 3 M 23A and M 23B Switch Machine field level maintenance procedures Field level maintenance adjustments for these machines consists of 1 Friction clutch adjustment 2 Switch machine to switch adjustment 3 Motor control contacts adjustment 4 5 1 Friction Clutch Adjustment A switch machine s friction clutch see Figure 5 1 must slip at just the right amount of torque This torque must be more than adequate to carry the switch machine s operational loading during the driving of the switch points At the sam
127. oosen the sensor lock nut and adjust the sensor position to obtain a gap between the sensor and its target of 0 075 inch Retighten the lock nut to hold the sensor in position SM 9662 Rev 1 October 2009 AnsaldoSTS Installation and Adjustments 5 Move the switch machine to the opposite full stroke position Ensure that the switch point 1 closed and up against the stock rail 6 The other lock box sensor will be aligned with its target on the lock box Loosen the sensor lock nut and adjust the sensor position to obtain a gap between the sensor and its target of 0 075 inch Retighten the lock nut to hold the sensor in position 7 Reinstall the ECC onto the controller frame refer to Section 5 5 6 8 Restore logic control power to the switch machine 9 Verify that the Point Locked LED for the current switch position 1 LIT 10 Move the switch machine to the opposite position and verify that the Point Locked LED for the current switch position 1s LIT SM 9662 Rev 1 October 2009 2 21 Installation and Adjustments 77 AnsaldoSTS Vital Sensor Gap 0 075 1 hau o lm gu 57 PS lt a we AC Non Figure 2 9 Lock Box Sensors 2 22 SM 9662 Rev 1 October 2009 m 4 AnsaldoSTS Installation and Adjustments 2 12 Lever Stand Adjustment Fo
128. op screw is used in hub of hand throw lever it will be necessary to remove this lever also and interchange stop screw and cap screw see Figure 2 10 Reinstall hand throw lever and fasten in place with clamping bolt b Reassemble lever support K with hole for the ball on motor side of shaft Insert steel ball and reassemble selector lever on shaft so that lever will be 180 degrees from its original position Stop screw if used may require positioning hand throw lever to align recess with hole in lever support so that ball will not interfere when selector lever is applied Reinstall hex nut and washers on end of shaft to hold selector lever in place and fasten lever support K with the two 1 2 inch bolts which also secure the bottom of the lever shaft bearing c Operate selector lever to motor position toward motor end of machine and check that it moves yoke N down Interchange MOTOR and HAND nameplates on selector lever to correspond with these lever positions WARNING The MOTOR and HAND nameplates must be interchanged on the selector lever to correspond with the lever positions to avoid possible physical injury Reassemble collar E with chamfer down on top of crank and with hand throw lever vertical apply hand throw bevel pinion D engaging tooth marked R for right hand assembly or L for left hand assembly with punched marked master tooth space on hand throw gear F Carefully place hand throw lever in Normal
129. osition both locking dogs clear of the lock rods while driving the switch operating bar full stroke to its opposite position and finally the main crank holds the switch operating bar while driving the slide bar to its full stroke position engaging the top locking dog in the corresponding lock rod notch Refer to Figure 3 1 Figure 3 2 and Figure 3 3 to understand how the crank imparts these motions Assuming that Figure 3 2A shows the Normal position a reverse movement is started by a clockwise rotation of the main crank Lug 1 on the main crank acting against roller 1 on the slide bar effects the unlocking of the lock rod by causing the slide bar to move to the left one half of its stroke Meanwhile roller 4 on the underside of the main crank is moved through an arc of 40 degrees in the radial portion of the groove in the switch operating bar thus freeing the bar for the reverse stroke During the next 140 degrees of rotation of the main crank roller 4 engages the straight reverse operating face of the groove in the switch operating bar and moves the bar to the reverse position Figure 3 2B shows the relative mid stroke positions of the switch operating bar and the slide bar with the main crank still rotating clockwise but not transmitting motion to the slide bar as lug 1 has become disengaged from roller 1 The surfaces of the slide bar are radial to the center of the shaft and prevent the slide bar from moving The full reverse position
130. ple Machine Setup If the machine is the first machine in the crossover 1 the indication output 15 not dependent upon the indication input from an adjacent machine the indication input circuits are to be jumpered as described in paragraph 2 6 1 for a single machine application If the machine 1 the second machine in a crossover application 1 e requires indication input from the first machine 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 SM 9662 Rev 1 October 2009 2 7 Installation and Adjustments AnsaldoSTS 77 AnsaldoSTS 2 8 SM 9662 Rev 1 October 2009 5 2 AnsaldoSTS Point Sensor 1 Point Sensor 2 Lock Sensor 1 Lock Sensor 2 Brown Auxiliary Sensor 1 Auxiliary Sensor 2 Red jumper 9N le To AAR 5 To AAR 4 14 51 18 AAR 49 50 18 BK AAR 52 14 Installation and Adjustments Cap Motor Control Unit 47304801 High voltage cum S O O J N47304802 Low voltage c Eg _ Yellow jumper 271
131. r 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 6 Terminals 21 and 23 are for field connections to the two wire bipolar auxiliary sensor output a Normal auxiliary indication is defined as on Terminal 23 and on Terminal 21 b Reverse auxiliary indication is defined as on Terminal 23 and on Terminal 21 WARNING The maintenance output is not vital and should never be used to clear signals 7 Terminals 24 25 and 26 are for field connections to use the local remote request switch option This function is particularly useful when conducting monthly inspections For this function to work however the wayside must be configured appropriately The two toggle switches in the machine L R and N R interface with the local control panel and provide the ability to control the machine as though operating directly from the local control panel The local remote L R switch normally 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 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
132. r M 23 machines only Make final check of adjustment of lever stands to assure that their adjustment permits transfer from power to hand operation under all conditions as follows 1 Remove the gearbox cover so that the action of the selector clutch see Figure 3 8 and its relation to the hand throw pinion can be observed as the selector lever is operated from MOTOR to HAND position 2 With the hand throw lever Normal operate the machine by power to Reverse and then back to Normal Operate the selector lever to HAND Check that selector clutch shifts up engaging the tooth on the bottom of the hand throw pinion and check that the hand throw lever will operate the machine If the selector clutch fails to shift up full stroke readjust the height of the Reverse hand throw lever stand to bring the clutch teeth into proper alignment 3 Repeat step 2 for opposite end of stroke With the hand throw lever in Reverse operate the machine by power to Normal then back to Reverse Operate the selector lever to the HAND position Check that selector clutch shifts up engaging the tooth on the bottom of the hand throw pinion and check that the hand throw lever will operate the machine If the selector clutch fails to shift up full stroke readjust the height of the Reverse hand throw lever stand to bring the clutch teeth into proper alignment 4 With the hand throw lever in Normal operate the machine by power to Reverse Operate the selector l
133. r left hand or right hand machines NOTE It is CRITICAL that the machined slot at the top of the crank 1 aligned with the roll pin at the top of the selector clutch housing 175 If the roll pin is not oriented properly the replacement crank cannot be fully inserted into the gear box 4 Insert the replacement crank from below up through the center hole the bottom of the gear box and into the machine Align the crank so that the lobe directly above the roller stud is positioned between the slide bar rollers see upper or lower views in Figure 5 4 CAUTION Forcing the replacement crank into the selector clutch assembly may break the roll pin This may put the machine out of time with the circuit controller and lock box at the end of the hand throw stroke 5 Apply a thin coat of grease to the crank stud to help hold the roller Assemble the roller onto the stud 6 Ensure that the crank lobe and slide bar roller relationship is the same as noted during removal of the failed crank marked on Figure 5 2 or Figure 5 3 Reinstall the operating bar and wearing brackets to the bottom of the machine SM 9662 Rev 1 October 2009 5 9 5 Shop Maintenance Z AnsaldoSTS l CRANK SWITCH OPERATING BAR SWITCH OPERATING BAR r Le zr D be T Thu D d at ul Ou SWITCH OPERATING 9 BAR Figure 5 4 Crank to Slide Bar Relation
134. rm switch machine Inspection as follows 1 Remove covers from switch machine circuit controller gearbox and motor compartments 2 Using hand crank for M 3 or hand throw lever for M 23 operate switch back and forth as often as necessary and check for a Proper and smooth operation of switch points without undue drag or spring and with points riding on all slide plates Also check for switch point obstructions at this time b Loose or damaged electrical connections c Burned frayed or broken insulation d Proper movement of switch machine main crank slide bar lock box switch operating bar and circuit controller point detector bar e Excessive wear lost motion or accumulation of foreign or conductive material f Excessive or unusual vibration and noise 3 Electrically operate switch machine and check for a Smooth movement of switch machine motor and gears no binding etc should be noticed b Conditions listed in step 2 above 4 Check that there are no signs of moisture accumulation within switch machine compartments 5 During semi annual inspections check for moisture in the compartments If 3 8 inch pipe plugs are installed in two drain holes located in the crank case compartment or slotted head bolts with lock washers are installed in circuit controller compartment remove plugs and allow whatever moisture is present to drain from compartment 4 2 SM 9662 Rev 1 October 2009 CAUTION
135. s Pour top crank periodically as bearing required Spur Gear Apply light coat to ue Lubriplate 5555 Fiske teeth as required Spec M 7652 3 Brothers Refining Co Gear Box Pour in Fill only to top of worm gear 1 Apply pressure gun grease ASTS USA Spec M 7650 01 a Point detector bar bearings use gun on grease fittings b Operating bar wearing plates use gun on grease fittings c Selector and hand throw lever shaft bearings use gun on grease fittings d Surfaces of slide bar and lock box using brush or paddle for application a heavy oil viscosity 120 200 SAE 140 may be used as an alternate on these surfaces 2 Apply medium body motor oil viscosity 130 F 185 220 SAE 30 to the following parts a Yoke bearings b Spur gear journals machines are equipped with Oilite bushings 1 Holes in box casting 5 22 SM 9662 Rev 1 October 2009 A 3 5 7 5 7 1 gt Z AnsaldoSTS Shop Maintenance NOTE Oil should be applied sparingly to clutch gear bearing to prevent seepage through clutch shaft packing to the friction discs c Holes in reduction gears and in clutch gear d For M 3 machines only 1 Main crank shaft remove oil plug in top cover Oil will collect in a recess and be led to shaft surfaces needing lubrication 2 Linkage connections for motor cutout e M 3 M 23A and M 23B machines fill recess on top crank bearing Apply a light oil ASTS USA Spec M 7610 02 sp
136. s are supported in the circuit controller compartment 1 4 SM 9662 Rev 1 October 2009 ZansaldoSTS General Information Switch operation and switch locking are performed by the vertical main crank in the gearbox The main crank is driven either by the motor or by the hand operation facilities Refer to Section 3 for detailed operation of the switch machine 1 2 2 Control Mechanism The ASTS USA Electronic Circuit Controller ECC is designed for use in M 3 and M 23 style switch machines using permanent magnet motors The ECC uses four vital proximity sensors two for detecting switch point position Normal or Reverse and two for detecting that the machine is fully locked in position at end of stroke Two non vital sensors can be installed as an option when auxiliary point indication is desired The ECC is a microprocessor based controller that vitally monitors the state of the four vital proximity sensors and can identify each possible sensor state ON OFF SHORTED or OPEN The sensing threshold of each auxiliary sensor when used is offset from the vital point detector sensors by 1 8 inch to detect switch point displacement before the vital sensors indicate point detector bar movement This system provides a normally ON bipolar output to warn maintenance personnel of marginal switch machine operation With this auxiliary system switch point displacement caused by debris build up or expansion and contraction of the rail can be
137. s approximately 18 VDC and is constant over an input voltage range of 9 8 to 16 2 VDC It can drive two EBNC equipped machines simultaneously with as much as 28 ohms of line wire See ASTS USA service manual SM 6A3 0001 for more details 2 7 2 3 Motor Overload The MCU equipped machines do not provide internal motor overload protection Protection must be provided by the wayside control equipment Refer to Section 3 7 for further information on typical wayside equipment protection circuits The EBNC equipped machines do provide internal motor overload protection refer to Table 1 6 for specific values This protection is based on the measured motor current as a function of time For very low current draw conditions only a few amps that will not damage the motor the EBNC takes no corrective action For higher current draw conditions up to the nominal clutch slip setting the EBNC will interrupt the motor current if the current draw is maintained for a time determined by the magnitude of the current draw For extremely high current draws the EBNC will interrupt the motor current in less than three seconds 2 8 Terminal Post Connections There are ten 10 AREMA binding post terminals labeled 1 through 10 see Figure 2 5 and Figure 2 6 1 Terminals 1 9 and 4 10 are termination points connecting input motor power to the machine On MCU equipped machines this input 1 bipolar On BNC equipped machines the polarity 1s fixed 2
138. s the main crank 1 never floating but is engaged with either the motor or the hand throw lever at all times 3 10 SM 9662 Rev 1 October 2009 7 j AnsaldoSTS Operation CLUTCH FOR HAND OPERATION ROLLER SELECTOR CLUTCH SPRING E a SELECTOR LEVER SHAFT 36 UPPER SPRING CUP LOWER SPRING WORM GEAR CLUTCH FOR MOTOR OPERATION MAIN CRANK UPPER SPRING CUP NOS 9 E A _ E 3 x S s UPPER ROLLER SELECTOR CLUTCH YOKE LOWER ROLLER NOTE SELECTOR CLUTCH ASSEMBLY COMPRISES PARTS MARKED BEARING CAP HAND THROW BEVEL GEAR HAND THROW LEVER SHAFT SELECTOR LEVER SHAFT d m WEE SELECTOR CLUTCH SPRING LOWER SPRING CUP WORM GEAR MAIN CRANK SHAFT o SEA PEE 2 Be HAND THROW PINION CLUTCH FOR HAND OPERATION ECCENTRIC BUSHING SELECTOR CLUTCH YOKE CLUTCH FOR MOTOR OPERATION Figure 3 8 Sectional Views of M 23 Dual Control Mechanism SM 9662 Rev 1 October 2009 3 11 gt Operation Z AnsaldoSTS NOTE In as much as the switch operating mechanism may remain in engagement with the motor rather than with the hand throw lever when the selector is operated to the Hand position it is necessary to actually operate the switch by the hand throw lever to assure that the machine is in the hand operation position 3 5 1 Operation By Selector Lever The selector clu
139. se the procedure To remove and replace 1 Motor Brushes Refer to Section 5 4 1 and 5 5 3 2 DC Motor Refer to Section 5 4 2 and 5 5 4 3 Friction Clutch Assembly Refer to Section 5 4 3 and 5 5 5 4 6 SM 9662 Rev 1 October 2009 gt 5 SHOP MAINTENANCE 5 1 Special Tools The following special tools are required to perform shop maintenance on the switch machine Maintenance tools for M 3 and M 23 switch machines are listed below Ordering reference for the complete set of tools is X296406 001 Drawing 012764 0001 M 3 and M 23 Maintenance Tools Screw driver 6 slotted Screw driver 10 slotted Slip joint pliers 6 Machinist hammer 12 oz ball peen Insulated socket wrench 1 2 Adjustable Crescent wrench Adjustable Crescent wrench 10 Set hex Sockets Ratchet wrench 1 2 drive Extension bar 1 2 drive 10 long Special pin wrench for clutch housing packing gland Thin head flat wrench 1 5 32 opening Allen wrench 3 16 Hex Clutch assembly gauge hand motor clutch Basket Wrench 2 1 16 open end ASTS USA M322680 or box wrench ASTS USA J49124401 5 2 Cleaning All major mechanical parts should be thoroughly cleaned to remove accumulation of dirt grease and grime Use only appropriate cleaning agents for the material being cleaned and follow the manufacturer s recommendations for use CAUTION Electrical components such as the motor heaters w
140. ship Viewed from Top of Machine 5 10 SM 9662 Rev 1 October 2009 10 11 12 13 14 15 16 gt Reinstall the gear box bottom cover and secure it with four 1 2 inch bolts and lock washers removed during disassembly Move Motor Hand selector lever to Motor This will compress the spring and ease assembly of the top bearing housing Reinstall the spacer 170 on top of the replacement crank NOTE Ensure that the hand throw lever is on the motor side of the machine CAUTION The hand throw pinion A B gear must be oriented correctly relative to the spring loaded clutch assembly Locate the applicable letter L or R stamp on the hand throw gear 100 and the marks made during disassembly on the hand throw pinion A B gear 95 With the hand throw lever held vertical count the teeth on the hand throw pinion A B gear needed to align the marks made during disassembly with the applicable letter L or R stamp Reinstall the hand throw pinion gear at the top of the crank in the correct position Align the motor cutout pushrods to the plunger Set the top bearing cap 10 over the two locating pins in the gear box casting Push the bearing cap down until it seats against the casting If required tap the bearing cap lightly and evenly until it seats on the casting Secure the bearing cap using four 1 2 inch bolts different lengths insert bolts in holes as noted during d
141. st should include mechanical operation of the switch mainline and electrical tests of power distribution and switch control and indication circuits Erratic or faulty operation and or indications should be promptly referred to the proper authority for corrective action SM 9662 Rev 1 October 2009 4 3 Field Maintenance 00515 4 4 EBNC Unit Test When an EBNC unit is installed In the switch machine and there is some question of its proper operation it can be tested using a 12 VDC test source power supply or battery and multimeter o 10 The top LED will light and the relays will switch The multimeter should display about 12 V DC Reverse the connections WAGO terminals 36 34 The top LED will light and the relays will switch The multimeter should display about 12 VDC m A 92 N 4 4 CAUTION Disconnect plug connectors and TB2 at the ECC before connecting an external supply at the WAGO terminal strip Failure to do so may result in damage to the ECC and or MCU EBNC Disconnect plug connectors and TB2 at the ECC Connect test source common to the WAGO terminal labeled 31 Connect test source positive to the WAGO terminals labeled 29 and 30 Connect test source common to Cable 1 GR Y Connect test source positive to Cable 1 Wire 3 Set the multimeter to DC volts Connect multimeter c
142. tasks is shown in Table 4 1 The actual time interval will depend on the customers own operating rules and or experience 4 1 1 Inspection Inspection is conducted in two areas the switch layout area and the switch machine itself Inspection consists of observing the appearance and integrity of the switch points switch rods connecting rods possible switch obstructions electrical connections and the interior of the switch machine A judgment 15 then made as to whether a potential or obvious faulty condition exists When any faulty condition is observed it 15 to be corrected immediately 4 1 2 Switch Layout Inspection Perform switch layout inspection as follows 1 Check that ties are well tamped to withstand vibration and strain caused by passing trains 2 Check that tie plates tie straps rail braces and switch fittings are secure 3 Check that there are no signs of water accumulation around switch machine proper drainage exists 4 Remove any material within the layout that could obstruct switch movement SM 9662 Rev 1 October 2009 4 1 N Field Maintenance AnsaldoSTS Table 4 1 Preventive Maintenance Schedule Functional Circuit Maintenance Action Interval or Equipment Route Insp Perf Test Monthly Switch Layout X Semi annually Switch Machine C LE Semi annually Switch Machine EE NN NE UE GET E Monthly Switch Machine Loue 4 1 3 Switch Machine Inspection Perfo
143. tch and on the bottom for the other position and as the lock box likewise has one dog on top and the other on the bottom it follows that the slide bar with its lock box can complete its stroke only if the lock rods are shifted by the switch points to the position corresponding to proper point closure When the stroke is completed the switch is secured by the locking The stroke of the slide bar and its lock box is such that the locking dogs provide adequate interlock with only the lock rod that the dog enters first Therefore the lock box and the lock rods must be so assembled that the dogs will enter the narrow notches first The procedure for inverting the lock box when necessary is given in paragraph 2 16 6 A TYPE GENERALLY USED WITH BALL AND SOCKET CONNECTION B TYPE USED WITH RIGID CONNECTION Figure 3 4 Adjustable Lock Rods for RH and LH Operation 3 3 Gear Train The reduction gear train between the motor and the worm gear comprises a pinion on the end of the motor shaft one or two reduction gears clutch gear friction clutch worm shaft and worm gear see Figure 3 5 and Figure 3 6 Note that each reduction gear actually comprises two SM 9662 Rev 1 October 2009 3 5 N Operation 77 AnsaldoSTS gears a large gear and a small gear made as a unit The gear ratio is changed by changing out the reduction gears using the combination indicated in the accompanying tabulation Table 3 1 Gear Ratio Reduction Gear R
144. tch assembly is shifted up or down by 180 degrees of rotation of the selector lever the inner crank finger of which swings the selector clutch yoke up or down This yoke has rollers on each side engaging the upper and lower spring cups of the selector clutch assembly The selector clutch assembly see Figure 3 8 has a spool shaped core made in two parts which are screwed together and are held from becoming unscrewed in service by the splines in both portions The upper part or clutch for hand operation has a single tooth on top for engaging the hand throw pinion which requires strict agreement of the hand throw lever position with the position of the switch when engaged The lower part has five teeth for engagement with the worm gear The upper and lower parts are separable only when the assembly is removed from the splined shaft this arrangement is used to permit assembly of the spring and two spring cups The spring cups are ordinarily held tightly against the upper and lower flanges of the core by the compression force of the spring When the selector lever is operated 180 degrees from the position shown one end of the selector clutch yoke lifts so that its lower rollers push upward against the underside of the flange on the lower spring cup If the switch is in the position corresponding to the position of the hand throw lever so that the tooth of the hand throw pinion 15 aligned to receive the tooth of the clutch for hand operation
145. troller compartment when the switch travels full stroke 1 Move the switch machine to either full stroke position N or it is not critical Ensure that the switch 1 locked with the switch point closed and up against the stock rail 2 Loosen the PD bracket AAR nuts Lift the serrated bracket and slide the sensor toward the PD target keeping the bracket elevated so as not to engage the serrations 3 Move the sensor to the target s edge until the corresponding Point Detected LED on the ECC box just turns Green 4 Lower the serrated bracket to determine the ON OFF threshold location in the serrations Lift and move the sensor bracket three 3 additional serration positions 3 16 inch toward the center of the machine to assure that the sensor is not adjusted right on the ON OFF threshold This will ensure that a 1 4 inch point obstruction 15 detected but the points will be allowed some movement up to 3 16 inch so as not to cause intermittent indication failures under shock and vibration conditions Auxiliary Sensor Gap 0 040 Gap 0 075 Figure 2 7 Sensor Gap Definition Non Vital Sensor Shown is Optional 2 18 SM 9662 Rev 1 October 2009 AnsaldoSTS Installation and Adjustments PD Target Position during Setup Figure 2 8 Initial Point Detector Bar Setup 5 The sensitivity of the vital sensors can be adjusted in 1 16 inch increments to accommodate for excessive lost motion in the external p
146. witch Rod Installation and Adjustment Connect the switch operating rod and adjust the rod nuts at the switch basket to obtain the proper point pressure in accordance with local operating rules Nothing is gained by using excessive pressure SM 9662 Rev 1 October 2009 2 1 Installation and Adjustments AnsaldoSTS Figure 2 1 M 3 Switch Machine Typical Application 2 2 SM 9662 Rev 1 October 2009 AnsaldoSTS Installation and Adjustments Figure 2 2 M 23 Switch Machine Typical Application SM 9662 Rev 1 October 2009 2 3 5 Installation and Adjustments Z AnsaldoSTS 12 1 4 2 TOP VIEW usd XY T FOR i 718 MOUNTING HOLES Pw a1 56 0 SOO 15 3 16 E UNFINISHED LUGS 18 50 FINISHED 18 250 LUGS 18 238 1 7 16 pn la BAR G LOCK 16 7 8 a 1 Fa I J 21 3 4 16 3 4 S i i i SHORT COVER 7 1 2 6 1 2 LONG COVER 5 3 1 2 SIDE VIEW END VIEW sp sas Figure 2 3 M 3 Switch Machine Typical Mounting Plan 2 4 SM 9662 Rev 1 October 2009 q Z AnsaldoSTS Installation and Adjustments EE 5 3 4 2 7 112 ehe 6 1 2 2 5 8 d 4 MOUNTING
147. y seated corrected go to C C ECC may be bad Replace ECC A Verify proper voltage at least 2 10 applied with proper If voltage is low or reversed correct some or all may or polarity to WAGO terminals 17 and verify operation may not return or and 20 with sufficient current appear to flash 1 1 If voltage applied is correct go to Could also appear B Remove JB1 from ECC and If condition is not as described go to C as a flickering check for both indication inputs conati Bir condition with motor disable and flashing RED si S Wen TUE possible clicking point locked detected indications PrOPadly Junction 00x or sensors B If connections are fully seated and ommonly on h JE be bad motor 222 Check TB1 connections to good E to lash If bad connection correct by reseating PP or replacing bad harness SM 9662 Rev 1 October 2009 6 5 N Troubleshooting 77 AnsaldoSTS Symptom Troubleshooting Possible Cause LEDs are properly red WAGO 3 to TB2 3 and lit on the ECC a green WAGO 1 to TB2 7 If connections bad replace harness continuous vertical row of GREEN LEDS is observed but no indication B ECC may be bad Replace ECC output present on WAGO terminals 1 and 3 Verify proper sensor air adjustment Should be 0 075 for vital sensors large diameter For auxiliary sensors small

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