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1. s 6 9 9 4 Uu Iv fo ro lt H OV 6 9 ALIGNMENT AND ADJUSTMENT PROCEDURES FIELD INSTALLATION RECORD TESTING AND FINAL CHECKS Operational Test Final Checkout CONTROL CIRCUITS AND FUNCTIONAL OPERATION GENERAL TRAIN DETECTION TRACK CIRCUITS Type C Track Circuit Motion Monitoring Track Circuit Audio Frequency Overlay AFO Track Circuit Direct Current DC Track Circuit High Frequency Track Circuit ACTIVATION CONTROL CIRCUITS POWER REQUIREMENTS FUNCTIONAL OPERATION Audio Frequency Overlay Train Detection Warning Activation Flashing Warning Lights Gate Activation Warning Bell Warning Activation by Manual Operation Control Optional Control and Timing Applications Signaling System Tie In Reverse Traffic Direction Warning Activation MAINTENANCE GENERAL PREVENTIVE MAINTENANCE Cleaning Equipment Materials Required General Cleaning Procedures Inspection Grade Crossing Equipment Control Equipment Lubrication SYSTEM OPERATIONAL TEST TROUBLESHOOTING CORRECTIVE MAINTENANCE REPLACEMENT PARTS GENERAL REPLACEMENT LAMPS ii PAGE 3 16 3 16 3 16 3 16 3 18 4 1 1 4 1 4 1 2 4 3 4 4 5 6 4 6 4 7 4 7 4 8 4 8 4 10 4 10 4 10 4 10 4 10 4 102. SERVICE MANUAL 5958 Description Installation and Maintenance GRADE CROSSING WARNING SYSTEMS THIS MANUAL SUPERCEDES SM5958 DATED SEPTEMBER 1982 WP0087D 5800 CORPORATE DRIVE PITTSBURGH PA 15237 A 3 85 300 1751 1 2INTED USA March 1985 UNION SWITCH SIGNAL INC RACE tri t T TH ak ern rim nan tnm amp D UNION SWITCH amp SIGNAL REVISION INDEX This service manual supercedes all previously issued SM5958 manuals Destroy all previously issued manuals Future revisions to this manual will be handled by and addendum where as revised pages will be provided only SECTION I e 9 e 9 9 5 41 9 85 NOAM EFEWNAYNNS lt l l3 L cA 1 H 9 4 9 96 9 H o e e nm N WOON DV gt Wi uU UJ UJ UJ UJ UJ 0 UJ UJ UJ UJ UJ UO UO OO CONTENTS GENERAL INFORMATION INTRODUCTION EQUIPMENT DESCRIPTION Flashing Light Assembly HC
3. ORDERING INFORMATION DESCRIPTION J026104 PINNACLE for 4 diameter mast J026111 PINNACLE for 5 diameter mast 451195 3601 RODENT COVER PLATE for 4 diameter mast M451195 3602 RODENT COVER PLATE for 5 diameter mast N199590 STEP GALVANIZED includes mounting hardware RSE 10B1 p 2 JUNCTION BOX BASES FOR 4 5 INCH MASTS U S amp S junction box bases are constructed of aluminum for easy handling long life and minimum main tenance They provide for terminating leads at the mast base These junction box bases facilitate installation and maintenance L 4 11 11 16 11 1176 11 11 16 C C1 C2 MAST FDN BOLT BASE NO PART NO DIA SPACING HEIGHT TERM NOTES 12 705049 0201 9 1 2 Not For Use With Gates J705049 0203 9 1 2 Plain Clamp Base J705049 0602 11 11 16 J705049 0801 11 11 16 J705049 0901 11 11 16 For FOUNDATION BOLTS see RSE 10F 1 UNION SWITCH amp SIGNAL DIVISION RSE 10B2 one AMERICAN STANDARD INC SWISSVALE PA 15218 REV 8 80 GRADE CROSSING SIGNS US amp S grade crossing warning signs are made of aluminum and include all hardware necessary for mounting Signs can be ordered in engineering grade Scotch Lit or Hi Intensity reflex reflection US amp S signs conform to AAR requirements RAILROAD CROSSING SIGN All aluminum construction with black lettering and includes mounting hardware STANDARD PART NO MA
4. well as normal traffic direction approaches to a grade crossing warning location If this were the warning activation would commence upon occupancy of the approach track eircuit for a normal direction running track and upon occupancy of the island track circuit slowed or stopped train or an additional approach track circuit for a reverse direction running track Warning deactivation would commence upon vacaney of the island track circuit for either direction of traffic 5958 Pe 10 4 UNION SWITCH amp SIGNAL D SECTION V MAINTENANCE 5 1 GENERAL The maintenance procedure provided in this manual are limited to field maintenance Maintenance procedures beyond the scope of this manual and shop maintenance are covered in the applicable equipment manuals Procedures covered in this section include preventive maintenance troubleshooting and corrective maintenance 5 2 PREVENTIVE MAINTENANCE Preventive maintenance consists of routine cleaning inspection and operational tests Proper preventive maintenance will help to assure continued uninterrupted operation of the Grade Crossing Warning System The procedures and intervals are those recommended by Union Switch amp Signal Actual procedures and intervals depend on the customers own operation and past experience Table IV lists the maintenance actions to be performed and recommended frequency Ideally perform all procedures that are due at the same time For examp
5. APPROACH CONTROL 7011758 AT SIGNALS From Sec Train clears Road B v From 8 Sec Train Speed MPH T Train Speed MPH Sec eae ee FOU TIMING RELAY SET GATE OPERATION A sec HE Down sec after sigais DOWN A B sec A paE MENU Ua c0 i 1 5 oU ATTESTED US amp S REPRESENTATIVE DATE CUSTOMER REPRESENTATIVE DATE Figure 3 9 Record of Field Installation Operational Check 4 UNION SWITCH amp SIGNAL b Simulate the movement of a train by first applying a shunt in the approach section This will start the bell ringing the lights flashing and after 3 5 seconds flashing cause the gate arm to descend With the first section still shunted shunt the island circuit There should be no change Shunt leaving section Remove the first shunt No change should take place Remove the island shunt When the island shunt is removed the gate arm should assume its vertical position the lights should stop flashing and the bell cease ringing Leaving section is still shunted but no warning stick relay is bridging track circuit down When leaving section is clear system should return to normal and is ready for next move Repeat this procedure beg
6. b UNION SWITCH amp SIGNAL APPROACH A APPROACH B Lm TRANSCEIVER N451580 0101 N451580 0102 N451580 0201 E TRACK RELAY Figure 4 5 High Frequency Track Circuit 4 3 ACTIVATION CONTROL CIRCUITS The types of control circuits used to activate the grade crossing warning devices depend upon the specific application Control circuits can be designed for the very basic grade crossing or for the very complex for example overlapping track circuits Because the control circuits are designed for specific applications it is not practical to cover them in this manual A typical grade crossing control circuit is shown in Figures 4 6 For specific control circuits refer to the circuit diagrams for the particular installation 4 4 POWER REQUIREMENTS When two sources of power are provided in a local control case and approach end case storage battery capacity 15 maintained at all times with 4 5 ampere automatic battery charger operated by commercial power If cammercial power fails the battery charge is suspended and the entire system is operated from standby battery until power is restored AFO approach end cases are also designed for operation with primary batteries where commercial ac power is not available Type C track circuits are operated with low voltage ac output from an inverter The inverter will also invert dc to ac in conjunction with a power off transfer relay and standby battery during power
7. on the rail to assure good contact a Check all track circuits to see that the proper relay is being controlled from its respective section Shunting of the track assures this and in addition it verifies that proper direction is being selected 5958 3 16 a UNION SWITCH amp SIGNAL D UNION SWITCH SIGNAL OLVISION MN Sacuvana Poet Office 15218 UNION SWITCH amp SIGNAL RECORD OF FIELD INSTALLATION OPERATING TESTS CUSTOMER PROJECT GO LOCATION gt PLAN DWG SHEET DWG CKT DWG 727 TEST HIGHWAY CROSSING WARNING SYSTEM verify proper operation of systems being placed in service CONDITION TRAINS DAY TIME 3ETWEEN TRAINS BALLAST f mn aw DNE 2a V A C JOINTS 2 A C LINE TRACK NO TRACK RELAYS TYPE CONTROL BATTERY FULLY CHARGED BATTERY CHARGER LOCAL 3 TRACK 1 E N V D C 1 51 W S _ _ _ d TRANSF SECOND TAPS SENSITIVITY ADJUSTM CAFO MM 10 E N W S D QI Mark Slot Positior CROSSING INACTIVE CROSSING ACTIVATED m Second V TOTAL SIGNALS Operate Time Tra RECEDING CONTROL Crossing Clears after
8. system refer to the applicable installation diagrams 3 5 1 Ringout Circuits and Cables Ringing out a circuit simply means applying a buzzer or ohmmeter to the open ends of the wire to check continuity Each line should be checked prior to hookup then re checked as units when they have been terminated 3 6 ALIGNMENT AND ADJUSTMENT PROCEDURES Generally the alignment and adjustment to be accomplished upon completion of installation include signal light units grade crossing gate mechanism track circuits and the lamp intensity Alignment procedures for the light units are covered in paragraph 3 4 4 2 Complete alignment and adjustment procedures for the other items are contained in their respective service manuals Refer to these manuals Table I for these procedures 3 7 FIELD INSTALLATION RECORD A permanent record of the installation adjustments values ete for each site should be made An example of a form that can be used for this purpose is shown in Figure 3 9 When properly filled out this form will be a valuable aid in future servicing the equipment 3 8 INSPECTION AND TESTING 3 8 1 Operational Test To perform this test track sections must be shunted at the battery or feed end and at the relay end A satisfactory shunt arrangement should be of 0 06 ohms resistance A fifteen 15 foot length of 16 gauge insulated wire with ends soldered to files provides an adequate shunt While shunting the files can be
9. 120A Flashing Light Unit HC 100 Light Unit 120 Junction Box Crossarm Model 75 Crossing Gate Assembly Model 75 Gate Mechanism Gate Arms Counterweights Bell Unit Masts Junetion Box Base Signs Equipment Cases CONTROL CIRCUITS SUPPORTING PUBLICATIONS MATERIAL TOOLS AND EQUIPMENT APPLICATIONS GENERAL INSTALLATION GENERAL PRE PLANNING Cable and Wire Requirements Standards Equipment Location Data SITE PREPARATION Excavation Signal Mast Foundations Cantilever Foundations Control Case Foundations Trenching for Cables Backfilling and Grading INSTALLATION PROCEDURES Installation of Plain Clamp Base and Mast Installation of Junction Box Base and Mast Installation of Junction Box Crossarm Installation of Light Units Installation of Bell or Pinnacle Installation of Signs Installation of Equipment Cases Installation of Relays Installation of Crossing Gate Mechanism CONNECTING EQUIPMENT Ring Out Cireuits and Cables Q UNION SWITCH amp SIGNAL PAGE 1 1 1 gd 1 oub ad 110 N 4 4I 3 1 8 Q D UNION SWITCH amp SIGNAL Contents Cont d e 4 e 9 9 9 lt amp e e
10. 7 1 2 69 1 4 30 x 30 1368 ib PRECAST CONCRETE FOUNDATIONS FOR FLASHER SIGNALS AND FLASHER SIGNALS WITH AUTOMATIC GATES BY PERMACRETE PRODUCTS CORP Order by Model No height bolt length and total weight FOUNDATION BOLT HEIGHT BOLT BASE TOTAL MODEL NO CENTERS LENGTH 3 1 2 THICK WEIGHT FLASHER ONLY FOUNDATIONS 5 1 9 1 2 x 9 1 2 2 6 32 1 4 30 30 544 1 51 9 1 2 x 9 1 2 3 e 44 1 4 30 x 30 702 Ib 5 1 9 1 2 x 9 1 2 46 56 1 4 30 x 30 806 Ib 5 1 9 1 2 x 9 1 2 56 68 1 4 30 x 30 910 Ib FLASHER AND GATE FOUNDATIONS 52 11 11 16 x 11 11 16 36 44 1 4 30 x 30 1096 Ib 52 11 11 16 x 77 11 16 4 6 56 1 4 30 30 1293 Ib 52 11 11 16 x 11 11 16 56 68 1 4 30 x 30 1490 Ib 52 11 11 16 x 11 11 16 66 80 1 4 30 x 30 1686 Ib 52 11 11 16 x 11 11 16 7 e 92 1 4 30 30 1882 Ib 11 11 16 x 11 11 16 86 104 1 4 30 30 2078 ib Figure 3 6 Precast Foundations 5956 p 3 8 UNION SWITCH amp SIGNAL b 3 3 6 Backfilling and Grading a Backfill of trenches should not be done until a megger has been used on the cables to ascertain there is proper continuity and no crossed exposed wires b Pull concrete forms c Fill and grade level d Tamp fill thoroughly especially around signals equipped with gates and cantilevers 3 4 INSTALLATION PROCEDURES This section deserib
11. aluminum for long service life minimum maintenance and ease of installation The junction box used for interconnecting the wiring contains standard AAR terminals complete with terminal nuts and washers Removable end plates are provided on the arms for easier access to the wires for stringing Threaded elbows allow for independent horizontal azmiuth and vertical range adjustments of each signal Attaching hardware consists of U bolt clamp and nuts The nuts are located in the junction box 1 2 2 Model 75 Crossing Gate Assembly Figure 1 4 The Model 75 Crossing Gate Assembly consists of the Model 75 Gate Mechanism and either aluminum fiberglass or wood gate arms The automatic crossing gate is canpletely adjustable and is adaptable to 2 wire or 3 wire circuitry 1 2 2 1 Model 75 Gate Mechanism Figure 1 4 The gate mechanism is mounted on a steel chassis and is housed in an aluminum enclosure The mechanism comes either with the DN 22A relay for 2 wire control circuitry or without for 3 wire control circuitry The Gate is locked into the clear position by an electromagnetic brake the power fails the gate arm drops to the horizontal The mechanism consists of the following a permanent magnet dc electric motor which requires a nominal 12 volt power supply driving through a 115 1 gear reduction train a hold clear unit sanetimes called electric brake which is located on the motor armature shaft and a circuit controller a
12. for proper gate arm balance and operation 1 2 3 Bell Unit Figure 1 5 The bell unit is a Model BA 10 with a 12 inch steel gong mounted on a cast aluminum housing with a rain hood A hinged aluminum cover is provided for easy access to the operating mechanism The operating mechanism a rotary solenoid driving a clapper The solenoid is sealed against dirt and foreign material and requires no lubrication Operating voltage is 10 Vde producing a sound level of 105 113 dbA at 180 190 strokes per minute 1 2 4 Masts Figure 1 2 Masts for grade crossing warning assemblies come in two lengths 13 6 and 15 3 The 13 6 mast is used in standard installations while the 15 3 mast used for converging highway applications the 15 3 mast an additional hole is drilled at the appropriate degree from center to accommodate the additional crossarm Masts are constructed of aluminum for easy handling long life and minimum maintenance Both 4 and 5 diameter masts are available In general the 5 diameter mast is used when the grade crossing warning assembly is equipped with 222 gates Refer to Section VI for additional data including ordering information UNION SWITCH amp SIGNAL 1 2 5 Junction Box Base Figure 1 2 Aluminum Junction Box Bases are available for both the 4 and 5 diameter mast They are used to support the mast and for terminating underground cable and for making circuit connnections B
13. manuals b Remove accumulation of heavy dirt and grime with a lint free cloth dampened in a detergent solution Dry with clean cloth c With a cloth dampened in an approved solvent wipe clean the gate mechanism circuit control motor control relay contacts and hold clear amature of any oil and dirt that may have accumulated dur ing operational service d Flashing Light Units 1 Clean glass roundels and glass reflectors with a clean cloth moistened with a detergent solution Wipe dry Use an approved solvent for hard to remove dirt or grease 2 Clean plastic roundels by flushing with clean water using a chamois or soft cloth Use a detergent for hard to remove dirt CAOTION Do not use any solvents on plastic roundels 3 Remove dirt from hoods and background witn a damp cloth moistened in a detergent solution 5 2 2 Inspection Inspect the equipment for damaged parts etc in accordance with the following paragraphs Any parts found to be damaged during inspection should immediately be repaired or replaced Refer to Section VII Corrective Maintenance 5958 p 5 2 5 2 2 1 UNION SWITCH amp SIGNAL D Grade Crossing Equipment Broken or cracked light unit roundel and or reflector Broken light unit case door or other parts Damaged lamp receptacle Faulty or damaged door gasket which would result in water leaking into the case Burned out or broken light unit or gate arm lamps Broken or cracked lens on gate
14. 005 4 Hi Intensity X392930 002 5 Engineering Grade X392930 006 5 Hi Intensity X392930 004 10 Pipe Mast Engineering Grade X392930 007 10 Pipe Mast Hi Intensity X451506 0720 10 11 Tapered Mast Engineering Grade X451506 0721 10 11 Tapered Mast Hi Intensity WITH STAND OFF for Wooden Gate Arms PART NO MAST SIZE LETTERING X438077 4 5 Engineering Grade X438007 001 4 5 Hi Intensity STAND OFF BRACKETS Includes hardware 4 5 MAST SIN N438004 001 Railroad Crossing N437999 Tracks N438078 Stop On Red Signal 10 11 MAST PART NO X451506 0710 Railroad Crossing X451506 0713 Tracks X451506 0719 Stop On Red Signal RSE 10B3 p 2
15. 10 b 4 UNION SWITCH amp SIGNAL D Remove the elbow from the crossarm bracket and fasten to the light unit Carefully feed the pigtail from the light unit through the bracket and through the arm to the junction box End plates on the arms may be removed to facilitate stringing the wires A fish tape may also be helpful NOTE If extension arms need to be attached signal light brackets must be removed from junction box assembly Remove the four screw nuts and washers that secure the signal light brackets to junction box assembly Brackets can now be removed Align the four holes in the extension arm cover plate with the holes in the junetion box assembly making sure that the gasket is between these two pieces Install the four screws Slide gasket and signal light bracket or an extension arm whichever is required onto the screws Install the four washers and nuts Renaining brackets must now be installed Align the four holes in the cover plate of signal light bracket with the holes in extension arm cover plate Make sure gasket is between these two pieces and install screws washers and nuts At this point it is best to have arranged a fish wire or fish string through the crossarm and any extensions there might be so that the signal unit with elbow attached can be assembled to the remaining part of the crossarm unit as the fish wire is tied to the lamp pigtail and pulled through to the jumction box Secure the light un
16. 4 9 4 11 UNION SWITCH amp SIGNAL Figure 1 1 Typical Grade Crossing Warning System iV HRS UNION SWITCH SIGNAL v SECTION I GENERAL INFORMATION 1 1 INTRODUCTION This manual provides a complete overview of Union Switch amp Signal s Grade Crossing Warning Systems Figure 1 1 information contained in this manual although general in nature can be used as a valuable guide in the installation operation and maintenance of the US amp S supplied equipment Specific application information if required is presented in separate supplements to this manual Grade Crossing Warning equipment Figure 1 2 is offered in many different configurations to satisfy various site requirements Systems can be provided with flashing lights only or with flashing lights and gates Flashing lights can be arranged for normal highway applications converging highways or for use with cantilevers The lights can be either one way or two way back to back TRACKS SIGN WHEN REQUIRED STOP ON RED FLASHING SIGNAL LIGHT ASSEMBLY MECHANISM GATE ARM FLEXIBLE CONDUIT WITH SEALTITE FITTING JUNCTION BOX 3 BASE PN HR Figure 1 2 Grade Crossing Warning Assembly with Gate 5958 p 1 1 qd UNION SWITCH amp SIGNAL Different control schemes are also available These range from the very basic for use at industrial sidings such as our AW 10 Area Directional Warning Syst
17. 5 1 5 1 5 1 5 1 5 1 5 1 5 2 5 3 5 3 5 4 5 4 5 4 5 7 6 1 6 1 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 4 1 4 5 4 6 4 7 UNION SWITCH SIGNAL ILLUSTRATIONS Grade Crossing Warning Systems Grade Crossing Warning Assembly With Gate Flashing Light Assembly Model 75 Gate Mechanism Crossing Bell Typical Grade Crossing Equipment Cases Typical Location Plan for Highway Crossing Signals With or Without Gates for Two way Highway Traffic Right Angle Typical Location Plan for Highway Crossing Signals With or Without Gates for Two way Highway Traffic Acute Angle Foundation Height Poured Conerete Foundations For Flasher Signals With Automatio Gates Poured Concrete Foundations For Flasher Signals Precast Foundations Record of Field Installation Operational Check Light Unit Alignment Record of Field Installation Operational Check C Track Circuit Motion Monitoring Track Circuit Audio Frequency Overlay Track Circuit Direct Current DC Track Circuit High Frequency Track Circuit Typical Grade Crossing Warning Control Scheme Using Non Overlapping AFO Track Circuit Typical Circuit Diagram AFO II Track Circuit Single Track AC Lighting 111 3 N 3 5 3 6 3 7 3 8 3 12 3 13 3 17 2 3 5 6
18. Light 16 Bells required Yes No No required Crossbuck SORS Tracks 17 Signs required 18 Track circuits DC AFO Type C Motion Monitor 19 Cases factory wired Yes No OO OL OOOO OOOOOON OOO OOO 1 UNION SWITCH SIGNAL 3 2 2 Standards Equi pment Location Data Following is a general list of standards and location data that should be observed in developing a layout plan for the site Figure 3 1 and 3 2 illustrate typical location plans a Width and surface of roadway at grade crossing should correspond to that of the adjolning highway and have the same number and width of traffic lanes as the adjoining highway without extra lanes at the crossing b The center of the foundations should be six feet from the edge of the curb or roadway and no eloser than 12 feet from the center of the closest track See Figures 3 1 and 3 2 Foundations shall be placed so that the signal assembly is square with the highway regardless of the angle of the erossing See Figure 3 2 d The top of all highway crossing signal foundations shall be 6 inches above the crown of the highway see Figure 3 3 e Location of control cases and far end approach cases should be determined by accessibility of AC power and circuit design of the installation f The location of bootlegs and other track connections are usually determined by the particular standards of each individual railr
19. N SWITCH amp SIGNAL TOP OF FOUNDATION 6 ABOVE CROWN OF HIGHWAY Figure 3 3 Foundation Height 3 3 3 Cantilever Foundations Details of concrete foundations for cantilevers depends on the type cantilever used This information will be detailed on the applicable plans 3 3 4 Control Case Foundations Cast iron piers are generally used with cases but precast foundations can also be used Some amount of excavation is required for both types 3 3 5 Trenching for Cables a Use of a trencher or backhoe is recommended for a more uniform depth and direction b Cables should be laid at a depth of 30 inches unless conditions or local regulations mandate otherwise Cables in most instances can be fed under roadways by using a driving pipe d If this is impractical the roadway must either be torn up or cables strung overhead 5958 p 3 5 UNION SWITCH 8 SIGNAL A suggested poured concrete foundation for junction box bases with 11 11 16 x 11 11 16 bolt spacing is shown below TRACK SIDE HIGHWAY SIDE FRONT LOCATION OF 2 1 2 DIAMETER DOOR OF CROSSING GATE MECHANISM HOLE IN TERMINAL CASE ON THIS SIDE COMPARTMENT BASE TOP OF RAIL OR TO SUIT LOCALITY 36 MINIMUM 3 BELOW i DETERMINED BY CEN GROUND CONDITIONS CHASE CHASE 4 x 6 FOR MULTIPLE OR SIMILAR CABLE Cu Ft Stone A Dimensions of chase may be varied to suit number Cu Ft Sa
20. ND APPROACH TC ISLAND TC TRANSMITTER 1 RELAY AFO TRAIN SOTR SXOTR DETECTION CIRCUITS AUTOMATIC NOTR NXOTR WARNING ACTIVATION CIRCUIT OPERATION MANUAL OPERATION CONTROL Figure 4 6 Typical Grade Crossing Warning Control Scheme Using Non Overlapping AFO Track Circuits L TRANSCEIVER 1 1 KM NORTHBOUND NORTHBOUND CROSSING OVERLAY TRACK NOTR N OVERLAY TRACK RELAY XR CONTROL OF OPTIONAL BELL GATE CONTROL CIRCUIT EO CONTROL OF MAST OR CANTILEVER ANO OR FLASHING GATE ARM LIGHTS LIGHT SIGNAL WARNING CIRCUIT Normal Direction Running XP CONTROL OF GATE ARM MOVEMENT 7IVNDIS HILIMS NOINN SS 4 UNION SWITCH amp SIGNAL 4 5 2 2 Gate Activation Deenergization of the XR and in turn the Crossing Repeater XP Relay causes the internal gate mechanism circuits to drive the gate to a horizontal position Deactivation XR relay reenergizes initiates gate drive up to the vertical 90 degree position once the island track circuit has been passed by the train 4 5 2 3 Warning Bell Deenergization of the XR causes the crossing warning bell to activate Bell shutoff is controlled by the movement of the gate arm during drive down via an adjustable cam controlled contact of the gate mechanism s circuit controller 4 5 3 Warning Activation by Manual Operation Control Each grade crossing location can contain a provision in the control circuits to effect act
21. ST SIZE BACKGROUND X392931 001 X392931 007 X392931 002 X392931 008 X392931 005 X392931 009 451506 0711 451506 0712 4 4 5 10 Pipe Mast 10 Pipe Mast 10 11 Tapered Mast 10 11 Tapered Mast WITH STAND OFF for Wooden Gate Arms PART NO MAST SIZE BACKGROUND X438002 002 X438002 4 5 47 5 B UNION SWITCH amp SIGNAL DIVISION AMERICAN STANDARD INC SWISSVALE PA 15218 Engineering Grade Hi Intensity Engineering Grade Hi Intensity Engineering Grade Hi Intensity Engineering Grade Hi Intensity Engineering Grade Hi Intensity RSE 10B3 8 79 D v UNION SWITCH amp SIGNAL TRACKS SIGN Specify number required All aluminum construction with black lettering and includes mounting hardware STANDARO PART NO MAST SIZE BACKGROUND 392929 001 Engineering Grade X392929 005 Hi Intensity X392929 002 Engineering Grade X392929 006 li Lntensity X392929 004 10 Pipe Mast Engineering Grade X392929 007 10 Pipe Mast Hi Intensity X451506 0714 10 11 Tapered Mast Engineering Grade X451506 0715 10 11 Tapered Mast Hi Intensity WITH STAND OFF for Wooden Gate Arms PART NO MAST SIZE BACKGROUND X437997 4 5 Engineering Grade X437997 001 4 5 Hi Intensity STOP ON RED SIGNAL SIGN aluminum construction with black background Includes mounting hardware STANDARD PART NO MAST 2 p LETTERING _ X392930 001 4 Engineering Grade X392930
22. Sigs a Position the signs on the mast as shown in Figure 1 2 Section VI and secure with the hardware provided 3 4 7 Installation of Equipment Cases Remove control case from shipping skid be Cut banding wire that secures ground pipe to bottom of case Set control ease in position on foundation aligning parkway cable with knockout in bottom of case Secure to foundation with appropriate hardware d Attach the flower pot or ground pipe coupler Tighten the setscrews Feed all cables or wires through ground pipe into the Pack oakum into the pipe to seal it and top with Johns Manville Dux Seal or equivalent 3 4 8 Installation of Relays Shelf mounted relays are shipped already installed in the case For installations using plug in relays the relays are shipped separately These relays should be carefully unpacked and plugged into their respective locations Keyed index plates prevent plugging the wrong relay in the wrong location 5958 p 3 15 4 UNION SWITCH 8 SIGNAL 3 4 9 Installation of Crossing Gate Mechanism Complete instructions for installing the Model 75 Gate Mechanism crossing gate arms and eounterweights are covered in Service Manual 6043 Refer to this manual for detail instruetions 3 5 CONNECTING EQUIPMENT Prior to installing the equipment it should have been ascertained that all cabling and wiring was completed connect the various components of the
23. TCH amp SIGNAL 1 4 SUPPORTING PUBLICATIONS For complete information on the components comprising a grade crossing warning system including maintenance and parts list refer to Table I for a listing of all applicable service manuals Table I List of Service Manuals Model 75 Crossing Gate SM6 043 Flashing Light Unit w Junction Box Crossarm SM6326 BA 10 DC Aluminum Bell SM6094 AFO IIC Audio Frequency Overlay Track Circuit SM6134 ATT 20 Audio Track Tranceiver SM6299 AW 10 Directional Area Warning Device SM6133 MM 25 Motion Monitor SM6252 Type C Track Circuit SM6120 1 5 MATERIAL TOOLS AND EQUIPMENT Normal cleaning materials consisting of clean lint free cloths soft bristle brush compressed air in aerosol can and a commercial detergent and solvent Other than the tools required for the gate mechanism refer to SM6043 no special tools are required to install and maintain the equipment and the only test equipment required would be a good multimeter Grease for the gate mechanism called for in paragraph 5 2 3 should be made available 5958 1 8 UNION SWITCH SIGNAL VITAL RELAYS LIGHTNING ARRESTERS NN DETECTION 7 UNIT TRANSFORMER RECTIFIER TERMINALS BATTERIES Figure 4 6 Typical Grade Crossing Control Equipment Case 5958 p 1 9 1 10 UNION SWITCH SIGNAL v SECTION II APPLICATIONS 2 l GENERAL Grade Crossing Warning Systems can be applied anywhere a highway crosses a r
24. TR for ATT 20 track circuits 4 5 2 Warning Activation The Warning Activation Cireuit provides for automatic or manual activation and deactivation of grade crossing warnings When under automatic control occupancy of approach and island track circuits determines the status of the Warning Activation XR Relay When warnings are deactivated gate in vertical position lights and bell off the XR relay is energized via contacts of energized approach OTR and island track relays XOTR Upon occupancy of an approach track circuit the XR deenergizes initiating warnings and remains deenergized until the originating approach track circuit and the island track circuit are unoccupied 4 5 2 1 Flashing Warning Lights Flashing warning lights commence upon deenergization of the XR relay and in turn the Crossing Gate Repeater XGP Relay When this occurs ac power is applied via contacts of an energized Element On EO Relay flasher relay to alternately flash gate lights and mast or cantilever mounted signal lights The signal lights continue to flash until the island track circuit has been passed by the train and the gate is driven to its deactivated vertical position 5958 p 4 8 6 t d 8566 SOUTHBOUND SOUTHBOUND CROSSING SOTR OVERLAY OVERLAY TRACK TRACK RELAY RELAY 0 TRACK 2 RETE TRANSCEIVER 2 im TRANSMITTER 2 SOUTHBOUND SOUTHBOUND ISLAND APPROACH TC NORTHBOUND NORTHBOU
25. ailroad The type of equipment installed and the type of control used is dependent upon many factors For example because of the terrain a cantilever may be required or warning lights for converging highways may have to be installed In certain areas warning gates may also be required When planning a grade crossing warning system all factors must be considered The train detection track circuit and control circuits must also be determined For example in coded track circuit territory AFO equipment should be used Where train traffic involves frequent stop restart and reverse movements motion monitor control is recammended Section IV provides a brief description of the different controls available For detail information refer to the applicable service manual listed in Table I Because of the many variables it is not practical to cover all the applications possible in this manual For the equipment and controls that apply to specific location refer to the applicable layout drawings and circuit diagrams 5958 p 2 1 2 2 UNION SWITCH amp SIGNAL v SECTION III INSTALLATION 3 1 GENERAL The plans and circuit diagrams developed for the specific location must be followed when installing a Grade Crossing Warning System The following data are provided to guide in the proper planning and installation of the equipment All equipment must be installed in accordance with rules and regulations imposed by municipal state and fed
26. arm lights Broken or cracked gate arms Damaged mast and or signs or other equipment Exterior damage to gate mechanism signs of vanadalism Interior of gate mechanism for the following 1 All wiring connections are tight wiring is free from cuts nicks and fraying 2 Damage to gears motor and contacts 3 Secure mounting of components 4 Contacts for proper opening refer to SM6043 5 Slide contacts on resistors are clean and are bearing on the resistor windings with firm pressure lLockserew securing the slide contact should be tight Control Equipment Check control case exterior for any signs of physical damage or of vandalism such as bullet holes Check for water leaks inside the case Check batteries for fluid and specific gravity Remove all corrosion to assure proper voltage and battery charging Check for loose or damaged electrical connections Check for loose or damaged components Check for wiring for burned frayed or damaged insulation Check track circuit cabling for secure connections to track and damage such as kinks cuts etc Cheek for insulated joints if applicable for damage or deterioration 5958 p 5 3 4 D UNION SWITCH amp SIGNAL h Check relays for 1 Cracked or broken cover broken seals 2 Pitted or damaged contacts contact misalignment 3 Corrosion or other contamination of relay components loose parts inside cover 5 2 3 Lubrication The only equipment requir
27. ases come with either 12 24 AAR terminals depending on application plain clamp base is also available for the 4 diameter mast Refer to Section VI for additional data including ordering information 1 2 6 Signs Figure 1 2 Grade crossing warning signs are made of aluminum and include all hardware necessary for mounting Signs are provided either in engineering grade Scotch Lite or Hi intensity reflex reflection and confom to AAR requirements The signs are Railroad Crossing Tracks and Stop on Red Signal Refer to Section VI for additional data including ordering information 1 2 7 Equipment Cases Figure 1 6 Equipment cases located at wayside are provided in different sizes to accommodate the control equipment and ancillary items They include the train detection equipment plug in relays batteries power supply components and miscellaneous These cases constructed fram Cor Ten Steel are provided with front and rear full size locking doors Provisions are made for shelves and backboard 1 3 CONTROL CIRCUITS Standard DC AC DC AFO Audio Frequency Overlay High Frequency and Motion Monitor track circuits are used to provide train detection for grade crossing warning control systems To properly maintain the system it is important to know what type of track circuit is used For information on the different control circuits refer to Section IV Figure 1 5 Crossing Bell 5958 p 1 7 4 UNION SWI
28. cuits and motion monitoring track circuits be superimposed on existing direct current de track circuits or applied separately in various combinations The motion monitoring track circuit is highly recommended in switching areas where frequent stop restart and reverse movements are made to minimize crossing down time 11 controls for the Motion Monitor are located at the crossing The Type C track circuit scheme because of its high shunting sensitivity is recommended for application at difficult shunting areas It is intended for use in non signalled territory The type C track circuit is not suitable for overlay track circuit application therefore it should not be used in a similar manner as AFO and motion detection track circuits Conventional direct current de track circuit schemes are also incorporated with various control packages as well as high frequency track circuits 4 2 TRAIN DETECTION TRACK CIRCUITS Train detection track circuits are used to determine track occupancy when train approaches the grade crossing When a track circuit is occupied a control circuit is activated and the warning signals start to flash and the gates if provided will drop Anyone of the following basic track circuits are most practical for non electrified railroad applications Most track layouts can be adapted to one of these basic schemes Equipment arrangement and circuitry can be modified to suit special applications when required The t
29. em to our very sophisticated MM 25 Motion Monitor equipment 1 2 EQUIPMENT DESCRIPTION 1 2 1 Flashing Light Assembly Figure 1 3 Flashing light assemblies consists of a XA 120 Junction Box Crossamm on which are mounted the flashing light units The flashing light units are either the standard HC 100 8 3 8 lens or for increased light output the HC 120A 12 lens Assemblies are available for l way and 2 way back to back applications and for use with crossing assemblies equipped with fiberglass aluminum or wood gate arms and for cantilever installations The light units are equipped with a hood and either the standard 20 background or the 24 background HC 120A Unit Only 1 2 1 1 HC 120A Flashing Light Unit Figure 1 3 The HC 120A Light Unit is constructed of aluminum with stainless steel hardware and utilizes a 12 deep dish paabolic refelector with a 12 red Lexan roundel The reflector is center mounted for easy replacement The roundels come in different beam spread and deflection combinations Therefore when replacing a roundel in the field it is important that it is replaced with one of the same kind The cover which is secured by a bolt that accepts the AAR terminal wrench swings open to provide easy access to the interior for changing the lamp interior cleaning or other mainterance The lamp socket is brass plated and its mounting allows for X Y Z axis lamp location adjustment The socket accepts 10 or 25 wa
30. eral government agencies 3 2 PRE PLANNING Because of the many variables involved a site survey is recommended to determine the specific system to be installed Table II is a typical site survey check list that can be adopted to suit particular needs Upon completion of the survey a plan should be made to show the location of all components and the sources of power Based on this plan cabling diagram can be developed showing the length of cable runs between components and track and the number of wires required for each cable Information to be considered in survey is covered in paragraphs 3 2 1 and 3 2 2 3 2 1 Cable and Wire Requirements Recommended cable and wire requirements are as follows a 8 AWG in lengths of less than 50 feet b No 6 AWG in lengths of 50 feet to 120 feet c Wire size would be proportional for longer lengths d For track circuit connectors use 1 conductor No 8 AWG underground cable non metallio sheath e For connections to signals use 5 conductor No 9 AWG underground cable non metallic sheath or single conductor No 10 AWG underground f For wiring signal units use 1 conductor No 14 AWG flexible wire 3 64 inch wall insulation neoprene compound sheath equivalent g For bonding track circuits use the Cadweld rail head type or equivalent h Track circuit bootleg connections and track rectifier connections Tigerweld 18 1 bond wires with 3 8 inch terminal on one end ot
31. es the general procedures for installing the components of a Highway Grade Crossing Warning System If more detailed information is required consult the individual service manuals which are provided with each major component refer to Table I NOTE If preferred with the exception of the gate mechanism and gate arm the equipment may be assembled and mounted on the mast while on the ground and raised into its final position on the foundation Make sure that all components are properly aligned to the road etc before raising in place 3 4 1 Installation of Plain Clamp and Mast NOTE Mast and base are usually received as an assembly a Feed the cables from the chase through the center of the base up the mast and out the pre drilled crossarm hole Position the base on the foundation bolts Check that the pre drilled hole for the crossarm is correctly oriented b Install nuts on foundation bolts and hand tighten e Use a level and check all sides of the mast to ascertain that the mast is plum If not shimming is required d Securely tighten all foundation bolt nuts 5958 3 9 3 4 2 a 3 4 4 UNION SWITCH amp SIGNAL Installation of Junction Box Base and Mast Open the access cover at the junction box base and feed the cable from the chase through the junction box opening Position the junction box base and mast on the foundation bolts Check that the pre drilled hole for the crossarm is correc
32. her end tinned 36 or 42 inch in length or equivalent i Ground wire is No 6 AWG 4 5958 3 1 UNION SWITCH amp SIGNAL Cu Location of Installation Table II Site Survey Check List The following is not meant to portray a complete site survey questionnaire but is typical of some of the information that will be found on a site survey that will aid in installation planning stomer Date 1 10 5958 No of Tracks Single Doubie Other Type of Operation Autornatic Manual If Automatic Area Warning Directional Type of Highway One Way Traffic Two Way Maximum speed of fastest train in mph Train switching or Yes stopping approach zones No of train movements per day over crossing Within the control Switches T or F Train Signals Track bonded O Metai guage rods O Rail Section 4 hole joints 6 hole joints Ties Wood O Steel Concrete Other O Power available at DC 8 crossing AC Lj Voltage Frequency p 3 2 11 Standby power Yes required No A Battery Yes 12 Track Ballast 2 ohm Condition 5 ohm Sand Other 13 Highway at crossing Width Angle Sides of street Center of street Other 14 Crossing Signals located at 15 Signals Gates Signal with 2 units Signal with 4 units Cantilevers Lights on main masts Gates Length No Turn
33. iameter may be substituted for chase B Foundation to be placed square with the high way regardless of the angle of the crossing C Refer to ordering reference for foundation bolt size and part number Poured Concrete Foundations For Flasher Signals 5958 p 3 7 D UNION SWITCH amp SIGNAL PRECAST CONCRETE FOUNDATIONS FOR FLASHER SIGNALS AND FLASHER SIGNALS WITH AUTOMATIC GATES BY SECTIONAL FOUNDATIONS INC Order by Model No height bolt length and total weight FOUNDATION BOLT HEIGHT BOLT BASE TOTAL MODEL NO CENTERS LENGTH 3 1 2 THICK WEIGHT FLASHER ONLY FOUNDATIONS SF 1 1 2 x 9 1 2 26 32 1 4 30 30 544 Ib SF 1 9 1 2 x 9 1 2 36 44 1 4 30 x 30 702 Ib SF 1 9 1 2 x 9 1 2 46 56 1 4 30 x 30 806 Ib 5 1 9 1 2 x 9 1 2 56 68 1 4 30 x 30 910 Ib SF 1X 91 2 x 9 1 2 477 1 2 58 1 4 30 x 30 860 Ib FLASHER AND GATE FOUNDATIONS SF 2 11 11 16 x 11 11 16 36 44 1 4 30 x 30 1096 Ib SF 2 11 11 16 x 11 11 16 46 56 1 4 30 30 1293 Ib SF 2 11 11 16 x 11 11 16 56 68 1 4 30 x 30 1490 Ib SF 2 11 11 16 x 11 11 16 66 8 1 4 30 5 30 1686 ib SF 2 11 11 16 x 11 11 16 7 6 92 1 4 30 30 1882 Ib _ SF 2 11 11 16 x 11 11 16 8 e 104 1 4 30 30 2078 Ib SF 2X 11 11 16 x 11 11 16 3 6 1 2 44 1 4 30 30 996 Ib SF 2X 11 11 16 x 11 11 16 5
34. ing lubrication is the gate mechanism Every six months or more frequently depending on operating conditions apply a light brush coat of lubricant to the gear teeth and circuit controller cam Texaco Regal Starfax 2 MIL G 3278 grease equivalent is recommended mechanism gear shaft and main shaft bearings are pre lubricated and double sealed at the factory and requires no lubrication in the field 5 3 SYSTEM OPERATIONAL TEST NOTE More frequent operating tests should be made in areas where the system is seldom or only periodically used Where the system is in use daily a visual observation of the system should suffice until normal periodic testing Keep test records for handy referral so that proper checks are made at regular intervals Every 30 days perform the operational test covered in paragraph 3 8 2 Observe the operation for any signs of malfunctioning or faulty operation Initiate corrective action if any faults are observed 5 4 TROUBLESHOOTING 5 4 1 Table V covers the more common problems encountered in system operation Faulty operation generally will occur in three major 1 Train detection circuits 2 Activation control circuits and 3 Gate mechanisn 5958 p 5 4 UNION SWITCH amp SIGNAL D Table V Troubleshooting 1 Erratic malfunc Improper gate mechanism Refer to gate tioning gate arm adjustments mechanism SM6043 operation warning system operating prope
35. inning at the opposite end of the circuit and observe the functions as before 3 8 2 Final Checkout The final checkout of the system should include these points Re check the focus and alignment of the signal units Measure the voltage of the lamp Voltage should be at least 85 of the lamp rated voltage Check of the gate mechanism for proper operation Check the discharge of the batteries with an ammeter and set the rectifier for proper charging rate This information is included with the installation plans Keep storage battery between 1215 and 1220 specific gravity as specified for the batteries used External resistance in the battery circuits should be adjusted to provide at the track terminals of the track relay the recanmended working voltage of the relay Make one last check of the site for items such as wire which could result in shorts After all checks and adjustments have been made turn on the entire System and observe that all track relays are energized the gate arm is in the vertical position and the lights and bell are not funetioning SECTION dE _ CONTROL CIRCUITS AND FUNCTIONAL OPERATION H I GENERAL For most systen applications all control equipment required to initiate planes grade crossing warning is located at the crossing Control packages designed for Audio Frequency Overlay AFO track circuit application require additional equipment at the approach end AFO track cir
36. it to the bracket Loosen the set screws on the elbow and position light unit to its approximate final position Repeat for all other light units Complete wiring by attaching leads to terminals in accordance with Figure 3 7 Secure junction box cover If crossarm end plates were removed replace and secure with attaching hardware Align the signal light units in accordance with paragraph 3 4 4 2 following 5958 3 11 7 UNION SNITCH amp SIGNAL CROSSARM _ JCT BOX HIGHWAY 4 UNIT SIGNAL 2 CROSSARM 7 E JCT BOX TRAFFIC DIRECTION R L 4 perso MAST HIGHWAY 2 UNIT SIGNAL Figure 3 7 Signal Lamp Wiring Diagrams 3 4 4 2 Light Units Alignment see Figure 3 8 Vertical adjustment should be made first with the horizontal adjustment tightly clamped so that unit wiggling does not cause a bad vertical adjustment sighting tube N170622 can be used to aid in the initial adjustment The final adjustment should be checked by an observer on the road safely AAR Signal Manual Part 268 1972 Revision is repeated herein as a Guide to Signal Unit Alignment Some sentences of manual Part 268 are omitted for simplicity sake ALIGNING HIGHWAY CROSSING SIGNAL REFLECTOR TYPE LIGHT UNITS REVISED SIGNAL MANUAL PART 268 a The aligning of electric light units in accordance with these instructions must not be started until proper protection has been afforded for highway and pedestrian traffic Whe
37. ith no occupancy 5958 p 5 6 Train detection equipment failure one or more track relays deenergize resulting in warning control relay deenergizing Open in energizing path to warning control relay resulting in deenergiz ation Open in manual activation circuit Malfunction relay in activation circuit Malfunctioning detection equipment Mal functioning activation equipment Malfunctioning i ghting control circuits Malfunctioning gate control circuit Check relays Refer to applicabie train detection manual Check relays Check continuity of energizing path to warning control relay Check operation of manual activation circuit Check relays Troubleshoot detection circuit equipment and correct Check relays Replace if faulty Troubleshoot acti vation circuits equip ment and correct Check relays Replace if faulty Troubleshoot con trol circuit equip ment and correct Replace if faulty Troubleshoot con trol circuit equip ment and correct Check relays Replace if faulty UNION SWITCH amp SIGNAL 5 5 CORRECTIVE MAINTENANCE Corrective maintenance consists of repairing or replacing damaged or faulty components or equipment In general most items can be replaced in the field to restore the system to full operation This would include control equipment such as relays rectifiers transformers and detection equipment Minor repairs can also be done in
38. ivation without occupancy of approach or island track circuits A normally closed pushbutton circuit in series with the coil energizing path to the XR relay can be utilized for this function as shown in Figure 4 6 4 5 4 Optional Control and Timing Applications When required control circuits can be modified to satisfy design criteria within a grade crossing subsystem or system The following paragraphs describe some of these applications 4 5 4 1 Signaling System Tie In Track circuits ordinarily used for train detection within interlocking and or automatic block signaling subsystems can be used in conjunction with grade crossing warning track circuits and provide an additional means of initiating warning activation and or deactivation Line control circuits between crossing locations containing contacts of grade crossing and signaling system track relays can provide varying warning times elapsed time between warning activation and occupancy of the island track circuit and protection against AFO or similar type track circuit failure In the event of warning activation upon grade crossing warning track relay failure timing circuits can be configured to deactivate warnings after a predetermined time delay to allow the gate to rise and flashing signal lights to go dark and avoid unnecessary vehicular or pedestrian traffic buildup 4 5 4 2 Reverse Traffic Direction Warning Activation Circuits can also be configured to accommodate reverse
39. le if cleaning and inspection fall at six month intervals these procedures should be performed together 5 2 1 Cleaning Cleaning consists of the removal of dust and dirt from the control equipment located in the instrument case dirt and grime from the flashing light units and internal cleaning of the gate mechanism 5 2 1 1 Equipment Materials Required a Lint free cloths b Soft bristle brush Compressed air in aerosol can d Cleaning solvent e Commercial cleaning detergent 5 2 1 2 General Cleaning Procedures WARNING HAZARDOUS VOLTAGES AND CURRENT MAY BE PRESENT EXERCISE EXTREME CARE WHEN WORKING AROUND EXPOSED TERMINALS NEVER USE WET CLOTHES NEAR EXPOSED ELECTRICAL TERMINALS a Remove dust and dirt from the surface of the canponents mounted in the equipment case and inside the gate mechanism housing with a soft bristle brush Blow out dust and dirt from hard to reach areas with compressed air in aerosol can 5958 5 1 D UNION SWITCH amp SIGNAL Table IV Maintenance Action Every 30 days Perform a systems operation test per paragraph 5 3 Every 6 months Clean and inspect all grade crossing equipment per paragraphs 5 2 1 and 5 2 2 Lubricate gate mechanism per paragraph 5 2 3 Every 12 months Vital flasher relays performance test per applicable service manual Every 24 months All vital track and control relays performance test per applicable service
40. list of components is shown in Figure 4 7 4 5 1 Audio Frequency Overlay AFO Train Detection Each Grade Crossing Warning System location provides the capability to automatically initiate warning gate driven to horizontal position bell and flashing lights activated with the presence of a train in one or more of the location s approach track circuits 5958 4 7 v UNION SWITCH amp SIGNAL Table III Relay Functional Designations Designation Funetion Southbound Crossing Overlay Track Relay Southbound Overlay Track Relay Northbound Crossing Overlay Track Relay Northbound Overlay Track Relay Crossing Relay Crossing Gate Repeater Relay Crossing Repeater Element On Relay Flasher AFO IIC track circuits designated with an assigned frequency and having separate transmitter and receiver are used for approaches in a northbound or southbound direction Island track circuits at grade crossing intersections utilize an ATT 20 transceiver and are also designated with an assigned frequency Regardless of type each track circuit when unoccupied energizes an associated track relay When a train enters the track circuit signal strength is shunted away from the associated track circuit receiver resulting in the deenergization of the track relay Each track relay utilized for grade crossing warning approach circuits can be identified by its assigned transmission reception frequency i e OTR for AFO IIC track circuits and XO
41. n aligning care must be exercised that no unsafe conditions are set up 5958 p 3 12 UNION SWITCH amp SIGNAL D HC 100 HC 120 Azimuth Horizontal Alignment AS REQUIRED HC 100 HC 120 Range Vertical Alignment Figure 3 8 Light Unit Alignment 5958 p 3 13 D Q UNION SWITCH amp SIGNAL 1 The lamp receptacles are positioned and sealed by the manufacturer using 1 64 inch precision based lamps To obtain the range and efficiency intended signal precision lamps must always be used in the light units 2 When aligning of light units has been completed tests must be made immediately to determine that the equipment funotions as intended b Procedure is as follows 1 Front Light Units a Continuously light one lamp b Open door wide so clear beam 1s displayed Adjust light unit vertically to align axis of beam five feet six inches above pavement at selected alignment distance Both lamps should be aligned to same point d Adjust light unit horizontally to align axis of beam to center of approach lane in approach to signal at selected alignment distance maintaining vertical alignment e Tighten clamps and close door f Repeat instructions for other front light units 2 Back Light Units Where Used a Continuously light one lamp b Open door wide so clear beam is displayed Adjust light unit vertically to align axis of beam five feet six inches above pavement at a poin
42. nd of electrical conductors Bags Cement Concrete Mixture Fibre or steel conduit of suitable diameter may be 1 2 4 substituted for chase Foundation Bolts with Hex Nuts and B Refer to ordering reference for foundation bolt Washers size and part number Figure 3 4 Poured Concrete Foundations For Flasher Signals With Autamatic Gates 5958 p 3 6 4 UNION SWITCH amp SIGNAL Y Suggested concrete foundations for clamp bases or junction box bases with 9 1 2 x 9 1 2 boit spacing are shown below JUNCTION BOX BASE HIGHWAY SIDE 3 HIGHWAY SIDE PLAIN CLAMP BASE LOCATION OF 2 1 2 HOLE IN TERMINAL COMPARTMENT BASE 6 ABOVE TOP OF RAIL OR TO SUIT LOCALITY 30 MIN TO BE DETERMINED BY GROUND CONDITIONS 2 BELOW GROUND LEVEL OR TO SUIT LOCAL CONDITIONS FOR MULTIPLE OR SIMILAR CABLE ARRANGEMENT WITH TERMINAL BOX LOCATED OPPOSITE SIDE FROM TRACK Cu Ft Stone Cu Ft Sand Bags Cement Concrete Mixture 1 2 4 Foundation Bolts 1 x 24 with Hex Nut and Washer Conduit as required See Note A Figure 3 5 TOP OF RAIL AND TRACK OR TO SUIT LOCALITY 3 0 MIN TO BE DETERMINED BY GROUND CONDITIONS eame 4 on n 18 BELOW GROUND LEVEL OR TO SUIT LOCAL CONDITIONS FOR MULTIPLE OR SIMILAR CABLE A Dimensions of chase mav be varied to suit number of electrival conductors Fibre or steel conduit of suitable d
43. oad 3 3 SITE PREPARATION 3 3 1 Excavation Excavation is required for foundations and underground cable trenches Foundation requirements are covered in the following paragraphs Cable trenches and holes for pedestal mounted junction boxes and bootlegs are dictated by local conditions and individual railroad standards Follow normal installation procedures 3 3 2 Signal Mast Foundations Figures 3 4 and 3 5 provide details of poured concrete foundation for grade erossing masts Figure 3 4 is for aluminum signal masts proposed for grade erossing warning systems with gate installations which have 11 11 16 x 11 11 16 bolt spacing at the base Figure 3 5 is for aluminum signal masts which have 9 1 2 x 9 1 2 bolt spacing at the base Precast foundations may be used in place of the poured foundation provided the correct bolt spacing is available Information for precast foundations is shown in Figures 3 6 5958 p 3 3 amp UNION SWITCH SIGNAL EDGE OF PAVEMENT PAVEMENT PLAN TRACK Figure 3 1 Typical Location Plan for Highway Crossing Signals With or Without Gates for Two way Highway Traffic Right Angle EDGE OF PAVEMENT P G PAVEMENT 3 PLAN EDGE OF PAVEMENT 6 12 2 MIN Figure 3 2 Typical Location Plan for Highway Crossing Signals With or Without Gates for Two way Highway Traffic Acute Angle 5958 p 3 4 Q UNIO
44. omical and provides good shunting characteristics where rails tem to be rusty All power supply equipment is located at the crossing 4 2 2 Motion Monitoring Track Circuit Figure 4 2 The Motion Monitor train detection device is designed for application without insulated rail joints except for special applications This device detects train motion by continuously measuring track circuit characteristics constant current signal is fed into the rails adjacent to the highway grade crossing This signal develops a rail to rail voltage proportional to the track circuit impedance a train proceeds toward the crossing the moving shunt effect of the train causes the impedance of the track circuit and the rail voltage to decrease at the feed point The rate at which the impedance decreases is related to train speed position of train within the warning zone length rail impedance and ballast resistance The detection device includes the island zone grade crossing area self contained receiver which is connected to the rails on the opposite side of the highway from the track feed continuously monitors the rail to rail voltage at that point a train shunt 5958 p 4 2 UNION SWITCH SIGNAL APPROACH ISLAND APPROACH ZONE _ ZONE ZONE HIGHWAY aans oot TRACK RELAY Figure 4 2 Motion Monitoring Detection Track Circuit For Signalled Territory Use hard wire shunt in place of t
45. ough the rails to each of the transponder units which can be buried beneath the rails at each of the approaches This signal is used as a source of power for each of the transponder units which reply with respective 37 5 kHz and 42 kHz signals to the receiver portion of the transceiver which consists of independent channels In the respective receiver channel the appropriate transponder signal frequency is detected and produces a negative dc drive voltage which energizes a corresponding vital output relay that interfaces with the highway warning apparatus train traffic is not within the 300 foot approach boundaries the input signal to the respective receiver channel is of sufficient strength to pick the corresponding track relay When train traffic approaches within 300 feet of the crossing signal energy fram the respective transponder is shunted away from the associated receiver channel input When this occurs the receiver output drive signal becames insufficient to maintain the vital output relay in a picked energized condition and the relay armature drops thereby enabling the highway crossing warning apparatus The high frequency signals used in the AW 10 provide for excellent track circuit definitions that permit less than 15 feet spillover or ringby Furthermore the unit can provide a shunting sensitivity of up to 0 6 ohm to permit effective system operation in industrial areas with a potential of rusted rails 5958 p 4 5
46. outage Control equipment normally operates fran a 10 Vdc or 12 Vdc power supply area warning and 151 track circuits use separate power supplies 5958 p 4 6 UNION SWITCH amp SIGNAL D 4 5 FUNCTIONAL OPERATION Although there are many different control schemes possible the principles of operation are basically the same The deseription that follows cover a typical control scheme using Audio Frequency Overlay equipment This functional deseription ean be applied to systens using other types of train detection equipment the differences primarily being in the train detection equipment itself Simply put operation of grade crossing warning system is basically controlled by the train detection and the warning activation circuits The train detection circuit indicates the presence of a train in the controlled area The warning activation circuits initiate the operation of the warning devices flashing lights gates bells When the train leaves the controlled area the warning circuits are deactivated A typical audio frequency overlay AFO IIC track circuit is shown in Figure 1 6 In this example audio frequency overlay AFO IIC track circuits are used for approaches in either a southbound or northbound direction for each track in the normal direction of traffic They are designated SOT and NOT southbound and northbound overlay track and each have an assigned frequency with a separate transmitter and recei
47. rack circuits which will be described are the basic track circuit motion monitoring track circuit audio frequency overlay direct current do and high frequency track circuits For detailed information on the specifie track circuits used refer to the applicable service manual listed in Table I of this manual 4 2 1 Type C Track Cireuit Figure 4 1 The Type C track circuit is an track circuit designed to detect the presence of a train A de relay is connected across an power source inverter which is connected to the rails A track rectifier is also connected across the rails at the opposite end of the track circuit a halfwave shunt across the relay coil This rectified ac signal energizes the relay A train on the track circuit shunts the rectifier and reduces the rail potential resulting in a low power ac wave being presented to the de relay This combination of events causes the track relay to become deenergized thus initiating grade crossing warning 5958 p 4 1 QJ UNION SWITCH amp SIGNAL APPROACH APPROACH ZONE ZONE ga Tl a 3 LZ HIGHWAY B TRACK RELAY TRACK RELAY TRACK RELAY Figure 4 1 Track Circuit Scheme track circuits must be isolated with insulated rail joints and all rail ends within the track circuit must be bonded to ensure proper electrical continuity This type of track circuit is econ
48. rcuit Figure 4 4 The dc type track circuit employs a constant energy flow to detect the approach of a train the battery end of the track circuits current is fed into both rails to energize a relay located at the opposite end of the circuit train shunt reduces the rail potential below the drop away value of the relay and de energizes the relay which activates the control circuit DC track circuits must be isolated fram adjacent track circuits with insulated rail joints Rail ends within the track circuit must be bonded to ensure proper electrical continuity 5958 pe 4 4 UNION SWITCH amp SIGNAL APPROACH APPROACH ZONE ZONE BATTERY 3 TRACK TRACK RELAY 1 RELAY 2 Figure 4 4 Direct Current DC Track Circuit 4 2 5 High Frequency Track Circuit Figure 4 5 The high fr quency AW 10 device is a short range train detection system suitable for applications involving restricted train speeds and limited approach distances A typical application provides a 20 second warning time for 10 mph traffic at highway crossing applications having a minimum approach length of 300 feet and may be operated in either a directional or non directional mode The device consists of a transceiver unit and two separate transponder units The transceiver unit contains a transmitter and two receivers each receiver is tuned to a dedicated transponder frequency The transceiver housed at the crossing transmits a 24 kHz signal thr
49. rly Gate arm remains Open motor up circuit Refer to gate down when track mechanism SM603 13 unoceupied Gate in horizontal Loss of primary ac and do Check distribution position with other power common source of primary ac power warnings not activated to signal lighting transformer and de rectifier Check transformer and rectifier Open gate fuse Check fuse for continuity If required replace with identical fuse Gate in horizontal Loss of de power Check distribution position with steady of de power to con lit gate and signal trol relays lights Check power supply or rectifier Malfunetioning flashing Check operation of signal lighting circuit flashing signal lighting circuit specifically the flasher relay and distribution of ac to signal lighting lamps Control system Malfunetioning flashing Check operation of activated gate and signal lighting circuit flashing signal signal lights mal lighting circuit functioning not specifically the flashing one side flasher relay not lit etc Cheek lamps 5958 5 5 4 UNION SWITCH amp SIGNAL Table V Troubleshooting Cont d Problem 6 Activation of warnings with no occupancy flashing lights on gate down System remains acti vated after train leaves control areas flashing lights on gate remains down Gate goes up flashing lights remain on with no occupancy Flashing lights go dark gate remains down w
50. rossing Gate Assembly 5958 pe 1 5 D UNION SWITCH amp SIGNAL 1 2 2 2 Gate Arms Figure 1 4 Gate arms are either wood or telescoping aluminum or fiberglass US amp S does not provide wood gate arms The telescoping aluminum gate arm consists of three sections of extruded aluminum The telescoping fiberglass gate arm consists of the first section of extruded aluminum and the second and third sections of pultruded glass reinfored polyester thermoset fiberglass Both came in adjustable lengths from 17 to 40 feet To warn on coming vehicular traffic three 10 volt weatherproof bi directional 4 or 7 lights are mounted on the arm Each is plug connected to the main harness A plug connector is provided in the wiring harness between the first and second arm sections to facilitate arm replacement Another plug connector is located between the gate arm and the mechanism Additional warning is provided by the alternate Scotchlite reflective red and reflective white sheeting on the arms The gate arm is linked to the support assembly by a shear pin which helps to prevent mechanism damage if the arm is struck 1 2 2 3 Counterweights Figure 1 4 Counterweights are supplied to suit each corresponding length of the gate arm The weights are approximately the same for both fiberglass and aluminum arms The weights are secured to the gate support arm supports with bolts and nuts This allows for moving the counterweights forward or backward
51. ssembly which has four contacts operated by a cam Two circuit controller contacts are wired for mechanism control and two contacts are available for controlling external circuits such as the bell ard the clear position repeater relay Contacts 1 1 and 2B 2C are adjustable fram 70 to 93 degrees Rubber bumpers are provided at 0 and 90 positions of the mechanism stop bolt is used in the top bumper to adjust the gate arm position when the arm is horizontal The splined ends of the main shaft extend out both sides of the mechanism for mounting the cast aluminum arm supporting members The counterweights are attached to these supporting members and the support bracket for fiberglass aluminum or wooden arms The total weight of the operating mechanism is approximately 225 pounds To facilitate maintenance torque readings can be taken directly off the main shaft and the gate arm can be manually cranked up or down Also provided is a power cut out link which cuts internal power to the mechanism without affecting power to the bell arm lights or signal flashers 5958 1 4 UNION SWITCH amp SIGNAL MECHANISM GATE ARM 4 ADAPTER E N COUNTER WEIGHTS GATE ARM ADAPTER GATE ARM e FOR WOOD GATE ARMS SUPPORT FLEXIBLE CONDUIT WITH SEALTITE FITTING CIRCUIT GATE CONTROL CONTROLLER RELAY MOTOR CONTROL RELAY Figure 1 4 Model 75 C
52. t 50 ft in approach to the Signal on opposite side of track d Adjust light unit horizontally to align axis of beam to a point 50 feet with symmetric patterned roundels 150 feet with non symmetrical roundels in approach to the signal on opposite side of track and in center of approach lane maintaining vertical alignment as in Instruction 2 Tighten clamps and close door f Repeat Instructions for other back light units 3 After units have been aligned clamps tightened and doors closed they must be checked with lights flashing and lamps burning at recommended voltage to make certain a flashing light aspect is visible within a range of 1 000 feet NOTE Torque on 3 8 U bolt nuts of the elbows Should be 15 20 ft lbs Torque on 3 8 bolt which holds junction box door should be 8 13 ft lbs Assemble background and hood on each signal unit Torque 10 32 screws which hold background and hood in place to 1 2 ft lbs 595 8 P 3 1 4 Q UNION SWITCH amp SIGNAL D 3 4 5 Installation of Bell or Pinnacle NOTE The bell or pinnacle slides over the top of the mast and is secured by tightening one setscrew a String wires from crossarm junction box through the mast and out the top b Position bell with face of gong parallel to the highway Open back of bell and feed wire to terminals Attach wires to bell terminals and position on top of mast Tighten setscrew 3 4 6 Installation of
53. the field such as replacing roundels lamps damaged signs broken gate arms etc Items requiring major repair should be returned to the shop such as a Gate mechanism for damage to gears contacts cams motor elutch etc b Relays for broken covers damaged or misaligned contacts 6 Light units for broken reflector lamp receptacle case and ease door d Train detection unit if it does not meet minimum performance standards and cannot be brought into specification through normal adjustments 5958 p 5 7 5 8 4 UNION SWITCH amp SIGNAL D SECTION REPLACEMENT PARTS 6 1 GENERAL For detail parts of the major components refer to the applicable service manual listed in Table I For parts and equipment associated with a specific installation refer to the applicable drawings see Figure 4 7 for an example Miscellaneous parts information for signs bases etc are covered in the following catalog sections included in this section Grade Crossing Masts RSE 10B1 Junction Box Bases RSE 10B2 Grade Crossing Signs RSE 10B3 6 2 REPLACEMENT LAMPS For eonvenience replacement lamps for the flashing light units and the gate arm lights are listed below Flashing Light Units and Gate Arm Lights 10 Volt 18W S C B C Base 1071463 a Flashing Light Units Only 10 Volt 16W Quartz Iodide J714283 10 Volt 36W Quartz Iodide J714284 5958 p 6 1 6 2 GRADE CROSSING MASTS US amp 5 masts are constr
54. ting de track circuits Deperding upon distance required a low power transmitter is used for track circuits up to approximately 3500 feet or a high power transmitter may be used for lengths over 3500 feet Frequencies vary fran 885 Hz to 6180 Hz for single track operation and 930 Hz to 6330 Hz for the second track in double track applications 5958 pe 4 3 SN UD y UNION SWITCH SIGNAL APPROACH APPROACH ZONE ZONE E E TRANSMITTER AFO AFO 2 1 TRACK TRACK RELAY 2 RELAY 1 Figure 4 3 Audio Frequency Overlay AFO Track Circuit with Overlapping Track Circuits The AFO system provides 16 different frequencies divided into two groups of eight each class 1 is recamended for single track and class 2 is recommended for the second track The AFO circuit introduces an audio frequency signal from a solid state oscill ator into the track at the transmitter approach end This signal is detected by a receiver located at a second position adjacent to the crossing In the receiver the signal is amplified and rectified into a dc control voltage which then energizes a relay The relay remains energized while the signal is being received and is deenergized by the train shunt This type of track circuit can be used for either signalled or non signalled applications Two track circuits are required for crossing warning The overlap at the crossing provides an equivalent island circuit 4 2 4 Direct Current DC Track Ci
55. tly oriented Install nuts on fo ndation bolts and hand tighten On the mast feed a cable through the pre drilled hole for the crossarm to the junction box base Use a level and check all sides of the mast to ascertain that the mast is plum If not shimming is required Securely tighten all foundation bolt nuts Installation of Junction Box Crossarm NOTE The light units may be fastened to the junction box crossarms and pre wired when received If not they may be mounted to the junction box crossarm before installing the junction box crossarm or installed after the junction box crossarm is mounted refer to paragraph 3 4 4 Open the junction box cover on the crossarm by loosening the two bolts and swinging the cover open Remove the U bolts and temporarily place them aside Lift the crossarm into position and feed the cable protruding from the mast into the junction box outlet Position the crossarm on the mast with the back of the junction box aligning with the pre drilled hole in the mast Install U bolt nuts and tighten securely Torque U bolts to 70 90 ft lbs Connect the cable to the terminals as shown in Figure 3 7 Close and secure the junction box cover Installation of Light Units Both the HC 100 and HC 120A Light Units are installed in the same manner 3 4 4 1 Installation Procedure Open the junction box cover on the crossarm by loosening the two bolts and swinging the cover open 5958 p 3
56. tt 10 volt S 11 lamps 25 watt 110 volt G 16 1 2 lamps or 10 volt 16 or 36 watt Quartz Iodide lamps Voltage reading can be taken at the bulb for battery adjustments The light unit has a standard 1 1 4 straight pipe thread suitable for mounting the unit to all type crossarms 1 2 1 2 HC 100 Light Unit Figure 1 3 The HC 100 Light Unit is constructed of aluminum for long service life and easy maintenance It is equipped with a standard reflector and 8 3 8 roundel roundels are available in red Lexan or red plexiglass and yellow glass for special applications Roundels came in different beam and spread cambinations Therefore when replacing a roundel in the field it is important that it is replaced with one of the same kind The cover swings open for easy access to the interior for lamp replacement and other mainterance The lamp holder is also J axis X Y and 2 adjustable and uses the same lamps as the HC 120A Light Unit described in paragraph 1 2 1 1 5958 p 1 2 UNION SWITCH amp SIGNAL XA 120 JUNCTION BOX CROSSARM BACKGROUND HC 120A UNIT ONE WAY FLASHING LIGHT ASSEMBLY HC 120 LIGHT UNIT HC 100 LIGHT UNIT Figure 1 3 Flashing Light Assembly 5958 p 1 3 b UNION SWITCH amp SIGNAL 1 2 1 3 120 Junction Box Crossarm Figure 1 3 Junction Box Crossarms are available in different configurations to provide a wide range of applications The crossarms are constructed of
57. ucted of aluminum for easy handling long life and minimum maintenance The 13 6 mast is used for mounting grade crossing signals signals with gate assemblies or gate assemblies only A 6 9 stub mast is available for mounting U S amp S s gate mechansim with gate arm The 15 3 mast is designed for converging highway applications An additional hole is drilled at appropriate angle from the center to accommodate additional crossarms 4 AND 5 INCH GRADE CROSSING ALUMINUM SIGNAL MASTS FOR USE WITH 17 HIGH JUNCTION BOX BASES WITH 11 11 16 BOLT SPACING ORDERING INFORMATION J B MAST MAST J B BASE CROSSARM PART NO DIA HEIGHT HOLE HOLE M451394 4301 69 M451394 4201 69 451394 4401 136 M451394 3902 13 6 M451394 4 101 15 3 451394 4001 153 451 394 4102 153 451394 4002 153 451394 4103 1573 451394 4003 153 451394 4104 153 M451394 4004 15 3 4 INCH GRADE CROSSING ALUMINUM SIGNAL MASTS FOR USE WITH 12 HIGH JUNCTION BOX BASE WITH 9 1 2 BOLT SPACING ORDERING INFORMATION J B MAST MAST J B BASE CROSSARM PART NO DIA HEIGHT HOLE HOLE 05 05 M451394 5101 M451394 5102 d fo CONVERGING ANGLE CROSSARM HOLE CONVERGING CROSSARM HOLE UNION SWITCH amp SIGNAL DIVISION uae AMERICAN STANDARD INC SWISSVALE PA 15218 85 108 8 79 UNION SWITCH amp SIGNAL PINNACLE AND APPLICATION HARDWARE 23
58. uned shunt in non signalled territory occurs within the island zone between rail connections the receiver input voltage will fall below the island receiver s threshold thus detecting the presence of a train motion monitoring detection circuit may be applied as a sole means of train detection where maximum train speeds are less than 20 mph is recammended where train speeds exceed 20 mph that AFO wrap around be installed to detect high resistance rail breaks or faulty connections motion monitoring detection circuit can be superimposed on existing dc or AFO track circuits which then serve as the wrap around however a motion monitoring track circuit cannot be superimposed on a Type C track circuit Track coupling units must be used to pass the current signal around insulated joints tuned shunt hard wired shunt in non signaled territory and where wrap around is not used is connected across the rails at the approach ends of the track to terminate the detection circuit All rail ems within the warning zone area must be bonded to ensure proper electrical continuity Double bonding is recammended for additional protection 4 2 3 Audio Frequency Overlay AFO Track Circuit Figure 4 3 The AFO track circuit is designed for use without insulated rail joints This is particularly useful when insulated rail joints would be a problem or where continuous welded rail is employed AFO circuits can also be superimposed on exis
59. ver Island circuits at grade crossing intersections designated SXOT and NXOT southbound and northbound crossing overlay track utilize an ATT 20 transceiver with an assigned frequency The block diagram shown in Figure 4 6 illustrates circuit interaction for a typical grade crossing location containing a gate mechanism with gate lights flashing mast mounted signal lights and warning bell Each block represents functional circuit arrow tipped lines between blocks are transfers of information from one circuit to another These transfers are accomplished via relay contact openings and closures The designated relay coils are contained in the circuit originating the transfer For example the Warning Activation Circuit conditions the status of the Crossing Relay XR Contacts of the normally energized XR relay are then used in the various warning circuits Therefore the warning activation deactivation sequence is controlled by the status of the XR relay For example as long as there is no occupancy of track circuits in the southbound or northbound approach SOT and NOT track relays energized and no occupancy of island track circuits SXOT and NXOT track relays energized the XR relay is kept in its energized state preventing warnings from activating Typical designations and functions of the relays used are given in Table III The designations are those found in AAR specifications on signaling typical track circuit diagram with a
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