Chicago Transit Authority
Contents
1. SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Installation 4 2 Installation Procedure The following procedure is for the replacement of an old DM style electromechanical or DM style solid state code transmitter relay with the shelf mounted SSCT relay Disable all power from the unit being replaced and from any nearby circuits Failure to do so could result in physical harm serious injury or loss of life CAUTION Observe voltage and current requirements listed on the label of the SSCT Do not exceed maximum voltages If these restrictions are not followed damage to equipment could result 1 Observe all warning and caution statements listed throughout this manual Follow the safety policies established for your work site regarding the installation of electronic equipment 2 To prevent wiring mistakes when installing the unit note the connections and arrangement of the wiring to the old unit 3 Detach the wire leads and remove the old unit 4 Place the unit in position making sure that at least one set of indicating LEDs is easily visible see Figure 1 1 5 Referto the locations of the tags identifying the terminals of the SSCT Do not remove the terminal identifying tags from the unit 6 Connect the wires to the AAR terminals of the unit in the same manner as they were connected to the old unit Verify that the wiring is in accordance with the schematic diagrams and wiring instructions for2. 0 130 3 2 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Functional Description 3 2 Detailed Functional Description Internal electronics are divided between two printed circuit boards PCBs a timing PCB and an output PCB The timing PCB generates timing signals used to actuate the switching circuits at the designated rate The output PCB contains the switching circuitry On the timing PCB the primary timing signal is generated by a sine wave oscillator This timing signal feeds a pair of comparators The non inverted square wave output of one of the comparators is used as a timing signal for front switch control This inverted square wave output of the other comparator is used for back switch control There is a time delay between the instant that the front switches off and the back switches turn on and conversely when the backs turn off and the fronts on This delay prevents the two on periods from overlapping and simulates a break before make contact operation On the output PCB the comparators timing signals are optically coupled to solid state switching devices These switching devices are of two different types The first type uses field effect transistors FETs for switching low voltage AC or DC signals The second type uses triacs for switching higher AC voltages The low voltage device is rated at 32 VDC rms or 22 VAC rms at 2 5 amp maximum The high level switching device is rated at 150 VAC rms and 4 0 amp m
3. UNION SWITCH amp SIGNAL List of Figures Shelf Mounted SSCT iei rtr dete re ret tnter tate ou tectis 1 1 Shelf Mounted SSCT Typical Identification Label 2 2 DM SSCT Functional Block Diagram 3 1 Relay Terminals and Internal 3 2 Overall Dimensions and Mounting Holes for the Shelf Mounted SSCT 4 1 Installation Check ESL ipeo odis t nismaa esae be ptg oratore tiones 4 3 DM SSGT GITOUIE esce coscessaesenececenccestauarcesapenseeseseaenssearercesboeassssanmerentbes 5 3 List of Tables Abbreviations and ACFOTVITIS FREE XR EUR 1 2 Part Number Cross Reference 1 3 General Specifications Cu uuu E AA AEA 2 1 Miming Parameters aaa auqa 3 2 SoGT Troubleshoolllgs BUSS UUES 6 1 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Introduction 1 Introduction 1 1 Introduction and Applications The shelf mounted solid state code transmitter SSCT Figure 1 1 is designed to be a functional electronic replacement for the Union Switch and Signal US amp S DM style electromechanical and DM style solid state code transmitters The original electromechanical DM style code transmitter is a relay that needs to be periodically inspected and serviced The shelf mounted SS
4. table lists the code rate operating voltage and the contact configuration of the relays Table 1 2 Part Number Cross Reference Shelf Replaced Old Mounted DM Style SSCT Electro Part mechanical Unit Number Part Number N242040 N242041 4 Front 4 Back WAO TATS NE N276412 92001507 EINEN Low Voltage sw 4 Front 4 Back High Voltage Replaced DM Style Operating Voltage VDC Contact Configuration N242042 N242043 N242043 N32001504 ETE 16 2 Front 2 Back Low Voltage 1 2 N40701603 N242045 2 Front 2 Back High Voltage 13 144 N40701604 N221553 N221558 N32001506 16 4 Front 4 Back Low Voltage N40701605 N221554 N221556 N32001503 n EN ante Back High Voltage 2 Front 2 Back Low Voltage 1 2 N40701606 N221560 16 2 Front 2 Back High Voltage 3 4 4 Front 4 Back N40701607 N221552 N221559 N32001505 ETE Low Volt ge N40701608 N221555 N221557 N32001502 ETE sw 4 Front 4 Back High Volttage 2 Front 2 Back Low Voltage 1 2 N40701609 N221561 N32001501 16 2 Front 2 Back High Voltage 3 4 SM 8524A Original August 2005 1 3 UNION SWITCH amp SIGNAL Introduction 1 4 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Specifications 2 Specifications Table 2 1 lists the general specifications for the shelf mounted SSCT Refer to the label of your particular unit for the specifications unique to
5. that configuration CAUTION Observe voltage and current requirements listed on the label of the DM SSCT Do not exceed maximum voltages If these restrictions are not followed damage to equipment could result Table 2 1 General Specifications Parameter Specification Power Supply Input Voltage 8 to 16 VDC Reverse voltage protected operating range Current Consumption 100mA maximum Output Switch Rating Low Voltage AC DC 2 5 A 32 VDC maximum or 22 VAC rms maximum on resistance is 0 5 ohms short circuit protected High Voltage AC only 4 0 A 150 VAC rms maximum AC only External 6A fuse required for short circuit protection Voltage drop across the switch is 1 25 VAC rms independent of current Outputs 4 pairs of front heel back Form C Operating Temperature 40 to 70 C non condensing at 0 to 95 humidity Dielectric Strength 2000 VAC rms between all external isolated connections and case except across open switches which are limited by TranZorb or metal oxide varistors MOV protection Maximum voltage is determined by a TranZorb to protect DC switches from excessive voltage spikes when operating code following relays for the AC version a 150 VAC rms MOV is similarly used anticipating 120VAC rms as the source voltage 2 1 Identification The identification label is mounted on the front of the unit This label provides important information about the shelf mounted SSCT A typical label is shown in Figure 2
6. your application 7 Complete the installation checklist Figure 4 2 8 Make a copy of the completed check list and file for future reference 9 Verify the unit is installed properly and is operational Section 4 3 4 2 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Installation Installer Date Installation Location SSCT Part No Code Rate Serial No Yes No Voltage restrictions on the label have been followed o o Replacement unit is connected in same manner as the unit being 3 3 replaced Wiring is in accordance with applicable schematic diagrams and n n wiring instructions Terminal identifying tags of the new unit have not been removed o o Insulating sleeve and insulating nut installed on all AAR terminals n n if required Figure 4 2 Installation Check List 4 3 Operational Verification Test This test is performed to verify proper installation before a unit or system is placed into regular service To properly verify the operation of the SSCT test the unit as follows 1 Make sure that all the requirements of Section 4 Installation have been met 2 Restore power to the system of which the shelf mount SSCT is part 3 Verify that the unit is functioning properly in an alternating manner with similar on and off periods If a problem is suspected check the connections and correct if necessary If a problem is still suspected see Section 6 4 Verify that the system of
7. 1 SM 8524A Original August 2005 2 1 UNION SWITCH amp SIGNAL Specifications SOLID STATE CODE TRANSMITTER CODE RATE CODE RATE 120 CONTACT CONFIGURATION 1F AC DC 1B AC DC 2F AC DC 2B AC DC VOLTAGE 3F AC ONLY 3B AC ONLY RESTRICTIONS 4F AC ONLY 4B AC ONLY NOTE AC DC LOW VOLTAGE ONLY 32 VDC OR 22 VAC RMS AC ONLY 150VAC RMS MAX Figure 2 1 Shelf Mounted SSCT Typical Identification Label 2 2 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Functional Description 3 Functional Description 3 1 Functional Overview Referring to Figure 3 1 the SSCT contains four pairs of output switches Each switch pair has three connections front F back B and heel H The number associated with each connection denotes the switch pair For example 1F is the front connection and 1B is the back connection of the switch pair 1 The terminals are mounted on the top of the relay and are shown in Figure 3 2 The function of the SSCT is to switch the heel H connection between the front F and back B connections at a specific rate The four back switches are actuated simultaneously by the front output controller The four back switches are actuated simultaneously by the back output controller NOTE Even though switching is accomplished by solid state components the familiar nomenclature of relays front back and heel is used A solid state switch pair perfo
8. CT like the DM style SSCT contains only electronic components The only difference between the DM style and the shelf mounted SSCT is the package and contact arrangement Code transmitters turn an AC or DC input on and off at a specific rate Standard electromechanical DM SSCT units are available for transmitting at nominal rates of 50 75 120 180 275 and 420 cycles per minute cpm Other rates are also available by customer order The shelf mounted SSCT relays replace the most popular code rates of 75 120 and 180 cpm 1 2 Purpose of Manual This service manual provides descriptive information specifications and installation and maintenance procedures for the shelf mounted SSCT LEDS ARE VISIBLE THROUGH THESE HOLES Figure 1 1 Shelf Mounted SSCT SM 8524A Original August 2005 1 1 Introduction UNION SWITCH amp SIGNAL 1 2 1 Abbreviations and Acronyms Table 1 1 lists the abbreviations and acronyms used in this manual Table 1 1 Abbreviations and Acronyms Term Definition A Ampere AAR Association of American Railroads AC Alternating Current CAUTION Caution statements indicate conditions that could cause damage to equipment Cpm Cycles per minute DC Direct Current DM Style The designation for a line of US amp S electromechanical code transmitters in cylindrical enclosures with AAR terminal connections designated for freestanding shelf installation FET Field Effect Transistor Form C A single p
9. Overview dalla eed cub tual dated o ita cett cati at td i eed a 3 2 Detailed Functional Crib a E 41 Installation OVerVI W sciiicet e Er Er eh Ex MAA t RETE E REPRE 4 2 Installation PIOGSdUre usse trot e a a A 43 Operational Verification 5 Operation Maintenance aS na bb life Abre Sul OPSAUON ecce takt ame 52 Field TS 2 2 l OMAD matma aada aa m a a 5 2 2 Preventive Maintenance nnnneneennnnnenennnnnnanennn naene nan 5 23 edoctus Gao ne DU DDR DNE DEOR DOLAR DUE DC RA ps 5 24 Adjustme ntzu uu u xm 2 9 Shop Maintenance u uuu TT 5 3 1 Equipment Required dem aa 5 32 TestiProeed r RERUMS 6 Troubleshooting oinnia erri nan av a vaa hd aaron duco Yan ra nasa aaa cut uad 6 1 Repairing Replacing rtt ttrtennnnn rnnr eene T Technical S pport u a aaea a RR SNR SM 8524A Original August 2005 Table of Contents Figure 1 1 Figure 2 1 Figure 3 1 Figure 3 2 Figure 4 1 Figure 4 2 Figure 5 1 Table 1 1 Table 1 2 Table 2 1 Table 3 1 Table 6 1
10. UNION SWITCH amp SIGNAL Union Switch amp Signal Inc an Ansaldo Signal company 1000 Technology Drive Pittsburgh PA 15219 e 645 Russell Street Batesburg SC 29006 SM 85 24 Shelf Mounted Style Solid State Code Transmitter N407016XX Replacement for DM Style Electromechanical and DM Style Solid State Code Transmitter 0585 Part No N40701601 N40701602 N40701603 N40701604 N40701605 N40701606 N40701607 N40701608 N40701609 Installation Operation Copyright 2005 SM 8524A August 2005 Union Switch amp Signal Inc Original UNION SWITCH amp SIGNAL Notices Proprietary Notice This document and its contents are the property of Union Switch amp Signal Inc hereinafter US amp S This document has been furnished to you on the following conditions no right or license under any patents or any other proprietary right in respect of this document or its content is given or waived in supplying this document This document or its content are not to be used or treated in any manner inconsistent with the rights of US amp S or to its detriment and are not to be copied reproduced disclosed to others or disposed of except with the prior written consent of US amp S Important Notice US amp S constantly strives to improve our products and keep our customers apprised of changes in technology Following the recommendations contained in the attached service manual will provide our customers with optimum o
11. aximum Refer to the product s label for each switching path s configuration and corresponding power restriction SM 8524A Original August 2005 3 3 Functional Description UNION SWITCH amp SIGNAL 3 4 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL 4 Installation 4 1 Installation Overview Installation The shelf mounted style code transmitters are freestanding units designed for installation on a shelf or on another flat surface The shelf mounted SSCT will replace an electromechanical DM style or a solid state DM style code transmitter The units connect in the same manner as the replaced model The overall dimensions of the shelf mounted units and their mounting holes are shown in Figure 4 1 lt 4 56 gt D S AAA TERN A Ls yo x CM ND I I II II I I I l lI A 1 1 I II Il li I II Il A li II ll II 0 0 I 0 i 0 0 I li II lI 1 li II Y MEETS 53 3 5 53 lt gt 63 229 63 14 E 317 Y 5 A E AM a y Ni E wd eR IL E aa 25 R sisi Sl et Y Y 2 2 a Y Y m Y ad 8 A i IN io Ie 225 gt 28 DIA HOLE 6 Figure 4 1 Overall Dimensions and Mounting Holes for the Shelf Mounted SSCT
12. ervice SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Operation Maintenance 2A FUSE 115 VAC UNIT UNDER TEST 4F 4H 3F 3H LOW VOLTAGE TRANSFORMER 12 VDC sO SO lt gt lt gt UJ CODE RATE MONITOR Figure 5 1 DM SSCT Test Circuit SM 8524A Original August 2005 5 3 UNION SWITCH amp SIGNAL Operation Maintenance 5 4 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Troubleshooting 6 Troubleshooting Table 6 1 lists various symptoms their possible cause and the recommended corrective action to take to eliminate the symptom Table 6 1 SSCT Troubleshooting Section Reference Symptom Possible Cause Corrective Action Not coding Check that power is Power input not applied at the unit present Check the connections Replace the SSCT SSCT internal failure Perform a shop test on the removed unit Symptom does Replace the SSCT not produce SSCT internal failure Perform a shop test on expected code the removed unit rate i Failure external to Perform a svstem test SSCT d 6 1 Repairing Replacing Components There are no repairable or replaceable components in the SSCT Return a malfunctioning unit to US amp S for service Call the US amp S Rail Team Section 7 for assistance SM 8524A Original August 2005 6 1 UNION SWITCH amp SIGNAL Troubl
13. eshooting 6 2 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Technical Support 7 Technical Support The Rapid Action Information Link Team RAIL Team is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this project Contact the RAIL Team at 1 800 652 7276 Or by e mail at railteam switch SM 8524A Original August 2005 7 1 Technical Support UNION SWITCH amp SIGNAL 7 2 SM 8524A Original August 2005
14. is functioning correctly Specifically the test will indicate if the code rate of the SSCT is within tolerance 5 3 1 Equipment Required e 12 VDC power supply e AC power supply with 15 VAC output SM 8524A Original August 2005 5 1 Operation Maintenance UNION SWITCH amp SIGNAL Code follower relay Code rate meter Diode bridge rectifier 2amp 15VAC fuse Test Procedure The testing equipment produces potentially hazardous electrical power Use caution when testing Failure to do so could result in physical harm serious injury or loss of life CAUTION Observe voltage and current requirements listed on the label of the SSCT Do not exceed maximum voltages If these restrictions are not followed damage to equipment could result CAUTION Do not attempt to electrically test the SSCT in any other manner than that depicted by the test circuit of Figure 5 1 If any other testing method is used damage to the equipment could result Construct the test circuit as shown in Figure 5 1 Connect the SSCT per Figure 5 1 Set the code rate meter to the code rate of the SSCT being tested Refer to the instruction manual for the code rate meter for operational details Check that the code rate meter indicates that the SSCT 15 within tolerance If the SSCT is within tolerance then the unit is functioning correctly If the SSCT is not within tolerance the unit is malfunctioning and should be returned to US amp S for s
15. ole double throw break before make contact set This type of contact set with front heel and back contacts was used in the original DM Style code transmitter The switch pair of the DM SSCT is the solid state equivalent of a Form C contact set FRA Federal Railroad Administration in Inch LED Light emitting diode MOV Metal Oxide Varistor protection device for electronic components PCB Printed Circuit Board RMS Root Mean Square method of expressing AC voltage rating SSCT Solid State Code Transmitter TranZorb Registered Trademark of a transient voltage suppression device manufactured by General Semiconductor Inc Triac Solid state semiconductor switch US amp S Union Switch and Signal Inc V Volt WARNING Warning statements indicate conditions that could cause physical harm serious injury or loss of life 1 2 SM 85244 Original August 2005 UNION SWITCH amp SIGNAL Introduction 1 3 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 1 4 Part Numbers Table 1 2 provides a list of the part numbers for the Shelf Mounted SSCT units and cross references part numbers for the old DM style electromechanical and SSCT units In addition the
16. perational reliability The data contained herein purports solely to describe the product and does not create any warranties Within the scope of the attached manual it is impossible to take into account every eventuality that may arise with technical equipment in service Please consult your local US amp S Account Executive in the event of any irregularities with our product We expressly disclaim liability resulting from any improper handling or use of our equipment even if these instructions contain no specific indication in this respect We strongly recommend that only approved US amp S spare parts be used as replacements SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Revision History REVISION HISTORY ii SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Tate ot Contents Table of Contents LEE isi PE 1 1 Introduction and Applications a 1 2 Manual eee aeaee eae anete artan arene etin iaeiei 1 2 1 Abbreviations and SAEPIUS 1 4 FAN IN UGS secte Ede duin 2 Specifications isss ene esie cui rcc inci ud ivi cx c na e Rc we C 21 91 11311182 19727 OPER ERE CUM DE LER PEE ES eo eto 3 Functional Description auct Braut UR V CE TY u 3 1 Functional
17. rms the same function as an electromechanical contact set Since the shelf mounted SSCT is a solid state replacement for an electromechanical unit its circuits are designed to emulate the toggling or pendulum action of relays With a code transmitter relay an electromagnet attracts and then releases an armature the resulting motion alternately closes and opens an opposing pair of contacts As with a pendulum there is a neutral position where neither set of contacts is closed consequently the on time for each front and back circuit is less than 50 of one full on off cycle See Table 3 1 for timing parameters STEADY Y 1F ENERGY INPUT 4H A MB COIL i o oF CODE RATE 2H GENERATOR T CONTROL 3H Es FRONT 1 4 SF LR 3B v BACK A SR CONTROL 4H Figure 3 1 DM SSCT Functional Block Diagram SM 8524A Original August 2005 3 1 UNION SWITCH amp SIGNAL Functional Description TYPICAL INTERNAL CONNECTION 4F 4H 4B 3H 3B 2 2 2B 1H 1B Figure 3 2 Relay Terminals and Internal Wiring Table 3 1 Timing Parameters Nominal Code Rate cpm On Time On Time Percentage Seconds 45 A7 0 4120 0 357 120 44 46 0 236 0 205 180 42 44 0 151
18. which the shelf mounted SSCT is part is functioning correctly If a problem is suspected with the SSCT see Section 6 SM 8524A Original August 2005 4 3 Installation UNION SWITCH amp SIGNAL 4 4 SM 8524A Original August 2005 UNION SWITCH amp SIGNAL Operation Maintenance 5 Operation Maintenance 5 1 Operation The SSCT is a component that when powered operates continuously without intervention There are no operating procedures for this unit 5 2 Field Maintenance 5 2 1 Schedule Since there are no Federal Railroad Administration FRA requirements for periodic inspections of solid state code transmitters periodic verification of the shelf mounted SSCT operation is at the customer s discretion 5 2 2 Preventive Maintenance Before beginning this procedure make sure that all power is disabled from the unit from any nearby circuits Failure to do so could result in physical harm serious injury or loss of life Clean any dust and dirt from the top assembly AAR terminals and attaching hardware with a clean dry cloth 5 2 3 Calibration The shelf mounted SSCT is calibrated at the factory There are no calibration procedures that can be performed by the customer 5 2 4 Adjustment There are no adjustment procedures for the SSCT 5 3 Shop Maintenance Because the shelf mounted SSCT does not contain any serviceable parts shop maintenance is limited to a performance test to determine if the unit
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